Komatsu D85EXi -18 D85PXi-18 Bulldozer Shop Manual SEN06576-12 PDF

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Komatsu D85EXi -18 D85PXi-18 Bulldozer Shop Manual SEN06576-12 – PDF DOWNLOAD

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Komatsu D85EXi -18 D85PXi-18 Bulldozer Shop Manual SEN06576-12 – PDF DOWNLOAD 

Language : English
Pages : 3196
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu D85EXi -18 D85PXi-18 Bulldozer Shop Manual SEN06576-12 – PDF DOWNLOAD 

SERIAL NUMBERS 22083 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 D85EXi -18 D85PXi-18 Bulldozer Shop Manual SEN06576-12 – PDF DOWNLOAD 

SERIAL NUMBERS 22083 and up

Cover 1
00 Index and Foreword 3
Index 4
Abbreviation List 23
Foreword, Safety, Basic Information 26
How to Read the Shop Manual 26
Safety Notice for Operation 28
Precautions to Prevent Fire 36
Procedures If Fire Occurs 38
Precautions for Disposing of Waste Materials 39
Procedures for Exhaust Gas Regulations 40
Precautions for DEF 41
General Character and Precautions for Handling 41
Precautions for Adding 41
Precautions for Storage 41
Precautions for Fire Hazard and Leakage 41
Other Precautions 41
Store DEF 42
Precautions When You Handle Hydraulic Equipment 43
Precautions When You Disconnect and Connect Pipings 46
Precautions When You Handle Electrical Equipment 53
Precautions When You Handle Fuel System Equipment 55
Precautions When You Handle Intake System Equipment 56
Practical Use of KOMTRAX 57
Disconnect and Connect Push-Pull Type Coupler 58
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 58
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 59
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 60
Precautions for Disconnection and Connection of Connectors 62
How to Disconnect and Connect Deutsch Connector 66
How to Disconnect and Connect Slide Lock Type Connector 67
How to Disconnect and Connect Connector with Lock to Pull 69
How to Disconnect and Connect Connector with Lock to Push 70
How to Disconnect and Connect Connector with Housing to Rotate 72
How to Read the Codes for Electric Cable 73
Explanation of Terms for Maintenance Standard 77
Standard Tightening Torque Table 80
Conversion Table 87
01 Specifications 93
Table of Contents 94
Specifications 95
Specification Drawing 95
Specification Drawing: D85EXI-18 95
Specification Drawing: D85PXI-18 97
Specifications 98
Specifications: D85EXI-18 98
Specifications: D85PXI-18 104
Weight Table 109
Weight Table: D85EXI-18 109
Weight Table: D85PXI-18 111
Table of Fuel, Coolant, and Lubricants 113
10 Structure and Function 115
Table of Contents 116
Urea SCR System 119
Layout Drawing of Urea SCR System 119
Urea SCR System Diagram 122
Function of Urea SCR System 123
Function of DEF System 123
Inducement Strategy 125
Component Parts of Urea SCR System 139
DEF Mixing Tube 139
SCR Assembly 140
DEF Tank 142
DEF Pump 144
DEF Injector 145
DEF Hose 146
DEF Tank Heating Valve 147
Boot-up System 148
Layout Drawing of Boot-up System 148
System Operating Lamp System 149
System Diagram of System Operating Lamp System 149
Function of Operation Lamp System 149
Battery Disconnect Switch 151
Layout Drawing of Battery Disconnect Switch 151
Function of Battery Disconnect Switch 151
Engine System 153
Layout Drawing of Engine System 153
Engine Control System 155
Layout Drawing of Engine Control System 155
System Diagram of Engine Control 156
Function of Engine Control System 158
Automatic Idle Stop System 160
System Diagram of Automatic Idle Stop System 160
Function of Automatic Idle Stop System 160
Component Parts of Engine System 163
Damper 163
VGT 165
EGR System 169
EGR Valve 171
EGR Cooler 173
KCCV System 174
KCCV Ventilator 176
KDPF 178
Cooling System 182
Layout Drawing of Cooling System 182
Specifications of Cooling System 183
Cooling Fan Control System 184
System Diagram of Cooling Fan Control System 184
Function of Cooling Fan Control System 185
Component Parts of Cooling System 187
Cooling Fan Pump 187
Cooling Fan Motor 196
Hydraulic Oil Cooler Bypass Valve 203
Control System 204
Layout Drawing of Control System 204
Machine Monitor System 205
System Diagram of Machine Monitor System 205
Function of Machine Monitor System 205
KOMTRAX System 207
System Diagram of KOMTRAX System 207
Function of KOMTRAX System 207
Component Parts of Control System 208
Machine Monitor 208
KOMTRAX Terminal 224
Power Train Controller 226
Engine Controller 230
Fuel Feed Pump 237
Fuel Feed Pump Switch 238
Hydraulic System 239
Layout Drawing of Hydraulic System 239
CLSS 240
Structure of CLSS 240
Function of CLSS 241
Component Parts of Hydraulic System 243
Hydraulic Tank 243
Work Equipment and HSS Pump 245
LS Valve 254
TVC Valve 259
Variable Throttle Valve 264
Control Valve 267
Power Train System 301
Layout Drawing of Power Train System 301
Operation of Power Train System 303
Transmission, Steering, and Brake Control 304
Layout Drawing of Transmission, Steering, and Brake Control System 304
Function of Transmission, Steering, and Brake Control 305
Palm Command Control System 307
Palm Command Control System Diagram 307
HSS System 311
HSS System Diagram 311
Function of HSS System 312
Centralized Pressure Pickup Port 314
Layout Drawing of Centralized Pressure Pickup Port 314
Function of Centralized Pressure Pickup Port 315
Component Parts of Power Train System 316
Universal Joint 316
Power Train Mount 317
Torque Converter and PTO 319
Transmission 322
Transmission ECMV 333
Main Relief Valve and Torque Converter Relief Valve 339
Transmission Lubrication Relief Valve 341
Bevel Gear Shaft, HSS, and Brake 342
Brake Valve 361
Final Drive 365
Scavenging Pump 369
Steering Lubrication Pump and Power Train Pump 370
HSS Motor 372
Electric Steering Electric Lever 378
Work Equipment System 381
Work Equipment Control 381
Layout Drawing of Work Equipment Control 381
Function of Work Equipment Control 382
Layout Drawing of Front Work Equipment 384
Layout Drawing of Fixed Multi-Shank Ripper 385
Component Parts of Work Equipment System 386
Self-Pressure Reducing Valve 386
Work Equipment Lock Solenoid Valve 392
Blade PPC Valve 394
Ripper PPC Valve 400
Blade Pitch Selector Solenoid Valve 403
Pilot Circuit Accumulator 404
Quick Drop Valve 405
Piston Valve 407
ICT System 408
Layout Drawing of ICT System 408
System Diagram of ICT Control System 410
Blade Control System 412
Function of Blade Control System 412
Leveling Mode System Diagram 414
Function of Leveling Mode 415
Operation of Leveling Mode 415
Dozing Mode System Diagram 416
Function of Dozing Mode 417
Operation of Dozing Mode 417
Smooth Start System 418
Smooth Start System Diagram 418
Function of Smooth Start System 418
Operation of Smooth Start System 418
Slip Control System 420
Slip Control System Diagram 420
Function of Slip Control System 421
Operation of Slip Control System 421
Assist Control System 422
Assist Control System Diagram 422
Function of Assist Control System 422
Operation of Assist Control System 423
Component Parts of ICT System 424
ICT Sensor Controller 424
Control Box 428
GNSS Receiver 431
GNSS Antenna 435
IMU Sensor 436
Cylinder EPC Valve Block Assembly 440
Stroke and Reset Sensor for Blade Lift Cylinder 444
Undercarriage and Frame 447
Main Frame 447
Structure of Main Frame 447
Suspension 448
Structure of Suspension 448
Function of Suspension 451
Track Frame and Idler Cushion 452
Structure of Track Frame and Idler Cushion 452
Function of Track Frame and Idler Cushion 453
Work Equipment 454
Structure of Front Work Equipment 454
Structure of Cylinder Stay 456
Structure of Fixed Multi-Shank Ripper 457
CAB Related Parts 458
ROPS CAB 458
Structure of ROPS CAB 458
Function of ROPS CAB 459
CAB Mount 460
Structure of CAB Mount 460
Function of CAB Mount 460
20 Standard Value Table 461
Table of Contents 462
Standard Value Table for Engine 463
Standard Value Table for Engine: D85EXI-18 463
Standard Value Table for Engine: D85PXI-18 467
Standard Value Table for Machine 471
Standard Value Table for Machine: D85EXI-18 471
Standard Value Table for Machine: D85PXI-18 489
Machine Posture and Procedures to Measure Performance 505
Standard Value Table for Electricity 508
Standard Value Table for Electricity 508
30 Testing and Adjusting 517
Table of Contents 518
Precautions Before Work 522
Related Information on Testing and Adjusting 523
Tools for Testing and Adjusting 523
Sketch of Tools for Testing and Adjusting 531
Engine and Cooling System 534
Examine Engine Speed 534
How to Examine Engine Speed 534
Examine Boost Pressure 538
How to Examine Boost Pressure 538
Examine Exhaust Gas Temperature 540
How to Examine Exhaust Gas Temperature 540
Examine Exhaust Gas Color 542
How to Examine Exhaust Gas Color with the Handy Smoke Checker 542
How to Examine Exhaust Gas Color with Smoke Meter 544
Examine Mass Air Flow and Temperature Sensor 546
How to Examine Mass Air Flow and Temperature Sensor 546
Examine and Adjust Valve Clearance 548
How to Examine Valve Clearance 548
How to Adjust Valve Clearance 549
Examine Compression Pressure 550
How to Examine Compression Pressure 550
Examine Blowby Pressure 554
How to Examine Blowby Pressure 554
Examine Engine Oil Pressure 557
How to Examine Engine Oil Pressure on Machine Monitor 557
How to Examine Engine Oil Pressure by Testing Tool 558
Examine EGR Valve and VGT Oil Pressure 559
How to Examine EGR Valve and VGT Oil Pressure 559
Examine Fuel Pressure 561
How to Examine Fuel Pressure 561
Examine Fuel Return Rate and Leakage 563
How to Examine Fuel Return Rate and Leakage 564
Bleed Air from Fuel System 567
How to Bleed Air from Fuel System 568
Examine Fuel Circuit for Leakage 569
How to Examine Fuel System for Leakage 569
Handle Cylinder Cut-out Mode Operation 571
Handle No-Injection Cranking Operation 572
Examine and Adjust Air Conditioner Compressor Belt Tension 573
How to Examine Air Conditioner Compressor Drive Belt Tension 573
How to Adjust Air Conditioner Compressor Belt Tension 573
Clean Fuel Doser 575
How to Clean Fuel Doser 575
Write Injector Compensation Value to Engine Controller 578
How to Write Injector Compensation Value 578
Write Correction for Ash in Soot Accumulation to Engine Controller 584
How to Write Correction for Ash in Soot Accumulation to Engine Controller 584
Examine SCR Related Functions 585
Examine DEF Pump Raised Pressure 589
Examine Injection Volume from DEF Injector 592
Examine DEF Line Heater Relay 1 597
Examine DEF Line Heater Relay 2 600
Examine DEF Pump Heater Relay 603
Examine DEF Tank Heater Valve 606
Examine SCR Denitration Efficiency 609
Clean DEF Tank 612
How to Clean DEF Tank 612
Clean DEF Pump 616
How to Clean DEF Pump 616
Clean DEF Tank Mounting Part 623
How to Clean DEF Tank Mounting Part 623
Adjust Decelerator Pedal 624
How to Adjust Decelerator Pedal 624
Power Train 626
Examine Power Train Oil Pressure 626
How to Examine Power Train Oil Pressure 627
Adjust Transmission Output Shaft Speed Sensor 638
How to Adjust Transmission Output Shaft Speed Sensor 638
Examine Brake Performance Simply 640
How to Examine Brake Performance Simply 640
Adjust Brake Pedal 641
How to Adjust Brake Pedal 641
Adjust Parking Brake Lever 643
How to Adjust Parking Brake Lever 643
Move Machine by Parking Brake Release When Machine Does Not Travel 645
How to Move Machine with Hydraulic Type Parking Brake Release System 645
How to Move Machine with Electric Type Parking Brake Release System 646
Undercarriage and Frame 648
Adjust Idler Clearance 648
How to Adjust Idler Clearance 648
How to Adjust Idler Clearance Horizontally 648
How to Adjust Idler Clearance Vertically 648
Examine and Adjust Track Tension 650
How to Examine 650
How to Adjust Track Tension 650
Hydraulic System 651
Release Remained Pressure in Hydraulic Circuit 651
How to Release Remained Pressure in Hydraulic System 651
Examine and Adjust Work Equipment and HSS Oil Pressure 652
How to Examine Work Equipment and HSS Oil Pressure 652
How to Adjust Oil Pressure of Work Equipment and HSS 656
Examine Oil Pressure of Control Circuit 657
How to Examine Oil Pressure in Control Circuit 657
Examine PPC Valve Outlet Pressure 659
How to Examine Outlet Pressure in PPC Valve 659
Bleed Air from HSS Pump 662
How to Bleed Air from HSS Pump 662
Examine and Adjust Play of Work Equipment PPC Valve 663
How to Examine Play of Work Equipment PPC Valve 663
How to Adjust Play of Work Equipment PPC Valve 664
Examine Cooling Fan Speed 665
How to Examine Cooling Fan Speed 665
Examine Cooling Fan Circuit Oil Pressure 666
How to Examine Cooling Fan Circuit Oil Pressure 666
Bleed Air in Cooling Fan Pump 668
How to Bleed Air in Cooling Fan Pump 668
Examine Parts Which Cause Hydraulic Drift of Work Equipment 669
How to Examine Parts Which Cause Hydraulic Drift of Blade Lift Cylinder 669
How to Examine the Parts Which Cause Hydraulic Drift of Blade Tilt Cylinder 669
How to Examine the Parts Which Cause Hydraulic Drift of Ripper Lift Cylinder 670
Examine Oil Leakage from Work Equipment Cylinder 671
How to Examine Internal Oil Leakage of Work Equipment Cylinder 671
Bleed Air from Work Equipment Cylinders 673
How to Bleed Air from Work Equipment Cylinder 673
Work Equipment 674
Adjust Work Equipment Lock Lever 674
How to Adjust Work Equipment Lock Lever 674
CAB Related Parts 676
Examine and Adjust Operator Cab 676
How to Examine Operator Cab 676
How to Adjust Operator Cab 678
Electrical System 681
Set and Operate Machine Monitor 681
Operator Mode 685
Function to Show Technician Identification Status Screen 685
Function to Show Operator Identification Input Screen 685
Examine Function by LCD (Liquid Crystal Display) 686
Examine Function of Service Meter 686
How to Set Usage Limitation and Change Maintenance Password 686
Service Mode 689
How to Operate Service Mode 689
How to See Pre-defined Monitoring Information 690
How to Examine Self-Define Monitor Information 697
Abnormality Record Menu 707
How to See Maintenance Record 711
Maintenance Mode Setting 712
How to Set Phone Number Entry 716
Default Menu 718
Diagnostic Tests Menu 725
Adjustment Menu 734
No-Injection Cranking Operation 790
KOMTRAX Settings Menu 792
How to Show Service Message 794
How to Start Up KOMTRAX Terminal 796
Adjust When Power Train Controller is Replaced 801
How to Adjust When Power Train Controller is Replaced 801
Adjust Rearview Camera Angle 804
How to Adjust Rearview Camera Angle 804
Handle Voltage Circuit of Engine Controller 805
Handle Battery Disconnect Switch 806
Examine Diodes 807
How to Examine Diodes by Digital Tester 807
How to Examine Diodes by Analog Tester 807
ICT System 808
Set and Operate Control Box 808
Examine and Adjust ICT Related Devices (SIGMA Power Tilt Pitch Dozer) 810
Examine and Adjust ICT Related Devices (Straight Tilt Dozer) 813
Calibrate Blade Edge Position (SIGMA Power Tilt Pitch Dozer) 816
Calibrate Blade Edge Position (Straight Tilt Dozer) 817
How to Operate Blade Calibration Menu (Pitch Rod Calibration) (Straight Tilt Dozer) 818
How to Operate Blade Calibration Menu (Machine Cal Step A) (SIGMA Power Tilt Pitch Dozer) 821
How to Operate Blade Calibration Menu (Machine Cal Step A) (Straight Tilt Dozer) 825
How to Operate Blade Calibration Menu (Machine Cal Step B) (SIGMA Power Tilt Pitch Dozer) 829
How to Operate Blade Calibration Menu (Machine Cal Step B) (Straight Tilt Dozer) 844
Calibrate IMU Sensor 859
How to Calibrate IMU Sensor 859
Reset Cylinder Stroke End 866
Set Standard Angle of Blade Edge 868
How to Input Wear Volume of Blade Edge and Track Shoes 870
Examine and Adjust Blade Elevation 871
Examine Blade Elevation (SIGMA Power Tilt Pitch Dozer) (For Old Control Box) 871
Examine Blade Elevation (SIGMA Power Tilt Pitch Dozer) (For New Control Box) 874
Examine Blade Elevation (Straight Tilt Dozer) (For Old Control Box) 877
Examine Blade Elevation (Straight Tilt Dozer) (For New Control Box) 880
Adjust Blade Elevation (For Old Control Box) 883
Adjust Blade Elevation (For New Control Box) 884
Examine Stroke Sensor for Lift Cylinder 885
How to Examine Stroke Sensor for Lift Cylinder 885
Examine and Adjust Reset Sensor for Lift Cylinder 889
How to Examine Reset Sensor for Lift Cylinder 889
How to Adjust Reset Sensor for Lift Cylinder (SIGMA Power Tilt Pitch Dozer) 890
How to Adjust Reset Sensor for Lift Cylinder (Straight Tilt Dozer) 890
Adjust When ICT Sensor Controller is Replaced 891
How to Adjust When ICT Sensor Controller is Replaced (SIGMA Power Tilt Pitch Dozer) 892
How to Adjust When ICT Sensor Controller is Replaced (Straight Tilt Dozer) 895
Adjust When ICT Related Devices are Repaired or Replaced (SIGMA Power Tilt Pitch Dozer) 898
Adjust When ICT Related Devices are Repaired or Replaced (Straight Tilt Dozer) 902
Pm Clinic 906
Pm Clinic Service 906
Pm Clinic Check Sheet: D85EXI-18 908
Pm Clinic Check Sheet: D85PXI-18 923
Pm Clinic Check Sheet for Undercarriage: D85EXI-18 936
Pm Clinic Check Sheet for Undercarriage: D85PXI-18 940
40 Troubleshooting 945
Table of Contents 946
Precautions Before Work 957
Related Information to Troubleshooting 958
General Troubleshooting Points 958
Troubleshooting Points for Urea SCR System 959
Sequence of Events in Troubleshooting 973
Checks Before Troubleshooting 975
Inspection Procedure Before Troubleshooting 977
Walk-Around Check 977
Test in Accordance with Testing Procedure 979
How to Examine Electric Equipment 979
Preparation for Troubleshooting of Electrical System 986
Procedure for Troubleshooting 994
Symptom and Troubleshooting Numbers 997
Information Shown in Troubleshooting Table 1001
Connector List and Layout 1003
Connector Contact Connection Table 1022
T-Branch Box and T-Branch Adapter Table 1062
Fuse Location Table 1068
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 1071
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 1075
Failure Code Table 1077
Troubleshooting by Failure Code (Display of Code) 1098
Failure Code [1500L0] 1098
Failure Code [15SAL1] 1099
Failure Code [15SALH] 1101
Failure Code [15SBL1] 1103
Failure Code [15SBLH] 1105
Failure Code [15SEL1] 1107
Failure Code [15SELH] 1109
Failure Code [15SFL1] 1111
Failure Code [15SFLH] 1113
Failure Code [15SGL1] 1115
Failure Code [15SGLH] 1117
Failure Code [1800MW] 1119
Failure Code [879AKA] 1120
Failure Code [879AKB] 1121
Failure Code [879BKA] 1122
Failure Code [879BKB] 1124
Failure Code [879CKA] 1126
Failure Code [879CKB] 1127
Failure Code [879DKZ] 1128
Failure Code [879EMC] 1130
Failure Code [879FMC] 1131
Failure Code [879GKX] 1132
Failure Code [989L00] 1134
Failure Code [989M00] 1135
Failure Code [989N00] 1136
Failure Code [A1U0N3] 1137
Failure Code [A1U0N4] 1139
Failure Code [A900FR] 1141
Failure Code [A900N6] 1142
Failure Code [A900NY] 1143
Failure Code [AA10NX] 1144
Failure Code [AB00KE] 1146
Failure Code [AQ10N3] 1148
Failure Code [AS00N3] 1150
Failure Code [AS00R2] 1152
Failure Code [AS00R3] 1153
Failure Code [AS00R4] 1154
Failure Code [AS00R5] 1155
Failure Code [AS00R6] 1156
Failure Code [AS00ZK] 1157
Failure Code [AS10KM] 1158
Failure Code [AS10NR] 1159
Failure Code [AS10NT] 1160
Failure Code [B@BAZG] 1161
Failure Code [B@BCNS] 1162
Failure Code [B@BCZK] 1163
Failure Code [B@CENS] 1165
Failure Code [B@HANS] 1166
Failure Code [CA115] 1167
Failure Code [CA122] 1168
Failure Code [CA123] 1170
Failure Code [CA131] 1172
Failure Code [CA132] 1174
Failure Code [CA135] 1176
Failure Code [CA141] 1178
Failure Code [CA144] 1180
Failure Code [CA145] 1182
Failure Code [CA153] 1184
Failure Code [CA154] 1187
Failure Code [CA187] 1190
Failure Code [CA221] 1192
Failure Code [CA222] 1194
Failure Code [CA227] 1196
Failure Code [CA234] 1197
Failure Code [CA238] 1198
Failure Code [CA239] 1200
Failure Code [CA249] 1202
Failure Code [CA256] 1204
Failure Code [CA271] 1206
Failure Code [CA272] 1208
Failure Code [CA273] 1209
Failure Code [CA274] 1211
Failure Code [CA322] 1212
Failure Code [CA323] 1214
Failure Code [CA324] 1216
Failure Code [CA325] 1218
Failure Code [CA331] 1220
Failure Code [CA332] 1222
Failure Code [CA343] 1224
Failure Code [CA351] 1225
Failure Code [CA352] 1226
Failure Code [CA356] 1229
Failure Code [CA357] 1231
Failure Code [CA386] 1233
Failure Code [CA441] 1234
Failure Code [CA442] 1237
Failure Code [CA449] 1238
Failure Code [CA451] 1239
Failure Code [CA452] 1241
Failure Code [CA515] 1243
Failure Code [CA516] 1245
Failure Code [CA553] 1247
Failure Code [CA555] 1248
Failure Code [CA556] 1249
Failure Code [CA559] 1250
Failure Code [CA595] 1255
Failure Code [CA687] 1256
Failure Code [CA689] 1258
Failure Code [CA691] 1260
Failure Code [CA692] 1262
Failure Code [CA697] 1264
Failure Code [CA698] 1265
Failure Code [CA731] 1266
Failure Code [CA778] 1267
Failure Code [CA1117] 1270
Failure Code [CA1664] 1271
Failure Code [CA1669] 1274
Failure Code [CA1673] 1275
Failure Code [CA1677] 1276
Failure Code [CA1678] 1277
Failure Code [CA1682] 1278
Failure Code [CA1683] 1280
Failure Code [CA1684] 1282
Failure Code [CA1686] 1284
Failure Code [CA1691] 1285
Failure Code [CA1694] 1288
Failure Code [CA1695] 1290
Failure Code [CA1696] 1291
Failure Code [CA1712] 1293
Failure Code [CA1713] 1296
Failure Code [CA1714] 1298
Failure Code [CA1715] 1299
Failure Code [CA1776] 1300
Failure Code [CA1777] 1303
Failure Code [CA1843] 1306
Failure Code [CA1844] 1308
Failure Code [CA1879] 1311
Failure Code [CA1881] 1314
Failure Code [CA1883] 1317
Failure Code [CA1885] 1321
Failure Code [CA1887] 1323
Failure Code [CA1921] 1325
Failure Code [CA1922] 1328
Failure Code [CA1923] 1333
Failure Code [CA1924] 1335
Failure Code [CA1925] 1337
Failure Code [CA1927] 1339
Failure Code [CA1928] 1341
Failure Code [CA1942] 1343
Failure Code [CA1963] 1344
Failure Code [CA1977] 1347
Failure Code [CA1993] 1350
Failure Code [CA2185] 1353
Failure Code [CA2186] 1354
Failure Code [CA2249] 1356
Failure Code [CA2265] 1357
Failure Code [CA2266] 1359
Failure Code [CA2271] 1362
Failure Code [CA2272] 1364
Failure Code [CA2349] 1366
Failure Code [CA2353] 1368
Failure Code [CA2357] 1370
Failure Code [CA2381] 1371
Failure Code [CA2382] 1373
Failure Code [CA2383] 1375
Failure Code [CA2386] 1377
Failure Code [CA2387] 1379
Troubleshooting Flowchart 1383
Failure Code [CA2555] 1384
Failure Code [CA2556] 1387
Failure Code [CA2637] 1389
Failure Code [CA2639] 1391
Failure Code [CA2732] 1394
Failure Code [CA2733] 1396
Failure Code [CA2741] 1398
Failure Code [CA2765] 1399
Failure Code [CA2771] 1400
Failure Code [CA2777] 1406
Failure Code [CA2878] 1409
Failure Code [CA2881] 1412
Failure Code [CA2976] 1415
Failure Code [CA3133] 1417
Failure Code [CA3134] 1419
Failure Code [CA3135] 1421
Failure Code [CA3142] 1425
Failure Code [CA3143] 1426
Failure Code [CA3144] 1427
Failure Code [CA3146] 1429
Failure Code [CA3147] 1430
Failure Code [CA3148] 1431
Failure Code [CA3151] 1433
Failure Code [CA3165] 1439
Failure Code [CA3167] 1441
Failure Code [CA3229] 1444
Failure Code [CA3231] 1446
Failure Code [CA3232] 1448
Failure Code [CA3235] 1452
Failure Code [CA3239] 1454
Failure Code [CA3241] 1457
Failure Code [CA3242] 1460
Failure Code [CA3251] 1463
Failure Code [CA3253] 1466
Failure Code [CA3254] 1470
Failure Code [CA3255] 1473
Failure Code [CA3256] 1477
Failure Code [CA3311] 1479
Failure Code [CA3312] 1481
Failure Code [CA3313] 1484
Failure Code [CA3314] 1485
Failure Code [CA3315] 1486
Failure Code [CA3316] 1489
Failure Code [CA3317] 1490
Failure Code [CA3318] 1491
Failure Code [CA3319] 1494
Failure Code [CA3321] 1495
Failure Code [CA3322] 1497
Failure Code [CA3419] 1500
Failure Code [CA3421] 1502
Failure Code [CA3497] 1504
Failure Code [CA3498] 1505
Failure Code [CA3543] 1506
Failure Code [CA3545] 1513
Failure Code [CA3547] 1515
Failure Code [CA3558] 1516
Failure Code [CA3559] 1518
Failure Code [CA3562] 1520
Failure Code [CA3563] 1522
Failure Code [CA3567] 1525
Failure Code [CA3568] 1528
Failure Code [CA3571] 1532
Failure Code [CA3572] 1534
Failure Code [CA3574] 1536
Failure Code [CA3575] 1538
Failure Code [CA3577] 1540
Failure Code [CA3578] 1542
Failure Code [CA3582] 1544
Failure Code [CA3583] 1551
Failure Code [CA3596] 1553
Failure Code [CA3649] 1555
Failure Code [CA3681] 1557
Failure Code [CA3682] 1562
Failure Code [CA3713] 1568
Failure Code [CA3717] 1571
Failure Code [CA3718] 1572
Failure Code [CA3725] 1573
Failure Code [CA3748] 1576
Failure Code [CA3751] 1579
Failure Code [CA3755] 1581
Failure Code [CA3866] 1583
Failure Code [CA3867] 1587
Failure Code [CA3868] 1590
Failure Code [CA3899] 1594
Failure Code [CA3911] 1596
Failure Code [CA3912] 1600
Failure Code [CA3932] 1602
Failure Code [CA3933] 1604
Failure Code [CA3934] 1606
Failure Code [CA3935] 1609
Failure Code [CA3936] 1611
Failure Code [CA4151] 1613
Failure Code [CA4152] 1617
Failure Code [CA4155] 1621
Failure Code [CA4156] 1623
Failure Code [CA4157] 1626
Failure Code [CA4158] 1628
Failure Code [CA4159] 1629
Failure Code [CA4161] 1630
Failure Code [CA4162] 1633
Failure Code [CA4163] 1636
Failure Code [CA4164] 1638
Failure Code [CA4165] 1640
Failure Code [CA4166] 1642
Failure Code [CA4168] 1644
Failure Code [CA4169] 1647
Failure Code [CA4171] 1649
Failure Code [CA4249] 1652
Failure Code [CA4251] 1654
Failure Code [CA4259] 1656
Failure Code [CA4261] 1659
Failure Code [CA4277] 1661
Failure Code [CA4281] 1665
Failure Code [CA4459] 1669
Failure Code [CA4461] 1672
Failure Code [CA4658] 1675
Failure Code [CA4731] 1679
Failure Code [CA4732] 1680
Failure Code [CA4739] 1681
Failure Code [CA4768] 1682
Failure Code [CA4769] 1684
Failure Code [CA4842] 1687
Failure Code [CA4952] 1691
Failure Code [CA5115] 1693
Failure Code [CA5383] 1696
Failure Code [D130KA] 1698
Failure Code [D130KB] 1701
Failure Code [D19DKA] 1703
Failure Code [D19DKB] 1705
Failure Code [D19JKZ] 1707
Failure Code [D811MC] 1710
Failure Code [D862KA] 1711
Failure Code [D8ALKA] 1712
Failure Code [D8ALKB] 1714
Failure Code [D8AQKR] 1716
Failure Code [DAF0MB] 1718
Failure Code [DAF0MC] 1719
Failure Code [DAF8KB] 1720
Failure Code [DAF9KQ] 1721
Failure Code [DAFGMC] 1722
Failure Code [DAFLKA] 1723
Failure Code [DAFLKB] 1725
Failure Code [DAFQKR] 1727
Failure Code [DAQW00] 1728
Failure Code [DAZ9KQ] 1729
Failure Code [DAZQKR] 1730
Failure Code [DB2QKR] 1731
Failure Code [DB2RKR] 1738
Failure Code [DBE0KT] 1744
Failure Code [DBE1KK] 1745
Failure Code [DBE2KK] 1748
Failure Code [DBE5KK] 1751
Failure Code [DBE6KK] 1753
Failure Code [DBE7KK] 1755
Failure Code [DBE9KQ] 1757
Failure Code [DBELKA] 1758
Failure Code [DBELKB] 1760
Failure Code [DBEQKR] 1762
Failure Code [DBERKR] 1763
Failure Code [DBR0KT] 1765
Failure Code [DBR0MC] 1766
Failure Code [DBR1KK] 1767
Failure Code [DBR2KK] 1770
Failure Code [DBR5KK] 1773
Failure Code [DBR7KK] 1775
Failure Code [DBRLKA] 1777
Failure Code [DBRLKB] 1779
Failure Code [DBRPMA] 1781
Failure Code [DBRQKR] 1782
Failure Code [DBRRKR] 1784
Failure Code [DBTSKR] 1785
Failure Code [DBUTKA] 1788
Failure Code [DD12KA] 1789
Failure Code [DD12KB] 1791
Failure Code [DD13KA] 1793
Failure Code [DD13KB] 1795
Failure Code [DD14KA] 1797
Failure Code [DD14KB] 1799
Failure Code [DDKHKA] 1801
Failure Code [DDKHKB] 1803
Failure Code [DDKQKA] 1805
Failure Code [DDKQKB] 1807
Failure Code [DDKRKA] 1809
Failure Code [DDKRKB] 1811
Failure Code [DDKSKA] 1813
Failure Code [DDKSKB] 1815
Failure Code [DDN7KA] 1817
Failure Code [DDN7KB] 1819
Failure Code [DDNLKA] 1821
Failure Code [DDNLKB] 1823
Failure Code [DGS1KA] 1825
Failure Code [DGS1KX] 1827
Failure Code [DGT1KA] 1829
Failure Code [DGT1KX] 1832
Failure Code [DH21KA] 1834
Failure Code [DH21KY] 1836
Failure Code [DHA4KA] 1838
Failure Code [DHAAMA] 1840
Failure Code [DHACMA] 1842
Failure Code [DHSKKA] 1844
Failure Code [DHSKKY] 1846
Failure Code [DHSLKA] 1848
Failure Code [DHSLKY] 1850
Failure Code [DHSWKA] 1852
Failure Code [DHSWKY] 1854
Failure Code [DHSXKA] 1856
Failure Code [DHSXKY] 1858
Failure Code [DHTDKA] 1860
Failure Code [DHTDKY] 1862
Failure Code [DK10KA] 1864
Failure Code [DK10KB] 1867
Failure Code [DK30KA] 1869
Failure Code [DK30KX] 1872
Failure Code [DK30KY] 1873
Failure Code [DK30KZ] 1875
Failure Code [DK30L8] 1876
Failure Code [DK31KA] 1877
Failure Code [DK31KY] 1880
Failure Code [DK40KA] 1882
Failure Code [DK40KY] 1884
Failure Code [DK55KX] 1886
Failure Code [DK55KZ] 1887
Failure Code [DK55L8] 1888
Failure Code [DK56KA] 1889
Failure Code [DK56KY] 1891
Failure Code [DK57KA] 1893
Failure Code [DK57KY] 1895
Failure Code [DK80KA] 1897
Failure Code [DKH1KA] 1900
Failure Code [DKH1KY] 1903
Failure Code [DKSGL8] 1905
Failure Code [DKSHKA] 1906
Failure Code [DKSHKB] 1908
Failure Code [DKSJKA] 1910
Failure Code [DKSJKB] 1912
Failure Code [DKSKKA] 1914
Failure Code [DKSKKB] 1916
Failure Code [DKSKMB] 1918
Failure Code [DKSLL8] 1920
Failure Code [DKSMKA] 1921
Failure Code [DKSMKB] 1923
Failure Code [DKSNKA] 1925
Failure Code [DKSNKB] 1927
Failure Code [DKSPKA] 1929
Failure Code [DKSPKB] 1931
Failure Code [DKSPMB] 1933
Failure Code [DLM3KA] 1935
Failure Code [DLM3KB] 1937
Failure Code [DLM3MB] 1938
Failure Code [DLT3KA] 1939
Failure Code [DLT3KB] 1941
Failure Code [DR21KX] 1943
Failure Code [DR31KX] 1944
Failure Code [DUMCKB] 1945
Failure Code [DUMCKY] 1947
Failure Code [DV20KB] 1949
Failure Code [DW5AKA] 1951
Failure Code [DW5AKB] 1953
Failure Code [DW5AKY] 1955
Failure Code [DW7BKA] 1957
Failure Code [DW7BKB] 1959
Failure Code [DW7BKY] 1961
Failure Code [DWN1KA] 1962
Failure Code [DWN1KB] 1964
Failure Code [DWN1KY] 1966
Failure Code [DWN2KA] 1968
Failure Code [DWN2KB] 1970
Failure Code [DWN2KY] 1972
Failure Code [DWN5KA] 1973
Failure Code [DWN5KB] 1975
Failure Code [DWN5KY] 1976
Failure Code [DXA2KA] 1978
Failure Code [DXA2KB] 1980
Failure Code [DXA2KY] 1982
Failure Code [DXH4KA] 1983
Failure Code [DXH4KB] 1985
Failure Code [DXH4KY] 1987
Failure Code [DXH5KA] 1989
Failure Code [DXH5KB] 1991
Failure Code [DXH5KY] 1993
Failure Code [DXH6KA] 1995
Failure Code [DXH6KB] 1997
Failure Code [DXH6KY] 1999
Failure Code [DXH7KA] 2001
Failure Code [DXH7KB] 2003
Failure Code [DXH7KY] 2005
Failure Code [DXH8KA] 2007
Failure Code [DXH8KB] 2009
Failure Code [DXH8KY] 2011
Failure Code [DXHRKA] 2013
Failure Code [DXHRKB] 2015
Failure Code [DXHRKY] 2016
Failure Code [DXHSKA] 2018
Failure Code [DXHSKB] 2020
Failure Code [DXHSKY] 2021
Failure Code [DXHTKA] 2023
Failure Code [DXHTKB] 2025
Failure Code [DXHTKY] 2026
Failure Code [DXHUKA] 2027
Failure Code [DXHUKB] 2029
Failure Code [DXHUKY] 2030
Failure Code [DXJ4KA] 2031
Failure Code [DXJ4KB] 2033
Troubleshooting of Electrical System (E-Mode) 2035
Engine Does Not Start (Engine Does Not Crank) 2035
Manual Preheating System Does Not Operate 2042
Automatic Preheating System Does Not Operate 2045
While Preheating is in Operation, Preheating Monitor Does Not Come On 2047
When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 2049
When Starting Switch is Turned to ON Position (with Engine Stopped), Basic Check Monitor Comes On 2053
Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation 2054
Charge Level Monitor Comes On in Red While Engine is in Operation 2055
Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 2057
Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation 2058
Power Train Oil Temperature Monitor Comes On in Red While Engine Runs 2059
Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 2060
Engine Coolant Temperature Gauge Does Not Show Correct Temperature 2061
DEF Level is Not Shown Correctly 2062
Fuel Gauge Does Not Show Normally 2065
Power Train Oil Temperature Gauge Does Not Show Correct Temperature 2067
Hydraulic Oil Temperature Gauge Does Not Show Correct Temperature 2068
Operation Mode Does Not Change 2069
Gear Shift Mode Does Not Change 2070
When You Operate Customize Switch Does Not Show Customize Screen 2071
When You Change Setting on Customize Screen, Setting of Machine is Not Changed 2072
Some Areas of Machine Monitor Screen are Not Shown 2073
REVERSE Slow Mode Function Does Not Operate Correctly 2074
Alarm Buzzer Does Not Operate or Does Not Stop Operation 2075
Service Meter is Not Shown While Starting Switch is in OFF Position 2076
Service Mode Cannot be Selected 2077
Horn Does Not Sound 2078
Horn Does Not Stop 2080
Backup Alarm Does Not Sound 2081
Backup Alarm Does Not Stop Operation 2083
Headlamp Does Not Come On 2084
Rear Lamp Does Not Come On 2088
No Wiper Operates 2091
Front Wiper Does Not Operate 2095
Rear Wiper Does Not Operate 2098
Left Door Wiper Does Not Operate 2101
Right Door Wiper Does Not Operate 2104
Front Washer Does Not Operate 2107
Rear Washer Does Not Operate 2109
Left Door Washer Does Not Operate 2111
Right Door Washer Does Not Operate 2113
KOMTRAX System Does Not Operate Correctly 2115
Control Box Shuts Down After It Shows Messages [GPS receiver not connected!] and [Slope sensor not connected!] 2116
Control Box Shows Messages [GPS receiver not connected !] and [Slope sensor not connected !] 2120
Control Box Shows Message [Waiting for radio link ] 2123
Control Box Shows Message [IMU sensor not connected] Show Production 2124
Control Box Shows Message [Waiting for satellites ] 2125
Control Box Shows Message [Komatsu controller not connected!] Show Production 2126
Control Box Shows Message [Cylinder Stroke Reading Abnormal] 2128
Control Box Shows Message [Komatsu CAN Comms Abnormal] 2129
Control Box Shows Message [Komatsu Machine Trouble] 2130
Control Box Shows Message [Waiting to initialize ] 2131
Control Box Shows Message [System initializing] 2132
Control Box Shows Message [Initializing ] 2133
Control Box Shows Message [Configuring GPS] 2134
Control Box Shows Message [No GPS Localization ] 2135
Control Box Shows Message [Low precisions ] 2136
Control Box Shows Message [Heading Initializing] 2137
Control Box Displays [Out of design area ] 2138
Control Box Can Not be Turned on 2139
Control Box Does Not Display Intelligent Machine Control Screen 2140
Control Box Does Not Display Bulldozer Image 2141
Control Box Does Not Display Design Surface 2142
Control Box Touch Panel Does Not Respond 2143
Control Box Touch Panel is Inaccurate 2144
Cylinder Stroke Reset Indication Does Not Go Out 2145
AUTO is Not Shown When AUTO/Manual Switch is Pushed (AUTO Indication Goes off) 2146
Blade Automatic Lower Control Does Not Start While AUTO is Shown 2147
Blade Automatic Raise Control Does Not Start While AUTO is Shown 2148
Blade Automatic Control Function is Not Activated While AUTO is Shown (Blade Automatic Control Stops) 2149
When You Examine and Adjust the Blade Elevation, the Value is Different from Actual Machine 2150
Finished Surface is Inaccurate (The Average Height of Finished Surface is Lower Than Designed Surface or Blade Does Not Touch the Surface) 2151
Finished Surface is Inaccurate (The Finished Surface is Not Smooth) 2152
Finished Surface is Inaccurate (When You Finish Slope Horizontally, Steps are Made in Each Direction) 2153
Machine Cannot Escape from Shoes Slip While Blade Automatic Control is Activated (Shoes Frequently Slips) 2155
Blade Tilt Angle Does Not Align with Design Surface 2156
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 2158
Information Shown in Troubleshooting Table (H-Mode) 2158
Failure Mode and Cause Table 2159
Machine Lacks Power (Drawbar Pull is Not Sufficient) 2165
Machine Does Not Travel (at 2nd or 3rd Gear Speed) 2167
Machine Does Not Move Off at All Gear Speeds 2168
Machine Travels Only in One Direction, Forward or in Reverse 2170
Large Time Lag is in Gear Shifting or Directional Change 2171
Brake Does Not Work 2173
Power Train Oil Overheats 2174
Unusual Noise is Heard from Around Work Equipment and HSS Pump or HSS Motor 2176
Machine Cannot be Steered (Machine Does Not Turn LEFT or RIGHT) 2177
Steering Speed or Power is Not Sufficient 2178
All Work Equipment Operate Slowly 2179
All Work Equipment Do Not Operate 2180
Blade Lift Speed or Power is Low 2181
Blade Tilt Speed or Power is Low 2182
Ripper Lift Speed or Power is Low 2183
Hydraulic Drift of Blade Lift is Large 2184
Hydraulic Drift of Tilted Blade is Large 2185
Hydraulic Drift of Lifted Ripper is Large 2186
Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) 2187
Unusual Noise is Heard from Around Fan 2189
Troubleshooting of Engine (S-Mode) 2190
Information Shown in Troubleshooting Table (S-Mode) 2190
Engine Does Not Crank When Starting Switch is Turned to Start Position 2191
Engine Cranks but No Exhaust Smoke Comes Out 2192
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 2193
Engine Startability is Unsatisfactory 2194
Engine Does Not Pick Up Smoothly 2196
Engine Stops During Operation 2198
Engine Does Not Rotate Smoothly 2200
Engine Lacks Output (or Lacks Power) 2201
KDPF Becomes Clogged in a Short Time 2203
Engine Oil Consumption is Excessive 2205
Engine Oil Becomes Dirty Quickly 2206
Fuel Consumption is Excessive 2207
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down) 2208
Engine Oil Pressure Drops 2209
Fuel Mixes Into Engine Oil 2211
Water Mixes Into Engine Oil (Milky) 2212
Coolant Temperature Increases Too High (Overheat) 2213
Unusual Noise is Heard 2214
Vibration is Excessive 2215
Air Cannot be Bled from Fuel Circuit 2216
Active Regeneration is Done Frequently 2217
Active Regeneration Continues Long 2219
White Smoke is Exhausted During Active Regeneration 2220
DEF Consumption is Excessive 2221
There is an Unusual Smell (Irritating Odor) 2223
Foreign Materials Enter DEF (DEF Increases) 2224
50 Disassembly and Assembly 2225
Table of Contents 2226
Precautions Before Work 2232
Related Information on Disassembly and Assembly 2233
How to Read This Manual 2233
Coating Materials List 2234
Special Tool List 2239
Sketches of Special Tools 2264
Engine and Cooling System 2272
Remove and Install Supply Pump Assembly 2272
How to Remove Supply Pump Assembly 2273
How to Install Supply Pump Assembly 2277
Remove and Install Injector Assembly 2284
How to Remove Injector Assembly 2285
How to Install Injector Assembly 2291
Remove and Install Fuel Doser Assembly 2302
How to Remove Fuel Doser Assembly 2302
How to Install Fuel Doser Assembly 2303
Remove and Install Cylinder Head Assembly 2305
How to Remove Cylinder Head Assembly 2305
How to Install Cylinder Head Assembly 2312
Remove and Install EGR Valve Assembly 2321
How to Remove EGR Valve Assembly 2321
How to Install EGR Valve Assembly 2323
Remove and Install EGR Cooler Assembly 2326
How to Remove EGR Cooler Assembly 2327
How to Install EGR Cooler Assembly 2331
Remove and Install Starter Assembly 2336
How to Remove Starting Motor Assembly 2336
How to Install Starting Motor Assembly 2338
Remove and Install Alternator Belt 2340
How to Remove Alternator Belt 2340
How to Install Alternator Belt 2342
Remove and Install Radiator Assembly 2344
How to Remove Radiator Assembly 2345
How to Install Radiator Assembly 2349
Remove and Install Hydraulic Oil Cooler Assembly 2355
How to Remove Hydraulic Oil Cooler Assembly 2356
How to Install Hydraulic Oil Cooler Assembly 2360
Remove and Install Aftercooler Assembly 2364
How to Remove Aftercooler Assembly 2364
How to Install Aftercooler Assembly 2365
Remove and Install Cooling Fan Drive Assembly 2366
How to Remove Cooling Fan Drive Assembly 2366
How to Install Cooling Fan Drive Assembly 2367
Remove and Install Cooling Fan Motor Assembly 2370
How to Remove Cooling Fan Motor Assembly 2370
How to Install Cooling Fan Motor Assembly 2372
Remove and Install Engine Assembly 2374
How to Remove Engine Assembly 2375
How to Install Engine Assembly 2382
Remove and Install Engine Front Oil Seal 2388
How to Remove Engine Front Oil Seal 2388
How to Install Engine Front Oil Seal 2389
Remove and Install Engine Rear Oil Seal 2392
How to Remove Engine Rear Oil Seal 2392
How to Install Engine Rear Oil Seal 2394
Remove and Install Engine Oil Pan 2399
How to Remove Engine Oil Pan 2399
How to Install Engine Oil Pan 2400
Remove and Install Engine Hood Assembly 2402
How to Remove Engine Hood Assembly 2402
How to Install Engine Hood Assembly 2404
Remove and Install Fuel Tank Assembly 2406
How to Remove Fuel Tank Assembly 2406
How to Install Fuel Tank Assembly 2408
Remove and Install DEF Tank Assembly 2411
How to Remove DEF Tank Assembly 2411
How to Install DEF Tank Assembly 2416
Remove and Install DEF Tank Sensor Flange Assembly 2420
How to Remove DEF Tank Sensor Flange Assembly 2420
How to Install DEF Tank Sensor Flange Assembly 2425
Remove and Install DEF Tank Sensor 2430
How to Remove DEF Tank Sensor 2430
How to Install DEF Tank Sensor 2430
Remove and Install DEF Strainer 2437
How to Remove DEF Strainer 2437
How to Install DEF Strainer 2437
Remove and Install DEF Tank Filler Port Filter 2438
How to Remove DEF Tank Filler Port Filter 2438
How to Install DEF Tank Filler Port Filter 2439
Remove and Install KDPF Assembly 2441
How to Remove KDPF Assembly 2441
How to Install KDPF Assembly 2445
Disassemble and Assemble KDPF Assembly 2450
How to Disassemble KDPF Assembly 2450
How to Assemble KDPF Assembly 2454
Remove and Install SCR Assembly 2458
How to Remove SCR Assembly 2458
How to Install SCR Assembly 2461
Remove and Install KDPF and SCR Assembly 2464
How to Remove KDPF and SCR Assembly 2464
How to Install KDPF and SCR Assembly 2474
Remove and Install KCCV Assembly 2484
How to Remove KCCV Assembly 2484
How to Install KCCV Assembly 2487
Remove and Install DEF Mixing Tube 2491
How to Remove DEF Mixing Tube 2491
How to Install DEF Mixing Tube 2494
Remove and Install DEF Injector 2500
How to Remove DEF Injector 2500
How to Install DEF Injector 2503
Remove and Install DEF Pump 2506
How to Remove DEF Pump 2506
How to Install DEF Pump 2509
Remove and Install DEF Hose 2513
How to Remove DEF Hose 2513
How to Install DEF Hose 2518
Remove and Install Air Cleaner Assembly 2524
How to Remove Air Cleaner Assembly 2524
How to Install Air Cleaner Assembly 2525
Remove and Install Air Conditioner Compressor Assembly 2526
How to Remove Air Conditioner Compressor Assembly 2526
How to Install Air Conditioner Compressor Assembly 2528
Power Train 2530
Remove and Install Damper Assembly 2530
How to Remove Damper Assembly 2530
How to Install Damper Assembly 2533
Disassemble and Assemble Damper Assembly 2536
How to Disassemble Damper Assembly 2537
How to Assemble Damper Assembly 2538
Remove and Install Power Train Unit Assembly 2541
How to Remove Power Train Unit Assembly 2541
How to Install Power Train Unit Assembly 2546
Disconnect and Connect Power Train Unit Assembly 2552
How to Disconnect Power Train Unit Assembly 2552
How to Connect Power Train Unit Assembly 2557
Disassemble and Assemble PTO Assembly 2562
How to Disassemble PTO Assembly 2562
How to Assemble PTO Assembly 2566
Disassemble and Assemble Torque Converter Assembly 2571
How to Disassemble Torque Converter Assembly 2571
How to Assemble Torque Converter Assembly 2574
Disassemble and Assemble Transmission Assembly 2578
How to Disassemble Transmission Assembly 2579
How to Assemble Transmission Assembly 2587
Disassemble and Assemble HSS Assembly 2599
How to Disassemble HSS Assembly 2601
How to Assemble HSS Assembly 2611
Remove and Install HSS Motor Assembly 2629
How to Remove HSS Motor Assembly 2629
How to Install HSS Motor Assembly 2630
Remove and Install Final Drive Assembly 2631
How to Remove Final Drive Assembly 2631
How to Install Final Drive Assembly 2633
Disassemble and Assemble Final Drive Assembly 2635
How to Disassemble Final Drive Assembly 2636
How to Assemble Final Drive Assembly 2643
Undercarriage and Frame 2655
Remove and Install Track Frame Assembly 2655
How to Remove Track Frame Assembly 2655
How to Install Track Frame Assembly 2658
Remove and Install Idler Assembly 2662
How to Remove Idler Assembly 2662
How to Install Idler Assembly 2663
Disassemble and Assemble Idler Assembly 2666
How to Disassemble Idler Assembly 2666
How to Assemble Idler Assembly 2668
Remove and Install Recoil Spring Assembly 2672
How to Remove Recoil Spring Assembly 2672
How to Install Recoil Spring Assembly 2674
Disassemble and Assemble Recoil Spring Assembly 2676
How to Disassemble Recoil Spring Assembly 2676
How to Assemble Recoil Spring Assembly 2680
Remove and Install Track Roller Assembly 2683
How to Remove Track Roller Assembly 2683
How to Install Track Roller Assembly 2685
Disassemble and Assemble Track Roller Assembly 2688
How to Disassemble Track Roller Assembly 2688
How to Assemble Track Roller Assembly 2689
Remove and Install Carrier Roller Assembly 2693
How to Remove Carrier Roller Assembly 2693
How to Install Carrier Roller Assembly 2694
Disassemble and Assemble Carrier Roller Assembly 2695
How to Disassemble Carrier Roller Assembly 2695
How to Assemble Carrier Roller Assembly 2696
Remove and Install Pivot Shaft Assembly 2699
How to Remove Pivot Shaft Assembly 2699
How to Install Pivot Shaft Assembly 2700
Separate and Connect Track Assembly 2702
How to Examine Before Separation of Track Assembly 2702
How to Separate Track Assembly (Standard) 2702
How to Separate Track Assembly (When Track Frame Has Internal Defect) 2703
How to Install Track Assembly 2705
Separate and Connect PLUS Type Track Assembly 2708
Separate PLUS Type Track Assembly Generally 2708
Install PLUS Type Track Assembly 2708
Disassemble and Assemble Track Assembly Generally 2709
How to Disassemble Full Track Shoes Assembly 2709
How to Assemble Full Track Shoes Assembly 2712
Disassemble and Assemble PLUS Type Track Assembly Generally 2725
Disassemble PLUS Type Track Assembly Generally 2725
How to Assemble PLUS Type Track Shoes Assembly Generally 2726
Disassemble and Assemble One Track Link Assembly in Field 2734
How to Disassemble One Track Link Assembly in Field 2736
How to Assemble One Track Link Assembly in Field 2736
Disassemble and Assemble Master Link 2744
How to Disassemble Master Link 2745
How to Assemble Master Link 2745
Remove and Install Equalizer Bar Assembly 2749
How to Remove Equalizer Bar Assembly 2749
How to Install Equalizer Bar Assembly 2751
Disassemble and Assemble Equalizer Bar Bushing 2752
How to Disassemble Equalizer Bar Bushing 2752
How to Assemble Equalizer Bar Bushing 2753
Open and Close Center Under Guard 2754
How to Open Under Guard 2754
How to Close Under Guard 2755
Remove and Install Center Under Guard Assembly 2757
How to Remove Underguard Assembly 2757
How to Install Underguard Assembly 2764
Hydraulic System 2772
Remove and Install Hydraulic Tank Assembly 2772
How to Remove Hydraulic Tank Assembly 2772
How to Install Hydraulic Tank Assembly 2775
Remove and Install Work Equipment Pump and HSS Pump Assembly 2779
How to Remove Work Equipment Pump and HSS Pump Assembly 2779
How to Install Work Equipment Pump and HSS Pump Assembly 2782
Remove and Install Power Train Pump and Steering Lubrication Pump Assembly 2784
How to Remove Power Train Pump and Steering Lubrication Pump Assembly 2784
How to Install Power Train Pump and Steering Lubrication Pump Assembly 2786
Remove and Install Cooling Fan Pump Assembly 2788
How to Remove Cooling Fan Pump Assembly 2788
How to Install Cooling Fan Pump Assembly 2790
Remove and Install Scavenging Pump Assembly 2793
How to Remove Scavenging Pump Assembly 2793
How to Install Scavenging Pump Assembly 2794
Remove and Install Control Valve Assembly 2796
How to Remove Control Valve Assembly 2796
How to Install Control Valve Assembly 2801
Work Equipment 2806
Remove and Install Blade Assembly 2806
How to Remove Blade Assembly 2806
How to Install Blade Assembly 2808
Disassemble and Assemble Fixed Multi-Shank Ripper Assembly 2812
How to Disassemble Fixed Multi-Shank Ripper Assembly 2812
How to Assemble Fixed Multi-Shank Ripper Assembly 2814
Remove and Install Stroke and Reset Sensing Blade Lift Cylinder Assembly 2817
How to Remove Stroke and Reset Sensing Blade Lift Cylinder Assembly 2818
How to Install Stroke and Reset Sensing Blade Lift Cylinder Assembly 2823
Disassemble and Assemble Stroke and Reset Sensing Blade Lift Cylinder Assembly 2828
How to Disassemble Stroke and Reset Sensing Blade Lift Cylinder Assembly 2829
How to Assemble Stroke and Reset Sensing Blade Lift Cylinder Assembly 2834
Disassemble and Assemble Work Equipment Cylinder Assembly 2844
How to Disassemble Work Equipment Cylinder Assembly 2845
How to Assemble Work Equipment Cylinder Assembly 2847
CAB Related Parts 2850
Remove and Install Operator Cab Assembly 2850
How to Remove Operator Cab Assembly 2850
How to Install Operator Cab Assembly 2858
Remove and Install Operator Cab Glass (Adhered Glass) 2867
How to Remove Operator Cab Glass (Adhered Glass) 2867
How to Install Operator Cab Glass (Adhered Glass) 2868
Remove and Install Air Conditioner Unit Assembly 2873
How to Remove Air Conditioner Unit Assembly 2873
How to Install Air Conditioner Unit Assembly 2878
Remove and Install Operator Seat 2883
How to Remove Operator Seat 2883
How to Install Operator Seat 2885
How to Remove and Install Seat Belt 2887
How to Remove Seat Belt 2887
How to Install Seatbelt 2888
Electrical System 2889
Remove and Install Engine Controller Assembly 2889
How to Remove Engine Controller Assembly 2889
How to Install Engine Controller Assembly 2890
Remove and Install Power Train Controller Assembly 2894
How to Remove Power Train Controller Assembly 2894
How to Install Power Train Controller Assembly 2895
Remove and Install Machine Monitor Assembly 2897
How to Remove Machine Monitor Assembly 2897
How to Install Machine Monitor Assembly 2898
Remove and Install Mass Air Flow and Temperature Sensor 2900
How to Remove Mass Air Flow and Temperature Sensor 2900
How to Install Mass Air Flow and Temperature Sensor 2901
Remove and Install KCCV Crankcase Pressure Sensor 2903
How to Remove KCCV Crankcase Pressure Sensor 2903
How to Install KCCV Crankcase Pressure Sensor 2905
Remove and Install SCR Temperature Sensor 2907
How to Remove SCR Temperature Sensor 2907
How to Install SCR Temperature Sensor 2909
Remove and Install KOMTRAX Terminal Assembly 2911
How to Remove KOMTRAX Terminal Assembly 2911
How to Install KOMTRAX Terminal Assembly 2914
Remove and Install Control Box 2917
How to Remove Control Box (For Old Control Box) 2917
How to Remove Control Box (For New Control Box) 2918
How to Install Control Box (For Old Control Box) 2918
How to Install Control Box (For New Control Box) 2919
Remove and Install GNSS Receiver 2921
How to Remove GNSS Receiver 2921
How to Install GNSS Receiver 2922
Remove and Install GNSS Antenna 2923
How to Remove GNSS Antenna 2923
How to Install GNSS Antenna 2924
Remove and Install IMU Sensor 2929
How to Remove IMU Sensor 2929
How to Install IMU Sensor 2930
60 Maintenance Standard 2933
Table of Contents 2934
Engine and Cooling System 2936
Maintenance Standard for Engine Mount 2936
Maintenance Standard for Damper 2938
Maintenance Standard for Cooling System 2940
Maintenance Standard for Cooling Fan Pump 2942
Maintenance Standard for Servo Valve 2943
Maintenance Standard for Cooling Fan Motor 2944
Power Train 2946
Maintenance Standard for Universal Joint 2946
Maintenance Standard for Power Train Mount 2947
Maintenance Standard for Torque Converter and PTO 2948
Maintenance Standard for Transmission 2951
Maintenance Standard for Transmission ECMV 2956
Maintenance Standard for Main Relief Valve and Torque Converter Relief Valve 2957
Maintenance Standard for Transmission Lubrication Relief Valve 2958
Maintenance Standard for Bevel Gear Shaft, HSS, and Brake 2959
Maintenance Standard for Brake Valve 2963
Maintenance Standard for Final Drive 2965
Maintenance Standard for Sprocket for Conventional Type Track Shoes 2968
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for Conventional Type Track Shoes 2969
Maintenance Standard for Sprocket for PLUS Type Track Shoes 2971
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for PLUS Type Track Shoes 2972
Undercarriage and Frame 2974
Maintenance Standard for Main Frame 2974
Maintenance Standard for Suspension 2976
Maintenance Standard for Track Frame and Idler Cushion 2980
Maintenance Standard for Idler 2982
Maintenance Standard for Track Roller for Conventional Type Track Shoes (Single Flange Type) 2984
Maintenance Standard for Track Roller for Conventional Type Track Shoes (Double Flange Type) 2986
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Single Flange Type) 2988
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Double Flange Type) 2990
Maintenance Standard for Carrier Roller for Conventional Type Track Shoes 2992
Maintenance Standard for Carrier Roller for PLUS Type Track Shoes 2994
Maintenance Standard for Conventional Type Track Shoes 2996
Maintenance Standard for PLUS Type Track Shoes 2998
Maintenance Standard for Single Shoes and Heavy Duty Shoes 3000
Hydraulic System 3001
Maintenance Standard for Hydraulic Tank 3001
Maintenance Standard for Scavenging Pump 3002
Maintenance Standard for Steering Lubrication Pump and Power Train Pump 3003
Maintenance Standard for Work Equipment and HSS Pump 3005
Maintenance Standard for HSS Motor 3006
Maintenance Standard for Control Valve 3008
Maintenance Standard for Blade PPC Valve 3015
Maintenance Standard for Ripper PPC Valve (Fixed Multi-Shank Ripper) 3017
Maintenance Standard for Quick Drop Valve 3019
Maintenance Standard for Work Equipment Lock Solenoid Valve 3020
Work Equipment 3021
Maintenance Standard for Cylinder Stay 3021
Maintenance Standard for Front Work Equipment 3022
Maintenance Standard for Cutting Edge and End Bit (Straight Blade) 3026
Maintenance Standard for Cutting Edge and End Bit (SIGMA Blade) 3027
Maintenance Standard for Stroke and Reset Sensing Blade Lift Cylinder 3028
Maintenance Standard for Blade Tilt Cylinder 3029
Maintenance Standard for Blade Pitch Cylinder (For Power Tilt Pitch Dozer Series) 3030
Maintenance Standard for Stroke and Reset Sensor for Blade Lift Cylinder 3031
Maintenance Standard for Fixed Multi-Shank Ripper 3032
Maintenance Standard for Ripper Lift Cylinder (Fixed Multi-Shank Ripper) 3035
CAB Related Parts 3036
Maintenance Standard for CAB Mount 3036
80 Appendix 3037
Table of Contents 3038
Precautions Before Work 3040
Air Conditioner System 3041
Precautions for Refrigerant 3041
Air Conditioner Component 3042
Specifications of Air Conditioner 3044
Structure and Function of Refrigeration Cycle 3045
Outline of Refrigeration Cycle 3046
Component Parts of Air Conditioner System 3048
Air Conditioner Unit 3048
Configuration Diagram of Air Conditioner Unit 3048
Function of Air Conditioner Unit 3050
Component Parts of Air Conditioner Unit 3052
Function of Evaporator as Air Conditioner Unit Component 3053
Function of Heater Core as Air Conditioner Unit Component 3053
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component 3053
Function of Servo Motor as Air Conditioner Unit Component 3053
Structure of Expansion Valve as Air Conditioner Unit Component 3054
Function of Expansion Valve as Air Conditioner Unit Component 3054
Operate Expansion Valve as Air Conditioner Unit Component 3054
Function of Dual Pressure Switch 3055
Air Conditioner Controller 3056
Structure of Air Conditioner Controller 3056
Compressor 3057
Structure of Compressor 3057
Specifications of Compressor 3057
Function of Compressor 3057
Condenser 3058
Structure of Condenser 3058
Specifications of Condenser 3058
Function of Condenser 3058
Structure of Wide Core Condenser 3059
Specifications of Wide Core Condenser 3059
Function of Wide Core Condenser 3059
Receiver Drier 3060
Structure of Receiver Dryer 3060
Specifications of Receiver Dryer 3060
Function of Receiver Dryer 3060
Air Conditioner Related Sensors 3061
Structure of Sunlight Sensor 3061
Function of Sunlight Sensor 3061
Structure of Outside Temperature Sensor 3061
Function of Outside Air Temperature Sensor 3061
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 3063
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 3065
System Diagram of Air Conditioner 3067
Input and Output Signals of Air Conditioner Controller 3068
Function of Air Conditioner Controller 3069
Locations of Air Conditioner Parts and Layout of Connectors 3070
Examine Air Leakage (Duct) 3079
How to Examine Air Leakage (Duct) 3079
Explanation for Test of Air Conditioner with Self-Diagnosis Function 3082
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor 3083
Examine Vent (Mode) Changeover 3084
How to Examine Vent (Mode) Changeover 3084
Examine Fresh/Recirc Air Changeover 3085
How to Examine Fresh/Recirc Air Changeover 3085
Examine Sunlight Sensor 3086
How to Examine Sunlight Sensor 3086
Examine Refrigerant (Dual) Pressure Switch 3087
How to Examine Refrigerant (Dual) Pressure Switch 3087
Examine Relay 3088
How to Examine Relay 3088
Air Conditioner Troubleshooting Chart 1 3089
Air Conditioner Troubleshooting Chart 2 3090
Information Shown in Troubleshooting Table 3093
Failure Code [879AKA] 3094
Failure Code [879AKB] 3095
Failure Code [879BKA] 3096
Failure Code [879BKB] 3098
Failure Code [879CKA] 3100
Failure Code [879CKB] 3101
Failure Code [879DKZ] 3102
Failure Code [879EMC] 3104
Failure Code [879FMC] 3105
Failure Code [879GKX] 3106
Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 3108
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 3110
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 3114
Troubleshooting for Fresh/Recirc Air Changeover 3116
Troubleshooting by Gauge Pressure 3118
Connect Service Tool 3121
How to Connect Service Tool 3121
Precautions for Disconnection and Connection of Air Conditioner Piping 3123
Handle Compressor Oil 3125
90 Circuit Diagrams 3127
Table of Contents 3128
Hydraulic Circuit Diagram 3129
Symbols Used in Hydraulic Circuit Diagram 3129
Hydraulic Circuit Diagram (For Power Tilt Pitch Dozer and Fixed Multi-Shank Ripper) 3133
Hydraulic Circuit Diagram (For Power Tilt Dozer) 3135
Hydraulic Circuit Diagram (For Power Tilt Dozer and Specification Which is Able to Pick Up Rear Oil Pressure) 3137
Hydraulic Circuit Diagram (For Power Tilt Pitch Dozer, Fixed Multi-Shank Ripper, and ICT) 3139
Power Train Hydraulic Circuit Diagram 3141
Electrical Circuit Diagram 3143
Symbols Used in Electric Circuit Diagram 3143
Electrical Circuit Diagram (1/14) 3147
Electrical Circuit Diagram (2/14) 3149
Electrical Circuit Diagram (3/14) 3151
Electrical Circuit Diagram (4/14) 3153
Electrical Circuit Diagram (5/14) 3155
Electrical Circuit Diagram (6/14) 3157
Electrical Circuit Diagram (7/14) 3159
Electrical Circuit Diagram (8/14) 3161
Electrical Circuit Diagram (9/14) 3163
Electrical Circuit Diagram (10/14) 3165
Electrical Circuit Diagram (11/14) 3167
Electrical Circuit Diagram (12/14) 3169
Electrical Circuit Diagram (13/14) 3171
Electrical Circuit Diagram (14/14) 3173
Index 3175

S.V  21/12/24