Komatsu D85EX-18 D85PX-18 Bulldozer Shop Manual SEN06517-13 PDF

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Komatsu D85EX-18 D85PX-18 Bulldozer Shop Manual SEN06517-13- PDF DOWNLOAD

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Komatsu D85EX-18 D85PX-18 Bulldozer Shop Manual SEN06517-13- PDF DOWNLOAD 

Language : English
Pages : 2816
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu D85EX-18 D85PX-18 Bulldozer Shop Manual SEN06517-13- PDF DOWNLOAD

SERIAL NUMBERS 22001 and up

Foreword, Safety, Basic Information:
How to Read the Shop Manual:
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
• The caution lamps, pilot lamps, and symbols of the switches on the machine monitor can be different in
accordance with the machine.
• For details of the symbols shown on the machine monitor, see Structure and Operation, “Caution
Lamps Shown on Machine Monitor” and “Pilot Lamps Shown on Machine Monitor”.
• For details of the switches of the machine monitor, see Testing and Adjusting, “Set and Operate Machine
Monitor”.
• For details of the switches, see the “Operation and Maintenance Manual”.
• All “AdBlue/DEF” shown on the machine monitor is referred to as “DEF” in the shop manual. Some machine
monitors installed to the product show “DEF” as “AdBlue/DEF” in the service mode. Thus, be sure to recognize
that “DEF” and “AdBlue/DEF” are the same when you read the shop manual.
Composition of the Shop Manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 Index and Foreword
This section describes the index, foreword, safety, and basic information.
01 Specification
This section describes the specifications of the machine.
10 Structure and Function
This section describes the structure and operation of each component with respect to each system. “Structure
and Function” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 Standard Value Table
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 Testing and Adjusting
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “Standard Value Table”.
40 Troubleshooting
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.

TABLE OF CONTENTS:

Komatsu D85EX-18 D85PX-18 Bulldozer Shop Manual SEN06517-13- PDF DOWNLOAD 

SERIAL NUMBERS 22001 and up

Cover 1
00 Index and Foreword 3
Index 4
Abbreviation List 21
Foreword, Safety, Basic Information 24
How to Read the Shop Manual 24
Safety Notice for Operation 26
Precautions to Prevent Fire 34
Procedures If Fire Occurs 36
Precautions for Disposing of Waste Materials 37
Procedures for Exhaust Gas Regulations 38
Precautions for DEF 39
General Character and Precautions for Handling 39
Precautions for Adding 39
Precautions for Storage 39
Precautions for Fire Hazard and Leakage 39
Other Precautions 39
Store DEF 40
Precautions When You Handle Hydraulic Equipment 41
Precautions When You Disconnect and Connect Pipings 44
Precautions When You Handle Electrical Equipment 51
Precautions When You Handle Fuel System Equipment 53
Precautions When You Handle Intake System Equipment 54
Practical Use of KOMTRAX 55
Disconnect and Connect Push-Pull Type Coupler 56
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 56
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 57
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 58
Precautions for Disconnection and Connection of Connectors 60
How to Disconnect and Connect Deutsch Connector 64
How to Disconnect and Connect Slide Lock Type Connector 65
How to Disconnect and Connect Connector with Lock to Pull 67
How to Disconnect and Connect Connector with Lock to Push 68
How to Disconnect and Connect Connector with Housing to Rotate 70
How to Read the Codes for Electric Cable 71
Explanation of Terms for Maintenance Standard 75
Standard Tightening Torque Table 78
Conversion Table 85
01 Specifications 91
Table of Contents 92
Specifications 93
Specification Drawing 93
Specification Drawing: D85EX-18 93
Specification Drawing: D85PX-18 96
Specifications 97
Specifications: D85EX-18 97
Specifications: D85PX-18 105
Weight Table 110
Weight Table: D85EX-18 110
Weight Table: D85PX-18 114
Table of Fuel, Coolant, and Lubricants 116
10 Structure and Function 119
Table of Contents 120
Urea SCR System 123
Layout Drawing of Urea SCR System 123
Urea SCR System Diagram 126
Function of Urea SCR System 127
Function of DEF System 127
Inducement Strategy 130
Component Parts of Urea SCR System 144
DEF Mixing Tube 144
SCR Assembly 144
DEF Tank 147
DEF Pump 149
DEF Injector 150
DEF Hose 151
DEF Tank Heating Valve 152
Boot-up System 153
Layout Drawing of Boot-up System 153
System Operating Lamp System 154
System Diagram of System Operating Lamp System 154
Function of Operation Lamp System 154
Battery Disconnect Switch 156
Layout Drawing of Battery Disconnect Switch 156
Function of Battery Disconnect Switch 156
Engine System 158
Layout Drawing of Engine System 158
Engine Control System 160
Layout Drawing of Engine Control System 160
System Diagram of Engine Control 161
Function of Engine Control System 163
Automatic Idle Stop System 165
System Diagram of Automatic Idle Stop System 165
Function of Automatic Idle Stop System 165
Component Parts of Engine System 168
Damper 168
VGT 169
EGR System 173
EGR Valve 175
EGR Cooler 177
KCCV System 178
KCCV Ventilator 180
KDPF 182
Cooling System 187
Layout Drawing of Cooling System 187
Specifications of Cooling System 188
Cooling Fan Control System 189
System Diagram of Cooling Fan Control System 189
Function of Cooling Fan Control System 190
Component Parts of Cooling System 192
Cooling Fan Pump 192
Cooling Fan Motor 201
Hydraulic Oil Cooler Bypass Valve 208
Control System 209
Layout Drawing of Control System 209
Machine Monitor System 210
System Diagram of Machine Monitor System 210
Function of Machine Monitor System 210
KOMTRAX System 212
System Diagram of KOMTRAX System 212
Function of KOMTRAX System 212
Component Parts of Control System 213
Machine Monitor 213
KOMTRAX Terminal 228
Power Train Controller 230
Engine Controller 234
Fuel Feed Pump 240
Fuel Feed Pump Switch 241
Hydraulic System 242
Layout Drawing of Hydraulic System 242
CLSS 243
Structure of CLSS 243
Function of CLSS 244
Component Parts of Hydraulic System 246
Hydraulic Tank 246
Work Equipment and HSS Pump 247
LS Valve 253
TVC Valve 257
Variable Throttle Valve 261
Control Valve 263
Power Train System 297
Layout Drawing of Power Train System 297
Operation of Power Train System 299
Transmission, Steering, and Brake Control 300
Layout Drawing of Transmission, Steering, and Brake Control System 300
Function of Transmission, Steering, and Brake Control 301
Palm Command Control System 303
Palm Command Control System Diagram 303
HSS System 307
HSS System Diagram 307
Function of HSS System 308
Centralized Pressure Pickup Port 310
Layout Drawing of Centralized Pressure Pickup Port 310
Function of Centralized Pressure Pickup Port 311
Component Parts of Power Train System 312
Universal Joint 312
Power Train Mount 313
Torque Converter and PTO 314
Transmission 317
Transmission ECMV 327
Main Relief Valve and Torque Converter Relief Valve 333
Transmission Lubrication Relief Valve 335
Bevel Gear Shaft, HSS, and Brake 335
Brake Valve 355
Final Drive 358
Scavenging Pump 362
Steering Lubrication Pump and Power Train Pump 363
HSS Motor 364
Electric Steering Electric Lever 369
Work Equipment System 373
Work Equipment Control 373
Layout Drawing of Work Equipment Control 373
Function of Work Equipment Control 374
Layout Drawing of Front Work Equipment 376
Layout Drawing of Fixed Multi-Shank Ripper 377
Layout Drawing of Variable Multi-Shank Ripper 378
Component Parts of Work Equipment System 379
Self-Pressure Reducing Valve 379
Work Equipment Lock Solenoid Valve 385
Blade PPC Valve 386
Ripper PPC Valve 392
Blade Pitch Selector Solenoid Valve 396
Pilot Circuit Accumulator 398
Quick Drop Valve 399
Piston Valve 400
Undercarriage and Frame 402
Main Frame 402
Structure of Main Frame 402
Suspension 403
Structure of Suspension 403
Function of Suspension 406
Track Frame and Idler Cushion 407
Structure of Track Frame and Idler Cushion 407
Function of Track Frame and Idler Cushion 408
Work Equipment 409
Structure of Front Work Equipment 409
Structure of Cylinder Stay 411
Structure of Fixed Multi-Shank Ripper 412
Structure of Variable Multi-Shank Ripper 413
CAB Related Parts 414
ROPS CAB 414
Structure of ROPS CAB 414
Function of ROPS CAB 415
CAB Mount 416
Structure of CAB Mount 416
Function of CAB Mount 416
20 Standard Value Table 417
Table of Contents 418
Standard Value Table for Engine 419
Standard Value Table for Engine: D85EX-18 419
Standard Value Table for Engine: D85PX-18 422
Standard Value Table for Machine 425
Standard Value Table for Machine: D85EX-18 425
Standard Value Table for Machine: D85PX-18 442
Machine Posture and Procedures to Measure Performance 457
Standard Value Table for Electricity 460
Standard Value Table for Electricity 460
30 Testing and Adjusting 469
Table of Contents 470
Precautions Before Work 473
Related Information on Testing and Adjusting 474
Tools for Testing and Adjusting 474
Sketch of Tools for Testing and Adjusting 481
Engine and Cooling System 482
Examine Engine Speed 482
How to Examine Engine Speed 482
Examine Boost Pressure 486
How to Examine Boost Pressure 486
Examine Exhaust Gas Temperature 488
How to Examine Exhaust Gas Temperature 488
Examine Exhaust Gas Color 490
How to Examine Exhaust Gas Color with the Handy Smoke Checker 490
How to Examine Exhaust Gas Color with Smoke Meter 491
Examine Mass Air Flow and Temperature Sensor 493
How to Examine Mass Air Flow and Temperature Sensor 493
Examine and Adjust Valve Clearance 495
How to Examine Valve Clearance 495
How to Adjust Valve Clearance 496
Examine Compression Pressure 497
How to Examine Compression Pressure 497
Examine Blowby Pressure 501
How to Examine Blowby Pressure 501
Examine Engine Oil Pressure 504
How to Examine Engine Oil Pressure on Machine Monitor 504
How to Examine Engine Oil Pressure by Testing Tool 504
Examine EGR Valve and VGT Oil Pressure 506
How to Examine EGR Valve and VGT Oil Pressure 506
Examine Fuel Pressure 508
How to Examine Fuel Pressure 508
Examine Fuel Return Rate and Leakage 510
How to Examine Fuel Return Rate and Leakage 511
Bleed Air from Fuel System 514
How to Bleed Air from Fuel System 515
Examine Fuel Circuit for Leakage 516
How to Examine Fuel System for Leakage 516
Handle Cylinder Cut-out Mode Operation 518
Handle No-Injection Cranking Operation 519
Examine and Adjust Air Conditioner Compressor Belt Tension 520
How to Examine Air Conditioner Compressor Drive Belt Tension 520
How to Adjust Air Conditioner Compressor Belt Tension 520
Clean Fuel Doser 522
How to Clean Fuel Doser 522
Write Injector Compensation Value to Engine Controller 525
How to Write Injector Compensation Value 525
Write Correction for Ash in Soot Accumulation to Engine Controller 531
How to Write Correction for Ash in Soot Accumulation to Engine Controller 531
Examine SCR Related Functions 532
Examine DEF Pump Raised Pressure 535
Examine Injection Volume from DEF Injector 537
Examine DEF Line Heater Relay 1 542
Examine DEF Line Heater Relay 2 544
Examine DEF Pump Heater Relay 547
Examine DEF Tank Heater Valve 550
Examine SCR Denitration Efficiency 552
Clean DEF Tank 556
How to Clean DEF Tank 556
Clean DEF Pump 560
How to Clean DEF Pump 560
Clean DEF Tank Mounting Part 567
How to Clean DEF Tank Mounting Part 567
Adjust Decelerator Pedal 568
How to Adjust Decelerator Pedal 568
Power Train 570
Examine Power Train Oil Pressure 570
How to Examine Power Train Oil Pressure 571
Adjust Transmission Output Shaft Speed Sensor 582
How to Adjust Transmission Output Shaft Speed Sensor 582
Examine Brake Performance Simply 584
How to Examine Brake Performance Simply 584
Adjust Brake Pedal 585
How to Adjust Brake Pedal 585
Adjust Parking Brake Lever 587
How to Adjust Parking Brake Lever 587
Move Machine by Parking Brake Release When Machine Does Not Travel 589
How to Move Machine with Hydraulic Type Parking Brake Release System 589
How to Move Machine with Electric Type Parking Brake Release System 590
Undercarriage and Frame 592
Adjust Idler Clearance 592
How to Adjust Idler Clearance 592
How to Adjust Idler Clearance Horizontally 592
How to Adjust Idler Clearance Vertically 592
Examine and Adjust Track Tension 594
How to Examine 594
How to Adjust Track Tension 594
Hydraulic System 595
Release Remained Pressure in Hydraulic Circuit 595
How to Release Remained Pressure in Hydraulic System 595
Examine and Adjust Work Equipment and HSS Oil Pressure 596
How to Examine Work Equipment and HSS Oil Pressure 596
How to Adjust Oil Pressure of Work Equipment and HSS 600
Examine Oil Pressure of Control Circuit 601
How to Examine Oil Pressure in Control Circuit 601
Examine PPC Valve Outlet Pressure 603
How to Examine Outlet Pressure in PPC Valve 603
Bleed Air from HSS Pump 606
How to Bleed Air from HSS Pump 606
Examine and Adjust Play of Work Equipment PPC Valve 607
How to Examine Play of Work Equipment PPC Valve 607
How to Adjust Play of Work Equipment PPC Valve 608
Examine Cooling Fan Speed 609
How to Examine Cooling Fan Speed 609
Examine Cooling Fan Circuit Oil Pressure 610
How to Examine Cooling Fan Circuit Oil Pressure 610
Bleed Air in Cooling Fan Pump 612
How to Bleed Air in Cooling Fan Pump 612
Examine Parts Which Cause Hydraulic Drift of Work Equipment 613
How to Examine Parts Which Cause Hydraulic Drift of Blade Lift Cylinder 613
How to Examine the Parts Which Cause Hydraulic Drift of Blade Tilt Cylinder 613
How to Examine the Parts Which Cause Hydraulic Drift of Ripper Lift Cylinder 614
Examine Oil Leakage from Work Equipment Cylinder 615
How to Examine Internal Oil Leakage of Work Equipment Cylinder 615
Bleed Air from Work Equipment Cylinders 617
How to Bleed Air from Work Equipment Cylinder 617
Work Equipment 618
Adjust Work Equipment Lock Lever 618
How to Adjust Work Equipment Lock Lever 618
CAB Related Parts 620
Examine and Adjust Operator Cab 620
How to Examine Operator Cab 620
How to Adjust Operator Cab 622
Electrical System 625
Set and Operate Machine Monitor 625
Operator Mode 628
Function to Show Technician Identification Status Screen 628
Function to Show Operator Identification Input Screen 628
Examine Function by LCD (Liquid Crystal Display) 629
Examine Function of Service Meter 630
How to Set Usage Limitation and Change Maintenance Password 630
Service Mode 632
How to Operate Service Mode 632
How to See Pre-defined Monitoring Information 634
How to Examine Self-Define Monitor Information 639
Abnormality Record Menu 649
How to See Maintenance Record 653
Maintenance Mode Setting 654
How to Set Phone Number Entry 658
Default Menu 659
Diagnostic Tests Menu 665
Adjustment Menu 675
No-Injection Cranking Operation 704
KOMTRAX Settings Menu 705
How to Show Service Message 707
How to Start Up KOMTRAX Terminal 709
Adjust When Power Train Controller is Replaced 714
How to Adjust When Power Train Controller is Replaced 714
Adjust Rearview Camera Angle 717
How to Adjust Rearview Camera Angle 717
Handle Voltage Circuit of Engine Controller 718
Handle Battery Disconnect Switch 719
Examine Diodes 720
How to Examine Diodes by Digital Tester 720
How to Examine Diodes by Analog Tester 720
Pm Clinic 721
Pm Clinic Service 721
Pm Clinic Check Sheet: D85EX-18 723
Pm Clinic Check Sheet: D85PX-18 737
Pm Clinic Check Sheet for Undercarriage: D85EX-18 749
Pm Clinic Check Sheet for Undercarriage: D85PX-18 753
40 Troubleshooting 757
Table of Contents 758
Precautions Before Work 767
Related Information to Troubleshooting 768
General Troubleshooting Points 768
Troubleshooting Points for Urea SCR System 769
Sequence of Events in Troubleshooting 783
Checks Before Troubleshooting 785
Inspection Procedure Before Troubleshooting 787
Walk-Around Check 787
Test in Accordance with Testing Procedure 789
How to Examine Electric Equipment 789
Preparation for Troubleshooting of Electrical System 796
Procedure for Troubleshooting 804
Symptom and Troubleshooting Numbers 807
Information Shown in Troubleshooting Table 810
Connector List and Layout 812
Connector Contact Connection Table 827
T-Branch Box and T-Branch Adapter Table 867
Fuse Location Table 873
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 876
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 880
Failure Code Table 882
Troubleshooting by Failure Code (Display of Code) 900
Failure Code [1500L0] 900
Failure Code [15SAL1] 901
Failure Code [15SALH] 903
Failure Code [15SBL1] 905
Failure Code [15SBLH] 907
Failure Code [15SEL1] 909
Failure Code [15SELH] 911
Failure Code [15SFL1] 913
Failure Code [15SFLH] 915
Failure Code [15SGL1] 917
Failure Code [15SGLH] 919
Failure Code [1800MW] 921
Failure Code [879AKA] 922
Failure Code [879AKB] 923
Failure Code [879BKA] 924
Failure Code [879BKB] 926
Failure Code [879CKA] 928
Failure Code [879CKB] 929
Failure Code [879DKZ] 930
Failure Code [879EMC] 932
Failure Code [879FMC] 933
Failure Code [879GKX] 934
Failure Code [989L00] 936
Failure Code [989M00] 937
Failure Code [989N00] 938
Failure Code [A1U0N3] 939
Failure Code [A1U0N4] 941
Failure Code [A900FR] 943
Failure Code [A900N6] 944
Failure Code [A900NY] 945
Failure Code [AA10NX] 946
Failure Code [AB00KE] 948
Failure Code [AQ10N3] 950
Failure Code [AS00N3] 952
Failure Code [AS00R2] 954
Failure Code [AS00R3] 955
Failure Code [AS00R4] 956
Failure Code [AS00R5] 957
Failure Code [AS00R6] 958
Failure Code [AS00ZK] 959
Failure Code [AS10KM] 960
Failure Code [AS10NR] 961
Failure Code [AS10NT] 962
Failure Code [B@BAZG] 963
Failure Code [B@BCNS] 964
Failure Code [B@BCZK] 965
Failure Code [B@CENS] 967
Failure Code [B@HANS] 968
Failure Code [CA115] 969
Failure Code [CA122] 970
Failure Code [CA123] 972
Failure Code [CA131] 974
Failure Code [CA132] 976
Failure Code [CA135] 978
Failure Code [CA141] 980
Failure Code [CA144] 982
Failure Code [CA145] 984
Failure Code [CA153] 986
Failure Code [CA154] 989
Failure Code [CA187] 992
Failure Code [CA221] 994
Failure Code [CA222] 996
Failure Code [CA227] 998
Failure Code [CA234] 999
Failure Code [CA238] 1000
Failure Code [CA239] 1002
Failure Code [CA249] 1004
Failure Code [CA256] 1006
Failure Code [CA271] 1008
Failure Code [CA272] 1010
Failure Code [CA273] 1011
Failure Code [CA274] 1013
Failure Code [CA322] 1014
Failure Code [CA323] 1016
Failure Code [CA324] 1018
Failure Code [CA325] 1020
Failure Code [CA331] 1022
Failure Code [CA332] 1024
Failure Code [CA343] 1026
Failure Code [CA351] 1027
Failure Code [CA352] 1028
Failure Code [CA356] 1031
Failure Code [CA357] 1033
Failure Code [CA386] 1035
Failure Code [CA441] 1036
Failure Code [CA442] 1039
Failure Code [CA449] 1040
Failure Code [CA451] 1041
Failure Code [CA452] 1043
Failure Code [CA515] 1045
Failure Code [CA516] 1047
Failure Code [CA553] 1049
Failure Code [CA555] 1050
Failure Code [CA556] 1051
Failure Code [CA559] 1052
Failure Code [CA595] 1057
Failure Code [CA687] 1058
Failure Code [CA689] 1060
Failure Code [CA691] 1062
Failure Code [CA692] 1064
Failure Code [CA697] 1066
Failure Code [CA698] 1067
Failure Code [CA731] 1068
Failure Code [CA778] 1069
Failure Code [CA1117] 1072
Failure Code [CA1664] 1073
Failure Code [CA1669] 1076
Failure Code [CA1673] 1077
Failure Code [CA1677] 1078
Failure Code [CA1678] 1079
Failure Code [CA1682] 1080
Failure Code [CA1683] 1082
Failure Code [CA1684] 1084
Failure Code [CA1686] 1086
Failure Code [CA1691] 1087
Failure Code [CA1694] 1090
Failure Code [CA1695] 1092
Failure Code [CA1696] 1093
Failure Code [CA1712] 1095
Failure Code [CA1713] 1098
Failure Code [CA1714] 1100
Failure Code [CA1715] 1101
Failure Code [CA1776] 1102
Failure Code [CA1777] 1105
Failure Code [CA1843] 1108
Failure Code [CA1844] 1110
Failure Code [CA1879] 1113
Failure Code [CA1881] 1116
Failure Code [CA1883] 1119
Failure Code [CA1885] 1123
Failure Code [CA1887] 1125
Failure Code [CA1921] 1127
Failure Code [CA1922] 1130
Failure Code [CA1923] 1135
Failure Code [CA1924] 1137
Failure Code [CA1925] 1139
Failure Code [CA1927] 1141
Failure Code [CA1928] 1143
Failure Code [CA1942] 1145
Failure Code [CA1963] 1146
Failure Code [CA1977] 1149
Failure Code [CA1993] 1152
Failure Code [CA2185] 1155
Failure Code [CA2186] 1156
Failure Code [CA2249] 1158
Failure Code [CA2265] 1159
Failure Code [CA2266] 1161
Failure Code [CA2271] 1164
Failure Code [CA2272] 1166
Failure Code [CA2349] 1168
Failure Code [CA2353] 1170
Failure Code [CA2357] 1172
Failure Code [CA2381] 1173
Failure Code [CA2382] 1175
Failure Code [CA2383] 1177
Failure Code [CA2386] 1179
Failure Code [CA2387] 1181
Troubleshooting Flowchart 1185
Failure Code [CA2555] 1186
Failure Code [CA2556] 1189
Failure Code [CA2637] 1191
Failure Code [CA2639] 1193
Failure Code [CA2732] 1196
Failure Code [CA2733] 1198
Failure Code [CA2741] 1200
Failure Code [CA2765] 1201
Failure Code [CA2771] 1202
Failure Code [CA2777] 1208
Failure Code [CA2878] 1211
Failure Code [CA2881] 1214
Failure Code [CA2976] 1217
Failure Code [CA3133] 1219
Failure Code [CA3134] 1221
Failure Code [CA3135] 1223
Failure Code [CA3142] 1227
Failure Code [CA3143] 1228
Failure Code [CA3144] 1229
Failure Code [CA3146] 1231
Failure Code [CA3147] 1232
Failure Code [CA3148] 1233
Failure Code [CA3151] 1235
Failure Code [CA3165] 1241
Failure Code [CA3167] 1243
Failure Code [CA3229] 1246
Failure Code [CA3231] 1248
Failure Code [CA3232] 1250
Failure Code [CA3235] 1254
Failure Code [CA3239] 1256
Failure Code [CA3241] 1259
Failure Code [CA3242] 1262
Failure Code [CA3251] 1265
Failure Code [CA3253] 1268
Failure Code [CA3254] 1272
Failure Code [CA3255] 1275
Failure Code [CA3256] 1279
Failure Code [CA3311] 1281
Failure Code [CA3312] 1283
Failure Code [CA3313] 1286
Failure Code [CA3314] 1287
Failure Code [CA3315] 1288
Failure Code [CA3316] 1291
Failure Code [CA3317] 1292
Failure Code [CA3318] 1293
Failure Code [CA3319] 1296
Failure Code [CA3321] 1297
Failure Code [CA3322] 1299
Failure Code [CA3419] 1302
Failure Code [CA3421] 1304
Failure Code [CA3497] 1306
Failure Code [CA3498] 1307
Failure Code [CA3543] 1308
Failure Code [CA3545] 1315
Failure Code [CA3547] 1317
Failure Code [CA3558] 1318
Failure Code [CA3559] 1320
Failure Code [CA3562] 1322
Failure Code [CA3563] 1324
Failure Code [CA3567] 1327
Failure Code [CA3568] 1330
Failure Code [CA3571] 1334
Failure Code [CA3572] 1336
Failure Code [CA3574] 1338
Failure Code [CA3575] 1340
Failure Code [CA3577] 1342
Failure Code [CA3578] 1344
Failure Code [CA3582] 1346
Failure Code [CA3583] 1353
Failure Code [CA3596] 1355
Failure Code [CA3649] 1357
Failure Code [CA3681] 1359
Failure Code [CA3682] 1364
Failure Code [CA3713] 1370
Failure Code [CA3717] 1373
Failure Code [CA3718] 1374
Failure Code [CA3725] 1375
Failure Code [CA3748] 1378
Failure Code [CA3751] 1381
Failure Code [CA3755] 1383
Failure Code [CA3866] 1385
Failure Code [CA3867] 1389
Failure Code [CA3868] 1392
Failure Code [CA3899] 1396
Failure Code [CA3911] 1398
Failure Code [CA3912] 1402
Failure Code [CA3932] 1404
Failure Code [CA3933] 1406
Failure Code [CA3934] 1408
Failure Code [CA3935] 1411
Failure Code [CA3936] 1413
Failure Code [CA4151] 1415
Failure Code [CA4152] 1419
Failure Code [CA4155] 1423
Failure Code [CA4156] 1425
Failure Code [CA4157] 1428
Failure Code [CA4158] 1430
Failure Code [CA4159] 1431
Failure Code [CA4161] 1432
Failure Code [CA4162] 1435
Failure Code [CA4163] 1438
Failure Code [CA4164] 1440
Failure Code [CA4165] 1442
Failure Code [CA4166] 1444
Failure Code [CA4168] 1446
Failure Code [CA4169] 1449
Failure Code [CA4171] 1451
Failure Code [CA4249] 1454
Failure Code [CA4251] 1456
Failure Code [CA4259] 1458
Failure Code [CA4261] 1461
Failure Code [CA4277] 1463
Failure Code [CA4281] 1467
Failure Code [CA4459] 1471
Failure Code [CA4461] 1474
Failure Code [CA4658] 1477
Failure Code [CA4731] 1481
Failure Code [CA4732] 1482
Failure Code [CA4739] 1483
Failure Code [CA4768] 1484
Failure Code [CA4769] 1486
Failure Code [CA4842] 1489
Failure Code [CA4952] 1493
Failure Code [CA5115] 1495
Failure Code [CA5383] 1498
Failure Code [D130KA] 1500
Failure Code [D130KB] 1503
Failure Code [D19DKA] 1505
Failure Code [D19DKB] 1507
Failure Code [D19JKZ] 1509
Failure Code [D811MC] 1512
Failure Code [D862KA] 1513
Failure Code [D8ALKA] 1514
Failure Code [D8ALKB] 1516
Failure Code [D8AQKR] 1518
Failure Code [DAF0MB] 1520
Failure Code [DAF0MC] 1521
Failure Code [DAF8KB] 1522
Failure Code [DAF9KQ] 1523
Failure Code [DAFGMC] 1524
Failure Code [DAFLKA] 1525
Failure Code [DAFLKB] 1527
Failure Code [DAFQKR] 1529
Failure Code [DAQW00] 1530
Failure Code [DAZ9KQ] 1531
Failure Code [DAZQKR] 1532
Failure Code [DB2QKR] 1533
Failure Code [DB2RKR] 1538
Failure Code [DBE0KT] 1543
Failure Code [DBE1KK] 1544
Failure Code [DBE2KK] 1547
Failure Code [DBE5KK] 1549
Failure Code [DBE6KK] 1551
Failure Code [DBE7KK] 1553
Failure Code [DBE9KQ] 1555
Failure Code [DBELKA] 1556
Failure Code [DBELKB] 1558
Failure Code [DBEQKR] 1560
Failure Code [DBERKR] 1561
Failure Code [DD12KA] 1563
Failure Code [DD12KB] 1565
Failure Code [DD13KA] 1567
Failure Code [DD13KB] 1569
Failure Code [DD14KA] 1571
Failure Code [DD14KB] 1573
Failure Code [DDKHKA] 1575
Failure Code [DDKHKB] 1577
Failure Code [DDN7KA] 1579
Failure Code [DDN7KB] 1581
Failure Code [DDNLKA] 1583
Failure Code [DDNLKB] 1585
Failure Code [DGS1KA] 1587
Failure Code [DGS1KX] 1589
Failure Code [DGT1KA] 1591
Failure Code [DGT1KX] 1594
Failure Code [DH21KA] 1596
Failure Code [DH21KY] 1598
Failure Code [DHA4KA] 1600
Failure Code [DHAAMA] 1602
Failure Code [DHACMA] 1604
Failure Code [DK10KA] 1606
Failure Code [DK10KB] 1609
Failure Code [DK30KA] 1611
Failure Code [DK30KX] 1614
Failure Code [DK30KY] 1615
Failure Code [DK30KZ] 1617
Failure Code [DK30L8] 1618
Failure Code [DK31KA] 1619
Failure Code [DK31KY] 1622
Failure Code [DK40KA] 1624
Failure Code [DK40KY] 1626
Failure Code [DK55KX] 1628
Failure Code [DK55KZ] 1629
Failure Code [DK55L8] 1630
Failure Code [DK56KA] 1631
Failure Code [DK56KY] 1633
Failure Code [DK57KA] 1635
Failure Code [DK57KY] 1637
Failure Code [DKH1KA] 1639
Failure Code [DKH1KY] 1642
Failure Code [DLM3KA] 1644
Failure Code [DLM3KB] 1646
Failure Code [DLM3MB] 1647
Failure Code [DLT3KA] 1648
Failure Code [DLT3KB] 1650
Failure Code [DR21KX] 1652
Failure Code [DR31KX] 1653
Failure Code [DV20KB] 1654
Failure Code [DW5AKA] 1656
Failure Code [DW5AKB] 1658
Failure Code [DW5AKY] 1660
Failure Code [DW7BKA] 1662
Failure Code [DW7BKB] 1664
Failure Code [DW7BKY] 1666
Failure Code [DWN1KA] 1667
Failure Code [DWN1KB] 1669
Failure Code [DWN1KY] 1671
Failure Code [DWN2KA] 1673
Failure Code [DWN2KB] 1675
Failure Code [DWN2KY] 1677
Failure Code [DWN5KA] 1678
Failure Code [DWN5KB] 1680
Failure Code [DWN5KY] 1681
Failure Code [DXA2KA] 1683
Failure Code [DXA2KB] 1685
Failure Code [DXA2KY] 1687
Failure Code [DXH4KA] 1688
Failure Code [DXH4KB] 1690
Failure Code [DXH4KY] 1692
Failure Code [DXH5KA] 1694
Failure Code [DXH5KB] 1696
Failure Code [DXH5KY] 1697
Failure Code [DXH6KA] 1698
Failure Code [DXH6KB] 1700
Failure Code [DXH6KY] 1702
Failure Code [DXH7KA] 1704
Failure Code [DXH7KB] 1706
Failure Code [DXH7KY] 1708
Failure Code [DXH8KA] 1710
Failure Code [DXH8KB] 1712
Failure Code [DXH8KY] 1714
Failure Code [DXJ4KA] 1716
Failure Code [DXJ4KB] 1718
Troubleshooting of Electrical System (E-Mode) 1720
E-1 Engine Does Not Start (Engine Does Not Crank) 1720
E-2 Manual Preheating System Does Not Operate 1727
E-3 Automatic Preheating System Does Not Operate 1730
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On 1732
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 1734
E-6 When Starting Switch is Turned to ON Position (with Engine Stopped), Basic Check Monitor Comes On 1738
E-7 Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation 1739
E-8 Charge Level Monitor Comes On in Red While Engine is in Operation 1740
E-9 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 1742
E-10 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation 1743
E-11 Power Train Oil Temperature Monitor Comes On in Red While Engine is in Operation 1744
E-12 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 1745
E-13 Engine Coolant Temperature Gauge Does Not Show Correct Temperature 1746
E-14 DEF Level is Not Shown Correctly 1747
E-15 Fuel Level Gauge Does Not Show Correct Level 1750
E-16 Power Train Oil Temperature Gauge Does Not Show Correct Temperature 1752
E-17 Hydraulic Oil Temperature Gauge Does Not Show Correct Temperature 1753
E-18 Operation Mode Does Not Change 1754
E-19 Gear Shift Mode Does Not Change 1755
E-20 Operating Customize Switch Does Not Display Customize Screen 1756
E-21 Modifying Setting on Customize Screen Does Not Change Setting of Machine 1757
E-22 Some Areas of Machine Monitor Screen are Not Shown 1758
E-23 Reverse Slow Mode Does Not Function Correctly 1759
E-24 Alarm Buzzer Does Not Sound or Does Not Stop Sounding 1760
E-25 Service Meter is Not Shown, While Starting Switch is in OFF Position 1761
E-26 Service Mode Cannot be Selected 1762
E-27 Horn Does Not Sound 1763
E-28 Horn Does Not Stop 1765
E-29 Backup Alarm Does Not Sound 1766
E-30 Backup Alarm Does Not Stop 1768
E-31 Headlamp Does Not Come On 1769
E-32 Rear Lamp Does Not Come On 1773
E-33 No Wiper Operates 1776
E-34 Front Wiper Does Not Operate 1780
E-35 Rear Wiper Does Not Operate 1783
E-36 Left Door Wiper Does Not Operate 1786
E-37 Right Door Wiper Does Not Operate 1789
E-38 Front Washer Does Not Operate 1792
E-39 Rear Washer Does Not Operate 1794
E-40 Left Door Washer Does Not Operate 1796
E-41 Right Door Washer Does Not Operate 1798
E-42 KOMTRAX System Does Not Operate Correctly 1800
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 1801
Information Shown in Troubleshooting Table (H-Mode) 1801
Failure Mode and Cause Table 1802
H-1 Machine Power is Not Sufficient (Not Sufficient Drawbar Pull) 1808
H-2 Machine Does Not Travel (at 2nd or 3rd Gear Speed) 1810
H-3 Machine Does Not Move Off at All Gear Speeds 1811
H-4 Machine Travels Only in One Direction, Forward or in Reverse 1813
H-5 Large Time Lag is in Gear Shifting or Directional Change 1814
H-6 Brake Does Not Work 1816
H-7 Power Train Oil Overheats 1817
H-8 Unusual Noise is Heard from Around Work Equipment and HSS Pump or HSS Motor 1819
H-9 Machine Cannot be Steered (Machine Does Not Turn LEFT or RIGHT) 1820
H-10 Steering Speed or Power is Not Sufficient 1821
H-11 All Work Equipment Operate Slowly 1822
H-12 All Work Equipment Do Not Operate 1823
H-13 Blade Lift Speed or Power is Low 1824
H-14 Blade Tilt Speed or Power is Low 1825
H-15 Ripper Lift Speed or Power is Low 1826
H-16 Hydraulic Drift of Lifted Blade is Large 1827
H-17 Hydraulic Drift of Tilted Blade is Large 1828
H-18 Hydraulic Drift of Lifted Ripper is Large 1829
H-19 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) 1830
H-20 Unusual Noise is Heard from Around Fan 1832
Troubleshooting of Engine (S-Mode) 1833
Information Shown in Troubleshooting Table (S-Mode) 1833
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position 1834
S-2 Engine Cranks but No Exhaust Smoke Comes Out 1835
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 1836
S-4 Engine Startability is Unsatisfactory 1837
S-5 Engine Does Not Pick Up Smoothly 1839
S-6 Engine Stops During Operation 1841
S-7 Engine Runs Rough or is Not Stable 1843
S-8 Engine Lacks Power 1844
S-9 KDPF Becomes Clogged in a Short Time 1846
S-10 Engine Oil Consumption is Excessive 1848
S-11 Oil Becomes Dirty Quickly 1849
S-12 Fuel Consumption is Excessive 1850
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant 1851
S-14 Oil Pressure Drops 1852
S-15 Fuel Mixes Into Engine Oil 1854
S-16 Water Mixes Into Engine Oil (Milky) 1855
S-17 Coolant Temperature Increases Too High (Overheating) 1856
S-18 Unusual Noise is Heard 1857
S-19 Vibration is Excessive 1858
S-20 Air Cannot be Bled from Fuel Circuit 1859
S-21 Active Regeneration is Done Frequently 1860
S-22 Active Regeneration Continues Long 1862
S-23 White Smoke is Exhausted During Active Regeneration 1863
S-24 DEF Consumption is Excessive 1864
S-25 There is Unusual Smell (Irritating Odor) 1866
S-26 Foreign Materials Enter DEF (DEF Increases) 1867
50 Disassembly and Assembly 1869
Table of Contents 1870
Precautions Before Work 1875
Related Information on Disassembly and Assembly 1876
How to Read This Manual 1876
Coating Materials List 1877
Special Tool List 1882
Sketches of Special Tools 1906
Engine and Cooling System 1914
Remove and Install Supply Pump Assembly 1914
How to Remove Supply Pump Assembly 1915
How to Install Supply Pump Assembly 1919
Remove and Install Injector Assembly 1926
How to Remove Injector Assembly 1927
How to Install Injector Assembly 1933
Remove and Install Fuel Doser Assembly 1944
How to Remove Fuel Doser Assembly 1944
How to Install Fuel Doser Assembly 1945
Remove and Install Cylinder Head Assembly 1947
How to Remove Cylinder Head Assembly 1947
How to Install Cylinder Head Assembly 1954
Remove and Install EGR Valve Assembly 1963
How to Remove EGR Valve Assembly 1963
How to Install EGR Valve Assembly 1965
Remove and Install EGR Cooler Assembly 1968
How to Remove EGR Cooler Assembly 1969
How to Install EGR Cooler Assembly 1973
Remove and Install Starter Assembly 1978
How to Remove Starting Motor Assembly 1978
How to Install Starting Motor Assembly 1980
Remove and Install Alternator Belt 1982
How to Remove Alternator Belt 1982
How to Install Alternator Belt 1984
Remove and Install Radiator Assembly 1986
How to Remove Radiator Assembly 1987
How to Install Radiator Assembly 1991
Remove and Install Hydraulic Oil Cooler Assembly 1997
How to Remove Hydraulic Oil Cooler Assembly 1998
How to Install Hydraulic Oil Cooler Assembly 2002
Remove and Install Aftercooler Assembly 2006
How to Remove Aftercooler Assembly 2006
How to Install Aftercooler Assembly 2007
Remove and Install Cooling Fan Drive Assembly 2008
How to Remove Cooling Fan Drive Assembly 2008
How to Install Cooling Fan Drive Assembly 2009
Remove and Install Cooling Fan Motor Assembly 2012
How to Remove Cooling Fan Motor Assembly 2012
How to Install Cooling Fan Motor Assembly 2014
Remove and Install Engine Assembly 2016
How to Remove Engine Assembly 2017
How to Install Engine Assembly 2024
Remove and Install Engine Front Oil Seal 2030
How to Remove Engine Front Oil Seal 2030
How to Install Engine Front Oil Seal 2031
Remove and Install Engine Rear Oil Seal 2034
How to Remove Engine Rear Oil Seal 2034
How to Install Engine Rear Oil Seal 2036
Remove and Install Engine Oil Pan 2041
How to Remove Engine Oil Pan 2041
How to Install Engine Oil Pan 2042
Remove and Install Engine Hood Assembly 2044
How to Remove Engine Hood Assembly 2044
How to Install Engine Hood Assembly 2046
Remove and Install Fuel Tank Assembly 2048
How to Remove Fuel Tank Assembly 2048
How to Install Fuel Tank Assembly 2050
Remove and Install DEF Tank Assembly 2053
How to Remove DEF Tank Assembly 2053
How to Install DEF Tank Assembly 2058
Remove and Install DEF Tank Sensor Flange Assembly 2062
How to Remove DEF Tank Sensor Flange Assembly 2062
How to Install DEF Tank Sensor Flange Assembly 2067
Remove and Install DEF Tank Sensor 2072
How to Remove DEF Tank Sensor 2072
How to Install DEF Tank Sensor 2072
Remove and Install DEF Strainer 2079
How to Remove DEF Strainer 2079
How to Install DEF Strainer 2079
Remove and Install DEF Tank Filler Port Filter 2080
How to Remove DEF Tank Filler Port Filter 2080
How to Install DEF Tank Filler Port Filter 2081
Remove and Install KDPF Assembly 2083
How to Remove KDPF Assembly 2083
How to Install KDPF Assembly 2087
Disassemble and Assemble KDPF Assembly 2092
How to Disassemble KDPF Assembly 2092
How to Assemble KDPF Assembly 2096
Remove and Install SCR Assembly 2100
How to Remove SCR Assembly 2100
How to Install SCR Assembly 2103
Remove and Install KDPF and SCR Assembly 2106
How to Remove KDPF and SCR Assembly 2106
How to Install KDPF and SCR Assembly 2116
Remove and Install KCCV Assembly 2126
How to Remove KCCV Assembly 2126
How to Install KCCV Assembly 2129
Remove and Install DEF Mixing Tube 2133
How to Remove DEF Mixing Tube 2133
How to Install DEF Mixing Tube 2136
Remove and Install DEF Injector 2142
How to Remove DEF Injector 2142
How to Install DEF Injector 2145
Remove and Install DEF Pump 2148
How to Remove DEF Pump 2148
How to Install DEF Pump 2151
Remove and Install DEF Hose 2155
How to Remove DEF Hose 2155
How to Install DEF Hose 2160
Remove and Install Air Cleaner Assembly 2166
How to Remove Air Cleaner Assembly 2166
How to Install Air Cleaner Assembly 2167
Remove and Install Air Conditioner Compressor Assembly 2168
How to Remove Air Conditioner Compressor Assembly 2168
How to Install Air Conditioner Compressor Assembly 2170
Power Train 2172
Remove and Install Damper Assembly 2172
How to Remove Damper Assembly 2172
How to Install Damper Assembly 2175
Disassemble and Assemble Damper Assembly 2178
How to Disassemble Damper Assembly 2179
How to Assemble Damper Assembly 2180
Remove and Install Power Train Unit Assembly 2183
How to Remove Power Train Unit Assembly 2183
How to Install Power Train Unit Assembly 2188
Disconnect and Connect Power Train Unit Assembly 2194
How to Disconnect Power Train Unit Assembly 2194
How to Connect Power Train Unit Assembly 2199
Disassemble and Assemble PTO Assembly 2204
How to Disassemble PTO Assembly 2204
How to Assemble PTO Assembly 2208
Disassemble and Assemble Torque Converter Assembly 2213
How to Disassemble Torque Converter Assembly 2213
How to Assemble Torque Converter Assembly 2216
Disassemble and Assemble Transmission Assembly 2220
How to Disassemble Transmission Assembly 2221
How to Assemble Transmission Assembly 2229
Disassemble and Assemble HSS Assembly 2241
How to Disassemble HSS Assembly 2243
How to Assemble HSS Assembly 2253
Remove and Install HSS Motor Assembly 2271
How to Remove HSS Motor Assembly 2271
How to Install HSS Motor Assembly 2272
Remove and Install Final Drive Assembly 2273
How to Remove Final Drive Assembly 2273
How to Install Final Drive Assembly 2275
Disassemble and Assemble Final Drive Assembly 2277
How to Disassemble Final Drive Assembly 2278
How to Assemble Final Drive Assembly 2285
Undercarriage and Frame 2297
Remove and Install Track Frame Assembly 2297
How to Remove Track Frame Assembly 2297
How to Install Track Frame Assembly 2300
Remove and Install Idler Assembly 2304
How to Remove Idler Assembly 2304
How to Install Idler Assembly 2305
Disassemble and Assemble Idler Assembly 2308
How to Disassemble Idler Assembly 2308
How to Assemble Idler Assembly 2310
Remove and Install Recoil Spring Assembly 2314
How to Remove Recoil Spring Assembly 2314
How to Install Recoil Spring Assembly 2316
Disassemble and Assemble Recoil Spring Assembly 2318
How to Disassemble Recoil Spring Assembly 2318
How to Assemble Recoil Spring Assembly 2322
Remove and Install Track Roller Assembly 2325
How to Remove Track Roller Assembly 2325
How to Install Track Roller Assembly 2327
Disassemble and Assemble Track Roller Assembly 2330
How to Disassemble Track Roller Assembly 2330
How to Assemble Track Roller Assembly 2331
Remove and Install Carrier Roller Assembly 2335
How to Remove Carrier Roller Assembly 2335
How to Install Carrier Roller Assembly 2336
Disassemble and Assemble Carrier Roller Assembly 2337
How to Disassemble Carrier Roller Assembly 2337
How to Assemble Carrier Roller Assembly 2338
Remove and Install Pivot Shaft Assembly 2341
How to Remove Pivot Shaft Assembly 2341
How to Install Pivot Shaft Assembly 2342
Separate and Connect Track Assembly 2344
How to Examine Before Separation of Track Assembly 2344
How to Separate Track Assembly (Standard) 2344
How to Separate Track Assembly (When Track Frame Has Internal Defect) 2345
How to Install Track Assembly 2347
Separate and Connect PLUS Type Track Assembly 2350
Separate PLUS Type Track Assembly Generally 2350
Install PLUS Type Track Assembly 2350
Disassemble and Assemble Track Assembly Generally 2351
How to Disassemble Full Track Shoes Assembly 2351
How to Assemble Full Track Shoes Assembly 2354
Disassemble and Assemble PLUS Type Track Assembly Generally 2367
Disassemble PLUS Type Track Assembly Generally 2367
How to Assemble PLUS Type Track Shoes Assembly Generally 2368
Disassemble and Assemble One Track Link Assembly in Field 2376
How to Disassemble One Track Link Assembly in Field 2378
How to Assemble One Track Link Assembly in Field 2378
Disassemble and Assemble Master Link 2386
How to Disassemble Master Link 2387
How to Assemble Master Link 2387
Remove and Install Equalizer Bar Assembly 2391
How to Remove Equalizer Bar Assembly 2391
How to Install Equalizer Bar Assembly 2393
Disassemble and Assemble Equalizer Bar Bushing 2394
How to Disassemble Equalizer Bar Bushing 2394
How to Assemble Equalizer Bar Bushing 2395
Open and Close Center Under Guard 2396
How to Open Under Guard 2396
How to Close Under Guard 2397
Remove and Install Center Under Guard Assembly 2399
How to Remove Underguard Assembly 2399
How to Install Underguard Assembly 2406
Hydraulic System 2414
Remove and Install Hydraulic Tank Assembly 2414
How to Remove Hydraulic Tank Assembly 2414
How to Install Hydraulic Tank Assembly 2417
Remove and Install Work Equipment Pump and HSS Pump Assembly 2421
How to Remove Work Equipment Pump and HSS Pump Assembly 2421
How to Install Work Equipment Pump and HSS Pump Assembly 2424
Remove and Install Power Train Pump and Steering Lubrication Pump Assembly 2426
How to Remove Power Train Pump and Steering Lubrication Pump Assembly 2426
How to Install Power Train Pump and Steering Lubrication Pump Assembly 2428
Remove and Install Cooling Fan Pump Assembly 2430
How to Remove Cooling Fan Pump Assembly 2430
How to Install Cooling Fan Pump Assembly 2432
Remove and Install Scavenging Pump Assembly 2435
How to Remove Scavenging Pump Assembly 2435
How to Install Scavenging Pump Assembly 2436
Remove and Install Control Valve Assembly 2438
How to Remove Control Valve Assembly 2438
How to Install Control Valve Assembly 2443
Work Equipment 2448
Remove and Install Blade Assembly 2448
How to Remove Blade Assembly 2448
How to Install Blade Assembly 2450
Remove and Install Blade Lift Cylinder Assembly 2454
How to Remove Blade Lift Cylinder Assembly 2455
How to Install Blade Lift Cylinder Assembly 2459
Disassemble and Assemble Fixed Multi-Shank Ripper Assembly 2464
How to Disassemble Fixed Multi-Shank Ripper Assembly 2464
How to Assemble Fixed Multi-Shank Ripper Assembly 2466
Disassemble and Assemble Variable Multi-Shank Ripper Assembly 2469
How to Disassemble Variable Multi-Shank Ripper Assembly 2469
How to Assemble Variable Multi-Shank Ripper Assembly 2472
How to Disassemble and Assemble Work Equipment Cylinder Assembly 2475
How to Disassemble Work Equipment Cylinder Assembly 2476
How to Assemble Work Equipment Cylinder Assembly 2479
CAB Related Parts 2483
Remove and Install Operator Cab Assembly 2483
How to Remove Operator Cab Assembly 2483
How to Install Operator Cab Assembly 2489
Remove and Install Operator Cab Glass (Adhered Glass) 2497
How to Remove Operator Cab Glass (Adhered Glass) 2497
How to Install Operator Cab Glass (Adhered Glass) 2498
Remove and Install Air Conditioner Unit Assembly 2503
How to Remove Air Conditioner Unit Assembly 2503
How to Install Air Conditioner Unit Assembly 2507
Remove and Install Operator Seat 2512
How to Remove Operator Seat 2512
How to Install Operator Seat 2514
How to Remove and Install Seat Belt 2516
How to Remove Seat Belt 2516
How to Install Seatbelt 2517
Electrical System 2518
Remove and Install Engine Controller Assembly 2518
How to Remove Engine Controller Assembly 2518
How to Install Engine Controller Assembly 2519
Remove and Install Power Train Controller Assembly 2523
How to Remove Power Train Controller Assembly 2523
How to Install Power Train Controller Assembly 2524
Remove and Install Machine Monitor Assembly 2526
How to Remove Machine Monitor Assembly 2526
How to Install Machine Monitor Assembly 2527
Remove and Install Mass Air Flow and Temperature Sensor 2529
How to Remove Mass Air Flow and Temperature Sensor 2529
How to Install Mass Air Flow and Temperature Sensor 2530
Remove and Install KCCV Crankcase Pressure Sensor 2532
How to Remove KCCV Crankcase Pressure Sensor 2532
How to Install KCCV Crankcase Pressure Sensor 2534
Remove and Install SCR Temperature Sensor 2536
How to Remove SCR Temperature Sensor 2536
How to Install SCR Temperature Sensor 2538
Remove and Install KOMTRAX Terminal Assembly 2540
How to Remove KOMTRAX Terminal Assembly 2540
How to Install KOMTRAX Terminal Assembly 2543
60 Maintenance Standard 2547
Table of Contents 2548
Engine and Cooling System 2550
Maintenance Standard for Engine Mount 2550
Maintenance Standard for Damper 2552
Maintenance Standard for Cooling System 2554
Maintenance Standard for Cooling Fan Pump 2556
Maintenance Standard for Servo Valve 2557
Maintenance Standard for Cooling Fan Motor 2558
Power Train 2560
Maintenance Standard for Universal Joint 2560
Maintenance Standard for Power Train Mount 2561
Maintenance Standard for Torque Converter and PTO 2562
Maintenance Standard for Transmission 2565
Maintenance Standard for Transmission ECMV 2570
Maintenance Standard for Main Relief Valve and Torque Converter Relief Valve 2571
Maintenance Standard for Transmission Lubrication Relief Valve 2572
Maintenance Standard for Bevel Gear Shaft, HSS, and Brake 2573
Maintenance Standard for Brake Valve 2577
Maintenance Standard for Final Drive 2579
Maintenance Standard for Sprocket for Conventional Type Track Shoes 2582
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for Conventional Type Track Shoes 2583
Maintenance Standard for Sprocket for PLUS Type Track Shoes 2585
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for PLUS Type Track Shoes 2586
Undercarriage and Frame 2588
Maintenance Standard for Main Frame 2588
Maintenance Standard for Suspension 2590
Maintenance Standard for Track Frame and Idler Cushion 2594
Maintenance Standard for Idler 2596
Maintenance Standard for Track Roller for Conventional Type Track Shoes (Single Flange Type) 2598
Maintenance Standard for Track Roller for Conventional Type Track Shoes (Double Flange Type) 2600
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Single Flange Type) 2602
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Double Flange Type) 2604
Maintenance Standard for Carrier Roller for Conventional Type Track Shoes 2606
Maintenance Standard for Carrier Roller for PLUS Type Track Shoes 2608
Maintenance Standard for Conventional Type Track Shoes 2610
Maintenance Standard for PLUS Type Track Shoes 2612
Maintenance Standard for Single Shoes and Heavy Duty Shoes 2614
Maintenance Standard for Swamp Shoes 2615
Hydraulic System 2616
Maintenance Standard for Hydraulic Tank 2616
Maintenance Standard for Scavenging Pump 2617
Maintenance Standard for Steering Lubrication Pump and Power Train Pump 2618
Maintenance Standard for Work Equipment and HSS Pump 2620
Maintenance Standard for HSS Motor 2621
Maintenance Standard for Control Valve 2623
Maintenance Standard for Blade PPC Valve 2630
Maintenance Standard for Ripper PPC Valve (Fixed Multi-Shank Ripper) 2632
Maintenance Standard for Ripper PPC Valve (Variable Multi-Shank Ripper) 2634
Maintenance Standard for Quick Drop Valve 2637
Maintenance Standard for Work Equipment Lock Solenoid Valve 2638
Work Equipment 2639
Maintenance Standard for Cylinder Stay 2639
Maintenance Standard for Front Work Equipment 2640
Maintenance Standard for Cutting Edge and End Bit (Straight Blade and Semi-U Blade 2644
Maintenance Standard for Cutting Edge and End Bit (SIGMA Blade) 2645
Maintenance Standard for Blade Lift Cylinder 2646
Maintenance Standard for Blade Tilt Cylinder 2647
Maintenance Standard for Blade Pitch Cylinder (For Power Tilt Pitch Dozer Series) 2648
Maintenance Standard for Fixed Multi-Shank Ripper 2649
Maintenance Standard for Variable Multi-Shank Ripper 2652
Maintenance Standard for Ripper Lift Cylinder (Fixed and Variable Multi-Shank Ripper) 2655
Maintenance Standard for Ripper Tilt Cylinder (Variable Multi-Shank Ripper) 2656
CAB Related Parts 2657
Maintenance Standard for CAB Mount 2657
80 Appendix 2659
Table of Contents 2660
Precautions Before Work 2662
Air Conditioner System 2663
Precautions for Refrigerant 2663
Air Conditioner Component 2664
Specifications of Air Conditioner 2666
Structure and Function of Refrigeration Cycle 2667
Outline of Refrigeration Cycle 2668
Component Parts of Air Conditioner System 2670
Air Conditioner Unit 2670
Configuration Diagram of Air Conditioner Unit 2670
Function of Air Conditioner Unit 2672
Component Parts of Air Conditioner Unit 2674
Function of Evaporator as Air Conditioner Unit Component 2675
Function of Heater Core as Air Conditioner Unit Component 2675
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component 2675
Function of Servo Motor as Air Conditioner Unit Component 2675
Structure of Expansion Valve as Air Conditioner Unit Component 2676
Function of Expansion Valve as Air Conditioner Unit Component 2676
Operate Expansion Valve as Air Conditioner Unit Component 2676
Function of Dual Pressure Switch 2677
Air Conditioner Controller 2678
Structure of Air Conditioner Controller 2678
Compressor 2679
Structure of Compressor 2679
Specifications of Compressor 2679
Function of Compressor 2679
Condenser 2680
Structure of Condenser 2680
Specifications of Condenser 2680
Function of Condenser 2680
Structure of Wide Core Condenser 2681
Specifications of Wide Core Condenser 2681
Function of Wide Core Condenser 2681
Receiver Drier 2682
Structure of Receiver Dryer 2682
Specifications of Receiver Dryer 2682
Function of Receiver Dryer 2682
Air Conditioner Related Sensors 2683
Structure of Sunlight Sensor 2683
Function of Sunlight Sensor 2683
Structure of Outside Temperature Sensor 2683
Function of Outside Air Temperature Sensor 2683
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 2685
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 2687
System Diagram of Air Conditioner 2689
Input and Output Signals of Air Conditioner Controller 2690
Function of Air Conditioner Controller 2691
Locations of Air Conditioner Parts and Layout of Connectors 2692
Examine Air Leakage (Duct) 2701
How to Examine Air Leakage (Duct) 2701
Explanation for Test of Air Conditioner with Self-Diagnosis Function 2704
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor 2705
Examine Vent (Mode) Changeover 2706
How to Examine Vent (Mode) Changeover 2706
Examine Fresh/Recirc Air Changeover 2707
How to Examine Fresh/Recirc Air Changeover 2707
Examine Sunlight Sensor 2708
How to Examine Sunlight Sensor 2708
Examine Refrigerant (Dual) Pressure Switch 2709
How to Examine Refrigerant (Dual) Pressure Switch 2709
Examine Relay 2710
How to Examine Relay 2710
Air Conditioner Troubleshooting Chart 1 2711
Air Conditioner Troubleshooting Chart 2 2712
Information Shown in Troubleshooting Table 2715
Failure Code [879AKA] 2716
Failure Code [879AKB] 2717
Failure Code [879BKA] 2718
Failure Code [879BKB] 2720
Failure Code [879CKA] 2722
Failure Code [879CKB] 2723
Failure Code [879DKZ] 2724
Failure Code [879EMC] 2726
Failure Code [879FMC] 2727
Failure Code [879GKX] 2728
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 2730
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 2732
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 2736
A-4 Troubleshooting for Fresh/Recirc Air Changeover 2738
Troubleshooting by Gauge Pressure 2740
Connect Service Tool 2743
How to Connect Service Tool 2743
Precautions for Disconnection and Connection of Air Conditioner Piping 2745
Handle Compressor Oil 2747
90 Circuit Diagrams 2749
Table of Contents 2750
Hydraulic Circuit Diagram 2751
Symbols Used in Hydraulic Circuit Diagram 2751
Hydraulic Circuit Diagram (For Power Tilt Pitch Dozer and Variable Multi-Shank Ripper) 2755
Hydraulic Circuit Diagram (For Power Tilt Pitch Dozer and Fixed Multi-Shank Ripper) 2757
Hydraulic Circuit Diagram (For Power Tilt Dozer and Variable Multi-Shank Ripper) 2759
Hydraulic Circuit Diagram (For Power Tilt Dozer and Fixed Multi-Shank Ripper) 2761
Hydraulic Circuit Diagram (For Power Tilt Dozer) 2763
Hydraulic Circuit Diagram (For Single Tilt Dozer and Fixed Multi-Shank Ripper) 2765
Power Train Hydraulic Circuit Diagram 2767
Electrical Circuit Diagram 2769
Symbols Used in Electric Circuit Diagram 2769
Electrical Circuit Diagram (1/13) 2773
Electrical Circuit Diagram (2/13) 2775
Electrical Circuit Diagram (3/13) 2777
Electrical Circuit Diagram (4/13) 2779
Electrical Circuit Diagram (5/13) 2781
Electrical Circuit Diagram (6/13) 2783
Electrical Circuit Diagram (7/13) 2785
Electrical Circuit Diagram (8/13) 2787
Electrical Circuit Diagram (9/13) 2789
Electrical Circuit Diagram (10/13) 2791
Electrical Circuit Diagram (11/13) 2793
Electrical Circuit Diagram (12/13) 2795
Electrical Circuit Diagram (13/13) 2797
Index 2799

IMAGES PREVIEW OF THE MANUAL:

S.V 27/12/24