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

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

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

Language : English
Pages : 2836
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

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

• SERIAL NUMBERS 25001 and up

00 INDEX AND FOREWORD . 3
INDEX . 4
FOREWORD, SAFETY, BASIC INFORMATION . 22
HOW TO READ THE SHOP MANUAL . 22
SAFETY NOTICE FOR OPERATION . 24
PRECAUTIONS TO PREVENT FIRE . 32
ACTIONS IF FIRE OCCURS 34
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 35
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 36
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS . 39
PRECAUTIONS WHEN YOU HANDLE ELECTRICAL EQUIPMENT 45
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 47
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 48
PRACTICAL USE OF KOMTRAX 49
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER . 50
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER . 50
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER . 51
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER . 52
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 54
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR . 58
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR . 59
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL . 61
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH . 62
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 64
HOW TO READ ELECTRICAL WIRE CODE 65
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD . 69
STANDARD TIGHTENING TORQUE TABLE 72
CONVERSION TABLE 79
ABBREVIATION LIST . 84
01 SPECIFICATIONS . 87
CONTENTS 88
SPECIFICATIONS 89
SPECIFICATION DRAWING . 89
SPECIFICATION DRAWING: D85EX-18E0 . 89
SPECIFICATION DRAWING: D85PX-18E0 . 91
SPECIFICATIONS 93
SPECIFICATIONS: D85EX-18E0 93
SPECIFICATIONS: D85PX-18E0 100
WEIGHT TABLE 105
WEIGHT TABLE: D85EX-18E0 105
WEIGHT TABLE: D85PX-18E0 108
FUEL, COOLANT, LUBRICANT 111
USE FUEL, COOLANT AND LUBRICANT TO MEET AMBIENT TEMPERATURE . 111
10 STRUCTURE AND FUNCTION . 113
CONTENTS 114
UREA SCR SYSTEM . 117
LAYOUT DRAWING OF UREA SCR SYSTEM . 117
UREA SCR SYSTEM DIAGRAM . 120
FUNCTION OF UREA SCR SYSTEM . 121
FUNCTION OF AdBlue/DEF SYSTEM . 121
INDUCEMENT STRATEGY . 123
COMPONENT PARTS OF UREA SCR SYSTEM 138
AdBlue/DEF MIXING TUBE 138
SCR ASSEMBLY 138
AdBlue/DEF TANK . 141
AdBlue/DEF PUMP . 143
AdBlue/DEF INJECTOR . 144
AdBlue/DEF HOSE . 145
AdBlue/DEF TANK HEATING VALVE . 146
BOOT-UP SYSTEM 147
LAYOUT DRAWING OF BOOT-UP SYSTEM 147
SYSTEM OPERATING LAMP SYSTEM 148
SYSTEM DIAGRAM OF SYSTEM OPERATING LAMP SYSTEM 148
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 148
BATTERY DISCONNECT SWITCH . 149
LAYOUT DRAWING OF BATTERY DISCONNECT SWITCH . 149
FUNCTION OF BATTERY DISCONNECT SWITCH . 149
ENGINE SYSTEM . 151
LAYOUT DRAWING OF ENGINE SYSTEM . 151
ENGINE CONTROL SYSTEM . 153
LAYOUT DRAWING OF ENGINE CONTROL SYSTEM . 153
SYSTEM DIAGRAM OF ENGINE CONTROL SYSTEM . 154
FUNCTION OF ENGINE CONTROL SYSTEM . 156
AUTOMATIC IDLE STOP SYSTEM 158
SYSTEM DIAGRAM OF AUTOMATIC IDLE STOP SYSTEM 158
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 158
COMPONENT PARTS OF ENGINE SYSTEM 161
DAMPER 161
VGT . 162
EGR SYSTEM 166
EGR VALVE . 168
EGR COOLER 170
KCCV SYSTEM . 171
KCCV VENTILATOR . 173
KDPF 175
COOLING SYSTEM 180
LAYOUT DRAWING OF COOLING SYSTEM 180
SPECIFICATIONS OF COOLING SYSTEM 181
COOLING FAN CONTROL SYSTEM 182
COOLING FAN CONTROL SYSTEM DIAGRAM 182
FUNCTION OF COOLING FAN CONTROL SYSTEM 183
COMPONENT PARTS OF COOLING SYSTEM . 185
COOLING FAN PUMP 185
COOLING FAN MOTOR . 194
HYDRAULIC OIL COOLER BYPASS VALVE . 201
CONTROL SYSTEM 202
LAYOUT DRAWING OF CONTROL SYSTEM 202
MACHINE MONITOR SYSTEM 203
SYSTEM DIAGRAM OF MACHINE MONITOR . 203
FUNCTION OF MACHINE MONITOR SYSTEM 203
KOMTRAX SYSTEM 205
KOMTRAX SYSTEM DIAGRAM 205
FUNCTION OF KOMTRAX SYSTEM 205
COMPONENT PARTS OF CONTROL SYSTEM . 206
MACHINE MONITOR . 206
GATEWAY FUNCTION CONTROLLER . 221
COMMUNICATION TERMINAL 224
POWER TRAIN CONTROLLER 226
ENGINE CONTROLLER . 230
FUEL FEED PUMP 236
FUEL FEED PUMP SWITCH . 237
HYDRAULIC SYSTEM 238
LAYOUT DRAWING OF HYDRAULIC SYSTEM 238
CLSS 239
STRUCTURE OF CLSS . 239
FUNCTION OF CLSS 240
COMPONENT PARTS OF HYDRAULIC SYSTEM . 242
HYDRAULIC TANK 242
WORK EQUIPMENT AND HSS PUMP . 243
LS VALVE 249
TVC VALVE . 253
VARIABLE THROTTLE VALVE . 257
CONTROL VALVE . 259
POWER TRAIN SYSTEM 293
LAYOUT DRAWING OF POWER TRAIN SYSTEM 293
OPERATION OF POWER TRAIN SYSTEM . 295
TRANSMISSION, STEERING, AND BRAKE CONTROL . 296
LAYOUT DRAWING OF TRANSMISSION, STEERING, AND BRAKE CONTROL SYSTEM 296
FUNCTION OF TRANSMISSION, STEERING, AND BRAKE CONTROL . 297
PALM COMMAND CONTROL SYSTEM . 299
PALM COMMAND CONTROL SYSTEM DIAGRAM . 299
HSS SYSTEM 303
HSS SYSTEM DIAGRAM 303
FUNCTION OF HSS SYSTEM 304
CENTRALIZED PRESSURE PICKUP PORT 306
LAYOUT OF CENTRALIZED PRESSURE PICKUP PORT 306
FUNCTION OF CENTRALIZED PRESSURE PICKUP PORT 307
COMPONENT PARTS OF POWER TRAIN SYSTEM . 308
UNIVERSAL JOINT . 308
POWER TRAIN MOUNT . 309
TORQUE CONVERTER AND PTO 310
TRANSMISSION 313
TRANSMISSION ECMV . 323
MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE . 329
TRANSMISSION LUBRICATION RELIEF VALVE . 331
BEVEL GEAR SHAFT, HSS, AND BRAKE 331
BRAKE VALVE . 351
FINAL DRIVE . 354
SCAVENGING PUMP . 358
STEERING LUBRICATION PUMP AND POWER TRAIN PUMP 359
HSS MOTOR . 360
ELECTRIC STEERING CONTROL LEVER . 366
WORK EQUIPMENT SYSTEM . 369
WORK EQUIPMENT CONTROL 369
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM . 369
FUNCTION OF WORK EQUIPMENT CONTROL 370
LAYOUT DRAWING OF FRONT WORK EQUIPMENT 372
LAYOUT OF FIXED MULTI-SHANK RIPPER 373
LAYOUT OF VARIABLE MULTI-SHANK RIPPER . 374
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 375
SELF-PRESSURE REDUCING VALVE 375
WORK EQUIPMENT LOCK SOLENOID VALVE 381
BLADE PPC VALVE . 382
RIPPER PPC VALVE 388
BLADE PITCH SELECTOR SOLENOID VALVE . 392
PILOT CIRCUIT ACCUMULATOR . 394
QUICK DROP VALVE 395
PISTON VALVE 396
UNDERCARRIAGE AND FRAME . 398
MAIN FRAME 398
STRUCTURE OF MAIN FRAME . 398
SUSPENSION 399
STRUCTURE OF SUSPENSION . 399
FUNCTION OF SUSPENSION 402
TRACK FRAME AND IDLER CUSHION . 403
STRUCTURE OF TRACK FRAME AND IDLER CUSHION 403
FUNCTION OF TRACK FRAME AND IDLER CUSHION . 404
WORK EQUIPMENT 405
STRUCTURE OF FRONT WORK EQUIPMENT . 405
STRUCTURE OF CYLINDER STAY 407
STRUCTURE OF FIXED MULTI-SHANK RIPPER . 408
STRUCTURE OF VARIABLE MULTI-SHANK RIPPER 409
CAB AND ITS ATTACHMENTS . 410
ROPS CAB 410
STRUCTURE OF ROPS CAB . 410
FUNCTION OF ROPS CAB 411
CAB MOUNT . 412
STRUCTURE OF CAB MOUNT 412
FUNCTION OF CAB MOUNT . 412
20 STANDARD VALUE TABLE . 413
CONTENTS 414
STANDARD VALUE TABLE FOR ENGINE . 415
STANDARD VALUE TABLE FOR ENGINE: D85EX-18E0 . 415
STANDARD VALUE TABLE FOR ENGINE: D85PX-18E0 . 418
STANDARD VALUE TABLE FOR MACHINE 421
STANDARD VALUE TABLE FOR MACHINE: D85EX-18E0 421
STANDARD VALUE TABLE FOR MACHINE: D85PX-18E0 438
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 453
30 TESTING AND ADJUSTING 457
CONTENTS 458
RELATED INFORMATION ON TESTING AND ADJUSTING 461
TOOLS FOR TESTING AND ADJUSTING . 461
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 468
ENGINE AND COOLING SYSTEM . 469
TEST ENGINE SPEED . 469
METHOD FOR TESTING ENGINE SPEED . 469
TEST BOOST PRESSURE . 473
METHOD FOR TESTING BOOST PRESSURE . 473
TEST EXHAUST GAS TEMPERATURE 475
METHOD FOR TESTING EXHAUST GAS TEMPERATURE 475
TEST EXHAUST GAS COLOR 477
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 477
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER . 478
TEST AND ADJUST VALVE CLEARANCE . 480
METHOD FOR TESTING VALVE CLEARANCE 480
METHOD FOR ADJUSTING VALVE CLEARANCE 481
TEST COMPRESSION PRESSURE . 482
METHOD FOR TESTING COMPRESSION PRESSURE . 482
TEST BLOWBY PRESSURE 486
METHOD FOR TESTING BLOWBY PRESSURE 486
TEST ENGINE OIL PRESSURE 489
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR . 489
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL 489
TEST EGR VALVE AND KVGT OIL PRESSURE 491
METHOD FOR TESTING EGR VALVE AND KVGT OIL PRESSURE 491
TEST FUEL PRESSURE 493
METHOD FOR TESTING FUEL PRESSURE 493
TEST FUEL DISCHARGE, RETURN AND LEAKAGE . 495
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE . 496
BLEED AIR FROM FUEL SYSTEM 499
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 500
TEST FUEL CIRCUIT FOR LEAKAGE . 501
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 501
HANDLE CYLINDER CUT-OUT MODE OPERATION 503
HANDLE NO-INJECTION CRANKING OPERATION 504
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION . 505
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT TENSION . 505
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 505
CLEAN FUEL DOSER 507
METHOD FOR CLEANING FUEL DOSER 507
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 510
METHOD FOR WRITING INJECTOR COMPENSATION VALUE 510
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 516
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 516
TEST SCR RELATED FUNCTIONS 517
TEST AdBlue/DEF PUMP RAISED PRESSURE 520
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 523
TEST AdBlue/DEF LINE HEATER RELAY 1 . 527
TEST AdBlue/DEF LINE HEATER RELAY 2 . 529
TEST AdBlue/DEF PUMP HEATER RELAY . 532
TEST AdBlue/DEF TANK HEATER VALVE . 535
TEST DENITRATION EFFICIENCY OF SCR 537
CLEAN AdBlue/DEF TANK . 541
METHOD FOR CLEANING AdBlue/DEF TANK . 541
CLEAN AdBlue/DEF PUMP . 545
METHOD FOR CLEAN AdBlue/DEF PUMP 545
CLEAN AdBlue/DEF TANK MOUNTING PORTION 552
METHOD FOR CLEANING AdBlue/DEF TANK MOUNTING PORTION 552
ADJUST DECELERATOR PEDAL 553
METHOD FOR ADJUSTING DECELERATOR PEDAL 553
POWER TRAIN . 555
TEST POWER TRAIN OIL PRESSURE . 555
METHOD FOR TESTING POWER TRAIN OIL PRESSURE . 556
ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR . 567
METHOD FOR ADJUSTING TRANSMISSION OUTPUT SHAFT SPEED SENSOR . 567
TEST BRAKE PERFORMANCE SIMPLY . 569
METHOD FOR TESTING BRAKE PERFORMANCE SIMPLY . 569
ADJUST BRAKE PEDAL 570
METHOD FOR ADJUSTING BRAKE PEDAL 570
ADJUST PARKING BRAKE LEVER 572
METHOD FOR ADJUSTING PARKING BRAKE LEVER 572
MOVE MACHINE BY RELEASING PARKING BRAKE WHEN MACHINE DOES NOT TRAVEL 574
METHOD FOR MOVING MACHINE WITH HYDRAULIC TYPE PARKING BRAKE RELEASE SYSTEM 574
METHOD FOR MOVING MACHINE WITH ELECTRIC TYPE PARKING BRAKE RELEASE SYSTEM . 575
UNDERCARRIAGE AND FRAME . 577
ADJUST IDLER CLEARANCE 577
METHOD FOR ADJUSTING IDLER CLEARANCE 577
METHOD FOR ADJUSTING IDLER CLEARANCE HORIZONTALLY . 577
METHOD FOR ADJUSTING IDLER CLEARANCE VERTICALLY . 577
TEST AND ADJUST TRACK TENSION . 579
METHOD OF CHECKING 579
METHOD FOR ADJUSTING TRACK TENSION 579
HYDRAULIC SYSTEM 580
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 580
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 580
TEST AND ADJUST WORK EQUIPMENT AND HSS OIL PRESSURES 581
METHOD FOR TESTING WORK EQUIPMENT AND HSS OIL PRESSURES . 581
METHOD FOR ADJUSTING WORK EQUIPMENT AND HSS OIL PRESSURES . 585
TEST OIL PRESSURE OF CONTROL CIRCUIT 586
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 586
TEST PPC VALVE OUTPUT PRESSURE 588
METHOD FOR TESTING PPC VALVE OUTPUT PRESSURE 588
BLEED AIR FROM HSS PUMP . 591
METHOD FOR BLEEDING AIR FROM HSS PUMP . 591
TEST AND ADJUST PLAY OF WORK EQUIPMENT PPC VALVE 592
METHOD FOR TESTING PLAY OF WORK EQUIPMENT PPC VALVE . 592
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT PPC VALVE . 593
TEST COOLING FAN SPEED 594
METHOD FOR TESTING COOLING FAN SPEED 594
TEST COOLING FAN CIRCUIT OIL PRESSURE . 595
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE . 595
BLEED AIR FROM COOLING FAN PUMP . 597
METHOD FOR BLEEDING AIR FROM COOLING FAN PUMP . 597
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 598
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE LIFT CYLINDER . 598
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE TILT CYLINDER . 598
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF RIPPER LIFT CYLINDER 599
TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER 600
METHOD FOR TESTING INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER 600
BLEED AIR FROM WORK EQUIPMENT CYLINDERS . 602
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT CYLINDERS . 602
WORK EQUIPMENT 603
ADJUST WORK EQUIPMENT LOCK LEVER 603
METHOD FOR ADJUSTING WORK EQUIPMENT LOCK LEVER 603
CAB AND ITS ATTACHMENTS . 605
TEST AND ADJUST OPERATOR’S CAB 605
METHOD FOR TESTING OPERATOR’S CAB . 605
METHOD FOR ADJUSTING OPERATOR’S CAB . 607
ELECTRICAL SYSTEM . 610
SET AND OPERATE MACHINE MONITOR . 610
OPERATOR MODE . 613
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN . 613
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 614
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) . 614
CHECKING FUNCTION OF SERVICE METER 615
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD . 615
SERVICE MODE 617
METHOD FOR OPERATING SERVICE MODE . 617
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 619
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 624
ABNORMALITY RECORD MENU . 634
METHOD FOR CONFIRMING MAINTENANCE RECORD 638
METHOD FOR OPERATING MAINTENANCE MODE SETTING . 639
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING . 643
DEFAULT MENU 644
DIAGNOSTIC TESTS MENU . 652
ADJUSTMENT MENU . 661
METHOD FOR PERFORMING NO-INJECTION CRANKING . 688
KOMTRAX SETTINGS MENU . 689
METHOD FOR DISPLAYING SERVICE MESSAGE . 692
START UP KOMTRAX SYSTEM . 694
STOP USING OF KOMTRAX SYSTEM 699
ADJUST WHEN POWER TRAIN CONTROLLER IS REPLACED 701
METHOD FOR ADJUSTING WHEN POWER TRAIN CONTROLLER IS REPLACED 701
ADJUST REARVIEW CAMERA ANGLE 704
ADJUST REARVIEW CAMERA ANGLE 704
SET REGION OF Bluetooth(R) COMPATIBLE RADIO . 705
SET REGION OF Bluetooth(R) COMPATIBLE RADIO . 705
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 707
HANDLE BATTERY DISCONNECT SWITCH 708
TEST DIODES . 709
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 709
METHOD FOR TESTING DIODE USING ANALOG TESTER 709
Pm CLINIC . 710
Pm CLINIC SERVICE . 710
Pm CLINIC CHECK SHEET: D85EX-18E0 . 711
Pm CLINIC CHECK SHEET: D85PX-18E0 . 725
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D85EX-18E0 . 736
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D85PX-18E0 . 740
40 TROUBLESHOOTING 745
CONTENTS 746
RELATED INFORMATION ON TROUBLESHOOTING 756
GENERAL TROUBLESHOOTING POINTS 756
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 757
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 772
CHECKS BEFORE TROUBLESHOOTING . 774
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 776
WALK-AROUND CHECK . 776
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 778
METHOD FOR CHECKING ELECTRIC EQUIPMENT 778
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 784
PROCEDURE FOR TROUBLESHOOTING . 792
SYMPTOM AND TROUBLESHOOTING NUMBERS . 795
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 798
CONNECTORS LIST AND LAYOUT 800
CONNECTOR CONTACT IDENTIFICATION 815
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE . 855
FUSE LOCATION TABLE . 861
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) . 864
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) . 868
FAILURE CODES TABLE . 870
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) . 889
FAILURE CODE [1500L0] . 889
FAILURE CODE [15SAL1] . 890
FAILURE CODE [15SALH] . 892
FAILURE CODE [15SBL1] . 894
FAILURE CODE [15SBLH] . 896
FAILURE CODE [15SEL1] . 898
FAILURE CODE [15SELH] . 900
FAILURE CODE [15SFL1] . 902
FAILURE CODE [15SFLH] . 904
FAILURE CODE [15SGL1] . 906
FAILURE CODE [15SGLH] . 908
FAILURE CODE [1800MW] . 910
FAILURE CODE [879AKA] . 911
FAILURE CODE [879AKB] . 912
FAILURE CODE [879BKA] . 913
FAILURE CODE [879BKB] . 915
FAILURE CODE [879CKA] . 917
FAILURE CODE [879CKB] . 918
FAILURE CODE [879DKZ] . 919
FAILURE CODE [879EMC] . 921
FAILURE CODE [879FMC] . 922
FAILURE CODE [879GKX] . 923
FAILURE CODE [989L00] . 925
FAILURE CODE [989M00] . 926
FAILURE CODE [989N00] . 927
FAILURE CODE [A1U0N3] . 928
FAILURE CODE [A1U0N4] . 930
FAILURE CODE [A900FR] . 932
FAILURE CODE [A900N6] . 933
FAILURE CODE [A900NY] . 934
FAILURE CODE [AA10NX] . 935
FAILURE CODE [AB00KE] . 937
FAILURE CODE [AQ10N3] . 939
FAILURE CODE [AS00N3] . 941
FAILURE CODE [AS00R2] . 943
FAILURE CODE [AS00R3] . 944
FAILURE CODE [AS00R4] . 945
FAILURE CODE [AS00R5] . 946
FAILURE CODE [AS00R6] . 947
FAILURE CODE [AS00ZK] . 948
FAILURE CODE [AS10KM] . 949
FAILURE CODE [AS10NR] . 950
FAILURE CODE [AS10NT] . 951
FAILURE CODE [B@BAZG] . 952
FAILURE CODE [B@BCNS] . 953
FAILURE CODE [B@BCZK] . 954
FAILURE CODE [B@CENS] . 956
FAILURE CODE [B@HANS] . 957
FAILURE CODE [CA115] 958
FAILURE CODE [CA122] 959
FAILURE CODE [CA123] 961
FAILURE CODE [CA131] 963
FAILURE CODE [CA132] 965
FAILURE CODE [CA135] 967
FAILURE CODE [CA141] 969
FAILURE CODE [CA144] 971
FAILURE CODE [CA145] 973
FAILURE CODE [CA153] 975
FAILURE CODE [CA154] 978
FAILURE CODE [CA187] 981
FAILURE CODE [CA221] 983
FAILURE CODE [CA222] 985
FAILURE CODE [CA227] 987
FAILURE CODE [CA234] 988
FAILURE CODE [CA238] 989
FAILURE CODE [CA239] 991
FAILURE CODE [CA249] 993
FAILURE CODE [CA256] 995
FAILURE CODE [CA271] 997
FAILURE CODE [CA272] 999
FAILURE CODE [CA273] 1000
FAILURE CODE [CA274] 1002
FAILURE CODE [CA322] 1003
FAILURE CODE [CA323] 1005
FAILURE CODE [CA324] 1007
FAILURE CODE [CA325] 1009
FAILURE CODE [CA331] 1011
FAILURE CODE [CA332] 1013
FAILURE CODE [CA343] 1015
FAILURE CODE [CA351] 1016
FAILURE CODE [CA352] 1017
FAILURE CODE [CA356] 1020
FAILURE CODE [CA357] 1022
FAILURE CODE [CA386] 1024
FAILURE CODE [CA441] 1025
FAILURE CODE [CA442] 1028
FAILURE CODE [CA449] 1029
FAILURE CODE [CA451] 1030
FAILURE CODE [CA452] 1032
FAILURE CODE [CA515] 1034
FAILURE CODE [CA516] 1036
FAILURE CODE [CA553] 1038
FAILURE CODE [CA555] 1039
FAILURE CODE [CA556] 1040
FAILURE CODE [CA559] 1041
FAILURE CODE [CA595] 1046
FAILURE CODE [CA687] 1047
FAILURE CODE [CA689] 1049
FAILURE CODE [CA691] 1051
FAILURE CODE [CA692] 1053
FAILURE CODE [CA697] 1055
FAILURE CODE [CA698] 1056
FAILURE CODE [CA731] 1057
FAILURE CODE [CA778] 1058
FAILURE CODE [CA1117] .1061
FAILURE CODE [CA1664] .1062
FAILURE CODE [CA1669] .1065
FAILURE CODE [CA1673] .1066
FAILURE CODE [CA1677] .1067
FAILURE CODE [CA1678] .1068
FAILURE CODE [CA1682] .1069
FAILURE CODE [CA1683] .1072
FAILURE CODE [CA1684] .1074
FAILURE CODE [CA1686] .1076
FAILURE CODE [CA1691] .1077
FAILURE CODE [CA1694] .1080
FAILURE CODE [CA1695] .1082
FAILURE CODE [CA1696] .1083
FAILURE CODE [CA1712] .1085
FAILURE CODE [CA1713] .1088
FAILURE CODE [CA1714] .1090
FAILURE CODE [CA1715] .1091
FAILURE CODE [CA1776] .1092
FAILURE CODE [CA1777] .1095
FAILURE CODE [CA1843] .1098
FAILURE CODE [CA1844] .1100
FAILURE CODE [CA1879] .1103
FAILURE CODE [CA1881] .1106
FAILURE CODE [CA1883] .1109
FAILURE CODE [CA1885] .1113
FAILURE CODE [CA1887] .1115
FAILURE CODE [CA1921] .1117
FAILURE CODE [CA1922] .1120
FAILURE CODE [CA1923] .1125
FAILURE CODE [CA1924] .1127
FAILURE CODE [CA1925] .1129
FAILURE CODE [CA1927] .1131
FAILURE CODE [CA1928] .1133
FAILURE CODE [CA1942] .1135
FAILURE CODE [CA1963] .1136
FAILURE CODE [CA1977] .1139
FAILURE CODE [CA1993] .1142
FAILURE CODE [CA2185] .1145
FAILURE CODE [CA2186] .1146
FAILURE CODE [CA2249] .1148
FAILURE CODE [CA2265] .1149
FAILURE CODE [CA2266] .1151
FAILURE CODE [CA2271] .1154
FAILURE CODE [CA2272] .1156
FAILURE CODE [CA2349] .1158
FAILURE CODE [CA2353] .1160
FAILURE CODE [CA2357] .1162
FAILURE CODE [CA2381] .1163
FAILURE CODE [CA2382] .1165
FAILURE CODE [CA2383] .1167
FAILURE CODE [CA2386] .1169
FAILURE CODE [CA2387] .1171
FAILURE CODE [CA2555] .1172
FAILURE CODE [CA2556] .1175
FAILURE CODE [CA2637] .1177
FAILURE CODE [CA2639] .1179
FAILURE CODE [CA2732] .1182
FAILURE CODE [CA2733] .1184
FAILURE CODE [CA2741] .1186
FAILURE CODE [CA2765] .1187
FAILURE CODE [CA2771] .1188
FAILURE CODE [CA2777] .1194
FAILURE CODE [CA2878] .1197
FAILURE CODE [CA2881] .1200
FAILURE CODE [CA2976] .1203
FAILURE CODE [CA3133] .1205
FAILURE CODE [CA3134] .1207
FAILURE CODE [CA3135] .1209
FAILURE CODE [CA3142] .1213
FAILURE CODE [CA3143] .1214
FAILURE CODE [CA3144] .1215
FAILURE CODE [CA3146] .1217
FAILURE CODE [CA3147] .1218
FAILURE CODE [CA3148] .1219
FAILURE CODE [CA3151] .1221
FAILURE CODE [CA3165] .1227
FAILURE CODE [CA3167] .1229
FAILURE CODE [CA3229] .1232
FAILURE CODE [CA3231] .1234
FAILURE CODE [CA3232] .1236
FAILURE CODE [CA3235] .1240
FAILURE CODE [CA3239] .1242
FAILURE CODE [CA3241] .1245
FAILURE CODE [CA3242] .1248
FAILURE CODE [CA3251] .1251
FAILURE CODE [CA3253] .1254
FAILURE CODE [CA3254] .1258
FAILURE CODE [CA3255] .1261
FAILURE CODE [CA3256] .1265
FAILURE CODE [CA3311] .1267
FAILURE CODE [CA3312] .1269
FAILURE CODE [CA3313] .1272
FAILURE CODE [CA3314] .1273
FAILURE CODE [CA3315] .1274
FAILURE CODE [CA3316] .1277
FAILURE CODE [CA3317] .1278
FAILURE CODE [CA3318] .1279
FAILURE CODE [CA3319] .1282
FAILURE CODE [CA3321] .1283
FAILURE CODE [CA3322] .1285
FAILURE CODE [CA3419] .1288
FAILURE CODE [CA3421] .1290
FAILURE CODE [CA3497] .1292
FAILURE CODE [CA3498] .1293
FAILURE CODE [CA3543] .1294
FAILURE CODE [CA3545] .1301
FAILURE CODE [CA3547] .1303
FAILURE CODE [CA3558] .1304
FAILURE CODE [CA3559] .1306
FAILURE CODE [CA3562] .1308
FAILURE CODE [CA3563] .1310
FAILURE CODE [CA3567] .1313
FAILURE CODE [CA3568] .1316
FAILURE CODE [CA3571] .1320
FAILURE CODE [CA3572] .1322
FAILURE CODE [CA3574] .1324
FAILURE CODE [CA3575] .1326
FAILURE CODE [CA3577] .1328
FAILURE CODE [CA3578] .1330
FAILURE CODE [CA3582] .1332
FAILURE CODE [CA3583] .1339
FAILURE CODE [CA3596] .1341
FAILURE CODE [CA3649] .1343
FAILURE CODE [CA3681] .1345
FAILURE CODE [CA3682] .1350
FAILURE CODE [CA3713] .1356
FAILURE CODE [CA3717] .1359
FAILURE CODE [CA3718] .1360
FAILURE CODE [CA3725] .1361
FAILURE CODE [CA3748] .1364
FAILURE CODE [CA3751] .1367
FAILURE CODE [CA3755] .1369
FAILURE CODE [CA3866] .1371
FAILURE CODE [CA3867] .1375
FAILURE CODE [CA3868] .1378
FAILURE CODE [CA3899] .1382
FAILURE CODE [CA3911] .1384
FAILURE CODE [CA3912] .1388
FAILURE CODE [CA3932] .1390
FAILURE CODE [CA3933] .1392
FAILURE CODE [CA3934] .1394
FAILURE CODE [CA3935] .1397
FAILURE CODE [CA3936] .1399
FAILURE CODE [CA4151] .1401
FAILURE CODE [CA4152] .1405
FAILURE CODE [CA4155] .1409
FAILURE CODE [CA4156] .1411
FAILURE CODE [CA4157] .1414
FAILURE CODE [CA4158] .1416
FAILURE CODE [CA4159] .1417
FAILURE CODE [CA4161] .1418
FAILURE CODE [CA4162] .1421
FAILURE CODE [CA4163] .1424
FAILURE CODE [CA4164] .1426
FAILURE CODE [CA4165] .1428
FAILURE CODE [CA4166] .1430
FAILURE CODE [CA4168] .1432
FAILURE CODE [CA4169] .1435
FAILURE CODE [CA4171] .1437
FAILURE CODE [CA4249] .1440
FAILURE CODE [CA4251] .1442
FAILURE CODE [CA4259] .1444
FAILURE CODE [CA4261] .1447
FAILURE CODE [CA4277] .1449
FAILURE CODE [CA4281] .1453
FAILURE CODE [CA4459] .1457
FAILURE CODE [CA4461] .1460
FAILURE CODE [CA4658] .1463
FAILURE CODE [CA4731] .1467
FAILURE CODE [CA4732] .1468
FAILURE CODE [CA4739] .1469
FAILURE CODE [CA4768] .1470
FAILURE CODE [CA4769] .1472
FAILURE CODE [CA4842] .1475
FAILURE CODE [CA4952] .1479
FAILURE CODE [CA5115] .1481
FAILURE CODE [CA5383] .1484
FAILURE CODE [D130KA] .1486
FAILURE CODE [D130KB] .1489
FAILURE CODE [D19DKA] .1491
FAILURE CODE [D19DKB] .1493
FAILURE CODE [D19JKZ] .1495
FAILURE CODE [D811MC] .1498
FAILURE CODE [D862KA] .1499
FAILURE CODE [D8ALKA] .1500
FAILURE CODE [D8ALKB] .1502
FAILURE CODE [D8AQKR] .1504
FAILURE CODE [D8ARKR] .1507
FAILURE CODE [D8G1KT] .1510
FAILURE CODE [D8G6KT] .1511
FAILURE CODE [DAF0MB] .1512
FAILURE CODE [DAF0MC] .1513
FAILURE CODE [DAF8KB] .1514
FAILURE CODE [DAF9KQ] .1515
FAILURE CODE [DAFGMC] .1516
FAILURE CODE [DAFLKA] .1517
FAILURE CODE [DAFLKB] .1519
FAILURE CODE [DAFQKR] .1521
FAILURE CODE [DAQW00] .1522
FAILURE CODE [DAZ9KQ] .1523
FAILURE CODE [DAZQKR] .1524
FAILURE CODE [DB2QKR] .1525
FAILURE CODE [DB2RKR] .1532
FAILURE CODE [DBE0KT] .1539
FAILURE CODE [DBE0MC] .1540
FAILURE CODE [DBE1KK] .1541
FAILURE CODE [DBE2KK] .1544
FAILURE CODE [DBE5KK] .1546
FAILURE CODE [DBE6KK] .1548
FAILURE CODE [DBE7KK] .1550
FAILURE CODE [DBE9KQ] .1552
FAILURE CODE [DBELKA] .1553
FAILURE CODE [DBELKB] .1555
FAILURE CODE [DBEQKR] .1557
FAILURE CODE [DBERKR] .1558
FAILURE CODE [DD12KA] .1561
FAILURE CODE [DD12KB] .1563
FAILURE CODE [DD13KA] .1565
FAILURE CODE [DD13KB] .1567
FAILURE CODE [DD14KA] .1569
FAILURE CODE [DD14KB] .1571
FAILURE CODE [DDKHKA] .1573
FAILURE CODE [DDKHKB] .1575
FAILURE CODE [DDN7KA] .1577
FAILURE CODE [DDN7KB] .1579
FAILURE CODE [DDNLKA] .1581
FAILURE CODE [DDNLKB] .1583
FAILURE CODE [DGS1KA] .1585
FAILURE CODE [DGS1KX] .1587
FAILURE CODE [DGT1KA] .1589
FAILURE CODE [DGT1KX] .1592
FAILURE CODE [DH21KA] .1594
FAILURE CODE [DH21KY] .1596
FAILURE CODE [DHA4KA] .1598
FAILURE CODE [DHAAMA] .1600
FAILURE CODE [DHACMA] .1602
FAILURE CODE [DK10KA] .1604
FAILURE CODE [DK10KB] .1607
FAILURE CODE [DK30KA] .1609
FAILURE CODE [DK30KX] .1612
FAILURE CODE [DK30KY] .1613
FAILURE CODE [DK30KZ] .1615
FAILURE CODE [DK30L8] .1616
FAILURE CODE [DK31KA] .1617
FAILURE CODE [DK31KY] .1620
FAILURE CODE [DK40KA] .1622
FAILURE CODE [DK40KY] .1624
FAILURE CODE [DK55KX] .1626
FAILURE CODE [DK55KZ] .1627
FAILURE CODE [DK55L8] .1628
FAILURE CODE [DK56KA] .1629
FAILURE CODE [DK56KY] .1631
FAILURE CODE [DK57KA] .1633
FAILURE CODE [DK57KY] .1635
FAILURE CODE [DKH1KA] .1637
FAILURE CODE [DKH1KY] .1640
FAILURE CODE [DLM3KA] .1642
FAILURE CODE [DLM3KB] .1644
FAILURE CODE [DLM3MB] .1645
FAILURE CODE [DLT3KA] .1646
FAILURE CODE [DLT3KB] .1648
FAILURE CODE [DR21KX] .1650
FAILURE CODE [DR31KX] .1651
FAILURE CODE [DV20KB] .1652
FAILURE CODE [DW5AKA] .1654
FAILURE CODE [DW5AKB] .1656
FAILURE CODE [DW5AKY] .1658
FAILURE CODE [DW7BKA] .1660
FAILURE CODE [DW7BKB] .1662
FAILURE CODE [DW7BKY] .1664
FAILURE CODE [DWN1KA] .1665
FAILURE CODE [DWN1KB] .1667
FAILURE CODE [DWN1KY] .1669
FAILURE CODE [DWN2KA] .1671
FAILURE CODE [DWN2KB] .1673
FAILURE CODE [DWN2KY] .1675
FAILURE CODE [DWN5KA] .1676
FAILURE CODE [DWN5KB] .1678
FAILURE CODE [DWN5KY] .1679
FAILURE CODE [DXA2KA] .1681
FAILURE CODE [DXA2KB] .1683
FAILURE CODE [DXA2KY] .1685
FAILURE CODE [DXH4KA] .1686
FAILURE CODE [DXH4KB] .1688
FAILURE CODE [DXH4KY] .1690
FAILURE CODE [DXH5KA] .1692
FAILURE CODE [DXH5KB] .1694
FAILURE CODE [DXH5KY] .1695
FAILURE CODE [DXH6KA] .1696
FAILURE CODE [DXH6KB] .1698
FAILURE CODE [DXH6KY] .1700
FAILURE CODE [DXH7KA] .1702
FAILURE CODE [DXH7KB] .1704
FAILURE CODE [DXH7KY] .1706
FAILURE CODE [DXH8KA] .1708
FAILURE CODE [DXH8KB] .1710
FAILURE CODE [DXH8KY] .1712
FAILURE CODE [DXJ4KA] .1714
FAILURE CODE [DXJ4KB] .1716
FAILURE CODE [F313KA] .1718
FAILURE CODE [F313KB] .1719
FAILURE CODE [F318KB] .1720
FAILURE CODE [F318KY] .1721
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .1722
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .1722
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1729
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .1732
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .1734
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .1736
E-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), BASIC CHECK MONITOR LIGHTS UP 1740
E-7 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING 1741
E-8 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1742
E-9 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1744
E-10 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1745
E-11 POWER TRAIN OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1746
E-12 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1747
E-13 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE .1748
E-14 AdBlue/DEF LEVEL IS NOT DISPLAYED PROPERLY .1749
E-15 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL .1752
E-16 POWER TRAIN OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE 1754
E-17 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE 1755
E-18 OPERATION MODE DOES NOT CHANGE .1756
E-19 GEAR SHIFT MODE DOES NOT CHANGE 1757
E-20 OPERATING CUSTOMIZE SWITCH DOES NOT DISPLAY CUSTOMIZE SCREEN .1758
E-21 MODIFYING SETTING ON CUSTOMIZE SCREEN DOES NOT CHANGE SETTING OF MACHINE .1759
E-22 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .1760
E-23 REVERSE SLOW MODE DOES NOT FUNCTION PROPERLY .1761
E-24 ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP SOUNDING 1762
E-25 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .1763
E-26 SERVICE MODE CANNOT BE SELECTED 1764
E-27 HORN DOES NOT SOUND 1765
E-28 HORN DOES NOT STOP SOUNDING 1767
E-29 BACKUP ALARM DOES NOT SOUND 1768
E-30 BACKUP ALARM DOES NOT STOP SOUNDING 1770
E-31 HEADLAMP DOES NOT LIGHT UP .1771
E-32 REAR LAMP DOES NOT LIGHT UP 1775
E-33 ALL WIPERS DO NOT OPERATE 1779
E-34 FRONT WIPER DOES NOT OPERATE .1783
E-35 REAR WIPER DOES NOT OPERATE 1786
E-36 LEFT DOOR WIPER DOES NOT OPERATE .1789
E-37 RIGHT DOOR WIPER DOES NOT OPERATE 1792
E-38 FRONT WASHER DOES NOT OPERATE 1795
E-39 REAR WASHER DOES NOT OPERATE .1797
E-40 LEFT DOOR WASHER DOES NOT OPERATE 1799
E-41 RIGHT DOOR WASHER DOES NOT OPERATE .1801
E-42 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .1803
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .1804
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) .1804
FAILURE MODE AND CAUSE TABLE 1805
H-1 MACHINE LACKS POWER (INSUFFICIENT DRAWBAR PULL) .1811
H-2 MACHINE DOES NOT TRAVEL (AT 2ND OR 3RD GEAR SPEED) 1813
H-3 MACHINE DOES NOT MOVE OFF AT ALL GEAR SPEEDS 1814
H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION, EITHER FORWARD OR IN REVERSE .1816
H-5 LARGE TIME LAG IS IN GEAR SHIFTING OR DIRECTIONAL CHANGE 1817
H-6 BRAKE DOES NOT WORK .1819
H-7 POWER TRAIN OIL OVERHEATS .1820
H-8 UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT AND HSS PUMP OR HSS MOTOR .1822
H-9 MACHINE CANNOT BE STEERED (MACHINE DOES NOT TURN LEFT OR RIGHT) .1823
H-10 STEERING SPEED OR POWER IS INSUFFICIENT 1824
H-11 ALL WORK EQUIPMENTS OPERATE SLOWLY .1825
H-12 ALL WORK EQUIPMENTS DO NOT OPERATE .1826
H-13 BLADE LIFT SPEED OR POWER IS LOW .1827
H-14 BLADE TILT SPEED OR POWER IS LOW .1828
H-15 RIPPER LIFT SPEED OR POWER IS LOW 1829
H-16 HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE .1830
H-17 HYDRAULIC DRIFT OF TILTED BLADE IS LARGE .1831
H-18 HYDRAULIC DRIFT OF LIFTED RIPPER IS LARGE 1832
H-19 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) .1833
H-20 UNUSUAL NOISE IS HEARD FROM AROUND FAN .1835
TROUBLESHOOTING OF ENGINE (S-MODE) 1836
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .1836
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 1837
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 1838
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 1839
S-4 ENGINE STARTABILITY IS POOR .1840
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 1842
S-6 ENGINE STOPS DURING OPERATION .1844
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 1846
S-8 ENGINE LACKS POWER 1847
S-9 KDPF GETS CLOGGED IN A SHORT TIME .1849
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 1851
S-11 OIL BECOMES CONTAMINATED QUICKLY .1852
S-12 FUEL CONSUMPTION IS EXCESSIVE 1853
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 1854
S-14 OIL PRESSURE DROPS .1855
S-15 FUEL MIXES INTO ENGINE OIL .1857
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 1858
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .1859
S-18 UNUSUAL NOISE IS HEARD .1860
S-19 VIBRATION IS EXCESSIVE .1861
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT .1862
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .1863
S-22 ACTIVE REGENERATION TAKES TIME .1865
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 1867
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 1868
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .1870
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 1871
50 DISASSEMBLY AND ASSEMBLY .1873
CONTENTS 1874
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .1879
HOW TO READ THIS MANUAL .1879
COATING MATERIALS LIST 1881
SPECIAL TOOLS LIST 1886
SKETCHES OF SPECIAL TOOLS .1910
ENGINE AND COOLING SYSTEM .1918
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .1918
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 1919
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 1923
REMOVE AND INSTALL INJECTOR ASSEMBLY 1930
METHOD FOR REMOVING INJECTOR ASSEMBLY .1931
METHOD FOR INSTALLING INJECTOR ASSEMBLY .1937
REMOVE AND INSTALL FUEL DOSER ASSEMBLY 1948
METHOD FOR REMOVING FUEL DOSER ASSEMBLY .1948
METHOD FOR INSTALLING FUEL DOSER ASSEMBLY .1949
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .1951
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 1951
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 1958
REMOVE AND INSTALL EGR VALVE ASSEMBLY .1967
METHOD FOR REMOVING EGR VALVE ASSEMBLY 1967
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 1969
REMOVE AND INSTALL EGR COOLER ASSEMBLY 1972
METHOD FOR REMOVING EGR COOLER ASSEMBLY .1973
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .1977
REMOVE AND INSTALL STARTER ASSEMBLY .1982
METHOD FOR REMOVING STARTER ASSEMBLY 1982
METHOD FOR INSTALLING STARTER ASSEMBLY 1984
REMOVE AND INSTALL ALTERNATOR BELT 1986
METHOD FOR REMOVING ALTERNATOR BELT .1986
METHOD FOR INSTALLING ALTERNATOR BELT .1988
REMOVE AND INSTALL RADIATOR ASSEMBLY 1990
METHOD FOR REMOVING RADIATOR ASSEMBLY .1991
METHOD FOR INSTALLING RADIATOR ASSEMBLY .1995
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2001
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .2002
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .2006
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2011
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2011
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2012
REMOVE AND INSTALL COOLING FAN DRIVE ASSEMBLY .2013
METHOD FOR REMOVING COOLING FAN DRIVE ASSEMBLY 2013
METHOD FOR INSTALLING COOLING FAN DRIVE ASSEMBLY 2014
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY .2017
METHOD FOR REMOVING COOLING FAN MOTOR ASSEMBLY 2017
METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY 2019
REMOVE AND INSTALL ENGINE ASSEMBLY 2021
METHOD FOR REMOVING ENGINE ASSEMBLY .2022
METHOD FOR INSTALLING ENGINE ASSEMBLY .2029
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2035
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .2035
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .2036
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2039
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2039
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2041
REMOVE AND INSTALL ENGINE OIL PAN .2046
METHOD FOR REMOVING ENGINE OIL PAN 2046
METHOD FOR INSTALLING ENGINE OIL PAN 2047
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2049
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2049
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2051
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2053
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2053
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2055
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2058
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2058
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2063
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2067
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2067
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2072
REMOVE AND INSTALL AdBlue/DEF SENSOR 2077
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2077
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2077
REMOVE AND INSTALL AdBlue/DEF STRAINER 2084
METHOD FOR REMOVING AdBlue/DEF STRAINER .2084
METHOD FOR INSTALLING AdBlue/DEF STRAINER .2084
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER .2085
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2085
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2086
REMOVE AND INSTALL KDPF ASSEMBLY 2088
METHOD FOR REMOVING KDPF ASSEMBLY .2088
METHOD FOR INSTALLING KDPF ASSEMBLY .2092
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .2097
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2097
METHOD FOR ASSEMBLING KDPF ASSEMBLY .2101
REMOVE AND INSTALL SCR ASSEMBLY .2105
METHOD FOR REMOVING SCR ASSEMBLY 2105
METHOD FOR INSTALLING SCR ASSEMBLY 2108
REMOVE AND INSTALL KDPF, SCR ASSEMBLY .2111
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2111
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2121
REMOVE AND INSTALL KCCV ASSEMBLY 2132
METHOD FOR REMOVING KCCV ASSEMBLY .2132
METHOD FOR INSTALLING KCCV ASSEMBLY .2135
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2139
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2139
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2142
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2148
METHOD FOR REMOVING AdBlue/DEF INJECTOR .2148
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .2151
REMOVE AND INSTALL AdBlue/DEF PUMP 2154
METHOD FOR REMOVING AdBlue/DEF PUMP .2154
METHOD FOR INSTALLING AdBlue/DEF PUMP .2157
REMOVE AND INSTALL AdBlue/DEF HOSE 2161
METHOD FOR REMOVING AdBlue/DEF HOSE .2161
METHOD FOR INSTALLING AdBlue/DEF HOSE .2166
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2172
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2172
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2173
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2174
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2174
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2176
POWER TRAIN .2178
REMOVE AND INSTALL DAMPER ASSEMBLY 2178
METHOD FOR REMOVING DAMPER ASSEMBLY .2178
METHOD FOR INSTALLING DAMPER ASSEMBLY .2181
DISASSEMBLE AND ASSEMBLE DAMPER ASSEMBLY 2184
METHOD FOR DISASSEMBLE DAMPER ASSEMBLY 2185
METHOD FOR ASSEMBLING DAMPER ASSEMBLY .2186
REMOVE AND INSTALL POWER TRAIN UNIT ASSEMBLY 2189
METHOD FOR REMOVING POWER TRAIN UNIT ASSEMBLY .2189
METHOD FOR INSTALLING POWER TRAIN UNIT ASSEMBLY .2194
DISCONNECTING AND CONNECTING POWER TRAIN UNIT ASSEMBLY 2200
METHOD FOR DISCONNECTING POWER TRAIN UNIT ASSEMBLY 2200
METHOD FOR CONNECTING POWER TRAIN UNIT ASSEMBLY .2205
DISASSEMBLE AND ASSEMBLE PTO ASSEMBLY .2210
METHOD FOR DISASSEMBLING PTO ASSEMBLY .2210
METHOD FOR ASSEMBLING PTO ASSEMBLY 2214
DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER ASSEMBLY 2219
METHOD FOR DISASSEMBLING TORQUE CONVERTER ASSEMBLY 2219
METHOD FOR ASSEMBLING TORQUE CONVERTER ASSEMBLY .2222
DISASSEMBLE AND ASSEMBLE TRANSMISSION ASSEMBLY 2226
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY 2227
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY 2235
DISASSEMBLE AND ASSEMBLE HSS ASSEMBLY .2247
METHOD FOR DISASSEMBLING HSS ASSEMBLY .2249
METHOD FOR ASSEMBLING HSS ASSEMBLY 2259
REMOVAL AND INSTALLATION OF HSS MOTOR .2277
METHOD FOR REMOVING HSS MOTOR ASSEMBLY 2277
METHOD FOR INSTALLING HSS MOTOR ASSEMBLY 2278
REMOVE AND INSTALL FINAL DRIVE ASSEMBLY .2279
METHOD FOR REMOVING FINAL DRIVE ASSEMBLY 2279
METHOD FOR INSTALLING FINAL DRIVE ASSEMBLY 2281
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY .2283
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY .2284
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2291
UNDERCARRIAGE AND FRAME .2303
REMOVE AND INSTALL TRACK FRAME ASSEMBLY .2303
REMOVE TRACK FRAME ASSEMBLY .2303
INSTALL TRACK FRAME ASSEMBLY 2307
REMOVE AND INSTALL IDLER ASSEMBLY .2311
METHOD FOR REMOVING IDLER ASSEMBLY 2311
METHOD FOR INSTALLING IDLER ASSEMBLY 2312
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2316
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .2316
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2318
REMOVE AND INSTALL RECOIL SPRING ASSEMBLY .2322
METHOD FOR REMOVING RECOIL SPRING ASSEMBLY 2322
METHOD FOR INSTALLING RECOIL SPRING ASSEMBLY 2324
DISASSEMBLE AND ASSEMBLE RECOIL SPRING 2326
METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING .2326
METHOD FOR ASSEMNLING RECOIL SPRING ASSEMBLY 2330
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY 2333
METHOD FOR REMOVING TRACK ROLLER ASSEMBLY .2333
METHOD FOR INSTALLING TRACK ROLLER ASSEMBLY .2335
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2338
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2338
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY .2339
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY 2343
METHOD FOR REMOVING CARRIER ROLLER ASSEMBLY .2343
METHOD FOR INSTALLING CARRIER ROLLER ASSEMBLY .2344
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .2345
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2345
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY .2346
REMOVE AND INSTALL PIVOT SHAFT ASSEMBLY .2349
METHOD FOR REMOVING PIVOT SHAFT ASSEMBLY 2349
METHOD FOR INSTALLING PIVOT SHAFT ASSEMBLY 2350
SEPARATION AND CONNECTION OF TRACK ASSEMBLY .2352
METHOD FOR CHECKING BEFORE SEPARATION OF THE TRACK ASSEMBLY .2352
METHOD FOR SEPARATING OF TRACK ASSEMBLY (NORMAL) 2352
METHOD FOR SEPARATING TRACK ASSEMBLY (WHEN TRACK FRAME HAS INTERNAL DEFECT) .2353
METHOD FOR INSTALLING TRACK ASSEMBLY 2355
SEPARATE AND CONNECT PLUS TYPE TRACK ASSEMBLY .2358
METHOD FOR SEPARATING PLUS TYPE TRACK ASSEMBLY 2358
METHOD FOR CONNECTING PLUS TYPE TRACK ASSEMBLY 2358
DISASSEMBLY AND ASSEMBLY OF TRACK ASSEMBLY GENERALLY 2359
METHOD FOR DISASSEMBLING TRACK ASSEMBLY GENERALLY .2359
METHOD FOR ASSEMBLING TRACK ASSEMBLY GENERALLY 2362
DISASSEMBLE AND ASSEMBLE PLUS TYPE TRACK ASSEMBLY GENERALLY .2375
METHOD FOR DISASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY .2375
METHOD FOR ASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY 2376
DISASSEMBLE AND ASSEMBLE ONE TRACK LINK ASSEMBLY IN FIELD .2384
METHOD FOR DISASSEMBLING ONE TRACK LINK ASSEMBLY IN FIELD .2386
METHOD FOR ASSEMBLING ONE TRACK LINK ASSEMBLY IN FIELD 2386
DISASSEMBLE AND ASSEMBLE MASTER LINK 2394
METHOD FOR DISASSEMBLING MASTER LINK 2395
METHOD FOR ASSEMBLING MASTER LINK .2395
REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY .2399
REMOVE EQUALIZER BAR ASSEMBLY .2399
INSTALL EQUALIZER BAR ASSEMBLY 2401
DISASSEMBLE AND ASSEMBLE EQUALIZER BAR BUSHINGS .2404
METHOD FOR DISASSEMBLING EQUALIZER BAR BUSHINGS .2404
METHOD FOR ASSEMBLING EQUALIZER BAR BUSHINGS 2405
OPEN AND CLOSE CENTER UNDER GUARD .2406
METHOD FOR OPENING UNDER GUARD 2406
METHOD FOR CLOSING UNDER GUARD 2407
REMOVE AND INSTALL CENTER UNDER GUARD ASSEMBLY 2409
METHOD FOR REMOVING UNDER GUARD ASSEMBLY 2409
METHOD FOR INSTALLING UNDER GUARD ASSEMBLY 2416
HYDRAULIC SYSTEM 2424
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2424
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2424
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2427
REMOVE AND INSTALL WORK EQUIPMENT PUMP AND HSS PUMP ASSEMBLY 2431
METHOD FOR REMOVING WORK EQUIPMENT PUMP AND HSS PUMP ASSEMBLY .2431
METHOD FOR INSTALLING WORK EQUIPMENT PUMP AND HSS PUMP ASSEMBLY .2434
REMOVE AND INSTALL POWER TRAIN PUMP AND STEERING LUBRICATION PUMP ASSEMBLY 2436
METHOD FOR REMOVING POWER TRAIN PUMP AND STEERING LUBRICATION PUMP ASSEMBLY .2436
METHOD FOR INSTALLING POWER TRAIN PUMP AND STEERING LUBRICATION PUMP ASSEMBLY .2438
REMOVE AND INSTALL COOLING FAN PUMP ASSEMBLY 2440
METHOD FOR REMOVING COOLING FAN PUMP ASSEMBLY .2440
METHOD FOR INSTALLING COOLING FAN PUMP ASSEMBLY .2442
REMOVE AND INSTALL SCAVENGING PUMP ASSEMBLY .2445
METHOD FOR REMOVING SCAVENGING PUMP ASSEMBLY 2445
METHOD FOR INSTALLING SCAVENGING PUMP ASSEMBLY 2446
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2448
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2448
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2453
WORK EQUIPMENT 2458
REMOVE AND INSTALL BLADE ASSEMBLY .2458
METHOD FOR REMOVING BLADE ASSEMBLY 2458
METHOD FOR INSTALLING BLADE ASSEMBLY 2460
REMOVE AND INSTALL BLADE LIFT CYLINDER ASSEMBLY .2464
REMOVE BLADE LIFT CYLINDER ASSEMBLY .2465
INSTALL BLADE LIFT CYLINDER ASSEMBLY 2469
DISASSEMBLE AND ASSEMBLE FIXED MULTI-SHANK RIPPER ASSEMBLY 2474
METHOD FOR DISASSEMBLING FIXED MULTI-SHANK RIPPER ASSEMBLY 2474
METHOD FOR ASSEMBLING FIXED MULTI-SHANK RIPPER ASSEMBLY .2476
DISASSEMBLE AND ASSEMBLE VARIABLE MULTI-SHANK RIPPER ASSEMBLY .2479
METHOD FOR DISASSEMBLING VARIABLE MULTI-SHANK RIPPER ASSEMBLY .2479
METHOD FOR ASSEMBLING VARIABLE MULTI-SHANK RIPPER ASSEMBLY 2482
METHOD FOR DISASSEMBLING AND ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2485
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2486
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2489
CAB AND ITS ATTACHMENTS .2493
REMOVE AND INSTALL OPERATOR CAB ASSEMBLY 2493
REMOVE OPERATOR CAB ASSEMBLY 2493
INSTALL OPERATOR CAB ASSEMBLY .2499
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS) .2506
METHOD FOR REMOVING OPERATOR’S CAB GLASS (ADHERED GLASS) 2506
METHOD FOR INSTALLING OPERATOR’S CAB GLASS (ADHERED GLASS) 2507
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2512
REMOVE AIR CONDITIONER UNIT ASSEMBLY 2512
INSTALL AIR CONDITIONER UNIT ASSEMBLY .2517
REMOVE AND INSTALL OPERATOR’S SEAT 2524
REMOVE OPERATOR’S SEAT 2524
INSTALL OPERATOR’S SEAT .2526
REMOVE AND INSTALL SEAT BELT 2529
METHOD FOR REMOVING SEAT BELT .2529
METHOD FOR INSTALLING SEAT BELT .2530
ELECTRICAL SYSTEM .2531
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2531
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2531
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2533
REMOVE AND INSTALL POWER TRAIN CONTROLLER ASSEMBLY 2536
METHOD FOR REMOVING POWER TRAIN CONTROLLER ASSEMBLY .2536
METHOD FOR INSTALLING POWER TRAIN CONTROLLER ASSEMBLY .2537
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2539
REMOVE MACHINE MONITOR ASSEMBLY .2539
INSTALL MACHINE MONITOR ASSEMBLY 2540
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2542
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2542
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2543
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2545
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2545
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2547
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2549
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2549
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2551
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY .2553
REMOVE GATEWAY FUNCTION CONTROLLER ASSEMBLY .2553
INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 2556
60 MAINTENANCE STANDARD .2561
CONTENTS 2562
ENGINE AND COOLING SYSTEM .2564
MAINTENANCE STANDARD OF ENGINE MOUNT 2564
MAINTENANCE STANDARD OF DAMPER 2566
MAINTENANCE STANDARD OF COOLING SYSTEM 2568
MAINTENANCE STANDARD OF COOLING FAN PUMP 2570
MAINTENANCE STANDARD OF SERVO VALVE .2571
MAINTENANCE STANDARD OF COOLING FAN MOTOR .2572
POWER TRAIN .2574
MAINTENANCE STANDARD OF UNIVERSAL JOINT .2574
MAINTENANCE STANDARD OF POWER TRAIN MOUNT .2575
MAINTENANCE STANDARD OF TORQUE CONVERTER AND PTO 2576
MAINTENANCE STANDARD OF TRANSMISSION 2579
MAINTENANCE STANDARD OF TRANSMISSION ECMV .2584
MAINTENANCE STANDARD OF MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE .2585
MAINTENANCE STANDARD OF TRANSMISSION LUBRICATION RELIEF VALVE .2586
MAINTENANCE STANDARD OF BEVEL GEAR SHAFT, HSS, AND BRAKE 2587
MAINTENANCE STANDARD OF BRAKE VALVE .2591
MAINTENANCE STANDARD OF FINAL DRIVE .2593
MAINTENANCE STANDARD OF SPROCKET FOR CONVENTIONAL TYPE TRACK SHOE .2596
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR CONVENTIONAL TYPE TRACK SHOE 2597
MAINTENANCE STANDARD OF SPROCKET FOR PLUS TYPE TRACK SHOE .2599
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR PLUS TYPE TRACK SHOE 2600
UNDERCARRIAGE AND FRAME .2602
MAINTENANCE STANDARD OF MAIN FRAME 2602
MAINTENANCE STANDARD OF SUSPENSION 2604
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .2608
MAINTENANCE STANDARD OF IDLER .2610
MAINTENANCE STANDARD OF TRACK ROLLER FOR CONVENTIONAL TYPE TRACK SHOES (SINGLE FLANGE TYPE) .2612
MAINTENANCE STANDARD OF TRACK ROLLER FOR CONVENTIONAL TYPE TRACK SHOES (DOUBLE FLANGE TYPE) .2614
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (SINGLE FLANGE TYPE) .2616
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (DOUBLE FLANGE TYPE) .2618
MAINTENANCE STANDARD OF CARRIER ROLLER FOR CONVENTIONAL TYPE TRACK SHOE .2620
MAINTENANCE STANDARD OF CARRIER ROLLER FOR PLUS TYPE TRACK SHOE .2622
MAINTENANCE STANDARD OF CONVENTIONAL TYPE TRACK SHOE 2624
MAINTENANCE STANDARD OF PLUS TYPE TRACK SHOE 2626
MAINTENANCE STANDARD OF SINGLE SHOE AND HEAVY DUTY SHOE .2628
MAINTENANCE STANDARD OF SWAMP SHOE 2629
HYDRAULIC SYSTEM 2630
MAINTENANCE STANDARD OF HYDRAULIC TANK 2630
MAINTENANCE STANDARD OF SCAVENGING PUMP .2631
MAINTENANCE STANDARD OF STEERING LUBRICATION PUMP AND POWER TRAIN PUMP 2632
MAINTENANCE STANDARD OF WORK EQUIPMENT AND HSS PUMP .2634
MAINTENANCE STANDARD OF HSS MOTOR .2635
MAINTENANCE STANDARD OF CONTROL VALVE .2637
MAINTENANCE STANDARD OF BLADE PPC VALVE .2644
MAINTENANCE STANDARD OF RIPPER PPC VALVE (FIXED MULTI-SHANK RIPPER) .2646
MAINTENANCE STANDARD OF RIPPER PPC VALVE (VARIABLE MULTI-SHANK RIPPER) 2648
MAINTENANCE STANDARD OF QUICK DROP VALVE 2651
MAINTENANCE STANDARD OF WORK EQUIPMENT LOCK SOLENOID VALVE 2652
WORK EQUIPMENT 2653
MAINTENANCE STANDARD OF CYLINDER STAY .2653
MAINTENANCE STANDARD OF FRONT WORK EQUIPMENT 2654
MAINTENANCE STANDARD OF CUTTING EDGE AND END BIT (STRAIGHT BLADE AND SEMI-U BLADE .2658
MAINTENANCE STANDARD OF CUTTING EDGE AND END BIT (SIGMA BLADE) 2659
MAINTENANCE STANDARD OF BLADE LIFT CYLINDER .2660
MAINTENANCE STANDARD OF BLADE TILT CYLINDER .2661
MAINTENANCE STANDARD OF BLADE PITCH CYLINDER (FOR POWER TILT PITCH DOZER SERIES) 2662
MAINTENANCE STANDARD OF FIXED MULTI-SHANK RIPPER 2663
MAINTENANCE STANDARD OF VARIABLE MULTI-SHANK RIPPER .2666
MAINTENANCE STANDARD OF RIPPER LIFT CYLINDER (FIXED AND VARIABLE MULTI-SHANK RIPPER) 2669
MAINTENANCE STANDARD OF RIPPER TILT CYLINDER (VARIABLE MULTI-SHANK RIPPER) 2670
CAB AND ITS ATTACHMENTS .2671
MAINTENANCE STANDARD OF CAB MOUNT .2671
80 APPENDIX .2673
CONTENTS 2674
AIR CONDITIONER SYSTEM 2676
PRECAUTIONS FOR REFRIGERANT .2676
AIR CONDITIONER COMPONENT .2677
SPECIFICATIONS OF AIR CONDITIONER .2679
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .2680
OUTLINE OF REFRIGERATION CYCLE 2681
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .2683
AIR CONDITIONER UNIT 2683
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .2683
FUNCTION OF AIR CONDITIONER UNIT 2685
COMPONENT PARTS OF AIR CONDITIONER UNIT .2687
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2688
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .2688
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .2688
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .2688
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2689
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2689
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2689
FUNCTION OF DUAL PRESSURE SWITCH 2690
AIR CONDITIONER CONTROLLER 2691
STRUCTURE OF AIR CONDITIONER CONTROLLER .2691
COMPRESSOR 2692
STRUCTURE OF COMPRESSOR .2692
SPECIFICATIONS OF COMPRESSOR 2692
FUNCTION OF COMPRESSOR 2692
CONDENSER .2693
STRUCTURE OF CONDENSER 2693
SPECIFICATIONS OF CONDENSER .2693
FUNCTION OF CONDENSER .2693
STRUCTURE OF WIDE CORE CONDENSER 2694
SPECIFICATIONS OF WIDE CORE CONDENSER .2694
FUNCTION OF WIDE CORE CONDENSER .2694
RECEIVER DRIER 2695
STRUCTURE OF RECEIVER DRIER .2695
SPECIFICATIONS OF RECEIVER DRIER 2695
FUNCTION OF RECEIVER DRIER 2695
SENSORS FOR AIR CONDITIONER SYSTEM 2696
STRUCTURE OF SUNLIGHT SENSOR 2696
FUNCTION OF SUNLIGHT SENSOR .2696
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .2696
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2696
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .2698
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .2700
AIR CONDITIONER SYSTEM DIAGRAM 2702
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2703
FUNCTION OF AIR CONDITIONER CONTROLLER 2704
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .2705
TESTING AIR LEAKAGE (DUCT) 2714
METHOD FOR TESTING AIR LEAKAGE (DUCT) .2714
EXPLANATION FOR TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .2717
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2718
TEST VENT (MODE) CHANGEOVER .2719
METHOD FOR TESTING VENT (MODE) CHANGEOVER .2719
TESTING FRESH/RECIRC AIR CHANGEOVER .2720
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2720
TEST SUNLIGHT SENSOR 2721
METHOD FOR TESTING SUNLIGHT SENSOR 2721
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2722
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2722
TEST RELAYS .2723
METHOD FOR TESTING RELAYS .2723
AIR CONDITIONER TROUBLESHOOTING CHART 1 .2724
AIR CONDITIONER TROUBLESHOOTING CHART 2 .2725
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2728
FAILURE CODE [879AKA] .2730
FAILURE CODE [879AKB] .2731
FAILURE CODE [879BKA] .2732
FAILURE CODE [879BKB] .2734
FAILURE CODE [879CKA] .2736
FAILURE CODE [879CKB] .2737
FAILURE CODE [879DKZ] .2738
FAILURE CODE [879EMC] .2740
FAILURE CODE [879FMC] .2741
FAILURE CODE [879GKX] .2742
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2744
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .2746
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2750
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .2752
TROUBLESHOOTING USING GAUGE PRESSURE 2754
CONNECTION OF SERVICE TOOL 2757
METHOD FOR CONNECTING SERVICE TOOL 2757
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .2759
HANDLE COMPRESSOR OIL .2761
90 CIRCUIT DIAGRAMS .2763
CONTENTS 2764
HYDRAULIC CIRCUIT DIAGRAM .2765
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .2765
HYDRAULIC CIRCUIT DIAGRAM (FOR POWER TILT PITCH DOZER AND VARIABLE MULTI-SHANK RIPPER) 2769
HYDRAULIC CIRCUIT DIAGRAM (FOR POWER TILT PITCH DOZER AND FIXED MULTI-SHANK RIPPER) .2771
HYDRAULIC CIRCUIT DIAGRAM (FOR POWER TILT DOZER AND VARIABLE MULTI-SHANK RIPPER) 2773
HYDRAULIC CIRCUIT DIAGRAM (FOR POWER TILT DOZER AND FIXED MULTI-SHANK RIPPER) .2775
HYDRAULIC CIRCUIT DIAGRAM (FOR POWER TILT DOZER) 2777
HYDRAULIC CIRCUIT DIAGRAM (FOR SINGLE TILT DOZER AND FIXED MULTI-SHANK RIPPER) 2779
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM .2781
ELECTRICAL CIRCUIT DIAGRAM 2783
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2783
ELECTRICAL CIRCUIT DIAGRAM (1/16) .2787
ELECTRICAL CIRCUIT DIAGRAM (2/16) .2789
ELECTRICAL CIRCUIT DIAGRAM (3/16) .2791
ELECTRICAL CIRCUIT DIAGRAM (4/16) .2793
ELECTRICAL CIRCUIT DIAGRAM (5/16) .2795
ELECTRICAL CIRCUIT DIAGRAM (6/16) .2797
ELECTRICAL CIRCUIT DIAGRAM (7/16) .2799
ELECTRICAL CIRCUIT DIAGRAM (8/16) .2801
ELECTRICAL CIRCUIT DIAGRAM (9/16) .2803
ELECTRICAL CIRCUIT DIAGRAM (10/16) 2805
ELECTRICAL CIRCUIT DIAGRAM (11/16) 2807
ELECTRICAL CIRCUIT DIAGRAM (12/16) 2809
ELECTRICAL CIRCUIT DIAGRAM (13/16) 2811
ELECTRICAL CIRCUIT DIAGRAM (14/16) 2813
ELECTRICAL CIRCUIT DIAGRAM (15/16) 2815
ELECTRICAL CIRCUIT DIAGRAM (16/16) 2817
INDEX 2819

DESCRIPTION:

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

• SERIAL NUMBERS 25001 and up

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

G.B 30/12/24