Komatsu D85EXi -18E0,D85PXi-18E0 Bulldozer Shop Manual SEN06910-06 PDF
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Komatsu D85EXi -18E0,D85PXi-18E0 Bulldozer Shop Manual SEN06910-06 – PDF DOWNLOAD
- SERIAL NUMBERS 25001 and up
Description
Komatsu D85EXi -18E0,D85PXi-18E0 Bulldozer Shop Manual SEN06910-06 – PDF DOWNLOAD
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Komatsu D85EXi -18E0,D85PXi-18E0 Bulldozer Shop Manual SEN06910-06 – PDF DOWNLOAD
Language : English
Pages : 3318
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
Komatsu D85EXi -18E0,D85PXi-18E0 Bulldozer Shop Manual SEN06910-06 – PDF DOWNLOAD
- SERIAL NUMBERS 25001 and up
Cover 1
00 Index and Foreword . 3
Index . 4
Abbreviation List . 24
Foreword, Safety, Basic Information . 27
How to Read the Shop Manual . 27
Safety Notice for Operation . 29
Precautions to Prevent Fire . 37
Procedures If Fire Occurs . 39
Precautions When You Discard Waste Materials 40
Procedures for Exhaust Gas Regulations 41
Precautions for DEF . 42
General Character and Precautions for Handling 42
Precautions for Adding 42
Precautions for Storage . 42
Precautions for Fire Hazard and Leakage . 42
Other Precautions . 42
Store DEF . 43
Precautions When You Handle Hydraulic Equipment . 44
Precautions When You Disconnect and Connect Pipings . 47
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-18E0 95
Specification Drawing: D85PXI-18E0 96
Specifications 98
Specification: D85EXI-18E0 98
Specification: D85PXI-18E0 103
Weight Table 108
Weight Table: D85EXI-18E0 . 108
Weight Table: D85PXI-18E0 . 110
Fuel, Coolant, Lubricant 112
How to Use Fuel, Coolant and Lubricants by Ambient Temperature 112
10 Structure and Function . 115
Table of Contents . 116
Urea SCR System . 120
Layout Drawing of Urea SCR System . 120
Urea SCR System Diagram . 123
Function of Urea SCR System . 124
Function of DEF System 124
Inducement Strategy . 126
Component Parts of Urea SCR System 141
DEF Mixing Tube . 141
SCR Assembly 141
DEF Tank 144
DEF Pump 146
DEF Injector 147
DEF Hose 148
DEF Tank Heating Valve 149
Boot-up System 150
Layout Drawing of Boot-up System 150
System Operating Lamp System 151
System Diagram of System Operating Lamp System 151
Function of Operation Lamp System . 151
Battery Disconnect Switch . 152
Layout Drawing of Battery Disconnect Switch . 152
Function of Battery Disconnect Switch . 152
Engine System . 154
Layout Drawing of Engine System . 154
Engine Control System . 156
Layout Drawing of Engine Control System . 156
System Diagram of Engine Control 157
Function of Engine Control System . 159
Automatic Idle Stop System 161
System Diagram of Automatic Idle Stop System 161
Function of Automatic Idle Stop System 161
Component Parts of Engine System 164
Damper 164
VGT . 165
EGR System 169
EGR Valve . 171
EGR Cooler 173
KCCV System . 174
KCCV Ventilator . 176
KDPF 178
Cooling System 183
Layout Drawing of Cooling System 183
Specifications of Cooling System 184
Cooling Fan Control System 185
System Diagram of Cooling Fan Control System 185
Function of Cooling Fan Control System 186
Component Parts of Cooling System . 188
Cooling Fan Pump 188
Cooling Fan Motor . 197
Hydraulic Oil Cooler Bypass Valve . 204
Control System 205
Layout Drawing of Control System 205
Machine Monitor System 206
System Diagram of Machine Monitor System 206
Function of Machine Monitor System 206
KOMTRAX System 208
System Diagram of KOMTRAX System 208
Function of KOMTRAX System 208
Component Parts of Control System . 209
Machine Monitor . 209
Gateway Function Controller . 225
Communication Terminal 228
Power Train Controller 230
Engine Controller . 234
Fuel Feed Pump 240
Fuel Feed Pump Switch . 241
Hydraulic System 242
Layout Drawing of Hydraulic System 242
CLSS 243
Structure of CLSS . 243
Function of CLSS 244
Component Parts of Hydraulic System . 246
Hydraulic Tank 246
Work Equipment and HSS Pump . 247
LS Valve 256
TVC Valve . 260
Variable Throttle Valve . 264
Control Valve . 266
Power Train System 300
Layout Drawing of Power Train System 300
Operation of Power Train System . 302
Transmission, Steering, and Brake Control . 303
Layout Drawing of Transmission, Steering, and Brake Control System 303
Function of Transmission, Steering, and Brake Control . 304
Palm Command Control System . 306
Palm Command Control System Diagram . 306
HSS System 310
HSS System Diagram 310
Function of HSS System 311
Centralized Pressure Pickup Port 313
Layout Drawing of Centralized Pressure Pickup Port 313
Function of Centralized Pressure Pickup Port 314
Component Parts of Power Train System . 315
Universal Joint . 315
Power Train Mount . 316
Torque Converter and PTO 317
Transmission 320
Transmission ECMV . 330
Main Relief Valve and Torque Converter Relief Valve . 336
Transmission Lubrication Relief Valve . 338
Bevel Gear Shaft, HSS, and Brake 338
Brake Valve . 358
Final Drive . 361
Scavenging Pump . 365
Steering Lubrication Pump and Power Train Pump 366
HSS Motor . 367
Electric Steering Electric Lever 372
Work Equipment System . 376
Work Equipment Control 376
Layout Drawing of Work Equipment Control 376
Function of Work Equipment Control 377
Layout Drawing of Front Work Equipment 379
Layout Drawing of Fixed Multi-Shank Ripper 380
Component Parts of Work Equipment System 381
Self-Pressure Reducing Valve 381
Work Equipment Lock Solenoid Valve 387
Blade PPC Valve . 388
Ripper PPC Valve 394
Blade Pitch Selector Solenoid Valve . 397
Pilot Circuit Accumulator . 399
Quick Drop Valve 400
Piston Valve 401
ICT System 403
Layout Drawing of ICT System 403
System Diagram of ICT Control System 405
Blade Control System 407
Function of Blade Control System 407
Simple Grading Mode System Diagram 409
Function of Simple Grading Mode . 410
Operation of Simple Grading Mode 410
Cut Control System Diagram 411
Function of Cut Control System 412
Operation of Cut Control System . 413
Smooth Start System . 424
Smooth Start System Diagram . 424
Function of Smooth Start System . 424
Operation of Smooth Start System 425
Slip Control System . 426
Slip Control System Diagram . 426
Function of Slip Control System . 427
Operation of Slip Control System 427
Assist Control System . 428
Assist Control System Diagram . 428
Function of Assist Control System . 428
Operation of Assist Control System 429
Back Grade Mode System 430
Back Grade Mode System Diagram 430
Function of Back Grade Mode System 431
Operation of Back Grade Mode System . 431
Straight Travel Correction System . 432
Straight Travel Correction System Diagram . 432
Function of Straight Travel Correction System . 433
Operation of Straight Travel Correction System 433
Quick Surface Control System 436
Quick Surface Control System Diagram 436
Function of Quick Surface Control System 436
Operation of Quick Surface Control System . 437
System of Triangulated Surface from AS-BUILT 438
System Diagram of Triangulated Surface from AS-BUILT 438
Function of System of Triangulated Surface from AS-BUILT 438
Operation of System of Triangulated Surface from AS-BUILT . 438
2 Surfaces Selection Control System . 440
2 Surfaces Selection Control System Diagram . 440
Function of 2 Surfaces Selection Control System . 441
Operation of 2 Surfaces Selection Control System 441
Lift Layer Control System . 442
Lift Layer Control System Diagram . 442
Function of Lift Layer Control System . 443
Operation of Lift Layer Control System 443
Component Parts of ICT System . 444
ICT Sensor Controller . 444
Control Box . 448
GNSS Receiver . 450
GNSS Antenna 452
IMU Sensor 453
Cylinder EPC Valve Block Assembly . 458
Stroke and Reset Sensor for Blade Lift Cylinder . 462
Undercarriage and Frame . 465
Main Frame 465
Structure of Main Frame . 465
Suspension 466
Structure of Suspension . 466
Function of Suspension 469
Track Frame and Idler Cushion . 470
Structure of Track Frame and Idler Cushion 470
Function of Track Frame and Idler Cushion . 471
Work Equipment 472
Structure of Front Work Equipment . 472
Structure of Cylinder Stay 474
Structure of Fixed Multi-Shank Ripper . 475
CAB Related Parts . 476
ROPS CAB 476
Structure of ROPS CAB . 476
Function of ROPS CAB 477
CAB Mount . 478
Structure of CAB Mount 478
Function of CAB Mount . 478
20 Standard Value Table . 479
Table of Contents . 480
Standard Value Table for Engine . 481
Standard Value Table for Engine: D85EXI-18E0 481
Standard Value Table for Engine: D85PXI-18E0 485
Standard Value Table for Machine 489
Standard Value Table for Machine: D85EXI-18E0 . 489
Standard Value Table for Machine: D85PXI-18E0 . 507
Machine Posture and Procedures to Measure Performance . 523
30 Testing and Adjusting 527
Table of Contents . 528
Precautions Before Work . 532
Related Information on Testing and Adjusting 533
Tools for Testing and Adjusting . 533
Sketch of Tools for Testing and Adjusting . 541
Engine and Cooling System . 544
Examine Engine Speed 544
How to Examine Engine Speed . 544
Examine Boost Pressure 548
How to Examine Boost Pressure . 548
Examine Exhaust Gas Temperature . 550
How to Examine Exhaust Gas Temperature 550
Examine Exhaust Gas Color . 552
How to Examine Exhaust Gas Color with the Handy Smoke Checker . 552
How to Examine Exhaust Gas Color with Smoke Meter . 553
Examine and Adjust Valve Clearance 555
How to Examine Valve Clearance 555
How to Adjust Valve Clearance . 556
Examine Compression Pressure 557
How to Examine Compression Pressure . 557
Examine Blowby Pressure . 561
How to Examine Blowby Pressure 561
Examine Engine Oil Pressure . 564
How to Examine Engine Oil Pressure on Machine Monitor . 564
How to Examine Engine Oil Pressure by Testing Tool 564
Examine EGR Valve and VGT Oil Pressure 566
How to Examine EGR Valve and VGT Oil Pressure . 566
Examine Fuel Pressure . 568
How to Examine Fuel Pressure 568
Examine Fuel Return Rate and Leakage 570
How to Examine Fuel Return Rate and Leakage . 571
Bleed Air from Fuel System 574
How to Bleed Air from Fuel System . 575
Examine Fuel Circuit for Leakage 576
How to Examine Fuel System for Leakage 576
Handle Cylinder Cut-out Mode Operation 578
Handle No-Injection Cranking Operation 579
Examine and Adjust Air Conditioner Compressor Belt Tension 580
How to Examine Air Conditioner Compressor Drive Belt Tension 580
How to Adjust Air Conditioner Compressor Belt Tension . 580
Clean Fuel Doser 582
How to Clean Fuel Doser . 582
Write Injector Compensation Value to Engine Controller 585
How to Write Injector Compensation Value 585
Write Correction for Ash in Soot Accumulation to Engine Controller 591
How to Write Correction for Ash in Soot Accumulation to Engine Controller . 591
Examine SCR Related Functions . 592
Examine DEF Pump Raised Pressure 595
Examine Injection Volume from DEF Injector 597
Examine DEF Line Heater Relay 1 . 602
Examine DEF Line Heater Relay 2 . 604
Examine DEF Pump Heater Relay . 607
Examine DEF Tank Heater Valve . 610
Examine SCR Denitration Efficiency 612
Clean DEF Tank 616
How to Clean DEF Tank . 616
Clean DEF Pump 620
How to Clean DEF Pump . 620
Clean DEF Tank Mounting Part 627
How to Clean DEF Tank Mounting Part . 627
Adjust Decelerator Pedal 628
How to Adjust Decelerator Pedal . 628
Power Train . 630
Examine Power Train Oil Pressure 630
How to Examine Power Train Oil Pressure . 631
Adjust Transmission Output Shaft Speed Sensor . 642
How to Adjust Transmission Output Shaft Speed Sensor 642
Examine Brake Performance Simply 644
How to Examine Brake Performance Simply . 644
Adjust Brake Pedal 645
How to Adjust Brake Pedal . 645
Adjust Parking Brake Lever 647
How to Adjust Parking Brake Lever . 647
Move Machine by Parking Brake Release When Machine Does Not Travel 649
How to Move Machine with Hydraulic Type Parking Brake Release System 649
How to Move Machine with Electric Type Parking Brake Release System . 650
Undercarriage and Frame . 652
Adjust Idler Clearance 652
How to Adjust Idler Clearance . 652
How to Adjust Idler Clearance Horizontally 652
How to Adjust Idler Clearance Vertically 652
Examine and Adjust Track Tension 654
How to Examine 654
How to Adjust Track Tension . 654
Hydraulic System 655
Release Remained Pressure in Hydraulic Circuit 655
How to Release Remained Pressure in Hydraulic System 655
Examine and Adjust Work Equipment and HSS Oil Pressure 656
How to Examine Work Equipment and HSS Oil Pressure 656
How to Adjust Oil Pressure of Work Equipment and HSS 660
Examine Oil Pressure of Control Circuit . 661
How to Examine Oil Pressure in Control Circuit 661
Examine PPC Valve Outlet Pressure . 663
How to Examine Outlet Pressure in PPC Valve . 663
Bleed Air from HSS Pump . 666
How to Bleed Air from HSS Pump 666
Examine and Adjust Play of Work Equipment PPC Valve . 667
How to Examine Play of Work Equipment PPC Valve . 667
How to Adjust Play of Work Equipment PPC Valve 668
Examine Cooling Fan Speed . 669
How to Examine Cooling Fan Speed 669
Examine Cooling Fan Circuit Oil Pressure 670
How to Examine Cooling Fan Circuit Oil Pressure . 670
Bleed Air in Cooling Fan Pump . 672
How to Bleed Air in Cooling Fan Pump 672
Examine Parts Which Cause Hydraulic Drift of Work Equipment . 673
How to Examine Parts Which Cause Hydraulic Drift of Blade Lift Cylinder . 673
How to Examine the Parts Which Cause Hydraulic Drift of Blade Tilt Cylinder . 673
How to Examine the Parts Which Cause Hydraulic Drift of Ripper Lift Cylinder 674
Examine Oil Leakage from Work Equipment Cylinder 675
How to Examine Internal Oil Leakage of Work Equipment Cylinder 675
Bleed Air from Work Equipment Cylinders . 677
How to Bleed Air from Work Equipment Cylinder . 677
Work Equipment 678
Adjust Work Equipment Lock Lever 678
How to Adjust Work Equipment Lock Lever . 678
CAB Related Parts . 680
Examine and Adjust Operator Cab . 680
How to Examine Operator Cab . 680
How to Adjust Operator Cab 682
Electrical System . 685
Set and Operate Machine Monitor . 685
Operator Mode . 688
Function to Show Technician Identification Status Screen 688
Function to Show Operator Identification Input Screen . 689
Examine Function by LCD (Liquid Crystal Display) 689
Examine Function of Service Meter . 690
How to Set Usage Limitation and Change Maintenance Password . 690
Service Mode 692
How to Operate Service Mode . 692
How to See Pre-defined Monitoring Information . 694
How to Examine Self-Define Monitor Information 700
Abnormality Record Menu . 711
How to See Maintenance Record . 715
Maintenance Mode Setting 716
How to Set Phone Number Entry . 720
Default Menu 721
Diagnostic Tests Menu . 729
Adjustment Menu . 738
No-Injection Cranking Operation . 790
KOMTRAX Settings Menu . 791
How to Show Service Message . 793
How to Start Up KOMTRAX System 795
How to Stop Use of KOMTRAX System . 800
Adjust When Power Train Controller is Replaced 802
How to Adjust When Power Train Controller is Replaced . 802
Adjust Rearview Camera Angle 805
How to Adjust Rearview Camera Angle . 805
Set Region of Bluetooth(R) Compatible Radio . 806
How to Set Region of Bluetooth(R) Compatible Radio 806
Handle Voltage Circuit of Engine Controller . 808
Handle Battery Disconnect Switch 809
Examine Diodes 810
How to Examine Diodes by Digital Tester . 810
How to Examine Diodes by Analog Tester 810
ICT System 811
Set and Operate Control Box . 811
Examine and Adjust ICT Related Devices (SIGMA Power Tilt Pitch Dozer) . 812
Examine and Adjust ICT Related Devices (Semi-U Dozer, Straight Tilt Dozer) 816
Machine Calibration . 820
Calibrate IMU Sensor 822
Operate Machine Calibration Step a (SIGMA Power Tilt Pitch Dozer) . 827
How to Operate Machine Calibration Step A (Semi-U Dozer, Straight Tilt Dozer) . 832
Operate Machine Calibration Step B (SIGMA Power Tilt Pitch Dozer) . 837
How to Operate Machine Calibration Step B (Semi-U Dozer, Straight Tilt Dozer) . 844
Calibrate GNSS Antenna (AUX) Location . 851
How to Operate Pitch Rod Calibration (Semi-U Dozer, Straight Tilt Dozer) 853
How to Input Wear Volume of Blade Edge and Track Shoes 855
Reset Cylinder Stroke End . 856
Set Standard Blade Angle (SIGMA Power Tilt Pitch Dozer) . 858
How to Operate Manual Machine Calibration . 860
Examine and Adjust Blade Elevation 862
How to Examine and Adjust Blade Elevation (SIGMA Power Tilt Pitch Dozer) 862
How to Examine and Adjust Blade Elevation (Semi-U Dozer, Straight Tilt Dozer) . 865
Examine Stroke Sensor for Lift Cylinder . 869
How to Examine Stroke Sensor for Lift Cylinder 869
Examine and Adjust Reset Sensor for Lift Cylinder . 873
How to Examine Reset Sensor for Lift Cylinder . 873
How to Adjust Reset Sensor for Lift Cylinder (SIGMA Power Tilt Pitch Dozer) . 874
How to Adjust Reset Sensor for Lift Cylinder (Semi-U Dozer, Straight Tilt Dozer) 874
Adjust When ICT Sensor Controller is Replaced . 875
Adjust When ICT Sensor Controller is Replaced (SIGMA Power Tilt Pitch Dozer) 875
How to Adjust When ICT Sensor Controller is Replaced (Semi-U Dozer, Straight Tilt Dozer) 877
Adjust After Replacement of IMU Sensor 880
How to Adjust After Replacement of IMU Sensor . 880
Adjust When ICT Related Devices are Repaired or Replaced (SIGMA Power Tilt Pitch Dozer) . 881
Adjust When ICT Related Devices are Repaired or Replaced (Semi-U Dozer, Straight Tilt Dozer) 885
Pm Clinic . 890
Pm Clinic Service . 890
Pm Clinic Check Sheet: D85EXI-18E0 891
Pm Clinic Check Sheet: D85PXI-18E0 906
Pm Clinic Check Sheet for Undercarriage: D85EXI-18E0 919
Pm Clinic Check Sheet for Undercarriage: D85PXI-18E0 923
40 Troubleshooting 927
Table of Contents . 928
Precautions Before Work . 940
Related Information to Troubleshooting 941
General Troubleshooting Points 941
Troubleshooting Points for Urea SCR System 942
Sequence of Events in Troubleshooting . 956
Checks Before Troubleshooting . 958
Inspection Procedure Before Troubleshooting . 960
Walk-Around Check . 960
Test in Accordance with Testing Procedure . 962
How to Examine Electric Equipment . 962
Preparation for Troubleshooting of Electrical System 969
Procedure for Troubleshooting . 977
Symptom and Troubleshooting Numbers . 980
Information Shown in Troubleshooting Table 985
Connector List and Layout (Applicable Machine:25001 to 25152) . 987
Connector List and Layout (Applicable Machine:25153 and up) .1007
Connector Contact Connection Table 1027
T-Branch Box and T-Branch Adapter Table .1067
Fuse Location Table .1073
Precautions When You Clean and Replace KDPF (KCSF and KDOC) .1076
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 1080
Failure Code Table 1082
Troubleshooting by Failure Code (Display of Code) .1103
Failure Code [1500L0] .1103
Failure Code [15SAL1] .1104
Failure Code [15SALH] .1106
Failure Code [15SBL1] .1108
Failure Code [15SBLH] .1110
Failure Code [15SEL1] .1112
Failure Code [15SELH] .1114
Failure Code [15SFL1] .1116
Failure Code [15SFLH] .1118
Failure Code [15SGL1] .1120
Failure Code [15SGLH] .1122
Failure Code [1800MW] .1124
Failure Code [879AKA] .1125
Failure Code [879AKB] .1126
Failure Code [879BKA] .1127
Failure Code [879BKB] .1129
Failure Code [879CKA] .1131
Failure Code [879CKB] .1132
Failure Code [879DKZ] .1133
Failure Code [879EMC] .1135
Failure Code [879FMC] .1136
Failure Code [879GKX] .1137
Failure Code [989L00] .1139
Failure Code [989M00] .1140
Failure Code [989N00] .1141
Failure Code [A1U0N3] .1142
Failure Code [A1U0N4] .1144
Failure Code [A900FR] .1146
Failure Code [A900N6] .1147
Failure Code [A900NY] .1148
Failure Code [AA10NX] .1149
Failure Code [AB00KE] .1151
Failure Code [AQ10N3] .1153
Failure Code [AS00N3] .1155
Failure Code [AS00R2] .1157
Failure Code [AS00R3] .1158
Failure Code [AS00R4] .1159
Failure Code [AS00R5] .1160
Failure Code [AS00R6] .1161
Failure Code [AS00ZK] .1162
Failure Code [AS10KM] .1163
Failure Code [AS10NR] .1164
Failure Code [AS10NT] .1165
Failure Code [B@BAZG] .1166
Failure Code [B@BCNS] .1167
Failure Code [B@BCZK] .1168
Failure Code [B@CENS] .1170
Failure Code [B@HANS] .1171
Failure Code [CA115] 1172
Failure Code [CA122] 1173
Failure Code [CA123] 1175
Failure Code [CA131] 1177
Failure Code [CA132] 1179
Failure Code [CA135] 1181
Failure Code [CA141] 1183
Failure Code [CA144] 1185
Failure Code [CA145] 1187
Failure Code [CA153] 1189
Failure Code [CA154] 1192
Failure Code [CA187] 1195
Failure Code [CA221] 1197
Failure Code [CA222] 1199
Failure Code [CA227] 1201
Failure Code [CA234] 1202
Failure Code [CA238] 1203
Failure Code [CA239] 1205
Failure Code [CA249] 1207
Failure Code [CA256] 1209
Failure Code [CA271] 1211
Failure Code [CA272] 1213
Failure Code [CA273] 1214
Failure Code [CA274] 1216
Failure Code [CA322] 1217
Failure Code [CA323] 1219
Failure Code [CA324] 1221
Failure Code [CA325] 1223
Failure Code [CA331] 1225
Failure Code [CA332] 1227
Failure Code [CA343] 1229
Failure Code [CA351] 1230
Failure Code [CA352] 1231
Failure Code [CA356] 1234
Failure Code [CA357] 1236
Failure Code [CA386] 1238
Failure Code [CA441] 1239
Failure Code [CA442] 1242
Failure Code [CA449] 1243
Failure Code [CA451] 1244
Failure Code [CA452] 1246
Failure Code [CA515] 1248
Failure Code [CA516] 1250
Failure Code [CA553] 1252
Failure Code [CA555] 1253
Failure Code [CA556] 1254
Failure Code [CA559] 1255
Failure Code [CA595] 1260
Failure Code [CA687] 1261
Failure Code [CA689] 1263
Failure Code [CA691] 1265
Failure Code [CA692] 1267
Failure Code [CA697] 1269
Failure Code [CA698] 1270
Failure Code [CA731] 1271
Failure Code [CA778] 1272
Failure Code [CA1117] .1275
Failure Code [CA1664] .1276
Failure Code [CA1669] .1279
Failure Code [CA1673] .1280
Failure Code [CA1677] .1281
Failure Code [CA1678] .1282
Failure Code [CA1682] .1283
Failure Code [CA1683] .1285
Failure Code [CA1684] .1287
Failure Code [CA1686] .1289
Failure Code [CA1691] .1290
Failure Code [CA1694] .1293
Failure Code [CA1695] .1295
Failure Code [CA1696] .1296
Failure Code [CA1712] .1298
Failure Code [CA1713] .1301
Failure Code [CA1714] .1303
Failure Code [CA1715] .1304
Failure Code [CA1776] .1305
Failure Code [CA1777] .1308
Failure Code [CA1843] .1311
Failure Code [CA1844] .1313
Failure Code [CA1879] .1316
Failure Code [CA1881] .1319
Failure Code [CA1883] .1322
Failure Code [CA1885] .1326
Failure Code [CA1887] .1328
Failure Code [CA1921] .1330
Failure Code [CA1922] .1333
Failure Code [CA1923] .1338
Failure Code [CA1924] .1340
Failure Code [CA1925] .1342
Failure Code [CA1927] .1344
Failure Code [CA1928] .1346
Failure Code [CA1942] .1348
Failure Code [CA1963] .1349
Failure Code [CA1977] .1352
Failure Code [CA1993] .1355
Failure Code [CA2185] .1358
Failure Code [CA2186] .1359
Failure Code [CA2249] .1361
Failure Code [CA2265] .1362
Failure Code [CA2266] .1364
Failure Code [CA2271] .1367
Failure Code [CA2272] .1369
Failure Code [CA2349] .1371
Failure Code [CA2353] .1373
Failure Code [CA2357] .1375
Failure Code [CA2381] .1376
Failure Code [CA2382] .1378
Failure Code [CA2383] .1380
Failure Code [CA2386] .1382
Failure Code [CA2387] .1384
Failure Code [CA2555] .1385
Failure Code [CA2556] .1388
Failure Code [CA2637] .1390
Failure Code [CA2639] .1392
Failure Code [CA2732] .1395
Failure Code [CA2733] .1397
Failure Code [CA2741] .1399
Failure Code [CA2765] .1400
Failure Code [CA2771] .1401
Failure Code [CA2777] .1407
Failure Code [CA2878] .1410
Failure Code [CA2881] .1413
Failure Code [CA2976] .1416
Failure Code [CA3133] .1418
Failure Code [CA3134] .1420
Failure Code [CA3135] .1422
Failure Code [CA3142] .1426
Failure Code [CA3143] .1427
Failure Code [CA3144] .1428
Failure Code [CA3146] .1430
Failure Code [CA3147] .1431
Failure Code [CA3148] .1432
Failure Code [CA3151] .1434
Failure Code [CA3165] .1440
Failure Code [CA3167] .1442
Failure Code [CA3229] .1445
Failure Code [CA3231] .1447
Failure Code [CA3232] .1449
Failure Code [CA3235] .1453
Failure Code [CA3239] .1455
Failure Code [CA3241] .1458
Failure Code [CA3242] .1461
Failure Code [CA3251] .1464
Failure Code [CA3253] .1467
Failure Code [CA3254] .1471
Failure Code [CA3255] .1474
Failure Code [CA3256] .1478
Failure Code [CA3311] .1480
Failure Code [CA3312] .1482
Failure Code [CA3313] .1485
Failure Code [CA3314] .1486
Failure Code [CA3315] .1487
Failure Code [CA3316] .1490
Failure Code [CA3317] .1491
Failure Code [CA3318] .1492
Failure Code [CA3319] .1495
Failure Code [CA3321] .1496
Failure Code [CA3322] .1498
Failure Code [CA3419] .1501
Failure Code [CA3421] .1503
Failure Code [CA3497] .1505
Failure Code [CA3498] .1506
Failure Code [CA3543] .1507
Failure Code [CA3545] .1514
Failure Code [CA3547] .1516
Failure Code [CA3558] .1517
Failure Code [CA3559] .1519
Failure Code [CA3562] .1521
Failure Code [CA3563] .1523
Failure Code [CA3567] .1526
Failure Code [CA3568] .1529
Failure Code [CA3571] .1533
Failure Code [CA3572] .1535
Failure Code [CA3574] .1537
Failure Code [CA3575] .1539
Failure Code [CA3577] .1541
Failure Code [CA3578] .1543
Failure Code [CA3582] .1545
Failure Code [CA3583] .1552
Failure Code [CA3596] .1554
Failure Code [CA3649] .1556
Failure Code [CA3681] .1558
Failure Code [CA3682] .1563
Failure Code [CA3713] .1569
Failure Code [CA3717] .1572
Failure Code [CA3718] .1573
Failure Code [CA3725] .1574
Failure Code [CA3748] .1577
Failure Code [CA3751] .1580
Failure Code [CA3755] .1582
Failure Code [CA3866] .1584
Failure Code [CA3867] .1588
Failure Code [CA3868] .1591
Failure Code [CA3899] .1595
Failure Code [CA3911] .1597
Failure Code [CA3912] .1601
Failure Code [CA3932] .1603
Failure Code [CA3933] .1605
Failure Code [CA3934] .1607
Failure Code [CA3935] .1610
Failure Code [CA3936] .1612
Failure Code [CA4151] .1614
Failure Code [CA4152] .1618
Failure Code [CA4155] .1622
Failure Code [CA4156] .1624
Failure Code [CA4157] .1627
Failure Code [CA4158] .1629
Failure Code [CA4159] .1630
Failure Code [CA4161] .1631
Failure Code [CA4162] .1634
Failure Code [CA4163] .1637
Failure Code [CA4164] .1639
Failure Code [CA4165] .1641
Failure Code [CA4166] .1643
Failure Code [CA4168] .1645
Failure Code [CA4169] .1648
Failure Code [CA4171] .1650
Failure Code [CA4249] .1653
Failure Code [CA4251] .1655
Failure Code [CA4259] .1657
Failure Code [CA4261] .1660
Failure Code [CA4277] .1662
Failure Code [CA4281] .1666
Failure Code [CA4459] .1670
Failure Code [CA4461] .1673
Failure Code [CA4658] .1676
Failure Code [CA4731] .1680
Failure Code [CA4732] .1681
Failure Code [CA4739] .1682
Failure Code [CA4768] .1683
Failure Code [CA4769] .1685
Failure Code [CA4842] .1688
Failure Code [CA4952] .1692
Failure Code [CA5115] .1694
Failure Code [CA5383] .1697
Failure Code [D130KA] .1699
Failure Code [D130KB] .1702
Failure Code [D19DKA] .1704
Failure Code [D19DKB] .1706
Failure Code [D19JKZ] .1708
Failure Code [D19UKA] .1711
Failure Code [D19UKB] .1713
Failure Code [D19UMC] .1715
Failure Code [D811MC] .1717
Failure Code [D862KA] .1718
Failure Code [D8ALKA] .1719
Failure Code [D8ALKB] .1721
Failure Code [D8AQKR] .1724
Failure Code [D8ARKR] .1726
Failure Code [D8G1KT] .1729
Failure Code [D8G6KT] .1730
Failure Code [DAF0MB] .1731
Failure Code [DAF0MC] .1732
Failure Code [DAF8KB] .1733
Failure Code [DAF9KQ] .1734
Failure Code [DAFGMC] .1735
Failure Code [DAFLKA] .1736
Failure Code [DAFLKB] .1738
Failure Code [DAFQKR] .1741
Failure Code [DAQW00] .1742
Failure Code [DAZ9KQ] .1743
Failure Code [DAZQKR] .1744
Failure Code [DB2QKR] .1745
Failure Code [DB2RKR] .1753
Failure Code [DBE0KT] .1759
Failure Code [DBE0MC] .1760
Failure Code [DBE1KK] .1761
Failure Code [DBE2KK] .1764
Failure Code [DBE2KT] .1767
Failure Code [DBE5KK] .1768
Failure Code [DBE6KK] .1770
Failure Code [DBE7KK] .1772
Failure Code [DBE9KQ] .1774
Failure Code [DBELKA] .1775
Failure Code [DBELKB] .1777
Failure Code [DBEQKR] .1779
Failure Code [DBERKR] .1780
Failure Code [DBR0KT] .1782
Failure Code [DBR0MC] .1783
Failure Code [DBR1KK] .1784
Failure Code [DBR2KK] .1787
Failure Code [DBR2KT] .1790
Failure Code [DBR5KK] .1791
Failure Code [DBR7KK] .1793
Failure Code [DBRLKA] .1795
Failure Code [DBRLKB] .1797
Failure Code [DBRPMA] .1799
Failure Code [DBRQKR] .1800
Failure Code [DBRRKR] .1802
Failure Code [DBU0KR] .1803
Failure Code [DBUSKR] .1804
Failure Code [DBUTKA] .1809
Failure Code [DBUTKN] .1810
Failure Code [DBUTMA] .1812
Failure Code [DBUUKA] .1813
Failure Code [DBUUKN] .1814
Failure Code [DD12KA] .1816
Failure Code [DD12KB] .1818
Failure Code [DD13KA] .1820
Failure Code [DD13KB] .1822
Failure Code [DD14KA] .1824
Failure Code [DD14KB] .1826
Failure Code [DDKHKA] .1828
Failure Code [DDKHKB] .1830
Failure Code [DDKQKA] .1832
Failure Code [DDKQKB] .1834
Failure Code [DDKRKA] .1836
Failure Code [DDKRKB] .1838
Failure Code [DDKSKA] .1840
Failure Code [DDKSKB] .1842
Failure Code [DDN7KA] .1844
Failure Code [DDN7KB] .1846
Failure Code [DDNLKA] .1848
Failure Code [DDNLKB] .1850
Failure Code [DGS1KA] .1852
Failure Code [DGS1KX] .1854
Failure Code [DGT1KA] .1856
Failure Code [DGT1KX] .1859
Failure Code [DH21KA] .1861
Failure Code [DH21KY] .1863
Failure Code [DHA4KA] .1865
Failure Code [DHAAMA] .1867
Failure Code [DHACMA] .1869
Failure Code [DHSKKA] .1871
Failure Code [DHSKKY] .1873
Failure Code [DHSLKA] .1875
Failure Code [DHSLKY] .1877
Failure Code [DHSWKA] .1879
Failure Code [DHSWKY] .1881
Failure Code [DHSXKA] .1883
Failure Code [DHSXKY] .1885
Failure Code [DHTDKA] .1887
Failure Code [DHTDKY] .1889
Failure Code [DK10KA] .1891
Failure Code [DK10KB] .1894
Failure Code [DK30KA] .1896
Failure Code [DK30KX] .1899
Failure Code [DK30KY] .1900
Failure Code [DK30KZ] .1902
Failure Code [DK30L8] .1903
Failure Code [DK31KA] .1904
Failure Code [DK31KY] .1907
Failure Code [DK40KA] .1909
Failure Code [DK40KY] .1911
Failure Code [DK55KX] .1913
Failure Code [DK55KZ] .1914
Failure Code [DK55L8] .1915
Failure Code [DK56KA] .1916
Failure Code [DK56KY] .1918
Failure Code [DK57KA] .1920
Failure Code [DK57KY] .1922
Failure Code [DK80KA] .1924
Failure Code [DK80KR] .1927
Failure Code [DK80KT] .1930
Failure Code [DKH1KA] .1933
Failure Code [DKH1KY] .1936
Failure Code [DKSGL8] .1938
Failure Code [DKSHKA] .1939
Failure Code [DKSHKB] .1941
Failure Code [DKSJKA] .1943
Failure Code [DKSJKB] .1945
Failure Code [DKSKKA] .1947
Failure Code [DKSKKB] .1949
Failure Code [DKSKMB] .1951
Failure Code [DKSLL8] .1953
Failure Code [DKSMKA] .1954
Failure Code [DKSMKB] .1956
Failure Code [DKSNKA] .1958
Failure Code [DKSNKB] .1960
Failure Code [DKSPKA] .1962
Failure Code [DKSPKB] .1964
Failure Code [DKSPMB] .1966
Failure Code [DLM3KA] .1968
Failure Code [DLM3KB] .1970
Failure Code [DLM3MB] .1971
Failure Code [DLT3KA] .1972
Failure Code [DLT3KB] .1974
Failure Code [DR21KX] .1976
Failure Code [DR31KX] .1977
Failure Code [DV20KB] .1978
Failure Code [DW5AKA] .1980
Failure Code [DW5AKB] .1982
Failure Code [DW5AKY] .1984
Failure Code [DW7BKA] .1986
Failure Code [DW7BKB] .1988
Failure Code [DW7BKY] .1990
Failure Code [DWN1KA] (Applicable Machine:25001 to 25152) .1991
Failure Code [DWN1KA] (Applicable Machine:25153 and up) .1993
Failure Code [DWN1KB] (Applicable Machine:25001 to 25152) .1995
Failure Code [DWN1KB] (Applicable Machine:25153 and up) .1997
Failure Code [DWN1KY] (Applicable Machine:25001 to 25152) .1999
Failure Code [DWN1KY] (Applicable Machine:25153 and up) .2001
Failure Code [DWN2KA] (Applicable Machine:25001 to 25152) .2003
Failure Code [DWN2KA] (Applicable Machine:25153 and up) .2005
Failure Code [DWN2KB] (Applicable Machine:25001 to 25152) .2007
Failure Code [DWN2KB] (Applicable Machine:25153 and up) .2009
Failure Code [DWN2KY] (Applicable Machine:25001 to 25152) .2011
Failure Code [DWN2KY] (Applicable Machine:25153 and up) .2012
Failure Code [DWN5KA] .2014
Failure Code [DWN5KB] .2016
Failure Code [DWN5KY] .2017
Failure Code [DXA2KA] .2019
Failure Code [DXA2KB] .2021
Failure Code [DXA2KY] .2023
Failure Code [DXH4KA] .2024
Failure Code [DXH4KB] .2026
Failure Code [DXH4KY] .2028
Failure Code [DXH5KA] .2030
Failure Code [DXH5KB] .2032
Failure Code [DXH5KY] .2034
Failure Code [DXH6KA] .2036
Failure Code [DXH6KB] .2038
Failure Code [DXH6KY] .2040
Failure Code [DXH7KA] .2042
Failure Code [DXH7KB] .2044
Failure Code [DXH7KY] .2046
Failure Code [DXH8KA] .2048
Failure Code [DXH8KB] .2050
Failure Code [DXH8KY] .2052
Failure Code [DXHRKA] .2054
Failure Code [DXHRKB] .2056
Failure Code [DXHRKY] .2057
Failure Code [DXHSKA] .2059
Failure Code [DXHSKB] .2061
Failure Code [DXHSKY] .2062
Failure Code [DXHTKA] .2064
Failure Code [DXHTKB] .2066
Failure Code [DXHTKY] .2067
Failure Code [DXHUKA] .2069
Failure Code [DXHUKB] .2071
Failure Code [DXHUKY] .2072
Failure Code [DXJ4KA] .2074
Failure Code [DXJ4KB] .2076
Failure Code [F313KA] .2078
Failure Code [F313KB] .2079
Failure Code [F318KB] .2080
Failure Code [F318KY] .2081
Failure Code [F7A0KQ] .2082
Failure Code [F7A0KT] .2083
Failure Code [F7A1KK] .2084
Failure Code [F7ALKB] .2087
Failure Code [F7AQKR] .2089
Failure Code [F7ASKA] .2090
Failure Code [FE0AKA] .2092
Troubleshooting of Electrical System (E-Mode) .2094
Engine Does Not Start (Engine Does Not Crank) .2094
Manual Preheating System Does Not Operate .2101
Automatic Preheating System Does Not Operate 2104
While Preheating is in Operation, Preheating Monitor Does Not Come On .2106
When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 2108
When Starting Switch is Turned to ON Position (with Engine Stopped), Basic Check Monitor Comes On .2112
Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation 2113
Charge Level Monitor Comes On in Red While Engine is in Operation .2114
Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation .2116
Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation 2117
Power Train Oil Temperature Monitor Comes On in Red While Engine Runs .2118
Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 2119
Engine Coolant Temperature Gauge Does Not Show Correct Temperature 2120
DEF Level is Not Shown Correctly 2121
Fuel Gauge Does Not Show Normally .2124
Power Train Oil Temperature Gauge Does Not Show Correct Temperature .2126
Hydraulic Oil Temperature Gauge Does Not Show Correct Temperature .2127
Operation Mode Does Not Change 2128
Gear Shift Mode Does Not Change .2129
When You Operate Customize Switch Does Not Show Customize Screen 2130
When You Change Setting on Customize Screen, Setting of Machine is Not Changed 2131
Some Areas of Machine Monitor Screen are Not Shown 2132
REVERSE Slow Mode Function Does Not Operate Correctly .2133
Alarm Buzzer Does Not Operate or Does Not Stop Operation 2134
Service Meter is Not Shown While Starting Switch is in OFF Position .2135
Service Mode Cannot be Selected .2136
Horn Does Not Sound .2137
Horn Does Not Stop 2139
Backup Alarm Does Not Sound .2140
Backup Alarm Does Not Stop Operation 2142
Headlamp Does Not Come On .2143
Rear Lamp Does Not Come On 2147
No Wiper Operates .2151
Front Wiper Does Not Operate 2155
Rear Wiper Does Not Operate .2158
Left Door Wiper Does Not Operate 2161
Right Door Wiper Does Not Operate .2164
Front Washer Does Not Operate .2167
Rear Washer Does Not Operate 2169
Left Door Washer Does Not Operate .2171
Right Door Washer Does Not Operate 2173
KOMTRAX System Does Not Operate Correctly .2175
Control Box Shows Message [Waiting for radio link .] .2176
Control Box Shows Message [Waiting for satellites .] .2177
Control Box Shows Message [GPS receiver not connected !] and [Komatsu Machine Trouble] 2178
Control Box Shows Message [Komatsu Machine Trouble] .2179
Control Box Shows Message [Waiting to initialize ] .2180
Control Box Shows Message [System initializing] .2181
Control Box Shows Message [Initializing ] 2182
Control Box Shows Message [Connecting to GPS .] 2183
Elevation Control Key on Control Box Shows Message [Low precisions .] 2184
Control Box Shows Message [Heading Initializing] 2185
Control Box Shows Message [Out of design area .] .2186
Control Box Shows Message [No GPS localization .] 2187
Control Box Shows Message [Loading Design Surface data .] 2188
Control Box Shows Message [Design Surface data invalid] .2189
Control Box Shows Message [Starting switch is OFF] 2190
Control Box Shows Message [Waiting for satellites .] and [Komatsu Machine Trouble] .2192
Control Box Can Not be Turned on 2193
Control Box Does Not Display Intelligent Machine Control Screen .2194
Control Box Does Not Display Bulldozer Image 2195
Control Box Does Not Display Design Surface .2196
Control Box Touch Panel Does Not Respond 2197
Control Box Touch Panel is Inaccurate .2198
Cylinder Stroke Reset Indication Does Not Go Out 2199
AUTO is Not Shown When AUTO/Manual Switch is Pushed (AUTO Indication Goes off) 2200
Blade Automatic Lower Control Does Not Start While AUTO is Shown 2201
Blade Automatic Raise Control Does Not Start While AUTO is Shown 2202
Blade Automatic Control Function is Not Activated While AUTO is Shown (Blade Automatic Control Stops) .2203
When You Examine and Adjust the Blade Elevation, the Value is Different from Actual Machine .2204
Finished Surface is Inaccurate (The Average Height of Finished Surface is Lower Than Designed Surface or Blade Does Not Touch the Surface) 2205
Finished Surface is Inaccurate (The Finished Surface is Not Smooth) .2206
Finished Surface is Inaccurate (When You Finish Slope Horizontally, Steps are Made in Each Direction) .2207
Machine Cannot Escape from Shoes Slip While Blade Automatic Control is Activated (Shoes Frequently Slips) .2209
Blade Tilt Angle Does Not Align with Design Surface .2210
Even After Lift Layer Control is Activated, Measured Lift Layer Terrain Shape Does Not Agree with Actual Terrain 2212
The Surface Made with Quick Surface Creation Function is Different from the One in Machine Front Direction, Blade Edge Position .2214
Machine Does Not Travel Straight While Tilt Steering Control is Activated .2215
Control Box Continues to Show Progress Bar in Machine Manual Cal Screen .2216
Engine Hunting Occurs When You Lower the Blade While Ground Line Assist is Activated 2217
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) .2218
Information Shown in Troubleshooting Table (H-Mode) .2218
Failure Mode and Cause Table 2219
Machine Lacks Power (Drawbar Pull is Not Sufficient) 2225
Machine Does Not Travel (at 2nd or 3rd Gear Speed) 2227
Machine Does Not Move Off at All Gear Speeds 2228
Machine Travels Only in One Direction, Forward or in Reverse 2230
Large Time Lag is in Gear Shifting or Directional Change 2231
Brake Does Not Work .2233
Power Train Oil Overheats .2234
Unusual Noise is Heard from Around Work Equipment and HSS Pump or HSS Motor .2236
Machine Cannot be Steered (Machine Does Not Turn LEFT or RIGHT) .2237
Steering Speed or Power is Not Sufficient .2238
All Work Equipment Operate Slowly .2239
All Work Equipment Do Not Operate .2240
Blade Lift Speed or Power is Low 2241
Blade Tilt Speed or Power is Low 2242
Ripper Lift Speed or Power is Low .2243
Hydraulic Drift of Blade Lift is Large 2244
Hydraulic Drift of Tilted Blade is Large 2245
Hydraulic Drift of Lifted Ripper is Large .2246
Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) .2247
Unusual Noise is Heard from Around Fan 2249
Troubleshooting of Engine (S-Mode) 2250
Information Shown in Troubleshooting Table (S-Mode) .2250
Engine Does Not Crank When Starting Switch is Turned to Start Position 2251
Engine Cranks but No Exhaust Smoke Comes Out 2252
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) .2253
Engine Startability is Unsatisfactory .2254
Engine Does Not Pick Up Smoothly 2256
Engine Stops During Operation .2258
Engine Does Not Rotate Smoothly .2260
Engine Lacks Output (or Lacks Power) 2261
KDPF Becomes Clogged in a Short Time 2263
Engine Oil Consumption is Excessive .2265
Engine Oil Becomes Dirty Quickly 2266
Fuel Consumption is Excessive .2267
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down) .2268
Engine Oil Pressure Drops .2269
Fuel Mixes Into Engine Oil 2271
Water Mixes Into Engine Oil (Milky) .2272
Coolant Temperature Increases Too High (Overheat) .2273
Unusual Noise is Heard 2274
Vibration is Excessive 2275
Air Cannot be Bled from Fuel Circuit 2276
Active Regeneration is Done Frequently 2277
Active Regeneration Continues Long 2279
White Smoke is Exhausted During Active Regeneration .2280
DEF Consumption is Excessive 2281
There is an Unusual Smell (Irritating Odor) .2283
Foreign Materials Enter DEF (DEF Increases) .2284
50 Disassembly and Assembly .2285
Table of Contents .2286
Precautions Before Work .2292
Related Information on Disassembly and Assembly .2293
How to Read This Manual .2293
Coating Materials List 2294
Special Tool List .2299
Sketches of Special Tools .2324
Engine and Cooling System .2332
Remove and Install Supply Pump Assembly .2332
How to Remove Supply Pump Assembly 2333
How to Install Supply Pump Assembly .2337
Remove and Install Injector Assembly 2344
How to Remove Injector Assembly .2345
How to Install Injector Assembly 2351
Remove and Install Fuel Doser Assembly 2362
How to Remove Fuel Doser Assembly .2362
How to Install Fuel Doser Assembly 2363
Remove and Install Cylinder Head Assembly .2365
How to Remove Cylinder Head Assembly 2365
How to Install Cylinder Head Assembly .2372
Remove and Install EGR Valve Assembly .2381
How to Remove EGR Valve Assembly 2381
How to Install EGR Valve Assembly .2383
Remove and Install EGR Cooler Assembly 2386
How to Remove EGR Cooler Assembly .2387
How to Install EGR Cooler Assembly 2391
Remove and Install Starter Assembly .2396
How to Remove Starting Motor Assembly .2396
How to Install Starting Motor Assembly 2398
Remove and Install Alternator Belt 2400
How to Remove Alternator Belt .2400
How to Install Alternator Belt 2402
Remove and Install Radiator Assembly 2404
How to Remove Radiator Assembly .2405
How to Install Radiator Assembly 2410
Remove and Install Hydraulic Oil Cooler Assembly 2416
How to Remove Hydraulic Oil Cooler Assembly .2417
How to Install Hydraulic Oil Cooler Assembly 2421
Remove and Install Aftercooler Assembly .2426
How to Remove Aftercooler Assembly 2426
How to Install Aftercooler Assembly .2427
Remove and Install Cooling Fan Drive Assembly .2428
How to Remove Cooling Fan Drive Assembly 2428
How to Install Cooling Fan Drive Assembly .2429
Remove and Install Cooling Fan Motor Assembly .2432
How to Remove Cooling Fan Motor Assembly 2432
How to Install Cooling Fan Motor Assembly .2434
Remove and Install Engine Assembly 2436
How to Remove Engine Assembly .2437
How to Install Engine Assembly 2444
Remove and Install Engine Front Oil Seal 2450
How to Remove Engine Front Oil Seal .2450
How to Install Engine Front Oil Seal 2451
Remove and Install Engine Rear Oil Seal .2454
How to Remove Engine Rear Oil Seal 2454
How to Install Engine Rear Oil Seal .2456
Remove and Install Engine Oil Pan .2461
How to Remove Engine Oil Pan 2461
How to Install Engine Oil Pan .2462
Remove and Install Engine Hood Assembly .2464
How to Remove Engine Hood Assembly 2464
How to Install Engine Hood Assembly .2466
Remove and Install Fuel Tank Assembly .2468
How to Remove Fuel Tank Assembly 2468
How to Install Fuel Tank Assembly .2470
Remove and Install DEF Tank Assembly 2473
How to Remove DEF Tank Assembly .2473
How to Install DEF Tank Assembly 2478
Remove and Install DEF Tank Sensor Flange Assembly 2482
How to Remove DEF Tank Sensor Flange Assembly .2482
How to Install DEF Tank Sensor Flange Assembly 2487
Remove and Install DEF Tank Sensor 2492
How to Remove DEF Tank Sensor .2492
How to Install DEF Tank Sensor 2492
Remove and Install DEF Strainer .2499
How to Remove DEF Strainer 2499
How to Install DEF Strainer .2499
Remove and Install DEF Tank Filler Port Filter 2500
How to Remove DEF Tank Filler Port Filter .2500
How to Install DEF Tank Filler Port Filter 2501
Remove and Install KDPF Assembly 2503
How to Remove KDPF Assembly .2503
How to Install KDPF Assembly 2507
Disassemble and Assemble KDPF Assembly 2512
How to Disassemble KDPF Assembly 2512
How to Assemble KDPF Assembly .2516
Remove and Install SCR Assembly .2520
How to Remove SCR Assembly 2520
How to Install SCR Assembly .2523
Remove and Install KDPF and SCR Assembly 2526
How to Remove KDPF and SCR Assembly .2526
How to Install KDPF and SCR Assembly 2536
Remove and Install KCCV Assembly 2546
How to Remove KCCV Assembly .2546
How to Install KCCV Assembly 2549
Remove and Install DEF Mixing Tube 2553
How to Remove DEF Mixing Tube .2553
How to Install DEF Mixing Tube 2556
Remove and Install DEF Injector .2562
How to Remove DEF Injector 2562
How to Install DEF Injector .2565
Remove and Install DEF Pump .2568
How to Remove DEF Pump 2568
How to Install DEF Pump .2571
Remove and Install DEF Hose .2575
How to Remove DEF Hose 2575
How to Install DEF Hose .2580
Remove and Install Air Cleaner Assembly .2586
How to Remove Air Cleaner Assembly 2586
How to Install Air Cleaner Assembly .2587
Remove and Install Air Conditioner Compressor Assembly 2588
How to Remove Air Conditioner Compressor Assembly .2588
How to Install Air Conditioner Compressor Assembly 2590
Power Train .2592
Remove and Install Damper Assembly 2592
How to Remove Damper Assembly .2592
How to Install Damper Assembly 2595
Disassemble and Assemble Damper Assembly 2598
How to Disassemble Damper Assembly 2599
How to Assemble Damper Assembly .2600
Remove and Install Power Train Unit Assembly 2603
How to Remove Power Train Unit Assembly .2603
How to Install Power Train Unit Assembly 2608
Disconnect and Connect Power Train Unit Assembly 2614
How to Disconnect Power Train Unit Assembly .2614
How to Connect Power Train Unit Assembly 2619
Disassemble and Assemble PTO Assembly .2624
How to Disassemble PTO Assembly .2624
How to Assemble PTO Assembly 2628
Disassemble and Assemble Torque Converter Assembly 2633
How to Disassemble Torque Converter Assembly 2633
How to Assemble Torque Converter Assembly .2636
Disassemble and Assemble Transmission Assembly 2640
How to Disassemble Transmission Assembly 2641
How to Assemble Transmission Assembly .2649
Disassemble and Assemble HSS Assembly .2661
How to Disassemble HSS Assembly .2663
How to Assemble HSS Assembly 2673
Remove and Install HSS Motor Assembly .2691
How to Remove HSS Motor Assembly 2691
How to Install HSS Motor Assembly .2692
Remove and Install Final Drive Assembly .2693
How to Remove Final Drive Assembly 2693
How to Install Final Drive Assembly .2695
Disassemble and Assemble Final Drive Assembly .2697
How to Disassemble Final Drive Assembly .2698
How to Assemble Final Drive Assembly 2705
Undercarriage and Frame .2717
Remove and Install Track Frame Assembly .2717
How to Remove Track Frame Assembly 2717
How to Install Track Frame Assembly .2721
Remove and Install Idler Assembly .2725
How to Remove Idler Assembly 2725
How to Install Idler Assembly .2726
Disassemble and Assemble Idler Assembly .2729
How to Disassemble Idler Assembly .2729
How to Assemble Idler Assembly 2731
Remove and Install Recoil Spring Assembly .2735
How to Remove Recoil Spring Assembly 2735
How to Install Recoil Spring Assembly .2737
Disassemble and Assemble Recoil Spring Assembly .2739
How to Disassemble Recoil Spring Assembly .2739
How to Assemble Recoil Spring Assembly 2743
Remove and Install Track Roller Assembly 2746
How to Remove Track Roller Assembly .2746
How to Install Track Roller Assembly 2748
Disassemble and Assemble Track Roller Assembly 2751
How to Disassemble Track Roller Assembly 2751
How to Assemble Track Roller Assembly .2752
Remove and Install Carrier Roller Assembly 2756
How to Remove Carrier Roller Assembly .2756
How to Install Carrier Roller Assembly 2757
Disassemble and Assemble Carrier Roller Assembly 2758
How to Disassemble Carrier Roller Assembly 2758
How to Assemble Carrier Roller Assembly .2759
Remove and Install Pivot Shaft Assembly .2762
How to Remove Pivot Shaft Assembly 2762
How to Install Pivot Shaft Assembly .2763
Separate and Connect Track Assembly .2765
How to Examine Before Separation of Track Assembly 2765
How to Separate Track Assembly (Standard) .2765
How to Separate Track Assembly (When Track Frame Has Internal Defect) .2766
How to Install Track Assembly .2768
Separate and Connect PLUS Type Track Assembly .2771
Separate PLUS Type Track Assembly Generally .2771
Install PLUS Type Track Assembly 2771
Disassemble and Assemble Track Assembly Generally .2772
How to Disassemble Full Track Shoes Assembly 2772
How to Assemble Full Track Shoes Assembly .2775
Disassemble and Assemble PLUS Type Track Assembly Generally .2788
Disassemble PLUS Type Track Assembly Generally 2788
How to Assemble PLUS Type Track Shoes Assembly Generally 2789
Disassemble and Assemble One Track Link Assembly in Field .2797
How to Disassemble One Track Link Assembly in Field .2799
How to Assemble One Track Link Assembly in Field 2799
Disassemble and Assemble Master Link 2807
How to Disassemble Master Link 2808
How to Assemble Master Link .2808
Remove and Install Equalizer Bar Assembly .2812
How to Remove Equalizer Bar Assembly 2812
How to Install Equalizer Bar Assembly .2814
Disassemble and Assemble Equalizer Bar Bushing 2817
How to Disassemble Equalizer Bar Bushing 2817
How to Assemble Equalizer Bar Bushing .2818
Open and Close Center Under Guard .2819
How to Open Under Guard .2819
How to Close Under Guard 2820
Remove and Install Center Under Guard Assembly 2822
How to Remove Underguard Assembly .2822
How to Install Underguard Assembly 2829
Hydraulic System 2837
Remove and Install Hydraulic Tank Assembly 2837
How to Remove Hydraulic Tank Assembly .2837
How to Install Hydraulic Tank Assembly 2840
Remove and Install Work Equipment Pump and HSS Pump Assembly 2844
How to Remove Work Equipment Pump and HSS Pump Assembly .2844
How to Install Work Equipment Pump and HSS Pump Assembly 2847
Remove and Install Power Train Pump and Steering Lubrication Pump Assembly 2849
How to Remove Power Train Pump and Steering Lubrication Pump Assembly .2849
How to Install Power Train Pump and Steering Lubrication Pump Assembly 2851
Remove and Install Cooling Fan Pump Assembly 2853
How to Remove Cooling Fan Pump Assembly .2853
How to Install Cooling Fan Pump Assembly 2855
Remove and Install Scavenging Pump Assembly .2858
How to Remove Scavenging Pump Assembly 2858
How to Install Scavenging Pump Assembly .2859
Remove and Install Control Valve Assembly .2861
How to Remove Control Valve Assembly 2861
How to Install Control Valve Assembly .2866
Work Equipment 2871
Remove and Install Blade Assembly .2871
How to Remove Blade Assembly 2871
How to Install Blade Assembly .2873
Disassemble and Assemble Fixed Multi-Shank Ripper Assembly 2877
How to Disassemble Fixed Multi-Shank Ripper Assembly 2877
How to Assemble Fixed Multi-Shank Ripper Assembly .2879
Remove and Install Stroke and Reset Sensing Blade Lift Cylinder Assembly 2882
How to Remove Stroke and Reset Sensing Blade Lift Cylinder Assembly .2883
How to Install Stroke and Reset Sensing Blade Lift Cylinder Assembly 2888
Disassemble and Assemble Stroke and Reset Sensing Blade Lift Cylinder Assembly 2893
How to Disassemble Stroke and Reset Sensing Blade Lift Cylinder Assembly 2894
Assemble Stroke and Reset Sensing Blade Lift Cylinder Assembly 2899
Disassemble and Assemble Work Equipment Cylinder Assembly .2910
How to Disassemble Work Equipment Cylinder Assembly .2911
How to Assemble Work Equipment Cylinder Assembly 2913
CAB Related Parts .2916
Remove and Install Operator Cab Assembly 2916
How to Remove Operator Cab Assembly .2916
How to Install Operator Cab Assembly 2924
Remove and Install Operator Cab Glass (Adhered Glass) .2934
How to Remove Operator Cab Glass (Adhered Glass) 2934
How to Install Operator Cab Glass (Adhered Glass) .2935
Remove and Install Air Conditioner Unit Assembly 2940
How to Remove Air Conditioner Unit Assembly .2940
How to Install Air Conditioner Unit Assembly 2946
Remove and Install Operator Seat 2954
How to Remove Operator Seat .2954
How to Install Operator Seat 2956
How to Remove and Install Seat Belt .2959
How to Remove Seat Belt .2959
How to Install Seatbelt .2960
Electrical System .2961
Remove and Install Engine Controller Assembly .2961
How to Remove Engine Controller Assembly 2961
How to Install Engine Controller Assembly .2962
Remove and Install Power Train Controller Assembly 2966
How to Remove Power Train Controller Assembly .2966
How to Install Power Train Controller Assembly 2967
Remove and Install Machine Monitor Assembly .2969
How to Remove Machine Monitor Assembly 2969
How to Install Machine Monitor Assembly .2970
Remove and Install Mass Air Flow and Temperature Sensor .2972
How to Remove Mass Air Flow and Temperature Sensor 2972
How to Install Mass Air Flow and Temperature Sensor .2973
Remove and Install KCCV Crankcase Pressure Sensor .2975
How to Remove KCCV Crankcase Pressure Sensor 2975
How to Install KCCV Crankcase Pressure Sensor .2977
Remove and Install SCR Temperature Sensor .2979
How to Remove SCR Temperature Sensor 2979
How to Install SCR Temperature Sensor .2981
Remove and Install Gateway Function Controller Assembly .2983
How to Remove Gateway Function Controller Assembly 2983
How to Install Gateway Function Controller Assembly .2986
Remove and Install Navigation Controller 2991
How to Remove Navigation Controller .2991
How to Install Navigation Controller 2995
Remove and Install Control Box 3001
How to Remove Control Box .3001
How to Install Control Box 3002
Remove and Install GNSS Receiver 3003
How to Remove GNSS Receiver .3003
How to Install GNSS Receiver 3004
Remove and Install GNSS Antenna .3006
How to Remove GNSS Antenna 3007
How to Install GNSS Antenna .3009
Remove and Install IMU Sensor .3015
How to Remove IMU Sensor 3015
How to Install IMU Sensor .3016
60 Maintenance Standard .3019
Table of Contents .3020
Engine and Cooling System .3022
Maintenance Standard for Engine Mount .3022
Maintenance Standard for Damper .3024
Maintenance Standard for Cooling System .3026
Maintenance Standard for Cooling Fan Pump .3028
Maintenance Standard for Servo Valve 3029
Maintenance Standard for Cooling Fan Motor 3030
Power Train .3032
Maintenance Standard for Universal Joint 3032
Maintenance Standard for Power Train Mount 3033
Maintenance Standard for Torque Converter and PTO .3034
Maintenance Standard for Transmission .3037
Maintenance Standard for Transmission ECMV 3042
Maintenance Standard for Main Relief Valve and Torque Converter Relief Valve 3043
Maintenance Standard for Transmission Lubrication Relief Valve 3044
Maintenance Standard for Bevel Gear Shaft, HSS, and Brake .3045
Maintenance Standard for Brake Valve 3049
Maintenance Standard for Final Drive 3051
Maintenance Standard for Sprocket for Conventional Type Track Shoes .3054
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for Conventional Type Track Shoes 3055
Maintenance Standard for Sprocket for PLUS Type Track Shoes .3057
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for PLUS Type Track Shoes 3058
Undercarriage and Frame .3060
Maintenance Standard for Main Frame .3060
Maintenance Standard for Suspension .3062
Maintenance Standard for Track Frame and Idler Cushion 3066
Maintenance Standard for Idler 3068
Maintenance Standard for Track Roller for Conventional Type Track Shoes (Single Flange Type) 3070
Maintenance Standard for Track Roller for Conventional Type Track Shoes (Double Flange Type) 3072
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Single Flange Type) 3074
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Double Flange Type) 3076
Maintenance Standard for Carrier Roller for Conventional Type Track Shoes .3078
Maintenance Standard for Carrier Roller for PLUS Type Track Shoes .3080
Maintenance Standard for Conventional Type Track Shoes 3082
Maintenance Standard for PLUS Type Track Shoes 3084
Maintenance Standard for Single Shoes and Heavy Duty Shoes 3086
Hydraulic System 3087
Maintenance Standard for Hydraulic Tank .3087
Maintenance Standard for Scavenging Pump 3088
Maintenance Standard for Steering Lubrication Pump and Power Train Pump .3089
Maintenance Standard for Work Equipment and HSS Pump 3091
Maintenance Standard for HSS Motor 3092
Maintenance Standard for Control Valve 3094
Maintenance Standard for Blade PPC Valve 3101
Maintenance Standard for Ripper PPC Valve (Fixed Multi-Shank Ripper) 3103
Maintenance Standard for Quick Drop Valve .3105
Maintenance Standard for Work Equipment Lock Solenoid Valve .3106
Work Equipment 3107
Maintenance Standard for Cylinder Stay 3107
Maintenance Standard for Front Work Equipment .3108
Maintenance Standard for Cutting Edge and End Bit (Straight Blade) 3112
Maintenance Standard for Cutting Edge and End Bit (SIGMA Blade) .3113
Maintenance Standard for Stroke and Reset Sensing Blade Lift Cylinder .3114
Maintenance Standard for Blade Tilt Cylinder 3115
Maintenance Standard for Blade Pitch Cylinder (For Power Tilt Pitch Dozer Series) .3116
Maintenance Standard for Stroke and Reset Sensor for Blade Lift Cylinder 3117
Maintenance Standard for Fixed Multi-Shank Ripper .3118
Maintenance Standard for Ripper Lift Cylinder (Fixed Multi-Shank Ripper) 3121
CAB Related Parts .3122
Maintenance Standard for CAB Mount 3122
80 Appendix .3123
Table of Contents .3124
Precautions Before Work .3126
Air Conditioner System 3127
Precautions for Refrigerant .3127
Air Conditioner Component .3128
Specifications of Air Conditioner .3130
Structure and Function of Refrigeration Cycle .3131
Outline of Refrigeration Cycle 3132
Component Parts of Air Conditioner System .3134
Air Conditioner Unit 3134
Configuration Diagram of Air Conditioner Unit .3134
Function of Air Conditioner Unit 3136
Component Parts of Air Conditioner Unit .3138
Function of Evaporator as Air Conditioner Unit Component 3139
Function of Heater Core as Air Conditioner Unit Component .3139
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component .3139
Function of Servo Motor as Air Conditioner Unit Component .3139
Structure of Expansion Valve as Air Conditioner Unit Component 3140
Function of Expansion Valve as Air Conditioner Unit Component .3140
Operate Expansion Valve as Air Conditioner Unit Component .3140
Function of Dual Pressure Switch 3141
Air Conditioner Controller 3142
Structure of Air Conditioner Controller .3142
Compressor 3143
Structure of Compressor .3143
Specifications of Compressor 3143
Function of Compressor 3143
Condenser .3144
Structure of Condenser 3144
Specifications of Condenser .3144
Function of Condenser .3144
Structure of Wide Core Condenser 3145
Specifications of Wide Core Condenser .3145
Function of Wide Core Condenser .3145
Receiver Drier 3146
Structure of Receiver Dryer .3146
Specifications of Receiver Dryer 3146
Function of Receiver Dryer 3146
Air Conditioner Related Sensors .3147
Structure of Sunlight Sensor 3147
Function of Sunlight Sensor .3147
Structure of Outside Temperature Sensor .3147
Function of Outside Air Temperature Sensor 3147
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner .3149
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 3151
System Diagram of Air Conditioner .3153
Input and Output Signals of Air Conditioner Controller 3154
Function of Air Conditioner Controller 3155
Locations of Air Conditioner Parts and Layout of Connectors .3156
Examine Air Leakage (Duct) 3165
How to Examine Air Leakage (Duct) .3165
Explanation for Test of Air Conditioner with Self-Diagnosis Function 3168
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor .3169
Examine Vent (Mode) Changeover 3170
How to Examine Vent (Mode) Changeover .3170
Examine Fresh/Recirc Air Changeover .3171
How to Examine Fresh/Recirc Air Changeover 3171
Examine Sunlight Sensor .3172
How to Examine Sunlight Sensor 3172
Examine Refrigerant (Dual) Pressure Switch 3173
How to Examine Refrigerant (Dual) Pressure Switch .3173
Examine Relay .3174
How to Examine Relay 3174
Air Conditioner Troubleshooting Chart 1 .3175
Air Conditioner Troubleshooting Chart 2 .3176
Information Shown in Troubleshooting Table 3179
Failure Code [879AKA] .3180
Failure Code [879AKB] .3181
Failure Code [879BKA] .3182
Failure Code [879BKB] .3184
Failure Code [879CKA] .3186
Failure Code [879CKB] .3187
Failure Code [879DKZ] .3188
Failure Code [879EMC] .3190
Failure Code [879FMC] .3191
Failure Code [879GKX] .3192
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 3194
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) .3196
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 3200
A-4 Troubleshooting for Fresh/Recirc Air Changeover .3202
Troubleshooting by Gauge Pressure .3204
Connect Service Tool 3207
How to Connect Service Tool .3207
Precautions for Disconnection and Connection of Air Conditioner Piping 3209
Handle Compressor Oil .3211
90 Circuit Diagrams .3213
Table of Contents .3214
Hydraulic Circuit Diagram .3215
Symbols Used in Hydraulic Circuit Diagram .3215
Hydraulic Circuit Diagram (For Power Tilt Pitch Dozer and Fixed Multi-Shank Ripper) .3219
Hydraulic Circuit Diagram (For Power Tilt Dozer) 3221
Hydraulic Circuit Diagram (For Power Tilt Dozer and Specification Which is Able to Pick Up Rear Oil Pressure) .3223
Hydraulic Circuit Diagram (For Power Tilt Pitch Dozer, Fixed Multi-Shank Ripper, and ICT) .3225
Power Train Hydraulic Circuit Diagram .3227
Electrical Circuit Diagram 3229
Symbols Used in Electric Circuit Diagram 3229
Electrical Circuit Diagram (1/16) (Applicable Machine:25001 to 25152) .3233
Electrical Circuit Diagram (2/16) (Applicable Machine:25001 to 25152) .3235
Electrical Circuit Diagram (3/16) (Applicable Machine:25001 to 25152) .3237
Electrical Circuit Diagram (4/16) (Applicable Machine:25001 to 25152) .3239
Electrical Circuit Diagram (5/16) (Applicable Machine:25001 to 25152) .3241
Electrical Circuit Diagram (6/16) (Applicable Machine:25001 to 25152) .3243
Electrical Circuit Diagram (7/16) (Applicable Machine:25001 to 25152) .3245
Electrical Circuit Diagram (8/16) (Applicable Machine:25001 to 25152) .3247
Electrical Circuit Diagram (9/16) (Applicable Machine:25001 to 25152) .3249
Electrical Circuit Diagram (10/16) (Applicable Machine:25001 to 25152) 3251
Electrical Circuit Diagram (11/16) (Applicable Machine:25001 to 25152) 3253
Electrical Circuit Diagram (12/16) (Applicable Machine:25001 to 25152) 3255
Electrical Circuit Diagram (13/16) (Applicable Machine:25001 to 25152) 3257
Electrical Circuit Diagram (14/16) (Applicable Machine:25001 to 25152) 3259
Electrical Circuit Diagram (15/16) (Applicable Machine:25001 to 25152) 3261
Electrical Circuit Diagram (16/16) (Applicable Machine:25001 to 25152) 3263
Electrical Circuit Diagram (1/16) (Applicable Machine:25153 and up) .3265
Electrical Circuit Diagram (2/16) (Applicable Machine:25153 and up) .3267
Electrical Circuit Diagram (3/16) (Applicable Machine:25153 and up) .3269
Electrical Circuit Diagram (4/16) (Applicable Machine:25153 and up) .3271
Electrical Circuit Diagram (5/16) (Applicable Machine:25153 and up) .3273
Electrical Circuit Diagram (6/16) (Applicable Machine:25153 and up) .3275
Electrical Circuit Diagram (7/16) (Applicable Machine:25153 and up) .3277
Electrical Circuit Diagram (8/16) (Applicable Machine:25153 and up) .3279
Electrical Circuit Diagram (9/16) (Applicable Machine:25153 and up) .3281
Electrical Circuit Diagram (10/16) (Applicable Machine:25153 and up) 3283
Electrical Circuit Diagram (11/16) (Applicable Machine:25153 and up) 3285
Electrical Circuit Diagram (12/16) (Applicable Machine:25153 and up) 3287
Electrical Circuit Diagram (13/16) (Applicable Machine:25153 and up) 3289
Electrical Circuit Diagram (14/16) (Applicable Machine:25153 and up) 3291
Electrical Circuit Diagram (15/16) (Applicable Machine:25153 and up) 3293
Electrical Circuit Diagram (16/16) (Applicable Machine:25153 and up) 3295
Index 3297
DESCRIPTION:
Komatsu D85EXi -18E0,D85PXi-18E0 Bulldozer Shop Manual SEN06910-06 – PDF DOWNLOAD
- SERIAL NUMBERS 25001 and up
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 “Ad Blue/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 “Ad Blue/DEF” in the service mode. Thus, be sure to recognize
that “DEF” and “Ad Blue/DEF” are the same when you read the shop manual.
REMARK
The illustrations in the shop manual reproduce the display of the machine monitor. They are not always the
same as the terminology in 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.
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 Others
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.
G.B 27/12/24
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