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KOMATSU D65EXi-18 D65PXi-18 BULLDOZER SHOP MANUAL SEN06899-04 – PDF DOWNLOAD
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KOMATSU D65EXi-18 D65PXi-18 BULLDOZER SHOP MANUAL SEN06899-04 – PDF DOWNLOAD
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KOMATSU D65EXi-18 D65PXi-18 BULLDOZER SHOP MANUAL SEN06899-04 – PDF DOWNLOAD
Language : English
Pages : 3410
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU D65EXi-18 D65PXi-18 BULLDOZER SHOP MANUAL SEN06899-04 – PDF DOWNLOAD
Cover...................................................................................................................................................... 1 00 Index and Foreword................................................................................................................................. 3 Index............................................................................................................................................. 4 Foreword, Safety, Basic Information............................................................................................................... 25 How to Read the Shop Manual................................................................................................................... 25 Safety Notice for Operation................................................................................................................... 27 Precautions to Prevent Fire................................................................................................................... 35 Procedures If Fire Occurs..................................................................................................................... 37 Precautions for Disposing of Waste Materials.................................................................................................. 38 Procedures for Exhaust Gas Regulations........................................................................................................ 39 Precautions for DEF........................................................................................................................... 40 General Character and Precautions for Handling............................................................................................ 40 Precautions for Adding.................................................................................................................... 40 Precautions for Storage................................................................................................................... 40 Precautions for Fire Hazard and Leakage................................................................................................... 40 Other Precautions......................................................................................................................... 40 Store DEF..................................................................................................................................... 41 Precautions When You Handle Hydraulic Equipment............................................................................................... 42 Precautions When You Disconnect and Connect Pipings........................................................................................... 45 Precautions When You Handle Electrical Equipment.............................................................................................. 52 Precautions When You Handle Fuel System Equipment............................................................................................. 54 Precautions When You Handle Intake System Equipment........................................................................................... 55 Practical Use of KOMTRAX...................................................................................................................... 56 Disconnect and Connect Push-Pull Type Coupler................................................................................................. 57 How to Disconnect and Connect Type 1 Push-Pull Type Coupler............................................................................... 57 How to Disconnect and Connect Type 2 Push-Pull Type Coupler............................................................................... 58 How to Disconnect and Connect Type 3 Push-Pull Type Coupler............................................................................... 59 Precautions for Disconnection and Connection of Connectors.................................................................................... 61 How to Disconnect and Connect Deutsch Connector............................................................................................... 65 How to Disconnect and Connect Slide Lock Type Connector....................................................................................... 66 How to Disconnect and Connect Connector with Lock to Pull..................................................................................... 68 How to Disconnect and Connect Connector with Lock to Push..................................................................................... 69 How to Disconnect and Connect Connector with Housing to Rotate................................................................................ 71 How to Read the Codes for Electric Cable...................................................................................................... 72 Explanation of Terms for Maintenance Standard................................................................................................. 76 Standard Tightening Torque Table.............................................................................................................. 79 Conversion Table.............................................................................................................................. 86 Abbreviation List............................................................................................................................. 91 01 Specifications..................................................................................................................................... 95 Table of Contents................................................................................................................................. 96 Specifications.................................................................................................................................... 97 Specification Drawing......................................................................................................................... 97 Specification Drawing: D65EXI-18.......................................................................................................... 97 Specification Drawing: D65PXI-18.......................................................................................................... 99 Specifications................................................................................................................................ 101 Specification: D65EXI-18.................................................................................................................. 101 Specification: D65PXI-18.................................................................................................................. 107 Weight Table.................................................................................................................................. 112 Weight Table: D65EXI-18................................................................................................................... 112 Weight Table: D65PXI-18................................................................................................................... 115 Fuel, Coolant, Lubricant...................................................................................................................... 117 How to Use Fuel, Coolant and Lubricants by Ambient Temperature............................................................................ 117 10 Structure and Function............................................................................................................................. 121 Table of Contents................................................................................................................................. 122 Urea SCR System................................................................................................................................... 126 Layout Drawing of Urea SCR System............................................................................................................. 126 Urea SCR System Diagram....................................................................................................................... 128 Function of Urea SCR System................................................................................................................... 129 FUNCTION OF DEF SYSTEM(APPLICABLE MACHINE: 96001 to 96348)................................................................................ 129 FUNCTION OF DEF SYSTEM(APPLICABLE MACHINE: 96349 and up).................................................................................. 131 Inducement Strategy....................................................................................................................... 134 Component Parts of Urea SCR System............................................................................................................ 148 DEF Mixing Tube........................................................................................................................... 148 SCR Assembly.............................................................................................................................. 149 DEF Tank.................................................................................................................................. 151 DEF Pump.................................................................................................................................. 153 DEF Injector.............................................................................................................................. 155 DEF Hose.................................................................................................................................. 156 DEF Tank Heating Valve.................................................................................................................... 157 Boot-up System.................................................................................................................................... 158 Layout Drawing of Boot-up System.............................................................................................................. 158 System Operating Lamp System.................................................................................................................. 160 System Diagram of System Operating Lamp System............................................................................................ 160 Function of Operation Lamp System......................................................................................................... 160 Battery Disconnect Switch..................................................................................................................... 162 Layout Drawing of Battery Disconnect Switch............................................................................................... 162 Function of Battery Disconnect Switch..................................................................................................... 162 Engine System..................................................................................................................................... 164 Layout Drawing of Engine System............................................................................................................... 164 Engine Control System......................................................................................................................... 166 Layout Drawing of Engine Control System................................................................................................... 166 System Diagram of Engine Control.......................................................................................................... 168 Function of Engine Control System......................................................................................................... 170 Automatic Idle Stop System.................................................................................................................... 172 System Diagram of Automatic Idle Stop System.............................................................................................. 172 Function of Automatic Idle Stop System.................................................................................................... 172 Component Parts of Engine System.............................................................................................................. 175 Damper.................................................................................................................................... 175 VGT....................................................................................................................................... 177 EGR System................................................................................................................................ 181 EGR Valve................................................................................................................................. 183 EGR Cooler................................................................................................................................ 185 KCCV System............................................................................................................................... 187 KCCV Ventilator........................................................................................................................... 189 KDPF...................................................................................................................................... 191 Cooling System.................................................................................................................................... 195 Layout Drawing of Cooling System.............................................................................................................. 195 Specifications of Cooling System.......................................................................................................... 196 Cooling Fan Control System.................................................................................................................... 197 System Diagram of Cooling Fan Control System.............................................................................................. 197 Function of Cooling Fan Control System.................................................................................................... 198 Component Parts of Cooling System............................................................................................................. 200 Cooling Fan Pump.......................................................................................................................... 200 Cooling Fan Motor......................................................................................................................... 209 Hydraulic Oil Cooler Bypass Valve......................................................................................................... 216 Control System.................................................................................................................................... 217 Layout Drawing of Control System.............................................................................................................. 217 Machine Monitor System........................................................................................................................ 218 System Diagram of Machine Monitor System.................................................................................................. 218 Function of Machine Monitor System........................................................................................................ 218 KOMTRAX System................................................................................................................................ 220 System Diagram of KOMTRAX System.......................................................................................................... 220 Function of KOMTRAX System................................................................................................................ 220 Component Parts of Control System............................................................................................................. 221 Machine Monitor........................................................................................................................... 221 Gateway Function Controller............................................................................................................... 238 Communication Terminal.................................................................................................................... 241 Power Train Controller.................................................................................................................... 243 Engine Controller......................................................................................................................... 247 Hydraulic System.................................................................................................................................. 254 Layout Drawing of Hydraulic System............................................................................................................ 254 CLSS.......................................................................................................................................... 255 Structure of CLSS......................................................................................................................... 255 Function of CLSS.......................................................................................................................... 256 Component Parts of Hydraulic System........................................................................................................... 258 Hydraulic Tank............................................................................................................................ 258 Work Equipment and HSS Pump............................................................................................................... 260 LS Valve.................................................................................................................................. 266 PC Valve.................................................................................................................................. 271 PC-EPC Valve.............................................................................................................................. 276 Control Valve............................................................................................................................. 279 Power Train System................................................................................................................................ 310 Layout Drawing of Power Train System.......................................................................................................... 310 Operation of Power Train System............................................................................................................... 313 Transmission, Steering, and Brake Control..................................................................................................... 314 Layout Drawing of Transmission, Steering, and Brake Control System........................................................................ 314 Function of Transmission, Steering, and Brake Control..................................................................................... 315 Palm Command Control System................................................................................................................... 316 Palm Command Control System Diagram....................................................................................................... 316 HSS System.................................................................................................................................... 320 HSS System Diagram........................................................................................................................ 320 Function of HSS System.................................................................................................................... 321 Centralized Pressure Pickup Port.............................................................................................................. 323 Layout Drawing of Centralized Pressure Pickup Port........................................................................................ 323 Function of Centralized Pressure Pickup Port.............................................................................................. 323 Component Parts of Power Train System......................................................................................................... 324 Universal Joint........................................................................................................................... 324 Power Train Mount......................................................................................................................... 325 Torque Converter and PTO.................................................................................................................. 326 Lockup Clutch ECMV........................................................................................................................ 332 Transmission.............................................................................................................................. 335 Transmission Control Valve................................................................................................................ 347 Forward and Reverse Clutch ECMV and Gear Speed Clutch ECMV................................................................................ 349 Main Relief Valve and Torque Converter Relief Valve....................................................................................... 354 Transmission Lubrication Relief Valve..................................................................................................... 356 Bevel Gear Shaft, HSS, and Brake.......................................................................................................... 357 Brake Valve............................................................................................................................... 376 Final Drive............................................................................................................................... 380 Scavenging Pump........................................................................................................................... 384 Steering Lubrication Pump and Power Train Pump............................................................................................ 385 HSS Motor................................................................................................................................. 386 Electric Steering Electric Lever.......................................................................................................... 392 Work Equipment System............................................................................................................................. 395 Work Equipment Control........................................................................................................................ 395 Layout Drawing of Work Equipment Control.................................................................................................. 395 Function of Work Equipment Control........................................................................................................ 396 Layout of Tilt Dozer and Power Tilt Pitch Dozer Series........................................................................................ 398 Layout Drawing of Fixed Multi-Shank Ripper.................................................................................................... 399 Component Parts of Work Equipment System...................................................................................................... 400 Self-Pressure Reducing Valve.............................................................................................................. 400 Work Equipment Lock Solenoid Valve........................................................................................................ 406 Blade PPC Valve........................................................................................................................... 409 Ripper PPC Valve.......................................................................................................................... 415 Blade Pitch Selector Solenoid Valve....................................................................................................... 418 Pilot Circuit Accumulator................................................................................................................. 419 Quick Drop Valve.......................................................................................................................... 420 Piston Valve.............................................................................................................................. 422 ICT System........................................................................................................................................ 423 Layout Drawing of ICT System.................................................................................................................. 423 System Diagram of ICT Control System.......................................................................................................... 425 Blade Control System.......................................................................................................................... 427 Function of Blade Control System.......................................................................................................... 427 Simple Grading Mode System Diagram........................................................................................................ 429 Function of Simple Grading Mode........................................................................................................... 430 Operation of Simple Grading Mode.......................................................................................................... 430 Cut Control System............................................................................................................................ 432 Cut Control System Diagram................................................................................................................ 432 Function of Cut Control System............................................................................................................ 433 Operation of Cut Control System........................................................................................................... 433 Smooth Start System........................................................................................................................... 445 Smooth Start System Diagram............................................................................................................... 445 Function of Smooth Start System........................................................................................................... 445 Operation of Smooth Start System.......................................................................................................... 446 Slip Control System........................................................................................................................... 447 Slip Control System Diagram............................................................................................................... 447 Function of Slip Control System........................................................................................................... 448 Operation of Slip Control System.......................................................................................................... 448 Assist Control System......................................................................................................................... 449 Assist Control System Diagram............................................................................................................. 449 Function of Assist Control System......................................................................................................... 449 Operation of Assist Control System........................................................................................................ 450 Back Grade Mode System........................................................................................................................ 451 Back Grade Mode System Diagram............................................................................................................ 451 Function of Back Grade Mode System........................................................................................................ 452 Operation of Back Grade Mode System....................................................................................................... 452 Straight Travel Correction System............................................................................................................. 453 Straight Travel Correction System Diagram................................................................................................. 453 Function of Straight Travel Correction System............................................................................................. 454 Operation of Straight Travel Correction System............................................................................................ 454 Quick Surface Control System.................................................................................................................. 457 Quick Surface Control System Diagram...................................................................................................... 457 Function of Quick Surface Control System.................................................................................................. 457 Operation of Quick Surface Control System................................................................................................. 458 System of Triangulated Surface from AS-BUILT.................................................................................................. 459 System Diagram of Triangulated Surface from AS-BUILT...................................................................................... 459 Function of System of Triangulated Surface from AS-BUILT.................................................................................. 459 Operation of System of Triangulated Surface from AS-BUILT................................................................................. 459 2 Surfaces Selection Control System........................................................................................................... 461 2 Surfaces Selection Control System Diagram............................................................................................... 461 Function of 2 Surfaces Selection Control System........................................................................................... 462 Operation of 2 Surfaces Selection Control System.......................................................................................... 462 Lift Layer Control System..................................................................................................................... 463 Lift Layer Control System Diagram......................................................................................................... 463 Function of Lift Layer Control System..................................................................................................... 464 Operation of Lift Layer Control System.................................................................................................... 464 Component Parts of ICT System................................................................................................................. 465 ICT Sensor Controller..................................................................................................................... 465 Control Box............................................................................................................................... 469 GNSS Receiver............................................................................................................................. 471 GNSS Antenna.............................................................................................................................. 473 IMU Sensor................................................................................................................................ 474 GNSS External Radio Device................................................................................................................ 478 Navigation Controller..................................................................................................................... 480 Cylinder EPC Valve Block Assembly......................................................................................................... 485 Stroke and Reset Sensor for Blade Lift Cylinder........................................................................................... 490 Undercarriage and Frame........................................................................................................................... 493 Main Frame.................................................................................................................................... 493 Structure of Main Frame................................................................................................................... 493 Suspension.................................................................................................................................... 495 Structure of Suspension................................................................................................................... 495 Specifications of Suspension.............................................................................................................. 496 Function of Suspension.................................................................................................................... 497 Track Frame and Idler Cushion................................................................................................................. 498 Structure of Track Frame and Idler Cushion................................................................................................ 498 Function of Track Frame and Idler Cushion................................................................................................. 500 Work Equipment.................................................................................................................................... 501 Structure of Front Work Equipment (For Tilt Dozer and Power Tilt Pitch Dozer Series).......................................................... 501 Structure of Fixed Multi-Shank Ripper......................................................................................................... 502 CAB Related Parts................................................................................................................................. 503 ROPS CAB...................................................................................................................................... 503 Structure of ROPS CAB..................................................................................................................... 503 Function of ROPS CAB...................................................................................................................... 504 CAB Mount..................................................................................................................................... 505 Structure of CAB Mount.................................................................................................................... 505 Function of CAB Mount..................................................................................................................... 505 20 Standard Value Table............................................................................................................................... 507 Table of Contents................................................................................................................................. 508 Standard Value Table for Engine................................................................................................................... 509 Standard Value Table for Engine: D65EXI-18.................................................................................................... 509 Standard Value Table for Engine: D65PXI-18.................................................................................................... 514 Standard Value Table for Machine.................................................................................................................. 519 Standard Value Table for Machine: D65EXI-18................................................................................................... 519 Standard Value Table for Machine: D65PXI-18................................................................................................... 535 Machine Posture and Procedures to Measure Performance......................................................................................... 550 30 Testing and Adjusting.............................................................................................................................. 553 Table of Contents................................................................................................................................. 554 Precautions Before Work........................................................................................................................... 558 Related Information on Testing and Adjusting...................................................................................................... 559 Differences In Machine Monitor Symbols........................................................................................................ 559 Tools for Testing and Adjusting............................................................................................................... 560 Sketch of Tools for Testing and Adjusting..................................................................................................... 568 Engine and Cooling System......................................................................................................................... 571 Examine Engine Speed.......................................................................................................................... 571 How to Examine Engine Speed............................................................................................................... 571 Examine Boost Pressure........................................................................................................................ 574 How to Examine Boost Pressure............................................................................................................. 574 Examine Exhaust Gas Temperature............................................................................................................... 576 How to Examine Exhaust Gas Temperature.................................................................................................... 576 Examine Exhaust Gas Color..................................................................................................................... 578 How to Examine Exhaust Gas Color with the Handy Smoke Checker............................................................................. 578 How to Examine Exhaust Gas Color with Smoke Meter......................................................................................... 578 Examine Mass Air Flow and Temperature Sensor.................................................................................................. 580 How to Examine Mass Air Flow and Temperature Sensor....................................................................................... 580 Examine and Adjust Valve Clearance............................................................................................................ 582 How to Examine Valve Clearance............................................................................................................ 582 How to Adjust Valve Clearance............................................................................................................. 583 Examine Compression Pressure.................................................................................................................. 585 How to Examine Compression Pressure....................................................................................................... 585 Examine Blowby Pressure....................................................................................................................... 587 How to Examine Blowby Pressure............................................................................................................ 587 Examine Engine Oil Pressure................................................................................................................... 590 How to Examine Engine Oil Pressure........................................................................................................ 590 Examine EGR Valve and VGT Oil Pressure........................................................................................................ 591 How to Examine EGR Valve and VGT Oil Pressure............................................................................................. 591 Examine Fuel Pressure......................................................................................................................... 593 How to Examine Fuel Pressure.............................................................................................................. 594 Examine Fuel Discharge, Return and Leakage.................................................................................................... 600 How to Examine Fuel Discharge, Return, and Leakage........................................................................................ 601 Bleed Air from Fuel System.................................................................................................................... 605 How to Bleed Air from Fuel System......................................................................................................... 605 Examine Fuel Circuit for Leakage.............................................................................................................. 607 How to Examine Fuel System for Leakage.................................................................................................... 607 Handle Cylinder Cut-out Mode Operation........................................................................................................ 609 Handle No-Injection Cranking Operation........................................................................................................ 610 Examine and Adjust Air Conditioner Compressor Belt Tension.................................................................................... 611 How to Examine Air Conditioner Compressor Belt Tension.................................................................................... 611 How to Adjust Air Conditioner Compressor Belt Tension..................................................................................... 611 Examine Alternator Belt....................................................................................................................... 612 How to Examine Alternator Belt............................................................................................................ 612 Examine Automatic Tensioner................................................................................................................... 614 How to Examine Automatic Tensioner........................................................................................................ 614 Write Correction for Ash in Soot Accumulation to Engine Controller............................................................................ 616 How to Write Correction for Ash in Soot Accumulation to Engine Controller................................................................. 616 Examine SCR Related Functions................................................................................................................. 617 Examine DEF Pump Raised Pressure.......................................................................................................... 621 Examine Injection Volume from DEF Injector................................................................................................ 624 Examine DEF Line Heater Relay 1........................................................................................................... 629 Examine DEF Line Heater Relay 2........................................................................................................... 632 Examine DEF Pump Heater Relay............................................................................................................. 635 Examine DEF Tank Heater Valve............................................................................................................. 638 Examine SCR Denitration Efficiency........................................................................................................ 641 Clean DEF Tank................................................................................................................................ 644 How to Clean DEF Tank..................................................................................................................... 644 Clean DEF Tank Mounting Part.................................................................................................................. 648 How to Clean DEF Tank Mounting Part....................................................................................................... 648 Clean DEF Pump................................................................................................................................ 650 How to Clean DEF Pump..................................................................................................................... 650 Adjust Decelerator Pedal...................................................................................................................... 656 How to Adjust Decelerator Pedal........................................................................................................... 656 Power Train....................................................................................................................................... 658 Examine Power Train Oil Pressure.............................................................................................................. 658 How to Examine Power Train Oil Pressure................................................................................................... 659 Adjust Transmission Output Shaft Speed Sensor................................................................................................. 670 How to Adjust Transmission Output Shaft Speed Sensor...................................................................................... 670 Examine Brake Performance Simply.............................................................................................................. 672 How to Examine Brake Performance Simply................................................................................................... 672 Adjust Brake Pedal............................................................................................................................ 673 How to Adjust Brake Pedal................................................................................................................. 673 Adjust Parking Brake Lever.................................................................................................................... 675 How to Adjust Parking Brake Lever......................................................................................................... 675 Move Machine by Parking Brake Release When Machine Does Not Travel............................................................................ 677 How to Move Machine with Hydraulic Type Parking Brake Release System...................................................................... 677 How to Move Machine with Electric Type Parking Brake Release System....................................................................... 678 Undercarriage and Frame........................................................................................................................... 680 Adjust Idler Clearance........................................................................................................................ 680 How to Adjust Idler Clearance............................................................................................................. 680 Examine and Adjust Track Tension.............................................................................................................. 681 How to Examine Track Tension.............................................................................................................. 681 How to Adjust Track Tension............................................................................................................... 681 Hydraulic System.................................................................................................................................. 682 Release Remained Pressure in Hydraulic Circuit................................................................................................ 682 How to Release Remained Pressure in Hydraulic System...................................................................................... 682 Examine and Adjust Work Equipment and HSS Oil Pressure........................................................................................ 683 How to Examine Work Equipment and HSS Oil Pressure........................................................................................ 683 How to Adjust Oil Pressure of Work Equipment and HSS...................................................................................... 686 Examine Oil Pressure of Control Circuit....................................................................................................... 688 How to Examine Oil Pressure in Control Circuit............................................................................................ 688 Examine PPC Valve Outlet Pressure............................................................................................................. 690 How to Examine Outlet Pressure in PPC Valve............................................................................................... 690 Bleed Air from HSS Pump....................................................................................................................... 692 How to Bleed Air from HSS Pump............................................................................................................ 692 Examine and Adjust Play of Work Equipment PPC Valve........................................................................................... 693 How to Examine Play of Work Equipment PPC Valve........................................................................................... 693 How to Adjust Play of Work Equipment PPC Valve............................................................................................ 694 Examine Cooling Fan Speed..................................................................................................................... 695 How to Examine Cooling Fan Speed.......................................................................................................... 695 Examine Cooling Fan Circuit Oil Pressure...................................................................................................... 696 How to Examine Cooling Fan Circuit Oil Pressure........................................................................................... 696 Bleed Air in Cooling Fan Pump................................................................................................................. 698 How to Bleed Air in Cooling Fan Pump...................................................................................................... 698 Examine Parts Which Cause Hydraulic Drift of Work Equipment................................................................................... 699 How to Examine Parts Which Cause Hydraulic Drift of Blade Lift Cylinder................................................................... 699 How to Examine the Parts Which Cause Hydraulic Drift of Blade Tilt Cylinder............................................................... 699 How to Examine the Parts Which Cause Hydraulic Drift of Ripper Lift Cylinder.............................................................. 700 Examine Oil Leakage from Work Equipment Cylinder.............................................................................................. 701 How to Examine Internal Oil Leakage of Work Equipment Cylinder............................................................................ 701 Bleed Air from Work Equipment Cylinders....................................................................................................... 703 How to Bleed Air from Work Equipment Cylinder............................................................................................. 703 Work Equipment.................................................................................................................................... 704 Adjust Work Equipment Lock Lever.............................................................................................................. 704 How to Adjust Work Equipment Lock Lever................................................................................................... 704 CAB Related Parts................................................................................................................................. 706 Examine and Adjust Operator Cab............................................................................................................... 706 How to Examine Operator Cab............................................................................................................... 706 How to Adjust Operator Cab................................................................................................................ 708 Electrical System................................................................................................................................. 711 Set and Operate Machine Monitor............................................................................................................... 711 Operator Mode............................................................................................................................. 715 Function to Show Technician Identification Status Screen.................................................................................. 715 Function to Show Operator Identification Input Screen..................................................................................... 715 Examine Function by LCD (Liquid Crystal Display).......................................................................................... 716 Examine Function of Service Meter......................................................................................................... 716 How to Set Usage Limitation and Change Maintenance Password............................................................................... 716 Service Mode.............................................................................................................................. 719 How to Operate Service Mode............................................................................................................... 719 How to See Pre-defined Monitoring Information............................................................................................. 720 How to Examine Monitoring Information..................................................................................................... 727 Abnormality Record Menu................................................................................................................... 739 How to See Maintenance Record............................................................................................................. 743 Maintenance Mode Setting.................................................................................................................. 744 How to Set Phone Number Entry............................................................................................................. 748 Default Setting Menu...................................................................................................................... 750 Testing Menu.............................................................................................................................. 759 Adjustment Menu........................................................................................................................... 768 No-Injection Cranking Operation........................................................................................................... 823 KOMTRAX Settings Menu..................................................................................................................... 825 How to Show Service Message............................................................................................................... 827 How to Start Up KOMTRAX System................................................................................................................ 829 How to Stop Use of KOMTRAX System............................................................................................................. 834 Adjust When Power Train Controller is Replaced................................................................................................ 836 How to Adjust When Power Train Controller is Replaced..................................................................................... 836 Adjust Rearview Camera Angle.................................................................................................................. 839 How to Adjust Rearview Camera Angle....................................................................................................... 839 Set Region of Bluetooth(R) Compatible Radio................................................................................................... 840 How to Set Region of Bluetooth(R) Compatible Radio........................................................................................ 840 Handle Voltage Circuit of Engine Controller................................................................................................... 842 Handle Battery Disconnect Switch.............................................................................................................. 843 Examine Diodes................................................................................................................................ 844 How to Examine Diodes by Digital Tester................................................................................................... 844 How to Examine Diodes by Analog Tester.................................................................................................... 844 ICT System........................................................................................................................................ 845 Set and Operate Control Box................................................................................................................... 845 Examine and Adjust ICT Related Devices (SIGMA Power Tilt Pitch Dozer)..................................................................... 846 Examine and Adjust ICT Related Devices (SIGMADOZER, Semi-U Dozer, Straight Tilt Dozer).................................................... 850 Machine Calibration........................................................................................................................... 854 Calibrate IMU Sensor...................................................................................................................... 856 Operate Machine Calibration Step a (SIGMA Power Tilt Pitch Dozer)......................................................................... 861 Operate Machine Calibration Step a (SIGMADOZER, Semi-U Dozer, Straight Tilt Dozer)........................................................ 866 Operate Machine Calibration Step B (SIGMA Power Tilt Pitch Dozer)......................................................................... 871 Operate Machine Calibration Step B (SIGMADOZER, Semi-U Dozer, Straight Tilt Dozer)........................................................ 878 Calibrate GNSS Antenna (AUX) Location..................................................................................................... 885 Operate Pitch Rod Calibration (SIGMADOZER, Semi-U Dozer, Straight Tilt Dozer)................................................................. 887 How to Input Wear Volume of Blade Edge and Track Shoes........................................................................................ 889 Reset Cylinder Stroke End..................................................................................................................... 890 Set Standard Blade Angle (SIGMA Power Tilt Pitch Dozer)....................................................................................... 892 How to Operate Manual Machine Calibration..................................................................................................... 894 Examine and Adjust Blade Elevation............................................................................................................ 896 How to Examine and Adjust Blade Elevation (SIGMA Power Tilt Pitch Dozer).................................................................. 896 How to Examine and Adjust Blade Elevation (SIGMADOZER, Semi-U Dozer, Straight Tilt Dozer)................................................. 899 Examine Stroke Sensor for Lift Cylinder....................................................................................................... 903 How to Examine Stroke Sensor for Lift Cylinder............................................................................................ 903 Examine and Adjust Reset Sensor for Lift Cylinder............................................................................................. 907 How to Examine Reset Sensor for Lift Cylinder............................................................................................. 907 How to Adjust Reset Sensor for Lift Cylinder (SIGMA Power Tilt Pitch Dozer)............................................................... 908 How to Adjust Reset Sensor for Lift Cylinder (SIGMADOZER, Semi-U Dozer, Straight Tilt Dozer).............................................. 908 Adjust When ICT Sensor Controller is Replaced................................................................................................. 909 Adjust When ICT Sensor Controller is Replaced (SIGMA Power Tilt Pitch Dozer).............................................................. 909 Adjust When ICT Sensor Controller is Replaced (SIGMADOZER, Semi-U Dozer, Straight Tilt Dozer)............................................. 911 Adjust After Replacement of IMU Sensor........................................................................................................ 914 How to Adjust After Replacement of IMU Sensor............................................................................................. 914 Adjust When ICT Related Devices are Repaired or Replaced (SIGMA Power Tilt Pitch Dozer)....................................................... 915 Adjust When ICT Related Devices are Repaired or Replaced (SIGMADOZER, Semi-U Dozer, Straight Tilt Dozer)...................................... 919 Pm Clinic......................................................................................................................................... 924 Pm Clinic Service............................................................................................................................. 924 Pm Clinic Check Sheet: D65EXI-18.......................................................................................................... 926 Pm Clinic Check Sheet: D65PXI-18.......................................................................................................... 937 Pm Clinic Check Sheet for Undercarriage: D65EXI-18........................................................................................ 947 Pm Clinic Check Sheet for Undercarriage: D65PXI-18........................................................................................ 950 40 Troubleshooting.................................................................................................................................... 953 Table of Contents................................................................................................................................. 954 Precautions Before Work........................................................................................................................... 966 Related Information to Troubleshooting............................................................................................................ 967 General Troubleshooting Points................................................................................................................ 967 Troubleshooting Points for Urea SCR System.................................................................................................... 968 Sequence of Events in Troubleshooting......................................................................................................... 982 Checks Before Troubleshooting................................................................................................................. 984 Inspection Procedure Before Troubleshooting................................................................................................... 986 Walk-Around Check......................................................................................................................... 986 Test in Accordance with Testing Procedure..................................................................................................... 988 How to Examine Electric Equipment......................................................................................................... 988 Preparation for Troubleshooting of Electrical System.......................................................................................... 996 Procedure for Troubleshooting.................................................................................................................1003 Symptom and Troubleshooting Numbers...........................................................................................................1006 Information Shown in Troubleshooting Table....................................................................................................1011 How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness...............................................................1013 Connector List and Layout.....................................................................................................................1015 Connector Contact Connection Table............................................................................................................1035 T-Branch Box and T-Branch Adapter Table.......................................................................................................1075 Fuse Location Table...........................................................................................................................1081 Precautions When You Clean and Replace KDPF (KCSF and KDOC)...................................................................................1084 Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135])..........................................................1088 Failure Code Table............................................................................................................................1090 Troubleshooting by Failure Code (Display of Code).................................................................................................1113 Failure Code [1500L0].........................................................................................................................1113 Failure Code [15SAL1].........................................................................................................................1114 Failure Code [15SALH].........................................................................................................................1116 Failure Code [15SBL1].........................................................................................................................1118 Failure Code [15SBLH].........................................................................................................................1120 Failure Code [15SEL1].........................................................................................................................1122 Failure Code [15SELH].........................................................................................................................1124 Failure Code [15SFL1].........................................................................................................................1126 Failure Code [15SFLH].........................................................................................................................1128 Failure Code [15SGL1].........................................................................................................................1130 Failure Code [15SGLH].........................................................................................................................1132 Failure Code [15SJL1].........................................................................................................................1134 Failure Code [15SJLH].........................................................................................................................1136 Failure Code [1800MW].........................................................................................................................1138 Failure Code [879AKA].........................................................................................................................1139 Failure Code [879AKB].........................................................................................................................1140 Failure Code [879BKA].........................................................................................................................1141 Failure Code [879BKB].........................................................................................................................1143 Failure Code [879CKA].........................................................................................................................1145 Failure Code [879CKB].........................................................................................................................1146 Failure Code [879DKZ].........................................................................................................................1147 Failure Code [879EMC].........................................................................................................................1149 Failure Code [879FMC].........................................................................................................................1150 Failure Code [879GKX].........................................................................................................................1151 Failure Code [989L00].........................................................................................................................1153 Failure Code [989M00].........................................................................................................................1154 Failure Code [989N00].........................................................................................................................1155 Failure Code [A1U0N3].........................................................................................................................1156 Failure Code [A1U0N4].........................................................................................................................1158 Failure Code [A900FR].........................................................................................................................1160 Failure Code [A900N6].........................................................................................................................1161 Failure Code [A900NY].........................................................................................................................1162 Failure Code [AA10NX].........................................................................................................................1163 Failure Code [AB00KE].........................................................................................................................1165 Failure Code [AQ10N3].........................................................................................................................1167 Failure Code [AS00N3].........................................................................................................................1169 Failure Code [AS00R2].........................................................................................................................1171 Failure Code [AS00R3].........................................................................................................................1172 Failure Code [AS00R4].........................................................................................................................1173 Failure Code [AS00R5].........................................................................................................................1174 Failure Code [AS00R6].........................................................................................................................1175 Failure Code [AS00ZK].........................................................................................................................1176 Failure Code [AS10KM].........................................................................................................................1177 Failure Code [AS10NR].........................................................................................................................1178 Failure Code [AS10NT].........................................................................................................................1179 Failure Code [B@BAZG].........................................................................................................................1180 Failure Code [B@BCNS].........................................................................................................................1181 Failure Code [B@BCQA].........................................................................................................................1182 Failure Code [B@BCZK].........................................................................................................................1184 Failure Code [B@CENS].........................................................................................................................1186 Failure Code [B@HANS].........................................................................................................................1187 Failure Code [CA115]..........................................................................................................................1188 Failure Code [CA122]..........................................................................................................................1189 Failure Code [CA123]..........................................................................................................................1191 Failure Code [CA131]..........................................................................................................................1193 Failure Code [CA132]..........................................................................................................................1195 Failure Code [CA144]..........................................................................................................................1198 Failure Code [CA145]..........................................................................................................................1200 Failure Code [CA153]..........................................................................................................................1202 Failure Code [CA154]..........................................................................................................................1205 Failure Code [CA187]..........................................................................................................................1208 Failure Code [CA221]..........................................................................................................................1210 Failure Code [CA222]..........................................................................................................................1212 Failure Code [CA227]..........................................................................................................................1214 Failure Code [CA234]..........................................................................................................................1215 Failure Code [CA238]..........................................................................................................................1216 Failure Code [CA239]..........................................................................................................................1218 Failure Code [CA249]..........................................................................................................................1220 Failure Code [CA256]..........................................................................................................................1222 Failure Code [CA271]..........................................................................................................................1224 Failure Code [CA272]..........................................................................................................................1226 Failure Code [CA281]..........................................................................................................................1228 Failure Code [CA322]..........................................................................................................................1229 Failure Code [CA323]..........................................................................................................................1231 Failure Code [CA324]..........................................................................................................................1233 Failure Code [CA325]..........................................................................................................................1235 Failure Code [CA331]..........................................................................................................................1237 Failure Code [CA332]..........................................................................................................................1239 Failure Code [CA343]..........................................................................................................................1241 Failure Code [CA351]..........................................................................................................................1242 Failure Code [CA352]..........................................................................................................................1243 Failure Code [CA356]..........................................................................................................................1246 Failure Code [CA357]..........................................................................................................................1248 Failure Code [CA386]..........................................................................................................................1250 Failure Code [CA428]..........................................................................................................................1251 Failure Code [CA429]..........................................................................................................................1253 Failure Code [CA435]..........................................................................................................................1255 Failure Code [CA441]..........................................................................................................................1257 Failure Code [CA442]..........................................................................................................................1259 Failure Code [CA449]..........................................................................................................................1260 Failure Code [CA451]..........................................................................................................................1264 Failure Code [CA452]..........................................................................................................................1267 Failure Code [CA515]..........................................................................................................................1269 Failure Code [CA516]..........................................................................................................................1271 Failure Code [CA553]..........................................................................................................................1273 Failure Code [CA555]..........................................................................................................................1274 Failure Code [CA556]..........................................................................................................................1275 Failure Code [CA559]..........................................................................................................................1276 Failure Code [CA595]..........................................................................................................................1280 Failure Code [CA687]..........................................................................................................................1281 Failure Code [CA689]..........................................................................................................................1283 Failure Code [CA691]..........................................................................................................................1288 Failure Code [CA692]..........................................................................................................................1290 Failure Code [CA697]..........................................................................................................................1292 Failure Code [CA698]..........................................................................................................................1293 Failure Code [CA731]..........................................................................................................................1294 Failure Code [CA778]..........................................................................................................................1296 Failure Code [CA1117].........................................................................................................................1301 Failure Code [CA1664].........................................................................................................................1302 Failure Code [CA1669].........................................................................................................................1305 Failure Code [CA1673].........................................................................................................................1306 Failure Code [CA1677].........................................................................................................................1307 Failure Code [CA1678].........................................................................................................................1308 Failure Code [CA1682].........................................................................................................................1309 Failure Code [CA1683].........................................................................................................................1314 Failure Code [CA1684].........................................................................................................................1316 Failure Code [CA1686].........................................................................................................................1318 Failure Code [CA1691].........................................................................................................................1319 Failure Code [CA1694].........................................................................................................................1322 Failure Code [CA1695].........................................................................................................................1325 Failure Code [CA1696].........................................................................................................................1326 Failure Code [CA1712].........................................................................................................................1328 Failure Code [CA1713].........................................................................................................................1331 Failure Code [CA1714].........................................................................................................................1333 Failure Code [CA1715].........................................................................................................................1334 Failure Code [CA1776].........................................................................................................................1335 Failure Code [CA1777].........................................................................................................................1338 Failure Code [CA1843].........................................................................................................................1341 Failure Code [CA1844].........................................................................................................................1343 Failure Code [CA1879].........................................................................................................................1346 Failure Code [CA1881].........................................................................................................................1349 Failure Code [CA1883].........................................................................................................................1352 Failure Code [CA1885].........................................................................................................................1356 Failure Code [CA1887].........................................................................................................................1358 Failure Code [CA1921].........................................................................................................................1360 Failure Code [CA1922].........................................................................................................................1363 Failure Code [CA1942].........................................................................................................................1368 Failure Code [CA1993].........................................................................................................................1369 Failure Code [CA2185].........................................................................................................................1372 Failure Code [CA2186].........................................................................................................................1374 Failure Code [CA2249].........................................................................................................................1376 Failure Code [CA2265].........................................................................................................................1377 Failure Code [CA2266].........................................................................................................................1379 Failure Code [CA2271].........................................................................................................................1381 Failure Code [CA2272].........................................................................................................................1384 Failure Code [CA2311].........................................................................................................................1387 Failure Code [CA2349].........................................................................................................................1388 Failure Code [CA2353].........................................................................................................................1391 Failure Code [CA2357].........................................................................................................................1393 Failure Code [CA2381].........................................................................................................................1394 Failure Code [CA2382].........................................................................................................................1397 Failure Code [CA2383].........................................................................................................................1400 Failure Code [CA2386].........................................................................................................................1403 Failure Code [CA2387].........................................................................................................................1405 Troubleshooting Flowchart.................................................................................................................1409 Failure Code [CA2555].........................................................................................................................1410 Failure Code [CA2556].........................................................................................................................1413 Failure Code [CA2637].........................................................................................................................1416 Failure Code [CA2639].........................................................................................................................1418 Failure Code [CA2771].........................................................................................................................1421 Failure Code [CA2777].........................................................................................................................1427 Failure Code [CA2976].........................................................................................................................1430 Failure Code [CA3133].........................................................................................................................1432 Failure Code [CA3134].........................................................................................................................1434 Failure Code [CA3135].........................................................................................................................1436 Failure Code [CA3142].........................................................................................................................1440 Failure Code [CA3143].........................................................................................................................1441 Failure Code [CA3144].........................................................................................................................1442 Failure Code [CA3146].........................................................................................................................1444 Failure Code [CA3147].........................................................................................................................1445 Failure Code [CA3148].........................................................................................................................1446 Failure Code [CA3151].........................................................................................................................1448 Failure Code [CA3165].........................................................................................................................1454 Failure Code [CA3229].........................................................................................................................1456 Failure Code [CA3231].........................................................................................................................1458 Failure Code [CA3232].........................................................................................................................1460 Failure Code [CA3235].........................................................................................................................1464 Failure Code [CA3239].........................................................................................................................1466 Failure Code [CA3241].........................................................................................................................1469 Failure Code [CA3242].........................................................................................................................1472 Failure Code [CA3251].........................................................................................................................1475 Failure Code [CA3253].........................................................................................................................1477 Failure Code [CA3254].........................................................................................................................1480 Failure Code [CA3255].........................................................................................................................1483 Failure Code [CA3256].........................................................................................................................1486 Failure Code [CA3311].........................................................................................................................1488 Failure Code [CA3312].........................................................................................................................1490 Failure Code [CA3313].........................................................................................................................1493 Failure Code [CA3314].........................................................................................................................1494 Failure Code [CA3315].........................................................................................................................1495 Failure Code [CA3316].........................................................................................................................1498 Failure Code [CA3317].........................................................................................................................1499 Failure Code [CA3318].........................................................................................................................1500 Failure Code [CA3319].........................................................................................................................1503 Failure Code [CA3321].........................................................................................................................1504 Failure Code [CA3322].........................................................................................................................1506 Failure Code [CA3419].........................................................................................................................1509 Failure Code [CA3421].........................................................................................................................1511 Failure Code [CA3497].........................................................................................................................1513 Failure Code [CA3498].........................................................................................................................1514 Failure Code [CA3543].........................................................................................................................1515 Failure Code [CA3545].........................................................................................................................1522 Failure Code [CA3547].........................................................................................................................1524 Failure Code [CA3558].........................................................................................................................1525 Failure Code [CA3559].........................................................................................................................1527 Failure Code [CA3562].........................................................................................................................1529 Failure Code [CA3563].........................................................................................................................1531 Failure Code [CA3567].........................................................................................................................1534 Failure Code [CA3568].........................................................................................................................1537 Failure Code [CA3571].........................................................................................................................1543 Failure Code [CA3572].........................................................................................................................1545 Failure Code [CA3574].........................................................................................................................1547 Failure Code [CA3575].........................................................................................................................1550 Failure Code [CA3577].........................................................................................................................1552 Failure Code [CA3578].........................................................................................................................1554 Failure Code [CA3582].........................................................................................................................1556 Failure Code [CA3583].........................................................................................................................1565 Failure Code [CA3596].........................................................................................................................1567 Failure Code [CA3649].........................................................................................................................1570 Failure Code [CA3681].........................................................................................................................1572 Failure Code [CA3682].........................................................................................................................1574 Failure Code [CA3713].........................................................................................................................1577 Failure Code [CA3717].........................................................................................................................1580 Failure Code [CA3718].........................................................................................................................1581 Failure Code [CA3725].........................................................................................................................1582 Failure Code [CA3741].........................................................................................................................1585 Failure Code [CA3748].........................................................................................................................1586 Failure Code [CA3751].........................................................................................................................1589 Failure Code [CA3755].........................................................................................................................1591 Failure Code [CA3866].........................................................................................................................1593 Failure Code [CA3867].........................................................................................................................1597 Failure Code [CA3868].........................................................................................................................1600 Failure Code [CA3899].........................................................................................................................1604 Failure Code [CA3911].........................................................................................................................1606 Failure Code [CA3912].........................................................................................................................1610 Failure Code [CA3932].........................................................................................................................1612 Failure Code [CA3933].........................................................................................................................1614 Failure Code [CA3934].........................................................................................................................1616 Failure Code [CA3935].........................................................................................................................1619 Failure Code [CA3936].........................................................................................................................1621 Failure Code [CA4151].........................................................................................................................1623 Failure Code [CA4152].........................................................................................................................1627 Failure Code [CA4155].........................................................................................................................1631 Failure Code [CA4156].........................................................................................................................1634 Failure Code [CA4157].........................................................................................................................1637 Failure Code [CA4158].........................................................................................................................1639 Failure Code [CA4159].........................................................................................................................1640 Failure Code [CA4161].........................................................................................................................1641 Failure Code [CA4162].........................................................................................................................1644 Failure Code [CA4163].........................................................................................................................1647 Failure Code [CA4164].........................................................................................................................1649 Failure Code [CA4165].........................................................................................................................1651 Failure Code [CA4166].........................................................................................................................1653 Failure Code [CA4168].........................................................................................................................1655 Failure Code [CA4169].........................................................................................................................1658 Failure Code [CA4171].........................................................................................................................1660 Failure Code [CA4249].........................................................................................................................1663 Failure Code [CA4251].........................................................................................................................1665 Failure Code [CA4259].........................................................................................................................1667 Failure Code [CA4261].........................................................................................................................1670 Failure Code [CA4277].........................................................................................................................1673 Failure Code [CA4281].........................................................................................................................1677 Failure Code [CA4459].........................................................................................................................1681 Failure Code [CA4461].........................................................................................................................1684 Failure Code [CA4658].........................................................................................................................1687 Failure Code [CA4731].........................................................................................................................1691 Failure Code [CA4732].........................................................................................................................1692 Failure Code [CA4739].........................................................................................................................1693 Failure Code [CA4768].........................................................................................................................1694 Failure Code [CA4769].........................................................................................................................1696 Failure Code [CA4842].........................................................................................................................1699 Failure Code [CA4952].........................................................................................................................1703 Failure Code [CA5115].........................................................................................................................1705 Failure Code [CA5383].........................................................................................................................1708 Failure Code [D130KA].........................................................................................................................1710 Failure Code [D130KB].........................................................................................................................1713 Failure Code [D19DKA].........................................................................................................................1715 Failure Code [D19DKB].........................................................................................................................1717 Failure Code [D19JKZ].........................................................................................................................1719 Failure Code [D19UKA].........................................................................................................................1722 Failure Code [D19UKB].........................................................................................................................1724 Failure Code [D19UMC].........................................................................................................................1726 Failure Code [D811MC].........................................................................................................................1728 Failure Code [D862KA].........................................................................................................................1729 Failure Code [D8ALKA].........................................................................................................................1730 Failure Code [D8ALKB].........................................................................................................................1732 Failure Code [D8AQKR].........................................................................................................................1735 Failure Code [D8ARKR].........................................................................................................................1737 Failure Code [D8G1KT].........................................................................................................................1740 Failure Code [D8G6KT].........................................................................................................................1741 Failure Code [DAF0MB].........................................................................................................................1742 Failure Code [DAF0MC].........................................................................................................................1743 Failure Code [DAF8KB].........................................................................................................................1744 Failure Code [DAF9KQ].........................................................................................................................1745 Failure Code [DAFGMC].........................................................................................................................1746 Failure Code [DAFLKA].........................................................................................................................1747 Failure Code [DAFLKB].........................................................................................................................1749 Failure Code [DAFQKR].........................................................................................................................1752 Failure Code [DAQW00].........................................................................................................................1753 Failure Code [DAZ9KQ].........................................................................................................................1754 Failure Code [DAZQKR].........................................................................................................................1755 Failure Code [DB2QKR].........................................................................................................................1756 Failure Code [DB2RKR].........................................................................................................................1765 Failure Code [DBE0KT].........................................................................................................................1771 Failure Code [DBE0MC].........................................................................................................................1772 Failure Code [DBE1KK].........................................................................................................................1773 Failure Code [DBE2KK].........................................................................................................................1776 Failure Code [DBE2KT].........................................................................................................................1779 Failure Code [DBE5KK].........................................................................................................................1780 Failure Code [DBE6KK].........................................................................................................................1782 Failure Code [DBE7KK].........................................................................................................................1784 Failure Code [DBE9KQ].........................................................................................................................1786 Failure Code [DBELKA].........................................................................................................................1787 Failure Code [DBELKB].........................................................................................................................1789 Failure Code [DBEQKR].........................................................................................................................1791 Failure Code [DBERKR].........................................................................................................................1792 Failure Code [DBR0KT].........................................................................................................................1795 Failure Code [DBR0MC].........................................................................................................................1796 Failure Code [DBR1KK].........................................................................................................................1797 Failure Code [DBR2KK].........................................................................................................................1800 Failure Code [DBR2KT].........................................................................................................................1803 Failure Code [DBR5KK].........................................................................................................................1804 Failure Code [DBR7KK].........................................................................................................................1806 Failure Code [DBRLKA].........................................................................................................................1808 Failure Code [DBRLKB].........................................................................................................................1810 Failure Code [DBRPMA].........................................................................................................................1812 Failure Code [DBRQKR].........................................................................................................................1813 Failure Code [DBRRKR].........................................................................................................................1815 Failure Code [DBU0KR].........................................................................................................................1816 Failure Code [DBUSKR].........................................................................................................................1817 Failure Code [DBUTKA].........................................................................................................................1822 Failure Code [DBUTKN].........................................................................................................................1823 Failure Code [DBUTMA].........................................................................................................................1825 Failure Code [DBUUKA].........................................................................................................................1826 Failure Code [DBUUKN].........................................................................................................................1827 Failure Code [DD12KA].........................................................................................................................1829 Failure Code [DD12KB].........................................................................................................................1831 Failure Code [DD13KA].........................................................................................................................1833 Failure Code [DD13KB].........................................................................................................................1835 Failure Code [DD14KA].........................................................................................................................1837 Failure Code [DD14KB].........................................................................................................................1839 Failure Code [DDKHKA].........................................................................................................................1841 Failure Code [DDKHKB].........................................................................................................................1843 Failure Code [DDKQKA].........................................................................................................................1845 Failure Code [DDKQKB].........................................................................................................................1847 Failure Code [DDKRKA].........................................................................................................................1849 Failure Code [DDKRKB].........................................................................................................................1851 Failure Code [DDKSKA].........................................................................................................................1853 Failure Code [DDKSKB].........................................................................................................................1855 Failure Code [DDN7KA].........................................................................................................................1857 Failure Code [DDN7KB].........................................................................................................................1859 Failure Code [DDNLKA].........................................................................................................................1861 Failure Code [DDNLKB].........................................................................................................................1863 Failure Code [DGS1KA].........................................................................................................................1865 Failure Code [DGS1KX].........................................................................................................................1867 Failure Code [DGT1KA].........................................................................................................................1869 Failure Code [DGT1KX].........................................................................................................................1872 Failure Code [DH21KA].........................................................................................................................1874 Failure Code [DH21KY].........................................................................................................................1876 Failure Code [DHA4KA].........................................................................................................................1878 Failure Code [DHAAMA].........................................................................................................................1880 Failure Code [DHACMA].........................................................................................................................1882 Failure Code [DHSKKA].........................................................................................................................1884 Failure Code [DHSKKY].........................................................................................................................1886 Failure Code [DHSLKA].........................................................................................................................1888 Failure Code [DHSLKY].........................................................................................................................1890 Failure Code [DHSWKA].........................................................................................................................1892 Failure Code [DHSWKY].........................................................................................................................1894 Failure Code [DHSXKA].........................................................................................................................1896 Failure Code [DHSXKY].........................................................................................................................1898 Failure Code [DHTDKA].........................................................................................................................1900 Failure Code [DHTDKY].........................................................................................................................1902 Failure Code [DK10KA].........................................................................................................................1904 Failure Code [DK10KB].........................................................................................................................1907 Failure Code [DK30KA].........................................................................................................................1909 Failure Code [DK30KX].........................................................................................................................1912 Failure Code [DK30KY].........................................................................................................................1913 Failure Code [DK30KZ].........................................................................................................................1915 Failure Code [DK30L8].........................................................................................................................1916 Failure Code [DK31KA].........................................................................................................................1917 Failure Code [DK31KY].........................................................................................................................1920 Failure Code [DK40KA].........................................................................................................................1922 Failure Code [DK40KY].........................................................................................................................1924 Failure Code [DK55KX].........................................................................................................................1926 Failure Code [DK55KZ].........................................................................................................................1927 Failure Code [DK55L8].........................................................................................................................1928 Failure Code [DK56KA].........................................................................................................................1929 Failure Code [DK56KY].........................................................................................................................1931 Failure Code [DK57KA].........................................................................................................................1933 Failure Code [DK57KY].........................................................................................................................1935 Failure Code [DK80KR].........................................................................................................................1937 Failure Code [DK80KT].........................................................................................................................1940 Failure Code [DKH1KA].........................................................................................................................1942 Failure Code [DKH1KY].........................................................................................................................1945 Failure Code [DKSGL8].........................................................................................................................1947 Failure Code [DKSHKA].........................................................................................................................1948 Failure Code [DKSHKB].........................................................................................................................1950 Failure Code [DKSJKA].........................................................................................................................1952 Failure Code [DKSJKB].........................................................................................................................1954 Failure Code [DKSKKA].........................................................................................................................1956 Failure Code [DKSKKB].........................................................................................................................1958 Failure Code [DKSKMB].........................................................................................................................1960 Failure Code [DKSLL8].........................................................................................................................1962 Failure Code [DKSMKA].........................................................................................................................1963 Failure Code [DKSMKB].........................................................................................................................1965 Failure Code [DKSNKA].........................................................................................................................1967 Failure Code [DKSNKB].........................................................................................................................1969 Failure Code [DKSPKA].........................................................................................................................1971 Failure Code [DKSPKB].........................................................................................................................1973 Failure Code [DKSPMB].........................................................................................................................1975 Failure Code [DLM3KA].........................................................................................................................1977 Failure Code [DLM3MB].........................................................................................................................1979 Failure Code [DLT3KA].........................................................................................................................1980 Failure Code [DLT3KB].........................................................................................................................1982 Failure Code [DR21KX].........................................................................................................................1984 Failure Code [DR31KX].........................................................................................................................1985 Failure Code [DV20KB].........................................................................................................................1986 Failure Code [DW5AKA].........................................................................................................................1988 Failure Code [DW5AKB].........................................................................................................................1990 Failure Code [DW5AKY].........................................................................................................................1992 Failure Code [DW7BKA].........................................................................................................................1994 Failure Code [DW7BKB].........................................................................................................................1996 Failure Code [DW7BKY].........................................................................................................................1998 Failure Code [DWN1KA] (Applicable Machine: 96001 to 96603)....................................................................................1999 Failure Code [DWN1KA] (Applicable Machine: 96604 and Up)......................................................................................2001 Failure Code [DWN1KB] (Applicable Machine: 96001 to 96603)....................................................................................2003 Failure Code [DWN1KB] (Applicable Machine: 96604 and Up)......................................................................................2005 Failure Code [DWN1KY] (Applicable Machine: 96001 to 96603)....................................................................................2007 Failure Code [DWN1KY] (Applicable Machine: 96604 and Up)......................................................................................2009 Failure Code [DWN2KA] (Applicable Machine: 96001 to 96603)....................................................................................2011 Failure Code [DWN2KA] (Applicable Machine: 96604 and Up)......................................................................................2013 Failure Code [DWN2KB] (Applicable Machine: 96001 to 96603)....................................................................................2015 Failure Code [DWN2KB] (Applicable Machine: 96604 and Up)......................................................................................2017 Failure Code [DWN2KY] (Applicable Machine: 96001 to 96603)....................................................................................2019 Failure Code [DWN2KY] (Applicable Machine: 96604 and Up)......................................................................................2020 Failure Code [DWN5KA].........................................................................................................................2022 Failure Code [DWN5KB].........................................................................................................................2024 Failure Code [DWN5KY].........................................................................................................................2025 Failure Code [DXA2KA].........................................................................................................................2027 Failure Code [DXA2KB].........................................................................................................................2029 Failure Code [DXA2KY].........................................................................................................................2031 Failure Code [DXH1KA].........................................................................................................................2032 Failure Code [DXH1KB].........................................................................................................................2034 Failure Code [DXH1KY].........................................................................................................................2036 Failure Code [DXH4KA].........................................................................................................................2038 Failure Code [DXH4KB].........................................................................................................................2040 Failure Code [DXH4KY].........................................................................................................................2042 Failure Code [DXH5KA].........................................................................................................................2044 Failure Code [DXH5KB].........................................................................................................................2046 Failure Code [DXH5KY].........................................................................................................................2048 Failure Code [DXH6KA].........................................................................................................................2050 Failure Code [DXH6KB].........................................................................................................................2052 Failure Code [DXH6KY].........................................................................................................................2054 Failure Code [DXH7KA].........................................................................................................................2056 Failure Code [DXH7KB].........................................................................................................................2058 Failure Code [DXH7KY].........................................................................................................................2060 Failure Code [DXH8KA].........................................................................................................................2062 Failure Code [DXH8KB].........................................................................................................................2064 Failure Code [DXH8KY].........................................................................................................................2066 Failure Code [DXHRKA].........................................................................................................................2068 Failure Code [DXHRKB].........................................................................................................................2070 Failure Code [DXHRKY].........................................................................................................................2071 Failure Code [DXHSKA].........................................................................................................................2073 Failure Code [DXHSKB].........................................................................................................................2075 Failure Code [DXHSKY].........................................................................................................................2076 Failure Code [DXHTKA].........................................................................................................................2078 Failure Code [DXHTKB].........................................................................................................................2080 Failure Code [DXHTKY].........................................................................................................................2081 Failure Code [DXHUKA].........................................................................................................................2083 Failure Code [DXHUKB].........................................................................................................................2085 Failure Code [DXHUKY].........................................................................................................................2086 Failure Code [DXJ4KA].........................................................................................................................2088 Failure Code [DXJ4KB].........................................................................................................................2090 Failure Code [F311KA].........................................................................................................................2092 Failure Code [F311KB].........................................................................................................................2094 Failure Code [F312KA].........................................................................................................................2096 Failure Code [F312KB].........................................................................................................................2098 Failure Code [F313KA].........................................................................................................................2100 Failure Code [F313KB].........................................................................................................................2102 Failure Code [F314KA].........................................................................................................................2105 Failure Code [F314KB].........................................................................................................................2107 Failure Code [F315KB].........................................................................................................................2109 Failure Code [F315KY].........................................................................................................................2111 Failure Code [F316KB].........................................................................................................................2113 Failure Code [F316KY].........................................................................................................................2115 Failure Code [F318KB].........................................................................................................................2117 Failure Code [F318KY].........................................................................................................................2120 Failure Code [F31AKB].........................................................................................................................2122 Failure Code [F31AKY].........................................................................................................................2124 Failure Code [F31BKB].........................................................................................................................2126 Failure Code [F31BKY].........................................................................................................................2128 Failure Code [F31CKB].........................................................................................................................2130 Failure Code [F31CKY].........................................................................................................................2132 Failure Code [F31DKB].........................................................................................................................2134 Failure Code [F31DKY].........................................................................................................................2136 Failure Code [F31EKB].........................................................................................................................2138 Failure Code [F31EKY].........................................................................................................................2140 Failure Code [F7A0KQ].........................................................................................................................2142 Failure Code [F7A0KT].........................................................................................................................2143 Failure Code [F7A1KK].........................................................................................................................2144 Failure Code [F7ALKB].........................................................................................................................2147 Failure Code [F7AQKR].........................................................................................................................2149 Failure Code [F7ASKA].........................................................................................................................2150 Failure Code [FE0AKA].........................................................................................................................2152 Failure Code [FS10ZE].........................................................................................................................2154 Troubleshooting of Electrical System (E-Mode).....................................................................................................2155 Engine Does Not Start (Engine Does Not Crank).................................................................................................2155 Manual Preheating System Does Not Operate.....................................................................................................2162 Automatic Preheating System Does Not Operate..................................................................................................2165 While Preheating is in Operation, Preheating Monitor Does Not Come On.........................................................................2167 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing..................................................................2169 When Starting Switch is Turned to ON Position (with Engine Stopped), Basic Check Monitor Comes On.............................................2173 Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation..................................................................2174 Charge Level Monitor Comes On in Red While Engine is in Operation.............................................................................2175 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation...............................................................2177 Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation......................................................................2178 Power Train Oil Temperature Monitor Comes On in Red While Engine Runs.........................................................................2179 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation................................................................2180 Engine Coolant Temperature Gauge Does Not Show Correct Temperature............................................................................2181 DEF Level is Not Shown Correctly..............................................................................................................2182 Fuel Gauge Does Not Show Normally.............................................................................................................2185 Power Train Oil Temperature Gauge Does Not Show Correct Temperature...........................................................................2187 Hydraulic Oil Temperature Gauge Does Not Show Correct Temperature.............................................................................2188 Operation Mode Does Not Change................................................................................................................2189 Gear Shift Mode Does Not Change...............................................................................................................2190 When You Operate Customize Switch Does Not Show Customize Screen..............................................................................2191 When You Change Setting on Customize Screen, Setting of Machine is Not Changed................................................................2192 Some Areas of Machine Monitor Screen are Not Shown............................................................................................2193 REVERSE Slow Mode Function Does Not Operate Correctly.........................................................................................2194 Alarm Buzzer Does Not Operate or Does Not Stop Operation......................................................................................2195 Service Meter is Not Shown While Starting Switch is in OFF Position...........................................................................2196 Service Mode Cannot be Selected...............................................................................................................2197 Horn Does Not Sound...........................................................................................................................2198 Horn Does Not Stop............................................................................................................................2200 Backup Alarm Does Not Sound...................................................................................................................2201 Backup Alarm Does Not Stop Operation..........................................................................................................2203 Headlamp Does Not Come On.....................................................................................................................2204 Rear Lamp Does Not Come On....................................................................................................................2208 No Wiper Operates.............................................................................................................................2211 Front Wiper Does Not Operate..................................................................................................................2215 Rear Wiper Does Not Operate...................................................................................................................2218 Left Door Wiper Does Not Operate..............................................................................................................2221 Right Door Wiper Does Not Operate.............................................................................................................2224 Front Washer Does Not Operate.................................................................................................................2227 Rear Washer Does Not Operate..................................................................................................................2229 Left Door Washer Does Not Operate.............................................................................................................2231 Right Door Washer Does Not Operate............................................................................................................2233 KOMTRAX System Does Not Operate Correctly.....................................................................................................2235 Control Box Shows Message [Waiting for radio link...].........................................................................................2236 Control Box Shows Message [Waiting for satellites...].........................................................................................2238 Control Box Shows Message [GPS receiver not connected !] and [Komatsu Machine Trouble]........................................................2239 Control Box Shows Message [Komatsu Machine Trouble]...........................................................................................2240 Control Box Shows Message [Waiting to initialize...]..........................................................................................2241 Control Box Shows Message [System initializing]...............................................................................................2242 Control Box Shows Message [Initializing...]...................................................................................................2243 Control Box Shows Message [Connecting to GPS...]..............................................................................................2244 Elevation Control Key on Control Box Shows Message [Low precisions...]........................................................................2245 Control Box Shows Message [Heading Initializing]..............................................................................................2246 Control Box Shows Message [Out of design area...].............................................................................................2247 Control Box Shows Message [No GPS localization...]............................................................................................2248 Control Box Shows Message [Loading Design Surface data...]....................................................................................2249 Control Box Shows Message [Design Surface data invalid].......................................................................................2250 Control Box Shows Message [Starting switch is OFF]............................................................................................2251 Control Box Shows Message [Waiting for satellites...] and [Komatsu Machine Trouble]...........................................................2253 Control Box Shows Message [Blade Pitch Angle is Not Adjusted yet for Finish Work] (This Message is Not Deleted)...............................2254 Control Box Can Not be Turned on..............................................................................................................2256 Control Box Does Not Display Intelligent Machine Control Screen...............................................................................2257 Control Box Does Not Display Bulldozer Image..................................................................................................2258 Control Box Does Not Display Design Surface...................................................................................................2259 Control Box Touch Panel Does Not Respond......................................................................................................2260 Control Box Touch Panel is Inaccurate.........................................................................................................2261 Cylinder Stroke Reset Indication Does Not Go Out..............................................................................................2262 AUTO or Strikethrough is Not Shown When AUTO/Manual Switch is Pushed (AUTO or Strikethrough Goes Out).........................................2263 Blade Automatic Lower Control Does Not Start While AUTO is Shown..............................................................................2264 Blade Automatic Raise Control Does Not Start While AUTO is Shown..............................................................................2265 Blade Automatic Control Function is Not Activated While AUTO is Shown (Blade Automatic Control Stops).........................................2266 When You Examine and Adjust the Blade Elevation, the Value is Different from Actual Machine...................................................2267 Finished Surface is Inaccurate (The Average Height of Finished Surface is Lower Than Designed Surface or Blade Does Not Touch the Surface)....2268 Finished Surface is Inaccurate (The Finished Surface is Not Smooth)...........................................................................2269 Finished Surface is Inaccurate (When You Finish Slope Horizontally, Steps are Made in Each Direction).........................................2270 Machine Cannot Escape from Shoes Slip While Blade Automatic Control is Activated (Shoes Frequently Slips).....................................2272 Blade Tilt Angle Does Not Align with Design Surface...........................................................................................2273 Blade Tilts While Blade Automatic Control is Activated........................................................................................2275 Even After Lift Layer Control is Activated, Measured Lift Layer Terrain Shape Does Not Agree with Actual Terrain..............................2277 The Surface Made with Quick Surface Creation Function is Different from the One in Machine Front Direction, Blade Edge Position...............2279 Machine Does Not Travel Straight While Tilt Steering Control is Activated.....................................................................2280 Control Box Continues to Show Progress Bar in Machine Manual Cal Screen.......................................................................2281 Engine Hunting Occurs When You Lower the Blade While Ground Line Assist is Activated..........................................................2282 In Cutting Operation, Work Equipment Pushes the Ground and Idlers Go Up from the Ground.......................................................2283 Troubleshooting for Hydraulic and Mechanical Systems (H Mode).....................................................................................2284 Information Shown in Troubleshooting Table (H-Mode)...........................................................................................2284 System Chart of Hydraulic and Mechanical Systems..............................................................................................2285 Failure Mode and Cause Table..................................................................................................................2287 Machine Lacks Power (Drawbar Pull is Not Sufficient)..........................................................................................2295 Machine Does Not Travel (at 2nd or 3rd Gear Speed)............................................................................................2297 Machine Does Not Move Off at All Gear Speeds..................................................................................................2298 Machine Travels Only in One Direction, Forward or in Reverse..................................................................................2300 Large Time Lag is in Gear Shifting or Directional Change......................................................................................2301 Brake Does Not Work...........................................................................................................................2303 Power Train Oil Overheats.....................................................................................................................2304 Unusual Noise is Heard from Around Work Equipment and HSS Pump or HSS Motor...................................................................2306 Torque Converter Lockup Clutch Does Not Engage................................................................................................2307 Machine Cannot be Steered (Machine Does Not Turn LEFT or RIGHT)...............................................................................2308 Steering Speed or Power is Not Sufficient.....................................................................................................2309 All Work Equipment Operate Slowly.............................................................................................................2310 All Work Equipment Do Not Operate.............................................................................................................2311 Blade Lift Speed or Power is Low..............................................................................................................2312 Blade Tilt Speed or Power is Low..............................................................................................................2313 Blade Angle Speed or Power is Low.............................................................................................................2314 Ripper Lift Speed or Power is Low.............................................................................................................2315 Hydraulic Drift of Blade Lift is Large........................................................................................................2316 Hydraulic Drift of Tilted Blade is Large......................................................................................................2317 Hydraulic Drift of Lifted Ripper is Large.....................................................................................................2318 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate)...................................................................................2319 Unusual Noise is Heard from Around Fan........................................................................................................2321 Troubleshooting of Engine (S-Mode)................................................................................................................2322 Information Shown in Troubleshooting Table (S-Mode)...........................................................................................2322 Engine Does Not Crank When Starting Switch is Turned to Start Position........................................................................2323 Engine Cranks but No Exhaust Smoke Comes Out..................................................................................................2324 Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start).......................................................2325 Engine Startability is Unsatisfactory.........................................................................................................2327 Engine Does Not Pick Up Smoothly..............................................................................................................2329 Engine Stops During Operation.................................................................................................................2331 Engine Does Not Rotate Smoothly...............................................................................................................2333 Engine Lacks Output (or Lacks Power)..........................................................................................................2334 KDPF Becomes Clogged in a Short Time..........................................................................................................2336 Engine Oil Consumption is Excessive...........................................................................................................2338 Engine Oil Becomes Dirty Quickly..............................................................................................................2339 Fuel Consumption is Excessive.................................................................................................................2340 Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down).........................................................................2341 Engine Oil Pressure Drops.....................................................................................................................2342 Fuel Mixes Into Engine Oil....................................................................................................................2344 Water Mixes Into Engine Oil (Milky)...........................................................................................................2345 Coolant Temperature Increases Too High (Overheat).............................................................................................2346 Unusual Noise is Heard........................................................................................................................2347 Vibration is Excessive........................................................................................................................2348 Air Cannot be Bled from Fuel Circuit..........................................................................................................2349 Active Regeneration is Done Frequently........................................................................................................2350 Active Regeneration Continues Long............................................................................................................2352 White Smoke is Exhausted During Active Regeneration...........................................................................................2353 DEF Consumption is Excessive..................................................................................................................2354 There is an Unusual Smell (Irritating Odor)...................................................................................................2356 Foreign Materials Enter DEF (DEF Increases)...................................................................................................2357 50 Disassembly and Assembly...........................................................................................................................2359 Table of Contents.................................................................................................................................2360 Precautions Before Work...........................................................................................................................2366 Related Information on Disassembly and Assembly...................................................................................................2367 How to Read This Manual.......................................................................................................................2367 Coating Materials List........................................................................................................................2368 Special Tool List.............................................................................................................................2373 Sketches of Special Tools.....................................................................................................................2395 Engine and Cooling System.........................................................................................................................2416 Remove and Install Supply Pump Assembly.......................................................................................................2416 How to Remove Supply Pump Assembly........................................................................................................2416 How to Install Supply Pump Assembly.......................................................................................................2420 Remove and Install Injector Assembly..........................................................................................................2425 How to Remove Injector Assembly...........................................................................................................2426 How to Install Injector Assembly..........................................................................................................2433 Remove and Install Cylinder Head Assembly.....................................................................................................2444 How to Remove Cylinder Head Assembly......................................................................................................2445 How to Install Cylinder Head Assembly.....................................................................................................2455 Remove and Install EGR Valve Assembly.........................................................................................................2471 How to Remove EGR Valve Assembly..........................................................................................................2471 How to Install EGR Valve Assembly.........................................................................................................2472 Remove and Install EGR Cooler Assembly........................................................................................................2473 How to Remove EGR Cooler Assembly.........................................................................................................2473 How to Install EGR Cooler Assembly........................................................................................................2474 Remove and Install Starter Assembly...........................................................................................................2476 How to Remove Starting Motor Assembly.....................................................................................................2476 How to Install Starting Motor Assembly....................................................................................................2478 Remove and Install Alternator Belt............................................................................................................2481 How to Remove Alternator Belt.............................................................................................................2481 How to Install Alternator Belt............................................................................................................2482 Remove and Install Automatic Tensioner........................................................................................................2484 How to Remove Automatic Tensioner.........................................................................................................2484 How to Install Automatic Tensioner........................................................................................................2484 Remove and Install Expansion Tank Assembly....................................................................................................2485 How to Remove Expansion Tank Assembly.....................................................................................................2485 How to Install Expansion Tank Assembly....................................................................................................2491 Remove and Install Radiator Assembly..........................................................................................................2498 How to Remove Radiator Assembly...........................................................................................................2498 How to Install Radiator Assembly..........................................................................................................2501 Remove and Install Hydraulic Oil Cooler Assembly..............................................................................................2505 How to Remove Hydraulic Oil Cooler Assembly...............................................................................................2505 How to Install Hydraulic Oil Cooler Assembly..............................................................................................2507 Remove and Install Aftercooler Assembly.......................................................................................................2511 How to Remove Aftercooler Assembly........................................................................................................2511 How to Install Aftercooler Assembly.......................................................................................................2513 Remove and Install Power Train Oil Cooler Assembly............................................................................................2516 How to Remove Power Train Oil Cooler Assembly.............................................................................................2516 How to Install Power Train Oil Cooler Assembly............................................................................................2518 Remove and Install Cooling Fan Drive Assembly.................................................................................................2521 How to Remove Cooling Fan Drive Assembly..................................................................................................2521 How to Install Cooling Fan Drive Assembly.................................................................................................2522 Remove and Install Cooling Fan Motor Assembly.................................................................................................2525 How to Remove Cooling Fan Motor Assembly..................................................................................................2525 How to Install Cooling Fan Motor Assembly.................................................................................................2527 Remove and Install Engine Assembly............................................................................................................2529 How to Remove Engine Assembly.............................................................................................................2529 How to Install Engine Assembly............................................................................................................2534 Remove and Install Engine Front Oil Seal......................................................................................................2540 How to Remove Engine Front Oil Seal.......................................................................................................2540 How to Install Engine Front Oil Seal......................................................................................................2542 Remove and Install Engine Rear Oil Seal.......................................................................................................2546 How to Remove Engine Rear Oil Seal........................................................................................................2546 How to Install Engine Rear Oil Seal.......................................................................................................2550 Remove and Install Engine Hood Assembly.......................................................................................................2558 How to Remove Engine Hood Assembly........................................................................................................2558 How to Install Engine Hood Assembly.......................................................................................................2564 Remove and Install Fuel Tank Assembly.........................................................................................................2570 How to Remove Fuel Tank Assembly..........................................................................................................2570 How to Install Fuel Tank Assembly.........................................................................................................2573 Remove and Install DEF Tank Assembly..........................................................................................................2576 How to Remove DEF Tank Assembly...........................................................................................................2577 How to Install DEF Tank Assembly..........................................................................................................2581 Remove and Install DEF Tank Sensor Flange Assembly............................................................................................2585 How to Remove DEF Tank Sensor Flange Assembly.............................................................................................2586 How to Install DEF Tank Sensor Flange Assembly............................................................................................2590 Remove and Install DEF Tank Sensor............................................................................................................2597 How to Remove DEF Tank Sensor.............................................................................................................2597 How to Install DEF Tank Sensor............................................................................................................2598 Remove and Install DEF Tank Strainer..........................................................................................................2605 How to Remove DEF Tank Strainer...........................................................................................................2605 How to Install DEF Tank Strainer..........................................................................................................2605 Remove and Install KDPF Assembly..............................................................................................................2606 How to Remove KDPF Assembly...............................................................................................................2606 How to Install KDPF Assembly..............................................................................................................2610 Disassemble and Assemble KDPF Assembly........................................................................................................2614 How to Disassemble KDPF Assembly..........................................................................................................2614 How to Assemble KDPF Assembly.............................................................................................................2618 Remove and Install SCR Assembly...............................................................................................................2624 How to Remove SCR Assembly................................................................................................................2624 How to Install SCR Assembly...............................................................................................................2626 Remove and Install KDPF and SCR Assembly......................................................................................................2629 How to Remove KDPF and SCR Assembly.......................................................................................................2629 How to Install KDPF and SCR Assembly......................................................................................................2636 Remove and Install KCCV Assembly..............................................................................................................2643 How to Remove KCCV Assembly...............................................................................................................2643 How to Install KCCV Assembly..............................................................................................................2645 Remove and Install DEF Mixing Tube............................................................................................................2647 How to Remove DEF Mixing Tube.............................................................................................................2647 How to Install DEF Mixing Tube............................................................................................................2650 Remove and Install DEF Injector...............................................................................................................2655 How to Remove DEF Injector................................................................................................................2655 How to Install DEF Injector...............................................................................................................2658 Remove and Install DEF Pump...................................................................................................................2662 How to Remove DEF Pump....................................................................................................................2662 How to Install DEF Pump...................................................................................................................2665 Remove and Install DEF Hose...................................................................................................................2668 How to Remove DEF Hose....................................................................................................................2668 How to Install DEF Hose...................................................................................................................2673 Remove and Install Air Cleaner Assembly.......................................................................................................2678 How to Remove Air Cleaner Assembly........................................................................................................2678 How to Install Air Cleaner Assembly.......................................................................................................2679 Remove and Install Air Conditioner Compressor Assembly........................................................................................2681 How to Remove Air Conditioner Compressor Assembly.........................................................................................2681 How to Install Air Conditioner Compressor Assembly........................................................................................2683 Remove and Install Air Conditioner Condenser Assembly.........................................................................................2686 How to Remove Air Conditioner Condenser Assembly..........................................................................................2686 How to Install Air Conditioner Condenser Assembly.........................................................................................2688 Power Train.......................................................................................................................................2690 Remove and Install Damper Assembly............................................................................................................2690 How to Remove Damper Assembly.............................................................................................................2690 How to Install Damper Assembly............................................................................................................2693 Remove and Install Power Train Unit Assembly..................................................................................................2698 How to Remove Power Train Unit Assembly...................................................................................................2698 How to Install Power Train Unit Assembly..................................................................................................2703 Disconnect and Connect Power Train Unit Assembly..............................................................................................2709 How to Disconnect Power Train Unit Assembly...............................................................................................2709 How to Connect Power Train Unit Assembly..................................................................................................2714 Disassemble and Assemble PTO Assembly.........................................................................................................2720 How to Disassemble PTO Assembly...........................................................................................................2720 How to Assemble PTO Assembly..............................................................................................................2723 Disassemble and Assemble Torque Converter Assembly............................................................................................2727 How to Disassemble Torque Converter Assembly..............................................................................................2728 How to Assemble Torque Converter Assembly.................................................................................................2734 Disassemble and Assemble Transmission Assembly................................................................................................2743 How to Disassemble Transmission Assembly..................................................................................................2744 How to Assemble Transmission Assembly.....................................................................................................2762 Disassemble and Assemble HSS Assembly.........................................................................................................2775 How to Disassemble HSS Assembly...........................................................................................................2777 How to Assemble HSS Assembly..............................................................................................................2788 Remove and Install HSS Motor Assembly.........................................................................................................2805 How to Remove HSS Motor Assembly..........................................................................................................2805 How to Install HSS Motor Assembly.........................................................................................................2807 Remove and Install Final Drive Assembly.......................................................................................................2810 How to Remove Final Drive Assembly........................................................................................................2810 How to Install Final Drive Assembly.......................................................................................................2813 Disassemble and Assemble Final Drive Assembly.................................................................................................2816 How to Disassemble Final Drive Assembly...................................................................................................2817 How to Assemble Final Drive Assembly......................................................................................................2822 Undercarriage and Frame...........................................................................................................................2830 Remove and Install Track Frame Assembly.......................................................................................................2830 How to Remove Track Frame Assembly........................................................................................................2830 How to Install Track Frame Assembly.......................................................................................................2833 Remove and Install Idler Assembly.............................................................................................................2837 How to Remove Idler Assembly..............................................................................................................2837 How to Install Idler Assembly.............................................................................................................2838 Disassemble and Assemble Idler Assembly.......................................................................................................2840 How to Disassemble Idler Assembly.........................................................................................................2840 How to Assemble Idler Assembly............................................................................................................2842 Remove and Install Recoil Spring Assembly.....................................................................................................2846 How to Remove Recoil Spring Assembly......................................................................................................2846 How to Install Recoil Spring Assembly.....................................................................................................2846 Disassemble and Assemble Recoil Spring Assembly...............................................................................................2848 How to Disassemble Recoil Spring Assembly.................................................................................................2848 How to Assemble Recoil Spring Assembly....................................................................................................2851 Remove and Install Track Roller Assembly......................................................................................................2854 How to Remove Track Roller Assembly.......................................................................................................2854 How to Install Track Roller Assembly......................................................................................................2855 Disassemble and Assemble Track Roller Assembly................................................................................................2856 How to Disassemble Track Roller Assembly..................................................................................................2856 How to Assemble Track Roller Assembly.....................................................................................................2858 Remove and Install Carrier Roller Assembly....................................................................................................2861 How to Remove Carrier Roller Assembly.....................................................................................................2861 How to Install Carrier Roller Assembly....................................................................................................2862 Disassemble and Assemble Carrier Roller Assembly..............................................................................................2863 How to Disassemble Carrier Roller Assembly................................................................................................2863 How to Assemble Carrier Roller Assembly...................................................................................................2864 Remove and Install Pivot Shaft Assembly.......................................................................................................2867 How to Remove Pivot Shaft Assembly........................................................................................................2867 How to Install Pivot Shaft Assembly.......................................................................................................2868 Separate and Connect Track Assembly...........................................................................................................2869 How to Examine Before Separation of Track Assembly........................................................................................2869 How to Separate Track Assembly (Standard).................................................................................................2869 How to Separate Track Assembly (When Track Frame Has Internal Defect).....................................................................2870 How to Install Track Assembly.............................................................................................................2871 Separate and Connect PLUS Type Track Assembly.................................................................................................2874 Separate PLUS Type Track Assembly Generally...............................................................................................2874 Install PLUS Type Track Assembly..........................................................................................................2874 Disassemble and Assemble Track Assembly Generally.............................................................................................2875 How to Disassemble Full Track Shoes Assembly..............................................................................................2875 How to Assemble Full Track Shoes Assembly.................................................................................................2878 Disassemble and Assemble PLUS Type Track Assembly Generally...................................................................................2890 Disassemble PLUS Type Track Assembly Generally............................................................................................2891 How to Assemble PLUS Type Track Shoes Assembly Generally..................................................................................2892 Disassemble and Assemble One Track Link Assembly in Field (Track Assembly)....................................................................2907 How to Disassemble One Track Link Assembly in Field (Track Assembly)......................................................................2908 How to Assemble One Track Link Assembly in Field (Track Assembly).........................................................................2909 Disassemble and Assemble One Track Link Assembly in Field (PLUS Type Track Assembly)..........................................................2916 Disassemble One Track Link Assembly in Field (PLUS Type Track Assembly)...................................................................2917 Assemble One Track Link Assembly in Field (PLUS Type Track Assembly)......................................................................2919 Remove and Install Equalizer Bar Assembly.....................................................................................................2923 How to Remove Equalizer Bar Assembly......................................................................................................2923 How to Install Equalizer Bar Assembly.....................................................................................................2925 Disassemble and Assemble Equalizer Bar Bushing................................................................................................2928 How to Disassemble Equalizer Bar Bushing..................................................................................................2928 How to Assemble Equalizer Bar Bushing.....................................................................................................2928 Hydraulic System..................................................................................................................................2930 Remove and Install Hydraulic Tank Assembly....................................................................................................2930 How to Remove Hydraulic Tank Assembly.....................................................................................................2930 How to Install Hydraulic Tank Assembly....................................................................................................2933 Remove and Install HSS Pump and Cooling Fan Pump Assembly.....................................................................................2938 How to Remove HSS Pump and Cooling Fan Pump Assembly......................................................................................2938 How to Install HSS Pump and Cooling Fan Pump Assembly.....................................................................................2939 Remove and Install Power Train Pump and Steering Lubrication Pump Assembly....................................................................2942 How to Remove Power Train Pump and Steering Lubrication Pump Assembly.....................................................................2942 How to Install Power Train Pump and Steering Lubrication Pump Assembly....................................................................2944 Remove and Install Scavenging Pump Assembly...................................................................................................2947 How to Remove Scavenging Pump Assembly....................................................................................................2947 How to Install Scavenging Pump Assembly...................................................................................................2947 Remove and Install 5 Spool Control Valve Assembly.............................................................................................2949 How to Remove 5 Spool Control Valve Assembly..............................................................................................2949 How to Install 5 Spool Control Valve Assembly.............................................................................................2951 Remove and Install 4 Spool Control Valve Assembly.............................................................................................2954 How to Remove 4 Spool Control Valve Assembly..............................................................................................2954 How to Install 4 Spool Control Valve Assembly.............................................................................................2957 Disassemble and Assemble Blade PPC Valve......................................................................................................2960 How to Disassemble Blade PPC Valve........................................................................................................2960 How to Assemble Blade PPC Valve...........................................................................................................2960 Disassemble and Assemble Ripper PPC Valve.....................................................................................................2962 How to Disassemble Ripper PPC Valve.......................................................................................................2962 How to Assemble Ripper PPC Valve..........................................................................................................2962 Work Equipment....................................................................................................................................2964 Remove and Install Straight Tilt Power Pitch Dozer Blade Assembly.............................................................................2964 How to Remove Straight Tilt Power Pitch Dozer Blade Assembly..............................................................................2964 How to Install Straight Tilt Power Pitch Dozer Blade Assembly.............................................................................2966 Remove and Install Ripper Assembly............................................................................................................2970 How to Remove Ripper Assembly.............................................................................................................2970 How to Install Ripper Assembly............................................................................................................2973 Remove and Install Stroke Sensing Blade Lift Cylinder Assembly (For Straight Tilt Power Pitch Dozer Series)...................................2976 How to Remove Stroke Sensing Blade Lift Cylinder Assembly (For Straight Tilt Power Pitch Dozer Series)....................................2976 How to Remove and Install Stroke Sensing Blade Lift Cylinder Assembly (For Straight Tilt Power Pitch Dozer Series)........................2978 Disassemble and Assemble Stroke and Reset Sensing Blade Lift Cylinder Assembly................................................................2982 How to Disassemble Stroke and Reset Sensing Blade Lift Cylinder Assembly..................................................................2983 Assemble Stroke and Reset Sensing Blade Lift Cylinder Assembly............................................................................2989 CAB Related Parts.................................................................................................................................3002 Remove and Install Operator Cab Assembly......................................................................................................3002 How to Remove Operator Cab Assembly.......................................................................................................3002 How to Install Operator Cab Assembly......................................................................................................3011 Remove and Install Operator Cab Glass (Adhered Glass).........................................................................................3021 How to Remove Operator Cab Glass (Adhered Glass)..........................................................................................3021 How to Install Operator Cab Glass (Adhered Glass).........................................................................................3022 Remove and Install Air Conditioner Unit Assembly..............................................................................................3027 How to Remove Air Conditioner Unit Assembly...............................................................................................3027 How to Install Air Conditioner Unit Assembly..............................................................................................3034 Remove and Install Operator Seat..............................................................................................................3043 How to Remove Operator Seat...............................................................................................................3043 How to Install Operator Seat..............................................................................................................3045 How to Remove and Install Seat Belt...........................................................................................................3048 How to Remove Seat Belt...................................................................................................................3048 How to Install Seatbelt...................................................................................................................3049 Electrical System.................................................................................................................................3050 Remove and Install Engine Controller Assembly.................................................................................................3050 How to Remove Engine Controller Assembly..................................................................................................3050 How to Install Engine Controller Assembly.................................................................................................3051 Remove and Install Power Train Controller Assembly............................................................................................3054 How to Remove Power Train Controller Assembly.............................................................................................3054 How to Install Power Train Controller Assembly............................................................................................3055 Remove and Install Machine Monitor Assembly...................................................................................................3057 How to Remove Machine Monitor Assembly....................................................................................................3057 How to Install Machine Monitor Assembly...................................................................................................3058 Remove and Install Mass Air Flow and Temperature Sensor.......................................................................................3060 How to Remove Mass Air Flow and Temperature Sensor........................................................................................3060 How to Install Mass Air Flow and Temperature Sensor.......................................................................................3061 Remove and Install KCCV Crankcase Pressure Sensor.............................................................................................3062 How to Remove KCCV Crankcase Pressure Sensor..............................................................................................3062 How to Install KCCV Crankcase Pressure Sensor.............................................................................................3063 Remove and Install SCR Temperature Sensor.....................................................................................................3064 How to Remove SCR Temperature Sensor......................................................................................................3064 How to Install SCR Temperature Sensor.....................................................................................................3065 Remove and Install Rearview Camera............................................................................................................3067 How to Remove Rearview Camera.............................................................................................................3067 How to Install Rearview Camera............................................................................................................3067 Remove and Install Gateway Function Controller Assembly.......................................................................................3069 How to Remove Gateway Function Controller Assembly........................................................................................3069 How to Install Gateway Function Controller Assembly.......................................................................................3072 Remove and Install Communication Terminal.....................................................................................................3077 How to Remove Communication Terminal......................................................................................................3077 How to Install Communication Terminal.....................................................................................................3080 Remove and Install ICT Sensor Controller Assembly.............................................................................................3083 How to Remove ICT Sensor Controller Assembly..............................................................................................3083 How to Install ICT Sensor Controller Assembly.............................................................................................3083 Remove and Install Control Box................................................................................................................3085 How to Remove Control Box.................................................................................................................3085 How to Install Control Box................................................................................................................3086 Remove and Install GNSS Receiver..............................................................................................................3087 How to Remove GNSS Receiver...............................................................................................................3087 How to Install GNSS Receiver..............................................................................................................3088 Remove and Install GNSS Antenna...............................................................................................................3090 How to Remove GNSS Antenna................................................................................................................3091 How to Install GNSS Antenna...............................................................................................................3093 Remove and Install IMU Sensor.................................................................................................................3099 How to Remove IMU Sensor..................................................................................................................3099 How to Install IMU Sensor.................................................................................................................3101 60 Maintenance Standard...............................................................................................................................3105 Table of Contents.................................................................................................................................3106 Explanation of Terms for Maintenance Standard.....................................................................................................3108 Engine and Cooling System.........................................................................................................................3110 Maintenance Standard for Engine Mount.........................................................................................................3110 Maintenance Standard for Damper...............................................................................................................3111 Maintenance Standard for Cooling System.......................................................................................................3113 Maintenance Standard for Cooling Fan Pump.....................................................................................................3115 Maintenance Standard for Servo Valve......................................................................................................3116 Maintenance Standard for Cooling Fan Motor....................................................................................................3117 Power Train.......................................................................................................................................3119 Maintenance Standard for Universal Joint......................................................................................................3119 Maintenance Standard for Power Train Mount....................................................................................................3120 Maintenance Standard for Torque Converter and PTO.............................................................................................3122 Maintenance Standard for Lockup Clutch ECMV...................................................................................................3125 Maintenance Standard for Transmission.........................................................................................................3126 Maintenance Standard for Transmission Control Valve...........................................................................................3131 Maintenance Standard for Forward and Reverse Clutch ECMV and Gear Speed Clutch ECMV...........................................................3132 Maintenance Standard for Main Relief Valve and Torque Converter Relief Valve..................................................................3133 Maintenance Standard for Transmission Lubrication Relief Valve................................................................................3134 Maintenance Standard for Bevel Gear Shaft, HSS, and Brake.....................................................................................3135 Maintenance Standard for Brake Valve..........................................................................................................3140 Maintenance Standard for Final Drive..........................................................................................................3142 Maintenance Standard for Sprocket for Conventional Type Track Shoes...........................................................................3144 Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for Conventional Type Track Shoes..........................................3145 Maintenance Standard for Sprocket for PLUS Type Track Shoes...................................................................................3147 Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for PLUS Type Track Shoes..................................................3148 Undercarriage and Frame...........................................................................................................................3150 Maintenance Standard for Main Frame...........................................................................................................3150 Maintenance Standard for Suspension...........................................................................................................3151 Maintenance Standard for Track Frame and Idler Cushion........................................................................................3153 Maintenance Standard for Idler................................................................................................................3155 Maintenance Standard for Track Roller for Conventional Type Track Shoes (Single Flange Type)..................................................3157 Maintenance Standard for Track Roller for Conventional Type Track Shoes (Double Flange Type)..................................................3158 Maintenance Standard for Track Roller for PLUS Type Track Shoes (Single Flange Type)..........................................................3159 Maintenance Standard for Track Roller for PLUS Type Track Shoes (Double Flange Type)..........................................................3160 Maintenance Standard for Carrier Roller for Conventional Type Track Shoes.....................................................................3161 Maintenance Standard for Carrier Roller for PLUS Type Track Shoes.............................................................................3162 Maintenance Standard for Conventional Type Track Shoes........................................................................................3163 Maintenance Standard for PLUS Type Track Shoes................................................................................................3165 Maintenance Standard for Single Shoes.........................................................................................................3167 Maintenance Standard for Swamp Shoes..........................................................................................................3168 Hydraulic System..................................................................................................................................3169 Maintenance Standard for Hydraulic Tank.......................................................................................................3169 Maintenance Standard for Scavenging Pump......................................................................................................3170 Maintenance Standard for Steering Lubrication Pump and Power Train Pump.......................................................................3171 Maintenance Standard for Work Equipment and HSS Pump..........................................................................................3172 Maintenance Standard for PC-EPC Valve.........................................................................................................3173 Maintenance Standard for HSS Motor............................................................................................................3174 Maintenance Standard for Control Valve........................................................................................................3176 Maintenance Standard for Blade PPC Valve......................................................................................................3184 Maintenance Standard for Ripper PPC Valve.....................................................................................................3186 Maintenance Standard for Quick Drop Valve.....................................................................................................3188 Maintenance Standard for Work Equipment Lock Solenoid Valve (For Tilt Dozer Series)...........................................................3190 Maintenance Standard for Work Equipment Lock Solenoid Valve (For Power Tilt Pitch Dozer Series)...............................................3191 Work Equipment....................................................................................................................................3192 Maintenance Standard for Front Work Equipment (For Tilt Dozer and Power Tilt Pitch Dozer Series)..............................................3192 Maintenance Standard for Cutting Edge and End Bit.............................................................................................3195 Maintenance Standard for Stroke and Reset Sensing Blade Lift Cylinder (For Tilt Dozer and Power Tilt Pitch Dozer Series)......................3197 Maintenance Standard for Blade Tilt Cylinder (For Tilt Dozer and Power Tilt Pitch Dozer Series)...............................................3198 Maintenance Standard for Blade Pitch Cylinder (For Power Tilt Pitch Dozer Series).............................................................3199 Maintenance Standard for Stroke and Reset Sensor for Blade Lift Cylinder (Tilt Dozer, Semi-U Dozer, Power Tilt Pitch Dozer Series)............3200 Maintenance Standard for Fixed Multi-Shank Ripper.............................................................................................3202 Maintenance Standard for Ripper Lift Cylinder.................................................................................................3203 CAB Related Parts.................................................................................................................................3204 Maintenance Standard for CAB Mount............................................................................................................3204 80 Appendix...........................................................................................................................................3205 Table of Contents.................................................................................................................................3206 Precautions Before Work...........................................................................................................................3208 Air Conditioner System............................................................................................................................3209 Precautions for Refrigerant...................................................................................................................3209 Air Conditioner Component.....................................................................................................................3210 Specifications of Air Conditioner.............................................................................................................3212 Structure and Function of Refrigeration Cycle.................................................................................................3213 Outline of Refrigeration Cycle................................................................................................................3214 Component Parts of Air Conditioner System.........................................................................................................3216 Air Conditioner Unit..........................................................................................................................3216 Configuration Diagram of Air Conditioner Unit.............................................................................................3216 Function of Air Conditioner Unit..........................................................................................................3218 Component Parts of Air Conditioner Unit.......................................................................................................3220 Function of Evaporator as Air Conditioner Unit Component..................................................................................3221 Function of Heater Core as Air Conditioner Unit Component.................................................................................3221 Function of Evaporator Temperature Sensor as Air Conditioner Unit Component...............................................................3221 Function of Servo Motor as Air Conditioner Unit Component.................................................................................3221 Structure of Expansion Valve as Air Conditioner Unit Component............................................................................3222 Function of Expansion Valve as Air Conditioner Unit Component.............................................................................3222 Operate Expansion Valve as Air Conditioner Unit Component.................................................................................3222 Function of Dual Pressure Switch..........................................................................................................3223 Air Conditioner Controller....................................................................................................................3224 Structure of Air Conditioner Controller...................................................................................................3224 Compressor....................................................................................................................................3225 Structure of Compressor...................................................................................................................3225 Specifications of Compressor..............................................................................................................3225 Function of Compressor....................................................................................................................3225 Condenser.....................................................................................................................................3226 Structure of Standard Core Condenser......................................................................................................3226 Specifications of Standard Core Condenser.................................................................................................3226 Function of Standard Core Condenser.......................................................................................................3226 Structure of Wide Core Condenser..........................................................................................................3227 Specifications of Wide Core Condenser.....................................................................................................3227 Function of Wide Core Condenser...........................................................................................................3227 Receiver Drier................................................................................................................................3228 Structure of Receiver Dryer...............................................................................................................3228 Specifications of Receiver Dryer..........................................................................................................3228 Function of Receiver Dryer................................................................................................................3228 Air Conditioner Related Sensors...............................................................................................................3229 Structure of Sunlight Sensor..............................................................................................................3229 Function of Sunlight Sensor...............................................................................................................3229 Structure of Outside Temperature Sensor...................................................................................................3229 Function of Outside Air Temperature Sensor................................................................................................3229 Explanation of Procedure for Test of and Troubleshooting of Air Conditioner.......................................................................3231 Circuit Diagram and Configuration of Connector Pins of Air Conditioner............................................................................3233 System Diagram of Air Conditioner.................................................................................................................3235 Input and Output Signals of Air Conditioner Controller........................................................................................3236 Function of Air Conditioner Controller....................................................................................................3237 Locations of Air Conditioner Parts and Layout of Connectors.......................................................................................3238 Examine Air Leakage (Duct)........................................................................................................................3247 How to Examine Air Leakage (Duct).............................................................................................................3247 Explanation for Test of Air Conditioner with Self-Diagnosis Function..............................................................................3250 Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor...........................................................3251 Examine Vent (Mode) Changeover....................................................................................................................3252 How to Examine Vent (Mode) Changeover.........................................................................................................3252 Examine Fresh/Recirc Air Changeover...............................................................................................................3253 How to Examine Fresh/Recirc Air Changeover....................................................................................................3253 Examine Sunlight Sensor...........................................................................................................................3254 How to Examine Sunlight Sensor................................................................................................................3254 Examine Refrigerant (Dual) Pressure Switch........................................................................................................3255 How to Examine Refrigerant (Dual) Pressure Switch.............................................................................................3255 Examine Relay.....................................................................................................................................3256 How to Examine Relay..........................................................................................................................3256 Air Conditioner Troubleshooting Chart 1...........................................................................................................3257 Air Conditioner Troubleshooting Chart 2...........................................................................................................3258 Information Shown in Troubleshooting Table........................................................................................................3261 Failure Code [879AKA].............................................................................................................................3262 Failure Code [879AKB].............................................................................................................................3263 Failure Code [879BKA].............................................................................................................................3264 Failure Code [879BKB].............................................................................................................................3266 Failure Code [879CKA].............................................................................................................................3268 Failure Code [879CKB].............................................................................................................................3269 Failure Code [879DKZ].............................................................................................................................3270 Failure Code [879EMC].............................................................................................................................3272 Failure Code [879FMC].............................................................................................................................3273 Failure Code [879GKX].............................................................................................................................3274 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)........................................................................3276 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled).........................................................................3278 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)................................................................3282 Troubleshooting for Fresh/Recirc Air Changeover...................................................................................................3284 Troubleshooting by Gauge Pressure.................................................................................................................3286 Connect Service Tool..............................................................................................................................3289 How to Connect Service Tool...................................................................................................................3289 Precautions for Disconnection and Connection of Air Conditioner Piping............................................................................3291 Handle Compressor Oil.............................................................................................................................3293 90 Circuit Diagrams...................................................................................................................................3295 Table of Contents.................................................................................................................................3296 How to Read the Codes for Electric Cable..........................................................................................................3297 Hydraulic Circuit Diagram.........................................................................................................................3301 Symbols Used in Hydraulic Circuit Diagram.....................................................................................................3301 Hydraulic Circuit Diagram (For Tilt Dozer Series).............................................................................................3305 Hydraulic Circuit Diagram (For Power Tilt Pitch Dozer Series).................................................................................3307 Power Train Hydraulic Circuit Diagram.........................................................................................................3309 Electrical Circuit Diagram........................................................................................................................3311 Symbols Used in Electric Circuit Diagram......................................................................................................3311 Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (1/18)........................................................................3315 Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (2/18)........................................................................3317 Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (3/18)........................................................................3319 Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (4/18)........................................................................3321 Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (5/18)........................................................................3323 Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (6/18)........................................................................3325 Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (7/18)........................................................................3327 Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (8/18)........................................................................3329 Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (9/18)........................................................................3331 Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (10/18).......................................................................3333 Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (11/18).......................................................................3335 Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (12/18).......................................................................3337 Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (13/18).......................................................................3339 Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (14/18).......................................................................3341 Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (15/18).......................................................................3343 Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (16/18).......................................................................3345 Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (17/18).......................................................................3347 Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (18/18).......................................................................3349 Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (1/18)..........................................................................3351 Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (2/18)..........................................................................3353 Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (3/18)..........................................................................3355 Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (4/18)..........................................................................3357 Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (5/18)..........................................................................3359 Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (6/18)..........................................................................3361 Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (7/18)..........................................................................3363 Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (8/18)..........................................................................3365 Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (9/18)..........................................................................3367 Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (10/18).........................................................................3369 Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (11/18).........................................................................3371 Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (12/18).........................................................................3373 Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (13/18).........................................................................3375 Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (14/18).........................................................................3377 Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (15/18).........................................................................3379 Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (16/18).........................................................................3381 Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (17/18).........................................................................3383 Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (18/18).........................................................................3385 Index..................................................................................................................................................3387
DESCRIPTION:
KOMATSU D65EXi-18 D65PXi-18 BULLDOZER SHOP MANUAL SEN06899-04 – PDF DOWNLOAD
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.
S.S 28/12/24
