Komatsu D85EX-18E0 D85PX-18E0 Bulldozer Shop Manual PDF

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Komatsu D85EX-18E0 D85PX-18E0 Bulldozer Shop Manual SEN06909-02 – PDF DOWNLOAD

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Komatsu D85EX-18E0 D85PX-18E0 Bulldozer Shop Manual SEN06909-02 – PDF DOWNLOAD 

Language : English
Pages : 2832
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Komatsu D85EX-18E0 D85PX-18E0 Bulldozer Shop Manual SEN06909-02 – PDF DOWNLOAD 

SERIAL NUMBERS 25001 and up

COVER 1
00 INDEX AND FOREWORD 3
INDEX 4
FOREWORD, SAFETY, BASIC INFORMATION 22
HOW TO READ THE SHOP MANUAL 22
SAFETY NOTICE FOR OPERATION 24
PRECAUTIONS TO PREVENT FIRE 32
ACTIONS IF FIRE OCCURS 34
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 35
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 36
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 39
PRECAUTIONS WHEN YOU HANDLE ELECTRICAL EQUIPMENT 45
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 47
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 48
PRACTICAL USE OF KOMTRAX 49
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 50
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 50
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 51
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 52
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 54
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 58
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 59
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 61
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 62
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 64
HOW TO READ ELECTRICAL WIRE CODE 65
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 69
STANDARD TIGHTENING TORQUE TABLE 72
CONVERSION TABLE 79
ABBREVIATION LIST 84
01 SPECIFICATIONS 87
CONTENTS 88
SPECIFICATIONS 89
SPECIFICATION DRAWING 89
SPECIFICATION DRAWING: D85EX-18E0 89
SPECIFICATION DRAWING: D85PX-18E0 91
SPECIFICATIONS 93
SPECIFICATIONS: D85EX-18E0 93
SPECIFICATIONS: D85PX-18E0 100
WEIGHT TABLE 105
WEIGHT TABLE: D85EX-18E0 105
WEIGHT TABLE: D85PX-18E0 108
FUEL, COOLANT, LUBRICANT 111
USE FUEL, COOLANT AND LUBRICANT TO MEET AMBIENT TEMPERATURE 111
10 STRUCTURE AND FUNCTION 113
CONTENTS 114
UREA SCR SYSTEM 117
LAYOUT DRAWING OF UREA SCR SYSTEM 117
UREA SCR SYSTEM DIAGRAM 120
FUNCTION OF UREA SCR SYSTEM 121
FUNCTION OF AdBlue/DEF SYSTEM 121
INDUCEMENT STRATEGY 123
COMPONENT PARTS OF UREA SCR SYSTEM 138
AdBlue/DEF MIXING TUBE 138
SCR ASSEMBLY 138
AdBlue/DEF TANK 141
AdBlue/DEF PUMP 143
AdBlue/DEF INJECTOR 144
AdBlue/DEF HOSE 145
AdBlue/DEF TANK HEATING VALVE 146
BOOT-UP SYSTEM 147
LAYOUT DRAWING OF BOOT-UP SYSTEM 147
SYSTEM OPERATING LAMP SYSTEM 148
SYSTEM DIAGRAM OF SYSTEM OPERATING LAMP SYSTEM 148
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 148
BATTERY DISCONNECT SWITCH 149
LAYOUT DRAWING OF BATTERY DISCONNECT SWITCH 149
FUNCTION OF BATTERY DISCONNECT SWITCH 149
ENGINE SYSTEM 151
LAYOUT DRAWING OF ENGINE SYSTEM 151
ENGINE CONTROL SYSTEM 153
LAYOUT DRAWING OF ENGINE CONTROL SYSTEM 153
SYSTEM DIAGRAM OF ENGINE CONTROL SYSTEM 154
FUNCTION OF ENGINE CONTROL SYSTEM 156
AUTOMATIC IDLE STOP SYSTEM 158
SYSTEM DIAGRAM OF AUTOMATIC IDLE STOP SYSTEM 158
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 158
COMPONENT PARTS OF ENGINE SYSTEM 161
DAMPER 161
VGT 162
EGR SYSTEM 166
EGR VALVE 168
EGR COOLER 170
KCCV SYSTEM 171
KCCV VENTILATOR 173
KDPF 175
COOLING SYSTEM 180
LAYOUT DRAWING OF COOLING SYSTEM 180
SPECIFICATIONS OF COOLING SYSTEM 181
COOLING FAN CONTROL SYSTEM 182
COOLING FAN CONTROL SYSTEM DIAGRAM 182
FUNCTION OF COOLING FAN CONTROL SYSTEM 183
COMPONENT PARTS OF COOLING SYSTEM 185
COOLING FAN PUMP 185
COOLING FAN MOTOR 194
HYDRAULIC OIL COOLER BYPASS VALVE 201
CONTROL SYSTEM 202
LAYOUT DRAWING OF CONTROL SYSTEM 202
MACHINE MONITOR SYSTEM 203
SYSTEM DIAGRAM OF MACHINE MONITOR 203
FUNCTION OF MACHINE MONITOR SYSTEM 203
KOMTRAX SYSTEM 205
KOMTRAX SYSTEM DIAGRAM 205
FUNCTION OF KOMTRAX SYSTEM 205
COMPONENT PARTS OF CONTROL SYSTEM 206
MACHINE MONITOR 206
GATEWAY FUNCTION CONTROLLER 221
COMMUNICATION TERMINAL 224
POWER TRAIN CONTROLLER 226
ENGINE CONTROLLER 230
FUEL FEED PUMP 236
FUEL FEED PUMP SWITCH 237
HYDRAULIC SYSTEM 238
LAYOUT DRAWING OF HYDRAULIC SYSTEM 238
CLSS 239
STRUCTURE OF CLSS 239
FUNCTION OF CLSS 240
COMPONENT PARTS OF HYDRAULIC SYSTEM 242
HYDRAULIC TANK 242
WORK EQUIPMENT AND HSS PUMP 243
LS VALVE 249
TVC VALVE 253
VARIABLE THROTTLE VALVE 257
CONTROL VALVE 259
POWER TRAIN SYSTEM 293
LAYOUT DRAWING OF POWER TRAIN SYSTEM 293
OPERATION OF POWER TRAIN SYSTEM 295
TRANSMISSION, STEERING, AND BRAKE CONTROL 296
LAYOUT DRAWING OF TRANSMISSION, STEERING, AND BRAKE CONTROL SYSTEM 296
FUNCTION OF TRANSMISSION, STEERING, AND BRAKE CONTROL 297
PALM COMMAND CONTROL SYSTEM 299
PALM COMMAND CONTROL SYSTEM DIAGRAM 299
HSS SYSTEM 303
HSS SYSTEM DIAGRAM 303
FUNCTION OF HSS SYSTEM 304
CENTRALIZED PRESSURE PICKUP PORT 306
LAYOUT OF CENTRALIZED PRESSURE PICKUP PORT 306
FUNCTION OF CENTRALIZED PRESSURE PICKUP PORT 307
COMPONENT PARTS OF POWER TRAIN SYSTEM 308
UNIVERSAL JOINT 308
POWER TRAIN MOUNT 309
TORQUE CONVERTER AND PTO 310
TRANSMISSION 313
TRANSMISSION ECMV 323
MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE 329
TRANSMISSION LUBRICATION RELIEF VALVE 331
BEVEL GEAR SHAFT, HSS, AND BRAKE 331
BRAKE VALVE 351
FINAL DRIVE 354
SCAVENGING PUMP 358
STEERING LUBRICATION PUMP AND POWER TRAIN PUMP 359
HSS MOTOR 360
ELECTRIC STEERING CONTROL LEVER 366
WORK EQUIPMENT SYSTEM 369
WORK EQUIPMENT CONTROL 369
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM 369
FUNCTION OF WORK EQUIPMENT CONTROL 370
LAYOUT DRAWING OF FRONT WORK EQUIPMENT 372
LAYOUT OF FIXED MULTI-SHANK RIPPER 373
LAYOUT OF VARIABLE MULTI-SHANK RIPPER 374
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 375
SELF-PRESSURE REDUCING VALVE 375
WORK EQUIPMENT LOCK SOLENOID VALVE 381
BLADE PPC VALVE 382
RIPPER PPC VALVE 388
BLADE PITCH SELECTOR SOLENOID VALVE 392
PILOT CIRCUIT ACCUMULATOR 394
QUICK DROP VALVE 395
PISTON VALVE 396
UNDERCARRIAGE AND FRAME 398
MAIN FRAME 398
STRUCTURE OF MAIN FRAME 398
SUSPENSION 399
STRUCTURE OF SUSPENSION 399
FUNCTION OF SUSPENSION 402
TRACK FRAME AND IDLER CUSHION 403
STRUCTURE OF TRACK FRAME AND IDLER CUSHION 403
FUNCTION OF TRACK FRAME AND IDLER CUSHION 404
WORK EQUIPMENT 405
STRUCTURE OF FRONT WORK EQUIPMENT 405
STRUCTURE OF CYLINDER STAY 407
STRUCTURE OF FIXED MULTI-SHANK RIPPER 408
STRUCTURE OF VARIABLE MULTI-SHANK RIPPER 409
CAB AND ITS ATTACHMENTS 410
ROPS CAB 410
STRUCTURE OF ROPS CAB 410
FUNCTION OF ROPS CAB 411
CAB MOUNT 412
STRUCTURE OF CAB MOUNT 412
FUNCTION OF CAB MOUNT 412
20 STANDARD VALUE TABLE 413
CONTENTS 414
STANDARD VALUE TABLE FOR ENGINE 415
STANDARD VALUE TABLE FOR ENGINE: D85EX-18E0 415
STANDARD VALUE TABLE FOR ENGINE: D85PX-18E0 418
STANDARD VALUE TABLE FOR MACHINE 421
STANDARD VALUE TABLE FOR MACHINE: D85EX-18E0 421
STANDARD VALUE TABLE FOR MACHINE: D85PX-18E0 438
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 453
30 TESTING AND ADJUSTING 457
CONTENTS 458
RELATED INFORMATION ON TESTING AND ADJUSTING 461
TOOLS FOR TESTING AND ADJUSTING 461
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 468
ENGINE AND COOLING SYSTEM 469
TEST ENGINE SPEED 469
METHOD FOR TESTING ENGINE SPEED 469
TEST BOOST PRESSURE 473
METHOD FOR TESTING BOOST PRESSURE 473
TEST EXHAUST GAS TEMPERATURE 475
METHOD FOR TESTING EXHAUST GAS TEMPERATURE 475
TEST EXHAUST GAS COLOR 477
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 477
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 478
TEST AND ADJUST VALVE CLEARANCE 480
METHOD FOR TESTING VALVE CLEARANCE 480
METHOD FOR ADJUSTING VALVE CLEARANCE 481
TEST COMPRESSION PRESSURE 482
METHOD FOR TESTING COMPRESSION PRESSURE 482
TEST BLOWBY PRESSURE 486
METHOD FOR TESTING BLOWBY PRESSURE 486
TEST ENGINE OIL PRESSURE 489
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR 489
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL 489
TEST EGR VALVE AND KVGT OIL PRESSURE 491
METHOD FOR TESTING EGR VALVE AND KVGT OIL PRESSURE 491
TEST FUEL PRESSURE 493
METHOD FOR TESTING FUEL PRESSURE 493
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 495
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE 496
BLEED AIR FROM FUEL SYSTEM 499
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 500
TEST FUEL CIRCUIT FOR LEAKAGE 501
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 501
HANDLE CYLINDER CUT-OUT MODE OPERATION 503
HANDLE NO-INJECTION CRANKING OPERATION 504
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 505
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT TENSION 505
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 505
CLEAN FUEL DOSER 507
METHOD FOR CLEANING FUEL DOSER 507
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 510
METHOD FOR WRITING INJECTOR COMPENSATION VALUE 510
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 516
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 516
TEST SCR RELATED FUNCTIONS 517
TEST AdBlue/DEF PUMP RAISED PRESSURE 520
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 523
TEST AdBlue/DEF LINE HEATER RELAY 1 527
TEST AdBlue/DEF LINE HEATER RELAY 2 529
TEST AdBlue/DEF PUMP HEATER RELAY 532
TEST AdBlue/DEF TANK HEATER VALVE 535
TEST DENITRATION EFFICIENCY OF SCR 537
CLEAN AdBlue/DEF TANK 541
METHOD FOR CLEANING AdBlue/DEF TANK 541
CLEAN AdBlue/DEF PUMP 545
METHOD FOR CLEAN AdBlue/DEF PUMP 545
CLEAN AdBlue/DEF TANK MOUNTING PORTION 552
METHOD FOR CLEANING AdBlue/DEF TANK MOUNTING PORTION 552
ADJUST DECELERATOR PEDAL 553
METHOD FOR ADJUSTING DECELERATOR PEDAL 553
POWER TRAIN 555
TEST POWER TRAIN OIL PRESSURE 555
METHOD FOR TESTING POWER TRAIN OIL PRESSURE 556
ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR 567
METHOD FOR ADJUSTING TRANSMISSION OUTPUT SHAFT SPEED SENSOR 567
TEST BRAKE PERFORMANCE SIMPLY 569
METHOD FOR TESTING BRAKE PERFORMANCE SIMPLY 569
ADJUST BRAKE PEDAL 570
METHOD FOR ADJUSTING BRAKE PEDAL 570
ADJUST PARKING BRAKE LEVER 572
METHOD FOR ADJUSTING PARKING BRAKE LEVER 572
MOVE MACHINE BY RELEASING PARKING BRAKE WHEN MACHINE DOES NOT TRAVEL 574
METHOD FOR MOVING MACHINE WITH HYDRAULIC TYPE PARKING BRAKE RELEASE SYSTEM 574
METHOD FOR MOVING MACHINE WITH ELECTRIC TYPE PARKING BRAKE RELEASE SYSTEM 575
UNDERCARRIAGE AND FRAME 577
ADJUST IDLER CLEARANCE 577
METHOD FOR ADJUSTING IDLER CLEARANCE 577
METHOD FOR ADJUSTING IDLER CLEARANCE HORIZONTALLY 577
METHOD FOR ADJUSTING IDLER CLEARANCE VERTICALLY 577
TEST AND ADJUST TRACK TENSION 579
METHOD OF CHECKING 579
METHOD FOR ADJUSTING TRACK TENSION 579
HYDRAULIC SYSTEM 580
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 580
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 580
TEST AND ADJUST WORK EQUIPMENT AND HSS OIL PRESSURES 581
METHOD FOR TESTING WORK EQUIPMENT AND HSS OIL PRESSURES 581
METHOD FOR ADJUSTING WORK EQUIPMENT AND HSS OIL PRESSURES 585
TEST OIL PRESSURE OF CONTROL CIRCUIT 586
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 586
TEST PPC VALVE OUTPUT PRESSURE 588
METHOD FOR TESTING PPC VALVE OUTPUT PRESSURE 588
BLEED AIR FROM HSS PUMP 591
METHOD FOR BLEEDING AIR FROM HSS PUMP 591
TEST AND ADJUST PLAY OF WORK EQUIPMENT PPC VALVE 592
METHOD FOR TESTING PLAY OF WORK EQUIPMENT PPC VALVE 592
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT PPC VALVE 593
TEST COOLING FAN SPEED 594
METHOD FOR TESTING COOLING FAN SPEED 594
TEST COOLING FAN CIRCUIT OIL PRESSURE 595
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE 595
BLEED AIR FROM COOLING FAN PUMP 597
METHOD FOR BLEEDING AIR FROM COOLING FAN PUMP 597
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 598
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE LIFT CYLINDER 598
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE TILT CYLINDER 598
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF RIPPER LIFT CYLINDER 599
TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER 600
METHOD FOR TESTING INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER 600
BLEED AIR FROM WORK EQUIPMENT CYLINDERS 602
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT CYLINDERS 602
WORK EQUIPMENT 603
ADJUST WORK EQUIPMENT LOCK LEVER 603
METHOD FOR ADJUSTING WORK EQUIPMENT LOCK LEVER 603
CAB AND ITS ATTACHMENTS 605
TEST AND ADJUST OPERATOR’S CAB 605
METHOD FOR TESTING OPERATOR’S CAB 605
METHOD FOR ADJUSTING OPERATOR’S CAB 607
ELECTRICAL SYSTEM 610
SET AND OPERATE MACHINE MONITOR 610
OPERATOR MODE 613
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 613
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 614
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 614
CHECKING FUNCTION OF SERVICE METER 615
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD 615
SERVICE MODE 617
METHOD FOR OPERATING SERVICE MODE 617
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 619
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 624
ABNORMALITY RECORD MENU 634
METHOD FOR CONFIRMING MAINTENANCE RECORD 638
METHOD FOR OPERATING MAINTENANCE MODE SETTING 639
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 643
DEFAULT MENU 644
DIAGNOSTIC TESTS MENU 652
ADJUSTMENT MENU 661
METHOD FOR PERFORMING NO-INJECTION CRANKING 688
KOMTRAX SETTINGS MENU 689
METHOD FOR DISPLAYING SERVICE MESSAGE 692
START UP KOMTRAX SYSTEM 694
STOP USING OF KOMTRAX SYSTEM 699
ADJUST WHEN POWER TRAIN CONTROLLER IS REPLACED 701
METHOD FOR ADJUSTING WHEN POWER TRAIN CONTROLLER IS REPLACED 701
ADJUST REARVIEW CAMERA ANGLE 704
ADJUST REARVIEW CAMERA ANGLE 704
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 705
HANDLE BATTERY DISCONNECT SWITCH 706
TEST DIODES 707
METHOD FOR TESTING DIODE USING DIGITAL TESTER 707
METHOD FOR TESTING DIODE USING ANALOG TESTER 707
Pm CLINIC 708
Pm CLINIC SERVICE 708
Pm CLINIC CHECK SHEET: D85EX-18E0 709
Pm CLINIC CHECK SHEET: D85PX-18E0 723
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D85EX-18E0 734
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D85PX-18E0 738
40 TROUBLESHOOTING 743
CONTENTS 744
RELATED INFORMATION ON TROUBLESHOOTING 754
GENERAL TROUBLESHOOTING POINTS 754
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 755
SEQUENCE OF EVENTS IN TROUBLESHOOTING 770
CHECKS BEFORE TROUBLESHOOTING 772
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 774
WALK-AROUND CHECK 774
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 776
METHOD FOR CHECKING ELECTRIC EQUIPMENT 776
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 782
PROCEDURE FOR TROUBLESHOOTING 790
SYMPTOM AND TROUBLESHOOTING NUMBERS 793
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 796
CONNECTORS LIST AND LAYOUT 798
CONNECTOR CONTACT IDENTIFICATION 813
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 853
FUSE LOCATION TABLE 859
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 862
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 866
FAILURE CODES TABLE 868
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 887
FAILURE CODE [1500L0] 887
FAILURE CODE [15SAL1] 888
FAILURE CODE [15SALH] 890
FAILURE CODE [15SBL1] 892
FAILURE CODE [15SBLH] 894
FAILURE CODE [15SEL1] 896
FAILURE CODE [15SELH] 898
FAILURE CODE [15SFL1] 900
FAILURE CODE [15SFLH] 902
FAILURE CODE [15SGL1] 904
FAILURE CODE [15SGLH] 906
FAILURE CODE [1800MW] 908
FAILURE CODE [879AKA] 909
FAILURE CODE [879AKB] 910
FAILURE CODE [879BKA] 911
FAILURE CODE [879BKB] 913
FAILURE CODE [879CKA] 915
FAILURE CODE [879CKB] 916
FAILURE CODE [879DKZ] 917
FAILURE CODE [879EMC] 919
FAILURE CODE [879FMC] 920
FAILURE CODE [879GKX] 921
FAILURE CODE [989L00] 923
FAILURE CODE [989M00] 924
FAILURE CODE [989N00] 925
FAILURE CODE [A1U0N3] 926
FAILURE CODE [A1U0N4] 928
FAILURE CODE [A900FR] 930
FAILURE CODE [A900N6] 931
FAILURE CODE [A900NY] 932
FAILURE CODE [AA10NX] 933
FAILURE CODE [AB00KE] 935
FAILURE CODE [AQ10N3] 937
FAILURE CODE [AS00N3] 939
FAILURE CODE [AS00R2] 941
FAILURE CODE [AS00R3] 942
FAILURE CODE [AS00R4] 943
FAILURE CODE [AS00R5] 944
FAILURE CODE [AS00R6] 945
FAILURE CODE [AS00ZK] 946
FAILURE CODE [AS10KM] 947
FAILURE CODE [AS10NR] 948
FAILURE CODE [AS10NT] 949
FAILURE CODE [B@BAZG] 950
FAILURE CODE [B@BCNS] 951
FAILURE CODE [B@BCZK] 952
FAILURE CODE [B@CENS] 954
FAILURE CODE [B@HANS] 955
FAILURE CODE [CA115] 956
FAILURE CODE [CA122] 957
FAILURE CODE [CA123] 959
FAILURE CODE [CA131] 961
FAILURE CODE [CA132] 963
FAILURE CODE [CA135] 965
FAILURE CODE [CA141] 967
FAILURE CODE [CA144] 969
FAILURE CODE [CA145] 971
FAILURE CODE [CA153] 973
FAILURE CODE [CA154] 976
FAILURE CODE [CA187] 979
FAILURE CODE [CA221] 981
FAILURE CODE [CA222] 983
FAILURE CODE [CA227] 985
FAILURE CODE [CA234] 986
FAILURE CODE [CA238] 987
FAILURE CODE [CA239] 989
FAILURE CODE [CA249] 991
FAILURE CODE [CA256] 993
FAILURE CODE [CA271] 995
FAILURE CODE [CA272] 997
FAILURE CODE [CA273] 998
FAILURE CODE [CA274] 1000
FAILURE CODE [CA322] 1001
FAILURE CODE [CA323] 1003
FAILURE CODE [CA324] 1005
FAILURE CODE [CA325] 1007
FAILURE CODE [CA331] 1009
FAILURE CODE [CA332] 1011
FAILURE CODE [CA343] 1013
FAILURE CODE [CA351] 1014
FAILURE CODE [CA352] 1015
FAILURE CODE [CA356] 1018
FAILURE CODE [CA357] 1020
FAILURE CODE [CA386] 1022
FAILURE CODE [CA441] 1023
FAILURE CODE [CA442] 1026
FAILURE CODE [CA449] 1027
FAILURE CODE [CA451] 1028
FAILURE CODE [CA452] 1030
FAILURE CODE [CA515] 1032
FAILURE CODE [CA516] 1034
FAILURE CODE [CA553] 1036
FAILURE CODE [CA555] 1037
FAILURE CODE [CA556] 1038
FAILURE CODE [CA559] 1039
FAILURE CODE [CA595] 1044
FAILURE CODE [CA687] 1045
FAILURE CODE [CA689] 1047
FAILURE CODE [CA691] 1049
FAILURE CODE [CA692] 1051
FAILURE CODE [CA697] 1053
FAILURE CODE [CA698] 1054
FAILURE CODE [CA731] 1055
FAILURE CODE [CA778] 1056
FAILURE CODE [CA1117] 1059
FAILURE CODE [CA1664] 1060
FAILURE CODE [CA1669] 1063
FAILURE CODE [CA1673] 1064
FAILURE CODE [CA1677] 1065
FAILURE CODE [CA1678] 1066
FAILURE CODE [CA1682] 1067
FAILURE CODE [CA1683] 1070
FAILURE CODE [CA1684] 1072
FAILURE CODE [CA1686] 1074
FAILURE CODE [CA1691] 1075
FAILURE CODE [CA1694] 1078
FAILURE CODE [CA1695] 1080
FAILURE CODE [CA1696] 1081
FAILURE CODE [CA1712] 1083
FAILURE CODE [CA1713] 1086
FAILURE CODE [CA1714] 1088
FAILURE CODE [CA1715] 1089
FAILURE CODE [CA1776] 1090
FAILURE CODE [CA1777] 1093
FAILURE CODE [CA1843] 1096
FAILURE CODE [CA1844] 1098
FAILURE CODE [CA1879] 1101
FAILURE CODE [CA1881] 1104
FAILURE CODE [CA1883] 1107
FAILURE CODE [CA1885] 1111
FAILURE CODE [CA1887] 1113
FAILURE CODE [CA1921] 1115
FAILURE CODE [CA1922] 1118
FAILURE CODE [CA1923] 1123
FAILURE CODE [CA1924] 1125
FAILURE CODE [CA1925] 1127
FAILURE CODE [CA1927] 1129
FAILURE CODE [CA1928] 1131
FAILURE CODE [CA1942] 1133
FAILURE CODE [CA1963] 1134
FAILURE CODE [CA1977] 1137
FAILURE CODE [CA1993] 1140
FAILURE CODE [CA2185] 1143
FAILURE CODE [CA2186] 1144
FAILURE CODE [CA2249] 1146
FAILURE CODE [CA2265] 1147
FAILURE CODE [CA2266] 1149
FAILURE CODE [CA2271] 1152
FAILURE CODE [CA2272] 1154
FAILURE CODE [CA2349] 1156
FAILURE CODE [CA2353] 1158
FAILURE CODE [CA2357] 1160
FAILURE CODE [CA2381] 1161
FAILURE CODE [CA2382] 1163
FAILURE CODE [CA2383] 1165
FAILURE CODE [CA2386] 1167
FAILURE CODE [CA2387] 1169
FAILURE CODE [CA2555] 1170
FAILURE CODE [CA2556] 1173
FAILURE CODE [CA2637] 1175
FAILURE CODE [CA2639] 1177
FAILURE CODE [CA2732] 1180
FAILURE CODE [CA2733] 1182
FAILURE CODE [CA2741] 1184
FAILURE CODE [CA2765] 1185
FAILURE CODE [CA2771] 1186
FAILURE CODE [CA2777] 1192
FAILURE CODE [CA2878] 1195
FAILURE CODE [CA2881] 1198
FAILURE CODE [CA2976] 1201
FAILURE CODE [CA3133] 1203
FAILURE CODE [CA3134] 1205
FAILURE CODE [CA3135] 1207
FAILURE CODE [CA3142] 1211
FAILURE CODE [CA3143] 1212
FAILURE CODE [CA3144] 1213
FAILURE CODE [CA3146] 1215
FAILURE CODE [CA3147] 1216
FAILURE CODE [CA3148] 1217
FAILURE CODE [CA3151] 1219
FAILURE CODE [CA3165] 1225
FAILURE CODE [CA3167] 1227
FAILURE CODE [CA3229] 1230
FAILURE CODE [CA3231] 1232
FAILURE CODE [CA3232] 1234
FAILURE CODE [CA3235] 1238
FAILURE CODE [CA3239] 1240
FAILURE CODE [CA3241] 1243
FAILURE CODE [CA3242] 1246
FAILURE CODE [CA3251] 1249
FAILURE CODE [CA3253] 1252
FAILURE CODE [CA3254] 1256
FAILURE CODE [CA3255] 1259
FAILURE CODE [CA3256] 1263
FAILURE CODE [CA3311] 1265
FAILURE CODE [CA3312] 1267
FAILURE CODE [CA3313] 1270
FAILURE CODE [CA3314] 1271
FAILURE CODE [CA3315] 1272
FAILURE CODE [CA3316] 1275
FAILURE CODE [CA3317] 1276
FAILURE CODE [CA3318] 1277
FAILURE CODE [CA3319] 1280
FAILURE CODE [CA3321] 1281
FAILURE CODE [CA3322] 1283
FAILURE CODE [CA3419] 1286
FAILURE CODE [CA3421] 1288
FAILURE CODE [CA3497] 1290
FAILURE CODE [CA3498] 1291
FAILURE CODE [CA3543] 1292
FAILURE CODE [CA3545] 1299
FAILURE CODE [CA3547] 1301
FAILURE CODE [CA3558] 1302
FAILURE CODE [CA3559] 1304
FAILURE CODE [CA3562] 1306
FAILURE CODE [CA3563] 1308
FAILURE CODE [CA3567] 1311
FAILURE CODE [CA3568] 1314
FAILURE CODE [CA3571] 1318
FAILURE CODE [CA3572] 1320
FAILURE CODE [CA3574] 1322
FAILURE CODE [CA3575] 1324
FAILURE CODE [CA3577] 1326
FAILURE CODE [CA3578] 1328
FAILURE CODE [CA3582] 1330
FAILURE CODE [CA3583] 1337
FAILURE CODE [CA3596] 1339
FAILURE CODE [CA3649] 1341
FAILURE CODE [CA3681] 1343
FAILURE CODE [CA3682] 1348
FAILURE CODE [CA3713] 1354
FAILURE CODE [CA3717] 1357
FAILURE CODE [CA3718] 1358
FAILURE CODE [CA3725] 1359
FAILURE CODE [CA3748] 1362
FAILURE CODE [CA3751] 1365
FAILURE CODE [CA3755] 1367
FAILURE CODE [CA3866] 1369
FAILURE CODE [CA3867] 1373
FAILURE CODE [CA3868] 1376
FAILURE CODE [CA3899] 1380
FAILURE CODE [CA3911] 1382
FAILURE CODE [CA3912] 1386
FAILURE CODE [CA3932] 1388
FAILURE CODE [CA3933] 1390
FAILURE CODE [CA3934] 1392
FAILURE CODE [CA3935] 1395
FAILURE CODE [CA3936] 1397
FAILURE CODE [CA4151] 1399
FAILURE CODE [CA4152] 1403
FAILURE CODE [CA4155] 1407
FAILURE CODE [CA4156] 1409
FAILURE CODE [CA4157] 1412
FAILURE CODE [CA4158] 1414
FAILURE CODE [CA4159] 1415
FAILURE CODE [CA4161] 1416
FAILURE CODE [CA4162] 1419
FAILURE CODE [CA4163] 1422
FAILURE CODE [CA4164] 1424
FAILURE CODE [CA4165] 1426
FAILURE CODE [CA4166] 1428
FAILURE CODE [CA4168] 1430
FAILURE CODE [CA4169] 1433
FAILURE CODE [CA4171] 1435
FAILURE CODE [CA4249] 1438
FAILURE CODE [CA4251] 1440
FAILURE CODE [CA4259] 1442
FAILURE CODE [CA4261] 1445
FAILURE CODE [CA4277] 1447
FAILURE CODE [CA4281] 1451
FAILURE CODE [CA4459] 1455
FAILURE CODE [CA4461] 1458
FAILURE CODE [CA4658] 1461
FAILURE CODE [CA4731] 1465
FAILURE CODE [CA4732] 1466
FAILURE CODE [CA4739] 1467
FAILURE CODE [CA4768] 1468
FAILURE CODE [CA4769] 1470
FAILURE CODE [CA4842] 1473
FAILURE CODE [CA4952] 1477
FAILURE CODE [CA5115] 1479
FAILURE CODE [CA5383] 1482
FAILURE CODE [D130KA] 1484
FAILURE CODE [D130KB] 1487
FAILURE CODE [D19DKA] 1489
FAILURE CODE [D19DKB] 1491
FAILURE CODE [D19JKZ] 1493
FAILURE CODE [D811MC] 1496
FAILURE CODE [D862KA] 1497
FAILURE CODE [D8ALKA] 1498
FAILURE CODE [D8ALKB] 1500
FAILURE CODE [D8AQKR] 1502
FAILURE CODE [D8ARKR] 1505
FAILURE CODE [D8G1KT] 1508
FAILURE CODE [D8G6KT] 1509
FAILURE CODE [DAF0MB] 1510
FAILURE CODE [DAF0MC] 1511
FAILURE CODE [DAF8KB] 1512
FAILURE CODE [DAF9KQ] 1513
FAILURE CODE [DAFGMC] 1514
FAILURE CODE [DAFLKA] 1515
FAILURE CODE [DAFLKB] 1517
FAILURE CODE [DAFQKR] 1519
FAILURE CODE [DAQW00] 1520
FAILURE CODE [DAZ9KQ] 1521
FAILURE CODE [DAZQKR] 1522
FAILURE CODE [DB2QKR] 1523
FAILURE CODE [DB2RKR] 1530
FAILURE CODE [DBE0KT] 1537
FAILURE CODE [DBE0MC] 1538
FAILURE CODE [DBE1KK] 1539
FAILURE CODE [DBE2KK] 1542
FAILURE CODE [DBE5KK] 1544
FAILURE CODE [DBE6KK] 1546
FAILURE CODE [DBE7KK] 1548
FAILURE CODE [DBE9KQ] 1550
FAILURE CODE [DBELKA] 1551
FAILURE CODE [DBELKB] 1553
FAILURE CODE [DBEQKR] 1555
FAILURE CODE [DBERKR] 1556
FAILURE CODE [DD12KA] 1559
FAILURE CODE [DD12KB] 1561
FAILURE CODE [DD13KA] 1563
FAILURE CODE [DD13KB] 1565
FAILURE CODE [DD14KA] 1567
FAILURE CODE [DD14KB] 1569
FAILURE CODE [DDKHKA] 1571
FAILURE CODE [DDKHKB] 1573
FAILURE CODE [DDN7KA] 1575
FAILURE CODE [DDN7KB] 1577
FAILURE CODE [DDNLKA] 1579
FAILURE CODE [DDNLKB] 1581
FAILURE CODE [DGS1KA] 1583
FAILURE CODE [DGS1KX] 1585
FAILURE CODE [DGT1KA] 1587
FAILURE CODE [DGT1KX] 1590
FAILURE CODE [DH21KA] 1592
FAILURE CODE [DH21KY] 1594
FAILURE CODE [DHA4KA] 1596
FAILURE CODE [DHAAMA] 1598
FAILURE CODE [DHACMA] 1600
FAILURE CODE [DK10KA] 1602
FAILURE CODE [DK10KB] 1605
FAILURE CODE [DK30KA] 1607
FAILURE CODE [DK30KX] 1610
FAILURE CODE [DK30KY] 1611
FAILURE CODE [DK30KZ] 1613
FAILURE CODE [DK30L8] 1614
FAILURE CODE [DK31KA] 1615
FAILURE CODE [DK31KY] 1618
FAILURE CODE [DK40KA] 1620
FAILURE CODE [DK40KY] 1622
FAILURE CODE [DK55KX] 1624
FAILURE CODE [DK55KZ] 1625
FAILURE CODE [DK55L8] 1626
FAILURE CODE [DK56KA] 1627
FAILURE CODE [DK56KY] 1629
FAILURE CODE [DK57KA] 1631
FAILURE CODE [DK57KY] 1633
FAILURE CODE [DKH1KA] 1635
FAILURE CODE [DKH1KY] 1638
FAILURE CODE [DLM3KA] 1640
FAILURE CODE [DLM3KB] 1642
FAILURE CODE [DLM3MB] 1643
FAILURE CODE [DLT3KA] 1644
FAILURE CODE [DLT3KB] 1646
FAILURE CODE [DR21KX] 1648
FAILURE CODE [DR31KX] 1649
FAILURE CODE [DV20KB] 1650
FAILURE CODE [DW5AKA] 1652
FAILURE CODE [DW5AKB] 1654
FAILURE CODE [DW5AKY] 1656
FAILURE CODE [DW7BKA] 1658
FAILURE CODE [DW7BKB] 1660
FAILURE CODE [DW7BKY] 1662
FAILURE CODE [DWN1KA] 1663
FAILURE CODE [DWN1KB] 1665
FAILURE CODE [DWN1KY] 1667
FAILURE CODE [DWN2KA] 1669
FAILURE CODE [DWN2KB] 1671
FAILURE CODE [DWN2KY] 1673
FAILURE CODE [DWN5KA] 1674
FAILURE CODE [DWN5KB] 1676
FAILURE CODE [DWN5KY] 1677
FAILURE CODE [DXA2KA] 1679
FAILURE CODE [DXA2KB] 1681
FAILURE CODE [DXA2KY] 1683
FAILURE CODE [DXH4KA] 1684
FAILURE CODE [DXH4KB] 1686
FAILURE CODE [DXH4KY] 1688
FAILURE CODE [DXH5KA] 1690
FAILURE CODE [DXH5KB] 1692
FAILURE CODE [DXH5KY] 1693
FAILURE CODE [DXH6KA] 1694
FAILURE CODE [DXH6KB] 1696
FAILURE CODE [DXH6KY] 1698
FAILURE CODE [DXH7KA] 1700
FAILURE CODE [DXH7KB] 1702
FAILURE CODE [DXH7KY] 1704
FAILURE CODE [DXH8KA] 1706
FAILURE CODE [DXH8KB] 1708
FAILURE CODE [DXH8KY] 1710
FAILURE CODE [DXJ4KA] 1712
FAILURE CODE [DXJ4KB] 1714
FAILURE CODE [F313KA] 1716
FAILURE CODE [F313KB] 1717
FAILURE CODE [F318KB] 1718
FAILURE CODE [F318KY] 1719
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 WORK 1727
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 1730
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 1732
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING 1734
E-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), BASIC CHECK MONITOR LIGHTS UP 1738
E-7 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING 1739
E-8 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1740
E-9 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1742
E-10 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1743
E-11 POWER TRAIN OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1744
E-12 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1745
E-13 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE 1746
E-14 AdBlue/DEF LEVEL IS NOT DISPLAYED PROPERLY 1747
E-15 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL 1750
E-16 POWER TRAIN OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE 1752
E-17 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE 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 DISPLAYED 1758
E-23 REVERSE SLOW MODE DOES NOT FUNCTION PROPERLY 1759
E-24 ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP SOUNDING 1760
E-25 SERVICE METER IS NOT DISPLAYED, 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 SOUNDING 1765
E-29 BACKUP ALARM DOES NOT SOUND 1766
E-30 BACKUP ALARM DOES NOT STOP SOUNDING 1768
E-31 HEADLAMP DOES NOT LIGHT UP 1769
E-32 REAR LAMP DOES NOT LIGHT UP 1773
E-33 ALL WIPERS DO NOT OPERATE 1777
E-34 FRONT WIPER DOES NOT OPERATE 1781
E-35 REAR WIPER DOES NOT OPERATE 1784
E-36 LEFT DOOR WIPER DOES NOT OPERATE 1787
E-37 RIGHT DOOR WIPER DOES NOT OPERATE 1790
E-38 FRONT WASHER DOES NOT OPERATE 1793
E-39 REAR WASHER DOES NOT OPERATE 1795
E-40 LEFT DOOR WASHER DOES NOT OPERATE 1797
E-41 RIGHT DOOR WASHER DOES NOT OPERATE 1799
E-42 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 1801
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 1802
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 1802
FAILURE MODE AND CAUSE TABLE 1803
H-1 MACHINE LACKS POWER (INSUFFICIENT DRAWBAR PULL) 1809
H-2 MACHINE DOES NOT TRAVEL (AT 2ND OR 3RD GEAR SPEED) 1811
H-3 MACHINE DOES NOT MOVE OFF AT ALL GEAR SPEEDS 1812
H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION, EITHER FORWARD OR IN REVERSE 1814
H-5 LARGE TIME LAG IS IN GEAR SHIFTING OR DIRECTIONAL CHANGE 1815
H-6 BRAKE DOES NOT WORK 1817
H-7 POWER TRAIN OIL OVERHEATS 1818
H-8 UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT AND HSS PUMP OR HSS MOTOR 1820
H-9 MACHINE CANNOT BE STEERED (MACHINE DOES NOT TURN LEFT OR RIGHT) 1821
H-10 STEERING SPEED OR POWER IS INSUFFICIENT 1822
H-11 ALL WORK EQUIPMENTS OPERATE SLOWLY 1823
H-12 ALL WORK EQUIPMENTS DO NOT OPERATE 1824
H-13 BLADE LIFT SPEED OR POWER IS LOW 1825
H-14 BLADE TILT SPEED OR POWER IS LOW 1826
H-15 RIPPER LIFT SPEED OR POWER IS LOW 1827
H-16 HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE 1828
H-17 HYDRAULIC DRIFT OF TILTED BLADE IS LARGE 1829
H-18 HYDRAULIC DRIFT OF LIFTED RIPPER IS LARGE 1830
H-19 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 1831
H-20 UNUSUAL NOISE IS HEARD FROM AROUND FAN 1833
TROUBLESHOOTING OF ENGINE (S-MODE) 1834
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 1834
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 1835
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 1836
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 1837
S-4 ENGINE STARTABILITY IS POOR 1838
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 1840
S-6 ENGINE STOPS DURING OPERATION 1842
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 1844
S-8 ENGINE LACKS POWER 1845
S-9 KDPF GETS CLOGGED IN A SHORT TIME 1847
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 1849
S-11 OIL BECOMES CONTAMINATED QUICKLY 1850
S-12 FUEL CONSUMPTION IS EXCESSIVE 1851
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 1852
S-14 OIL PRESSURE DROPS 1853
S-15 FUEL MIXES INTO ENGINE OIL 1855
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 1856
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 1857
S-18 UNUSUAL NOISE IS HEARD 1858
S-19 VIBRATION IS EXCESSIVE 1859
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 1860
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 1861
S-22 ACTIVE REGENERATION TAKES TIME 1863
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 1865
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 1866
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) 1868
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 1869
50 DISASSEMBLY AND ASSEMBLY 1871
CONTENTS 1872
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 1877
HOW TO READ THIS MANUAL 1877
COATING MATERIALS LIST 1879
SPECIAL TOOLS LIST 1883
SKETCHES OF SPECIAL TOOLS 1907
ENGINE AND COOLING SYSTEM 1915
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 1915
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 1916
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 1920
REMOVE AND INSTALL INJECTOR ASSEMBLY 1927
METHOD FOR REMOVING INJECTOR ASSEMBLY 1928
METHOD FOR INSTALLING INJECTOR ASSEMBLY 1934
REMOVE AND INSTALL FUEL DOSER ASSEMBLY 1945
METHOD FOR REMOVING FUEL DOSER ASSEMBLY 1945
METHOD FOR INSTALLING FUEL DOSER ASSEMBLY 1946
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 1948
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 1948
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 1955
REMOVE AND INSTALL EGR VALVE ASSEMBLY 1964
METHOD FOR REMOVING EGR VALVE ASSEMBLY 1964
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 1966
REMOVE AND INSTALL EGR COOLER ASSEMBLY 1969
METHOD FOR REMOVING EGR COOLER ASSEMBLY 1970
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 1974
REMOVE AND INSTALL STARTER ASSEMBLY 1979
METHOD FOR REMOVING STARTER ASSEMBLY 1979
METHOD FOR INSTALLING STARTER ASSEMBLY 1981
REMOVE AND INSTALL ALTERNATOR BELT 1983
METHOD FOR REMOVING ALTERNATOR BELT 1983
METHOD FOR INSTALLING ALTERNATOR BELT 1985
REMOVE AND INSTALL RADIATOR ASSEMBLY 1987
METHOD FOR REMOVING RADIATOR ASSEMBLY 1988
METHOD FOR INSTALLING RADIATOR ASSEMBLY 1992
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 1998
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 1999
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 2003
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 2008
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2008
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2009
REMOVE AND INSTALL COOLING FAN DRIVE ASSEMBLY 2010
METHOD FOR REMOVING COOLING FAN DRIVE ASSEMBLY 2010
METHOD FOR INSTALLING COOLING FAN DRIVE ASSEMBLY 2011
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY 2014
METHOD FOR REMOVING COOLING FAN MOTOR ASSEMBLY 2014
METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY 2016
REMOVE AND INSTALL ENGINE ASSEMBLY 2018
METHOD FOR REMOVING ENGINE ASSEMBLY 2019
METHOD FOR INSTALLING ENGINE ASSEMBLY 2026
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2032
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 2032
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 2033
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2036
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2036
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2038
REMOVE AND INSTALL ENGINE OIL PAN 2043
METHOD FOR REMOVING ENGINE OIL PAN 2043
METHOD FOR INSTALLING ENGINE OIL PAN 2044
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 2046
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2046
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2048
REMOVE AND INSTALL FUEL TANK ASSEMBLY 2050
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 2050
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2052
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 2055
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2055
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2060
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2064
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2064
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2069
REMOVE AND INSTALL AdBlue/DEF SENSOR 2074
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2074
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2074
REMOVE AND INSTALL AdBlue/DEF STRAINER 2081
METHOD FOR REMOVING AdBlue/DEF STRAINER 2081
METHOD FOR INSTALLING AdBlue/DEF STRAINER 2081
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER 2082
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2082
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2083
REMOVE AND INSTALL KDPF ASSEMBLY 2085
METHOD FOR REMOVING KDPF ASSEMBLY 2085
METHOD FOR INSTALLING KDPF ASSEMBLY 2089
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY 2094
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2094
METHOD FOR ASSEMBLING KDPF ASSEMBLY 2098
REMOVE AND INSTALL SCR ASSEMBLY 2102
METHOD FOR REMOVING SCR ASSEMBLY 2102
METHOD FOR INSTALLING SCR ASSEMBLY 2105
REMOVE AND INSTALL KDPF, SCR ASSEMBLY 2108
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2108
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2118
REMOVE AND INSTALL KCCV ASSEMBLY 2128
METHOD FOR REMOVING KCCV ASSEMBLY 2128
METHOD FOR INSTALLING KCCV ASSEMBLY 2131
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 2135
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2135
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2138
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2144
METHOD FOR REMOVING AdBlue/DEF INJECTOR 2144
METHOD FOR INSTALLING AdBlue/DEF INJECTOR 2147
REMOVE AND INSTALL AdBlue/DEF PUMP 2150
METHOD FOR REMOVING AdBlue/DEF PUMP 2150
METHOD FOR INSTALLING AdBlue/DEF PUMP 2153
REMOVE AND INSTALL AdBlue/DEF HOSE 2157
METHOD FOR REMOVING AdBlue/DEF HOSE 2157
METHOD FOR INSTALLING AdBlue/DEF HOSE 2162
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 2168
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2168
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2169
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2170
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 2170
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY 2172
POWER TRAIN 2174
REMOVE AND INSTALL DAMPER ASSEMBLY 2174
METHOD FOR REMOVING DAMPER ASSEMBLY 2174
METHOD FOR INSTALLING DAMPER ASSEMBLY 2177
DISASSEMBLE AND ASSEMBLE DAMPER ASSEMBLY 2180
METHOD FOR DISASSEMBLE DAMPER ASSEMBLY 2181
METHOD FOR ASSEMBLING DAMPER ASSEMBLY 2182
REMOVE AND INSTALL POWER TRAIN UNIT ASSEMBLY 2185
METHOD FOR REMOVING POWER TRAIN UNIT ASSEMBLY 2185
METHOD FOR INSTALLING POWER TRAIN UNIT ASSEMBLY 2190
DISCONNECTING AND CONNECTING POWER TRAIN UNIT ASSEMBLY 2196
METHOD FOR DISCONNECTING POWER TRAIN UNIT ASSEMBLY 2196
METHOD FOR CONNECTING POWER TRAIN UNIT ASSEMBLY 2201
DISASSEMBLE AND ASSEMBLE PTO ASSEMBLY 2206
METHOD FOR DISASSEMBLING PTO ASSEMBLY 2206
METHOD FOR ASSEMBLING PTO ASSEMBLY 2210
DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER ASSEMBLY 2215
METHOD FOR DISASSEMBLING TORQUE CONVERTER ASSEMBLY 2215
METHOD FOR ASSEMBLING TORQUE CONVERTER ASSEMBLY 2218
DISASSEMBLE AND ASSEMBLE TRANSMISSION ASSEMBLY 2222
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY 2223
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY 2231
DISASSEMBLE AND ASSEMBLE HSS ASSEMBLY 2243
METHOD FOR DISASSEMBLING HSS ASSEMBLY 2245
METHOD FOR ASSEMBLING HSS ASSEMBLY 2255
REMOVAL AND INSTALLATION OF HSS MOTOR 2273
METHOD FOR REMOVING HSS MOTOR ASSEMBLY 2273
METHOD FOR INSTALLING HSS MOTOR ASSEMBLY 2274
REMOVE AND INSTALL FINAL DRIVE ASSEMBLY 2275
METHOD FOR REMOVING FINAL DRIVE ASSEMBLY 2275
METHOD FOR INSTALLING FINAL DRIVE ASSEMBLY 2277
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY 2279
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY 2280
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2287
UNDERCARRIAGE AND FRAME 2299
REMOVE AND INSTALL TRACK FRAME ASSEMBLY 2299
REMOVE TRACK FRAME ASSEMBLY 2299
INSTALL TRACK FRAME ASSEMBLY 2303
REMOVE AND INSTALL IDLER ASSEMBLY 2307
METHOD FOR REMOVING IDLER ASSEMBLY 2307
METHOD FOR INSTALLING IDLER ASSEMBLY 2308
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 2312
METHOD FOR DISASSEMBLING IDLER ASSEMBLY 2312
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2314
REMOVE AND INSTALL RECOIL SPRING ASSEMBLY 2318
METHOD FOR REMOVING RECOIL SPRING ASSEMBLY 2318
METHOD FOR INSTALLING RECOIL SPRING ASSEMBLY 2320
DISASSEMBLE AND ASSEMBLE RECOIL SPRING 2322
METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING 2322
METHOD FOR ASSEMNLING RECOIL SPRING ASSEMBLY 2326
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY 2329
METHOD FOR REMOVING TRACK ROLLER ASSEMBLY 2329
METHOD FOR INSTALLING TRACK ROLLER ASSEMBLY 2331
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2334
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2334
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY 2335
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY 2339
METHOD FOR REMOVING CARRIER ROLLER ASSEMBLY 2339
METHOD FOR INSTALLING CARRIER ROLLER ASSEMBLY 2340
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY 2341
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2341
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY 2342
REMOVE AND INSTALL PIVOT SHAFT ASSEMBLY 2345
METHOD FOR REMOVING PIVOT SHAFT ASSEMBLY 2345
METHOD FOR INSTALLING PIVOT SHAFT ASSEMBLY 2346
SEPARATION AND CONNECTION OF TRACK ASSEMBLY 2348
METHOD FOR CHECKING BEFORE SEPARATION OF THE TRACK ASSEMBLY 2348
METHOD FOR SEPARATING OF TRACK ASSEMBLY (NORMAL) 2348
METHOD FOR SEPARATING TRACK ASSEMBLY (WHEN TRACK FRAME HAS INTERNAL DEFECT) 2349
METHOD FOR INSTALLING TRACK ASSEMBLY 2351
SEPARATE AND CONNECT PLUS TYPE TRACK ASSEMBLY 2354
METHOD FOR SEPARATING PLUS TYPE TRACK ASSEMBLY 2354
METHOD FOR CONNECTING PLUS TYPE TRACK ASSEMBLY 2354
DISASSEMBLY AND ASSEMBLY OF TRACK ASSEMBLY GENERALLY 2355
METHOD FOR DISASSEMBLING TRACK ASSEMBLY GENERALLY 2355
METHOD FOR ASSEMBLING TRACK ASSEMBLY GENERALLY 2358
DISASSEMBLE AND ASSEMBLE PLUS TYPE TRACK ASSEMBLY GENERALLY 2371
METHOD FOR DISASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY 2371
METHOD FOR ASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY 2372
DISASSEMBLE AND ASSEMBLE ONE TRACK LINK ASSEMBLY IN FIELD 2380
METHOD FOR DISASSEMBLING ONE TRACK LINK ASSEMBLY IN FIELD 2382
METHOD FOR ASSEMBLING ONE TRACK LINK ASSEMBLY IN FIELD 2382
DISASSEMBLE AND ASSEMBLE MASTER LINK 2390
METHOD FOR DISASSEMBLING MASTER LINK 2391
METHOD FOR ASSEMBLING MASTER LINK 2391
REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY 2395
REMOVE EQUALIZER BAR ASSEMBLY 2395
INSTALL EQUALIZER BAR ASSEMBLY 2397
DISASSEMBLE AND ASSEMBLE EQUALIZER BAR BUSHINGS 2400
METHOD FOR DISASSEMBLING EQUALIZER BAR BUSHINGS 2400
METHOD FOR ASSEMBLING EQUALIZER BAR BUSHINGS 2401
OPEN AND CLOSE CENTER UNDER GUARD 2402
METHOD FOR OPENING UNDER GUARD 2402
METHOD FOR CLOSING UNDER GUARD 2403
REMOVE AND INSTALL CENTER UNDER GUARD ASSEMBLY 2405
METHOD FOR REMOVING UNDER GUARD ASSEMBLY 2405
METHOD FOR INSTALLING UNDER GUARD ASSEMBLY 2412
HYDRAULIC SYSTEM 2420
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2420
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 2420
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 2423
REMOVE AND INSTALL WORK EQUIPMENT PUMP AND HSS PUMP ASSEMBLY 2427
METHOD FOR REMOVING WORK EQUIPMENT PUMP AND HSS PUMP ASSEMBLY 2427
METHOD FOR INSTALLING WORK EQUIPMENT PUMP AND HSS PUMP ASSEMBLY 2430
REMOVE AND INSTALL POWER TRAIN PUMP AND STEERING LUBRICATION PUMP ASSEMBLY 2432
METHOD FOR REMOVING POWER TRAIN PUMP AND STEERING LUBRICATION PUMP ASSEMBLY 2432
METHOD FOR INSTALLING POWER TRAIN PUMP AND STEERING LUBRICATION PUMP ASSEMBLY 2434
REMOVE AND INSTALL COOLING FAN PUMP ASSEMBLY 2436
METHOD FOR REMOVING COOLING FAN PUMP ASSEMBLY 2436
METHOD FOR INSTALLING COOLING FAN PUMP ASSEMBLY 2438
REMOVE AND INSTALL SCAVENGING PUMP ASSEMBLY 2441
METHOD FOR REMOVING SCAVENGING PUMP ASSEMBLY 2441
METHOD FOR INSTALLING SCAVENGING PUMP ASSEMBLY 2442
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 2444
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2444
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2449
WORK EQUIPMENT 2454
REMOVE AND INSTALL BLADE ASSEMBLY 2454
METHOD FOR REMOVING BLADE ASSEMBLY 2454
METHOD FOR INSTALLING BLADE ASSEMBLY 2456
REMOVE AND INSTALL BLADE LIFT CYLINDER ASSEMBLY 2460
REMOVE BLADE LIFT CYLINDER ASSEMBLY 2461
INSTALL BLADE LIFT CYLINDER ASSEMBLY 2465
DISASSEMBLE AND ASSEMBLE FIXED MULTI-SHANK RIPPER ASSEMBLY 2470
METHOD FOR DISASSEMBLING FIXED MULTI-SHANK RIPPER ASSEMBLY 2470
METHOD FOR ASSEMBLING FIXED MULTI-SHANK RIPPER ASSEMBLY 2472
DISASSEMBLE AND ASSEMBLE VARIABLE MULTI-SHANK RIPPER ASSEMBLY 2475
METHOD FOR DISASSEMBLING VARIABLE MULTI-SHANK RIPPER ASSEMBLY 2475
METHOD FOR ASSEMBLING VARIABLE MULTI-SHANK RIPPER ASSEMBLY 2478
METHOD FOR DISASSEMBLING AND ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2481
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2482
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2485
CAB AND ITS ATTACHMENTS 2489
REMOVE AND INSTALL OPERATOR CAB ASSEMBLY 2489
REMOVE OPERATOR CAB ASSEMBLY 2489
INSTALL OPERATOR CAB ASSEMBLY 2495
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS) 2502
METHOD FOR REMOVING OPERATOR’S CAB GLASS (ADHERED GLASS) 2502
METHOD FOR INSTALLING OPERATOR’S CAB GLASS (ADHERED GLASS) 2503
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2508
REMOVE AIR CONDITIONER UNIT ASSEMBLY 2508
INSTALL AIR CONDITIONER UNIT ASSEMBLY 2513
REMOVE AND INSTALL OPERATOR’S SEAT 2519
REMOVE OPERATOR’S SEAT 2519
INSTALL OPERATOR’S SEAT 2521
REMOVE AND INSTALL SEAT BELT 2524
METHOD FOR REMOVING SEAT BELT 2524
METHOD FOR INSTALLING SEAT BELT 2525
ELECTRICAL SYSTEM 2526
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 2526
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2526
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2527
REMOVE AND INSTALL POWER TRAIN CONTROLLER ASSEMBLY 2531
METHOD FOR REMOVING POWER TRAIN CONTROLLER ASSEMBLY 2531
METHOD FOR INSTALLING POWER TRAIN CONTROLLER ASSEMBLY 2532
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 2534
REMOVE MACHINE MONITOR ASSEMBLY 2534
INSTALL MACHINE MONITOR ASSEMBLY 2535
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 2537
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2537
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2538
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 2540
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2540
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2542
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 2544
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2544
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2546
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 2548
REMOVE GATEWAY FUNCTION CONTROLLER ASSEMBLY 2548
INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 2551
60 MAINTENANCE STANDARD 2557
CONTENTS 2558
ENGINE AND COOLING SYSTEM 2560
MAINTENANCE STANDARD OF ENGINE MOUNT 2560
MAINTENANCE STANDARD OF DAMPER 2562
MAINTENANCE STANDARD OF COOLING SYSTEM 2564
MAINTENANCE STANDARD OF COOLING FAN PUMP 2566
MAINTENANCE STANDARD OF SERVO VALVE 2567
MAINTENANCE STANDARD OF COOLING FAN MOTOR 2568
POWER TRAIN 2570
MAINTENANCE STANDARD OF UNIVERSAL JOINT 2570
MAINTENANCE STANDARD OF POWER TRAIN MOUNT 2571
MAINTENANCE STANDARD OF TORQUE CONVERTER AND PTO 2572
MAINTENANCE STANDARD OF TRANSMISSION 2575
MAINTENANCE STANDARD OF TRANSMISSION ECMV 2580
MAINTENANCE STANDARD OF MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE 2581
MAINTENANCE STANDARD OF TRANSMISSION LUBRICATION RELIEF VALVE 2582
MAINTENANCE STANDARD OF BEVEL GEAR SHAFT, HSS, AND BRAKE 2583
MAINTENANCE STANDARD OF BRAKE VALVE 2587
MAINTENANCE STANDARD OF FINAL DRIVE 2589
MAINTENANCE STANDARD OF SPROCKET FOR CONVENTIONAL TYPE TRACK SHOE 2592
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR CONVENTIONAL TYPE TRACK SHOE 2593
MAINTENANCE STANDARD OF SPROCKET FOR PLUS TYPE TRACK SHOE 2595
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR PLUS TYPE TRACK SHOE 2596
UNDERCARRIAGE AND FRAME 2598
MAINTENANCE STANDARD OF MAIN FRAME 2598
MAINTENANCE STANDARD OF SUSPENSION 2600
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 2604
MAINTENANCE STANDARD OF IDLER 2606
MAINTENANCE STANDARD OF TRACK ROLLER FOR CONVENTIONAL TYPE TRACK SHOES (SINGLE FLANGE TYPE) 2608
MAINTENANCE STANDARD OF TRACK ROLLER FOR CONVENTIONAL TYPE TRACK SHOES (DOUBLE FLANGE TYPE) 2610
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (SINGLE FLANGE TYPE) 2612
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (DOUBLE FLANGE TYPE) 2614
MAINTENANCE STANDARD OF CARRIER ROLLER FOR CONVENTIONAL TYPE TRACK SHOE 2616
MAINTENANCE STANDARD OF CARRIER ROLLER FOR PLUS TYPE TRACK SHOE 2618
MAINTENANCE STANDARD OF CONVENTIONAL TYPE TRACK SHOE 2620
MAINTENANCE STANDARD OF PLUS TYPE TRACK SHOE 2622
MAINTENANCE STANDARD OF SINGLE SHOE AND HEAVY DUTY SHOE 2624
MAINTENANCE STANDARD OF SWAMP SHOE 2625
HYDRAULIC SYSTEM 2626
MAINTENANCE STANDARD OF HYDRAULIC TANK 2626
MAINTENANCE STANDARD OF SCAVENGING PUMP 2627
MAINTENANCE STANDARD OF STEERING LUBRICATION PUMP AND POWER TRAIN PUMP 2628
MAINTENANCE STANDARD OF WORK EQUIPMENT AND HSS PUMP 2630
MAINTENANCE STANDARD OF HSS MOTOR 2631
MAINTENANCE STANDARD OF CONTROL VALVE 2633
MAINTENANCE STANDARD OF BLADE PPC VALVE 2640
MAINTENANCE STANDARD OF RIPPER PPC VALVE (FIXED MULTI-SHANK RIPPER) 2642
MAINTENANCE STANDARD OF RIPPER PPC VALVE (VARIABLE MULTI-SHANK RIPPER) 2644
MAINTENANCE STANDARD OF QUICK DROP VALVE 2647
MAINTENANCE STANDARD OF WORK EQUIPMENT LOCK SOLENOID VALVE 2648
WORK EQUIPMENT 2649
MAINTENANCE STANDARD OF CYLINDER STAY 2649
MAINTENANCE STANDARD OF FRONT WORK EQUIPMENT 2650
MAINTENANCE STANDARD OF CUTTING EDGE AND END BIT (STRAIGHT BLADE AND SEMI-U BLADE 2654
MAINTENANCE STANDARD OF CUTTING EDGE AND END BIT (SIGMA BLADE) 2655
MAINTENANCE STANDARD OF BLADE LIFT CYLINDER 2656
MAINTENANCE STANDARD OF BLADE TILT CYLINDER 2657
MAINTENANCE STANDARD OF BLADE PITCH CYLINDER (FOR POWER TILT PITCH DOZER SERIES) 2658
MAINTENANCE STANDARD OF FIXED MULTI-SHANK RIPPER 2659
MAINTENANCE STANDARD OF VARIABLE MULTI-SHANK RIPPER 2662
MAINTENANCE STANDARD OF RIPPER LIFT CYLINDER (FIXED AND VARIABLE MULTI-SHANK RIPPER) 2665
MAINTENANCE STANDARD OF RIPPER TILT CYLINDER (VARIABLE MULTI-SHANK RIPPER) 2666
CAB AND ITS ATTACHMENTS 2667
MAINTENANCE STANDARD OF CAB MOUNT 2667
80 APPENDIX 2669
CONTENTS 2670
AIR CONDITIONER SYSTEM 2672
PRECAUTIONS FOR REFRIGERANT 2672
AIR CONDITIONER COMPONENT 2673
SPECIFICATIONS OF AIR CONDITIONER 2675
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 2676
OUTLINE OF REFRIGERATION CYCLE 2677
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 2679
AIR CONDITIONER UNIT 2679
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 2679
FUNCTION OF AIR CONDITIONER UNIT 2681
COMPONENT PARTS OF AIR CONDITIONER UNIT 2683
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2684
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 2684
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 2684
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT 2684
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2685
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2685
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2685
FUNCTION OF DUAL PRESSURE SWITCH 2686
AIR CONDITIONER CONTROLLER 2687
STRUCTURE OF AIR CONDITIONER CONTROLLER 2687
COMPRESSOR 2688
STRUCTURE OF COMPRESSOR 2688
SPECIFICATIONS OF COMPRESSOR 2688
FUNCTION OF COMPRESSOR 2688
CONDENSER 2689
STRUCTURE OF CONDENSER 2689
SPECIFICATIONS OF CONDENSER 2689
FUNCTION OF CONDENSER 2689
STRUCTURE OF WIDE CORE CONDENSER 2690
SPECIFICATIONS OF WIDE CORE CONDENSER 2690
FUNCTION OF WIDE CORE CONDENSER 2690
RECEIVER DRIER 2691
STRUCTURE OF RECEIVER DRIER 2691
SPECIFICATIONS OF RECEIVER DRIER 2691
FUNCTION OF RECEIVER DRIER 2691
SENSORS FOR AIR CONDITIONER SYSTEM 2692
STRUCTURE OF SUNLIGHT SENSOR 2692
FUNCTION OF SUNLIGHT SENSOR 2692
STRUCTURE OF AMBIENT TEMPERATURE SENSOR 2692
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2692
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 2694
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 2696
AIR CONDITIONER SYSTEM DIAGRAM 2698
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2699
FUNCTION OF AIR CONDITIONER CONTROLLER 2700
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 2701
TESTING AIR LEAKAGE (DUCT) 2710
METHOD FOR TESTING AIR LEAKAGE (DUCT) 2710
EXPLANATION FOR TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 2713
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2714
TEST VENT (MODE) CHANGEOVER 2715
METHOD FOR TESTING VENT (MODE) CHANGEOVER 2715
TESTING FRESH/RECIRC AIR CHANGEOVER 2716
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2716
TEST SUNLIGHT SENSOR 2717
METHOD FOR TESTING SUNLIGHT SENSOR 2717
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT 2718
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT 2718
TEST RELAYS 2719
METHOD FOR TESTING RELAYS 2719
AIR CONDITIONER TROUBLESHOOTING CHART 1 2720
AIR CONDITIONER TROUBLESHOOTING CHART 2 2721
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2724
FAILURE CODE [879AKA] 2726
FAILURE CODE [879AKB] 2727
FAILURE CODE [879BKA] 2728
FAILURE CODE [879BKB] 2730
FAILURE CODE [879CKA] 2732
FAILURE CODE [879CKB] 2733
FAILURE CODE [879DKZ] 2734
FAILURE CODE [879EMC] 2736
FAILURE CODE [879FMC] 2737
FAILURE CODE [879GKX] 2738
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2740
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 2742
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2746
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 2748
TROUBLESHOOTING USING GAUGE PRESSURE 2750
CONNECTION OF SERVICE TOOL 2753
METHOD FOR CONNECTING SERVICE TOOL 2753
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 2755
HANDLE COMPRESSOR OIL 2757
90 CIRCUIT DIAGRAMS 2759
CONTENTS 2760
HYDRAULIC CIRCUIT DIAGRAM 2761
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 2761
HYDRAULIC CIRCUIT DIAGRAM (FOR POWER TILT PITCH DOZER AND VARIABLE MULTI-SHANK RIPPER) 2765
HYDRAULIC CIRCUIT DIAGRAM (FOR POWER TILT PITCH DOZER AND FIXED MULTI-SHANK RIPPER) 2767
HYDRAULIC CIRCUIT DIAGRAM (FOR POWER TILT DOZER AND VARIABLE MULTI-SHANK RIPPER) 2769
HYDRAULIC CIRCUIT DIAGRAM (FOR POWER TILT DOZER AND FIXED MULTI-SHANK RIPPER) 2771
HYDRAULIC CIRCUIT DIAGRAM (FOR POWER TILT DOZER) 2773
HYDRAULIC CIRCUIT DIAGRAM (FOR SINGLE TILT DOZER AND FIXED MULTI-SHANK RIPPER) 2775
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 2777
ELECTRICAL CIRCUIT DIAGRAM 2779
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2779
ELECTRICAL CIRCUIT DIAGRAM (1/16) 2783
ELECTRICAL CIRCUIT DIAGRAM (2/16) 2785
ELECTRICAL CIRCUIT DIAGRAM (3/16) 2787
ELECTRICAL CIRCUIT DIAGRAM (4/16) 2789
ELECTRICAL CIRCUIT DIAGRAM (5/16) 2791
ELECTRICAL CIRCUIT DIAGRAM (6/16) 2793
ELECTRICAL CIRCUIT DIAGRAM (7/16) 2795
ELECTRICAL CIRCUIT DIAGRAM (8/16) 2797
ELECTRICAL CIRCUIT DIAGRAM (9/16) 2799
ELECTRICAL CIRCUIT DIAGRAM (10/16) 2801
ELECTRICAL CIRCUIT DIAGRAM (11/16) 2803
ELECTRICAL CIRCUIT DIAGRAM (12/16) 2805
ELECTRICAL CIRCUIT DIAGRAM (13/16) 2807
ELECTRICAL CIRCUIT DIAGRAM (14/16) 2809
ELECTRICAL CIRCUIT DIAGRAM (15/16) 2811
ELECTRICAL CIRCUIT DIAGRAM (16/16) 2813
INDEX 2815

DESCRIPTION:

Komatsu D85EX-18E0 D85PX-18E0 Bulldozer Shop Manual SEN06909-02 – PDF DOWNLOAD 

SERIAL NUMBERS 25001 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.
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 SPECIFICATIONS
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.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

IMAGES PREVIEW OF THE MANUAL:

S.V 28/12/24