SEN05536-17
BULLDOZER
SERIAL NUMBERS
D65EX- 1001 D65PX- 1001 D65WX- 1001
and up
00 Index and foreword
Index
Writing compensation amount for soot accumulation caused by ash on engine controller ..................................................................................................................... 30-46 Power train ....................................................................................................................................... 30-48 Measuring power train oil pressure ........................................................................................... 30-48 Adjusting transmission output shaft speed sensor (replacement procedure) ........................... 30-53 Simple test procedure for brake performance .......................................................................... 30-54 Adjusting brake pedal ............................................................................................................... 30-55 Adjusting parking brake lever .................................................................................................... 30-57 Retrieval of disabled machine using brake release device ....................................................... 30-59 Undercarriage and frame ................................................................................................................. 30-62 Adjusting idler clearance ........................................................................................................... 30-62 Checking sprocket wear............................................................................................................ 30-63 Testing and adjusting track tension........................................................................................... 30-64 Hydraulic system .............................................................................................................................. 30-65 Releasing remaining pressure in work equipment cylinder ...................................................... 30-65 Measuring and adjusting work equipment and HSS oil pressure ............................................. 30-66 Measuring source pressure of control circuit ............................................................................ 30-69 Measuring PPC valve output pressure ......................................................................................30-70 Adjusting play of work equipment PPC valve.............................................................................30-73 Isolating the parts causing hydraulic drift in blade and ripper ...................................................30-75 Measure internal oil leakage of work equipment cylinder ..........................................................30-76 Checking fan speed ...................................................................................................................30-77 Measuring fan circuit oil pressure ..............................................................................................30-78 Bleeding air from hydraulic circuit ..............................................................................................30-79 Work equipment ............................................................................................................................... 30-81 Adjusting work equipment lock lever......................................................................................... 30-81 Adjustment of straight tilt dozer ................................................................................................. 30-82 Cab and its attachments .................................................................................................................. 30-84 Adjusting operator’s cab ........................................................................................................... 30-84 Adjusting play of blade center ball ............................................................................................ 30-87 Electrical system .............................................................................................................................. 30-88 Special functions of machine monitor ....................................................................................... 30-88 Handling voltage circuit of engine controller ............................................................................30-150 Adjustment method when controller has been replaced .......................................................... 30-151 Testing diodes ..........................................................................................................................30-153 Pm clinic ..........................................................................................................................................30-154 Pm Clinic service .....................................................................................................................30-154 Pm Clinic check sheet..............................................................................................................30-160 40 Troubleshooting .....................................................................................................................................40-1 Table of contents .................................................................................................................................40-2 Related information on troubleshooting ............................................................................................. 40-9 Troubleshooting points ................................................................................................................ 40-9 Sequence of events in troubleshooting ...................................................................................... 40-11 Check before troubleshooting ....................................................................................................40-13 Inspection procedure before troubleshooting ............................................................................40-15 Preparation for troubleshooting of electrical system ................................................................. 40-35 .................................................................... 40-39 .....................................................40-41 Information in troubleshooting table.......................................................................................... 40-44 Troubleshooting method for open circuit in wiring harness of pressure sensor system ........... 40-46 Connector/electrical wiring connection table ............................................................................ 40-48 Layout of connector ................................................................................................................. 40-111 .............................................................................................. 40-118 T-branch box and T-branch adapter table................................................................................40-157 Fuse locations table .................................................................................................................40-162 Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ..................................40-165 Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) .............................................................40-168 Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) ................................................................40-169
00-4
D65EX,PX,WX-17
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00 Index and foreword Index
Failure codes table................................................................................................................... 40-170 Troubleshooting by failure code (Display of code) .......................................................................... 40-181 Failure code [1500L0] .............................................................................................................. 40-181 Failure code [15SAL1] ..............................................................................................................40-182 Failure code [15SALH] .............................................................................................................40-184 Failure code [15SBL1] ..............................................................................................................40-186 Failure code [15SBLH] .............................................................................................................40-188 Failure code [15SEL1] ..............................................................................................................40-190 Failure code [15SELH] .............................................................................................................40-192 Failure code [15SFL1] ..............................................................................................................40-194 Failure code [15SFLH] .............................................................................................................40-196 Failure code [15SGL1] ..............................................................................................................40-198 Failure code [15SGLH] ............................................................................................................ 40-200 Failure code [15SJL1] ...............................................................................................................40-202 Failure code [15SJLH]............................................................................................................. 40-204 Failure code [1800MW] ........................................................................................................... 40-206 Failure code [879AKA] ............................................................................................................ 40-208 Failure code [879AKB] ............................................................................................................ 40-209 Failure code [879BKA] .............................................................................................................40-210 Failure code [879BKB] ............................................................................................................. 40-211 Failure code [879CKA] .............................................................................................................40-212 Failure code [879CKB] .............................................................................................................40-213 Failure code [879DKZ] .............................................................................................................40-214 Failure code [879EMC] ............................................................................................................40-215 Failure code [879FMC].............................................................................................................40-216 Failure code [879GKX] ............................................................................................................40-217 Failure code [989L00] ..............................................................................................................40-218 Failure code [989M00] .............................................................................................................40-219 Failure code [989N00] .............................................................................................................40-220 Failure code [A1U0N3] .............................................................................................................40-221 Failure code [A1U0N4] .............................................................................................................40-224 Failure code [AA10NX] ............................................................................................................40-227 Failure code [AB00KE] ........................................................................................................... 40-229 Failure code [B@BAZG] ..........................................................................................................40-231 Failure code [B@BCNS] ..........................................................................................................40-232 Failure code [B@CENS] ..........................................................................................................40-233 Failure code [B@HANS] ......................................................................................................... 40-234 Failure code [CA115] ................................................................................................................40-235 Failure code [CA122] ............................................................................................................... 40-236 Failure code [CA123] ................................................................................................................40-239 Failure code [CA131] ................................................................................................................40-242 Failure code [CA132] ................................................................................................................40-245 Failure code [CA144] ................................................................................................................40-248 Failure code [CA145] ................................................................................................................40-251 Failure code [CA153] ............................................................................................................... 40-254 Failure code [CA154] ................................................................................................................40-257 Failure code [CA187] ............................................................................................................... 40-260 Failure code [CA221] ...............................................................................................................40-263 Failure code [CA222] ...............................................................................................................40-267 Failure code [CA227] ...............................................................................................................40-270 Failure code [CA234] ...............................................................................................................40-271 Failure code [CA238] ...............................................................................................................40-273 Failure code [CA239] ...............................................................................................................40-275 Failure code [CA271]................................................................................................................40-277 Failure code [CA272] ...............................................................................................................40-280 Failure code [CA281] ...............................................................................................................40-283 Failure code [CA295] .............................................................................................................. 40-284 Failure code [CA322] ...............................................................................................................40-285 Failure code [CA323] ...............................................................................................................40-288 D65EX,PX,WX-17
00-5
00 Index and foreword
Index
Failure code [CA324] ...............................................................................................................40-291 Failure code [CA325] .............................................................................................................. 40-294 Failure code [CA331]................................................................................................................40-297 Failure code [CA332] .............................................................................................................. 40-300 Failure code [CA343] .............................................................................................................. 40-303 Failure code [CA351]............................................................................................................... 40-304 Failure code [CA352] .............................................................................................................. 40-305 Failure code [CA356] .............................................................................................................. 40-307 Failure code [CA357] ...............................................................................................................40-310 Failure code [CA386] ...............................................................................................................40-314 Failure code [CA428] ...............................................................................................................40-315 Failure code [CA429] ...............................................................................................................40-317 Failure code [CA435] .............................................................................................................. 40-320 Failure code [CA441]............................................................................................................... 40-322 Failure code [CA442] .............................................................................................................. 40-325 Failure code [CA449] .............................................................................................................. 40-326 Failure code [CA451]............................................................................................................... 40-330 Failure code [CA452] .............................................................................................................. 40-333 Failure code [CA488] .............................................................................................................. 40-336 Failure code [CA515]............................................................................................................... 40-337 Failure code [CA516]............................................................................................................... 40-339 Failure code [CA553] .............................................................................................................. 40-342 Failure code [CA555] .............................................................................................................. 40-343 Failure code [CA556] .............................................................................................................. 40-344 Failure code [CA559] .............................................................................................................. 40-346 Failure code [CA595] ...............................................................................................................40-351 Failure code [CA687] .............................................................................................................. 40-352 Failure code [CA689] .............................................................................................................. 40-355 Failure code [CA691]................................................................................................................40-361 Failure code [CA692] .............................................................................................................. 40-364 Failure code [CA697] .............................................................................................................. 40-367 Failure code [CA698] .............................................................................................................. 40-368 Failure code [CA731] ............................................................................................................... 40-369 Failure code [CA778] ...............................................................................................................40-372 Failure code [CA1117] ..............................................................................................................40-378 Failure code [CA1664]..............................................................................................................40-379 Failure code [CA1691] ............................................................................................................. 40-383 Failure code [CA1695]............................................................................................................. 40-387 Failure code [CA1696]............................................................................................................. 40-389 Failure code [CA1843]..............................................................................................................40-391 Failure code [CA1844]............................................................................................................. 40-394 Failure code [CA1879] ............................................................................................................. 40-397 Failure code [CA1881] ............................................................................................................. 40-400 Failure code [CA1883] ............................................................................................................. 40-403 Failure code [CA1921] ............................................................................................................. 40-409 Failure code [CA1922] ..............................................................................................................40-412 Failure code [CA1942] ..............................................................................................................40-419 Failure code [CA1993] ............................................................................................................. 40-421 Failure code [CA2185] ............................................................................................................ 40-425 Failure code [CA2186] ............................................................................................................ 40-427 Failure code [CA2249] ............................................................................................................ 40-429 Failure code [CA2265] ............................................................................................................ 40-430 Failure code [CA2266] ............................................................................................................ 40-433 Failure code [CA2271]............................................................................................................. 40-436 Failure code [CA2272] ............................................................................................................ 40-440 Failure code [CA2288] ............................................................................................................ 40-445 Failure code [CA2311] ............................................................................................................. 40-446 Failure code [CA2349] ............................................................................................................ 40-447 Failure code [CA2353] .............................................................................................................40-451
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D65EX,PX,WX-17
00 Index and foreword Index
Failure code [CA2357] ............................................................................................................ 40-454 Failure code [CA2373] ............................................................................................................ 40-457 Failure code [CA2374]............................................................................................................. 40-460 Failure code [CA2375] ............................................................................................................ 40-463 Failure code [CA2376] ............................................................................................................ 40-466 Failure code [CA2381] ........................................................................................................... 40-469 Failure code [CA2382] .............................................................................................................40-472 Failure code [CA2383] .............................................................................................................40-476 Failure code [CA2386] ............................................................................................................ 40-480 Failure code [CA2387] ............................................................................................................ 40-483 Failure code [CA2554] ............................................................................................................ 40-486 Failure code [CA2555] ............................................................................................................ 40-490 Failure code [CA2556] ............................................................................................................ 40-493 Failure code [CA2637] ............................................................................................................ 40-496 Failure code [CA2639] ............................................................................................................ 40-500 Failure code [CA2961] ............................................................................................................ 40-503 Failure code [CA2973] ............................................................................................................ 40-504 Failure code [CA3133]............................................................................................................. 40-505 Failure code [CA3134]............................................................................................................. 40-508 Failure code [CA3135].............................................................................................................. 40-511 Failure code [CA3251] ..............................................................................................................40-517 Failure code [CA3253] ............................................................................................................ 40-522 Failure code [CA3254] ............................................................................................................ 40-526 Failure code [CA3255] ............................................................................................................ 40-531 Failure code [CA3256] ............................................................................................................ 40-536 Failure code [CA3311] ..............................................................................................................40-541 Failure code [CA3312]............................................................................................................. 40-546 Failure code [CA3313]..............................................................................................................40-551 Failure code [CA3314]............................................................................................................. 40-556 Failure code [CA3315]............................................................................................................. 40-562 Failure code [CA3316] ............................................................................................................ 40-570 Failure code [CA3317]..............................................................................................................40-575 Failure code [CA3318]............................................................................................................. 40-581 Failure code [CA3319]............................................................................................................. 40-589 Failure code [CA3321]............................................................................................................. 40-595 Failure code [CA3322] ............................................................................................................ 40-600 Failure code [CA3419]............................................................................................................. 40-608 Failure code [CA3421]..............................................................................................................40-610 Failure code [CA3741] ..............................................................................................................40-613 Failure code [D130KA] .............................................................................................................40-614 Failure code [D130KB] .............................................................................................................40-617 Failure code [D19DKA] ........................................................................................................... 40-620 Failure code [D19DKB] ........................................................................................................... 40-623 Failure code [D19JKZ] ............................................................................................................ 40-625 Failure code [D811MC]............................................................................................................ 40-629 Failure code [D862KA] ........................................................................................................... 40-630 Failure code [D8ALKA] ........................................................................................................... 40-631 Failure code [D8ALKB] ........................................................................................................... 40-633 Failure code [D8AQKR] .......................................................................................................... 40-635 Failure code [DAF0MB] ........................................................................................................... 40-637 Failure code [DAF0MC] .......................................................................................................... 40-638 Failure code [DAF8KB] ........................................................................................................... 40-639 Failure code [DAF9KQ] ............................................................................................................40-641 Failure code [DAFGMC] .......................................................................................................... 40-642 Failure code [DAFLKA] ........................................................................................................... 40-643 Failure code [DAFLKB] ........................................................................................................... 40-645 Failure code [DAFQKR] .......................................................................................................... 40-647 Failure code [DAZ9KQ] ........................................................................................................... 40-648 Failure code [DAZQKR] .......................................................................................................... 40-649 D65EX,PX,WX-17
00-7
00 Index and foreword
Index
Failure code [DB2QKR] .......................................................................................................... 40-656 Failure code [DB2RKR]........................................................................................................... 40-663 Failure code [DBE0KT] ........................................................................................................... 40-670 Failure code [DBE1KK] ............................................................................................................40-671 Failure code [DBE2KK] ........................................................................................................... 40-675 Failure code [DBE5KK]........................................................................................................... 40-679 Failure code [DBE6KK] ........................................................................................................... 40-682 Failure code [DBE7KK] ........................................................................................................... 40-684 Failure code [DBE9KQ] ........................................................................................................... 40-686 Failure code [DBELKA] ........................................................................................................... 40-687 Failure code [DBELKB] ........................................................................................................... 40-689 Failure code [DBEQKR] .......................................................................................................... 40-691 Failure code [DBERKR] .......................................................................................................... 40-693 Failure code [DD12KA] ........................................................................................................... 40-695 Failure code [DD12KB] ........................................................................................................... 40-697 Failure code [DD13KA] ........................................................................................................... 40-699 Failure code [DD13KB] ............................................................................................................40-701 Failure code [DD14KA] ............................................................................................................40-703 Failure code [DD14KB] ............................................................................................................40-705 Failure code [DDKFL4] ............................................................................................................40-707 Failure code [DDKGL4] ............................................................................................................ 40-710 Failure code [DDKHKA] ........................................................................................................... 40-713 Failure code [DDKHKB] ........................................................................................................... 40-715 Failure code [DDN7KA] ........................................................................................................... 40-717 Failure code [DDN7KB] ............................................................................................................ 40-719 Failure code [DDNLKA] ...........................................................................................................40-721 Failure code [DDNLKB]............................................................................................................40-723 Failure code [DGS1KA] ............................................................................................................40-725 Failure code [DGS1KX]............................................................................................................40-726 Failure code [DGT1KA] ............................................................................................................40-729 Failure code [DGT1KX] ............................................................................................................40-730 Failure code [DH21KA] ............................................................................................................40-733 Failure code [DH21KB] ............................................................................................................40-736 Failure code [DHA4KA]............................................................................................................40-739 Failure code [DHTDKA] ........................................................................................................... 40-741 Failure code [DHTDKB] ...........................................................................................................40-744 Failure code [DK10KA]............................................................................................................. 40-747 Failure code [DK10KB] .............................................................................................................40-750 Failure code [DK30KA] ............................................................................................................40-753 Failure code [DK30KB] ............................................................................................................40-757 Failure code [DK30KX] ............................................................................................................40-760 Failure code [DK30KZ] ............................................................................................................40-761 Failure code [DK30L8] .............................................................................................................40-762 Failure code [DK31KA].............................................................................................................40-763 Failure code [DK31KB] .............................................................................................................40-767 Failure code [DK40KA] ............................................................................................................40-770 Failure code [DK40KB] ............................................................................................................40-773 Failure code [DK55KX] ............................................................................................................40-776 Failure code [DK55KZ] ............................................................................................................40-777 Failure code [DK55L8] .............................................................................................................40-778 Failure code [DK56KA] ............................................................................................................40-779 Failure code [DK56KB] ............................................................................................................40-783 Failure code [DK57KA] ............................................................................................................40-786 Failure code [DK57KB] ............................................................................................................40-790 Failure code [DKH1KA] ............................................................................................................40-793 Failure code [DKH1KB] ............................................................................................................40-796 Failure code [DLM3KA]............................................................................................................40-799 Failure code [DLM3MB] .......................................................................................................... 40-801 Failure code [DLT3KA] ............................................................................................................ 40-802
00-8
D65EX,PX,WX-17
00 Index and foreword Index
Failure code [DLT3KB] ............................................................................................................ 40-805 Failure code [DR21KX] ........................................................................................................... 40-807 Failure code [DR31KX] ........................................................................................................... 40-808 Failure code [DV20KB] ........................................................................................................... 40-809 Failure code [DW5AKA] ...........................................................................................................40-811 Failure code [DW5AKB] ...........................................................................................................40-813 Failure code [DW5AKY] ...........................................................................................................40-815 Failure code [DW7BKA] ...........................................................................................................40-818 Failure code [DW7BKB] .......................................................................................................... 40-820 Failure code [DWN1KA] .......................................................................................................... 40-822 Failure code [DWN1KB] .......................................................................................................... 40-824 Failure code [DWN1KY] .......................................................................................................... 40-826 Failure code [DWN2KA] .......................................................................................................... 40-829 Failure code [DWN2KB] .......................................................................................................... 40-831 Failure code [DWN2KY] ......................................................................................................... 40-833 Failure code [DWN5KA].......................................................................................................... 40-836 Failure code [DWN5KB] .......................................................................................................... 40-838 Failure code [DWN5KY] ......................................................................................................... 40-840 Failure code [DXA2KA] ........................................................................................................... 40-843 Failure code [DXA2KB] ........................................................................................................... 40-845 Failure code [DXA2KY]........................................................................................................... 40-847 Failure code [DXH1KA] ........................................................................................................... 40-850 Failure code [DXH1KB] ........................................................................................................... 40-852 Failure code [DXH1KY] ........................................................................................................... 40-854 Failure code [DXH4KA] ........................................................................................................... 40-857 Failure code [DXH4KB] ........................................................................................................... 40-859 Failure code [DXH4KY]........................................................................................................... 40-861 Failure code [DXH5KA] ........................................................................................................... 40-864 Failure code [DXH5KB] ........................................................................................................... 40-866 Failure code [DXH5KY]........................................................................................................... 40-868 Failure code [DXH6KA]............................................................................................................40-871 Failure code [DXH6KB] ........................................................................................................... 40-873 Failure code [DXH6KY] ...........................................................................................................40-875 Failure code [DXH7KA] ........................................................................................................... 40-878 Failure code [DXH7KB] ........................................................................................................... 40-880 Failure code [DXH7KY] ........................................................................................................... 40-882 Failure code [DXH8KA] ........................................................................................................... 40-885 Failure code [DXH8KB] ........................................................................................................... 40-887 Failure code [DXH8KY]........................................................................................................... 40-889 Failure code [DXJ4KA]............................................................................................................ 40-892 Failure code [DXJ4KB] ............................................................................................................ 40-894 Failure code [DXJCKA] ........................................................................................................... 40-896 Failure code [DXJCKB] ........................................................................................................... 40-898 Failure code [DXJCKY] ........................................................................................................... 40-900 Failure code [DXJDKA] ........................................................................................................... 40-902 Failure code [DXJDKB] ........................................................................................................... 40-904 Failure code [DXJDKY] ........................................................................................................... 40-906 Troubleshooting of electrical system (E-mode) .............................................................................. 40-908 E-1 Engine does not start (Engine does not crank) ................................................................ 40-908 E-2 Manual preheating does not work .....................................................................................40-914 E-3 Automatic preheating does not work .................................................................................40-917 E-4 While preheating is working, preheating monitor does not light up...................................40-919 E-5 When starting switch is turned to ON position, machine monitor displays nothing...........40-921 E-6 When starting switch is turned to ON position (with engine stopped), basic check monitor lights up ....................................................................................................... 40-924 E-7 Air cleaner clogging monitor lights up in yellow while engine is running .......................... 40-925 E-8 Charge level monitor lights up in red while engine is running .......................................... 40-926 E-9 Engine coolant temperature monitor lights up while engine is running ............................ 40-928
D65EX,PX,WX-17
00-9
00 Index and foreword
Index
E-10 Engine oil pressure monitor lights up in red while engine is running .............................. 40-929 E-11 Power train oil temperature monitor lights up while engine is running............................ 40-930 E-12 Hydraulic oil temperature monitor lights up while engine is running................................40-931 E-13 Engine coolant temperature gauge does not indicate correct temparature.................... 40-932 E-14 Fuel level gauge does not indicate correct level ............................................................. 40-933 E-15 Power train oil temperature gauge does not indicate correct temperature..................... 40-935 E-16 Hydraulic oil temperature gauge does not indicate correct temperature ........................ 40-936 E-17 Operation mode does not change .................................................................................. 40-937 E-18 Gearshift mode does not change ................................................................................... 40-938 E-19 Operating customize switch does not display customize screen.................................... 40-939 E-20 Modifying setting on customize screen does not change setting of machine ................ 40-940 E-21 Reverse slow mode does not function properly ..............................................................40-941 E-22 Alarm buzzer does not sound or does not stop sounding .............................................. 40-942 E-23 While starting switch is in OFF position, service meter is not displayed ........................ 40-943 E-24 Service mode cannot be selected .................................................................................. 40-944 E-25 Horn does not sound ...................................................................................................... 40-945 E-26 Horn does not stop sounding ......................................................................................... 40-946 E-27 Backup alarm does not sound ........................................................................................ 40-947 E-28 Backup alarm does not stop sounding ........................................................................... 40-949 E-29 Headlamp does not light up ............................................................................................ 40-950 E-30 Rear lamp does not light up ........................................................................................... 40-953 E-31 No wiper operates continuously or intermittently ........................................................... 40-955 E-32 Front wiper does not operate (Failure in both continuous and intermittent operations) ................................................................................................................ 40-958 E-33 Rear wiper does not operate (Failure in both continuous and intermittent operations) ................................................................................................................ 40-961 E-34 Left door wiper does not operate (Failure of both continuous and intermittent operations) ................................................................................................................ 40-964 E-35 Right door wiper does not operate (Failure of both continuous and intermittent operations) ................................................................................................................ 40-967 E-36 KOMTRAX system does not operate properly ................................................................40-970 Troubleshooting of hydraulic and mechanical system (H-mode) ...................................................40-972 Information described in troubleshooting table (H-mode)........................................................40-972 System diagram of hydraulic and mechanical system .............................................................40-973 List of Failure Mode and Cause ...............................................................................................40-975 ................................................................40-978 H-2 Machine cannot travel (at 2nd or 3rd speed) ................................................................... 40-980 H-3 Machine does not start at all gear speeds ....................................................................... 40-981 H-4 Machine travels only in one direction, either forward or in reverse ................................. 40-982 H-5 Large time lag at gear shifting or directional selection .................................................... 40-983 H-6 Machine cannot be steered (machine does not turn left or right) .................................... 40-984 ............................................................................ 40-985 H-8 Brake does not operate.................................................................................................... 40-986 H-9 Torque converter does not lock up .................................................................................. 40-987 H-10 Power train oil overheats ................................................................................................ 40-988 H-11 Unusual noise is heard from around HSS and work equipment pump or HSS motor.... 40-989 H-12 All work equipment operates slowly ............................................................................... 40-990 H-13 All work equipment does not operate ............................................................................. 40-991 H-14 Blade lift speed or power is low ...................................................................................... 40-992 H-15 Blade tilt speed or power is low ...................................................................................... 40-993 H-16 Blade angle speed or power is low................................................................................. 40-994 H-17 Ripper lift speed or power is low .................................................................................... 40-995 H-18 Hydraulic drift of lifted blade is large .............................................................................. 40-996 H-19 Hydraulic drift of tilted blade is large .............................................................................. 40-997 H-20 Hydraulic drift of lifted ripper is large ............................................................................. 40-998 H-21 Fan speed is abnormal (high, low, or no rotation) .......................................................... 40-999 H-22 Unusual noise is heard from around fan .......................................................................40-1001 Troubleshooting of engine (S-mode) .............................................................................................40-1002
00-10
D65EX,PX,WX-17
Information mentioned in troubleshooting table (S mode) .....................................................40-1002 S-1 Engine does not crank when starting switch is turned to START position ......................40-1003 S-2 The engine cranks but exhaust smoke does not come out .............................................40-1004 S-3 Fuel is being injected but engine does not start (incomplete combustion: engine cranks but does not start) ....................................................................................................40-1005 S-4 Startability is poor ...........................................................................................................40-1006 S-5 Engine does not pick up smoothly ..................................................................................40-1008 S-6 Engine stops during operation ........................................................................................ 40-1010 S-7 Engine runs rough or is unstable .................................................................................... 40-1012 S-8 Engine lacks power ......................................................................................................... 40-1013 S-9 KDPF gets clogged in a short time ................................................................................. 40-1015 S-10 Engine oil consumption is excessive ............................................................................. 40-1017 S-11 Engine oil becomes contaminated early ........................................................................ 40-1018 S-12 Fuel consumption is excessive ...................................................................................... 40-1019 S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ....................................40-1020 S-14 Oil pressure drops ......................................................................................................... 40-1021 S-15 Fuel mixes into engine oil ..............................................................................................40-1022 S-16 Water mixes into engine oil (milky) ................................................................................40-1023 S-17 Coolant temperature rises too high (overheating) .........................................................40-1024 S-18 Unusual noise is heard ..................................................................................................40-1025 S-19 Vibration is excessive ....................................................................................................40-1026 S-20 Air cannot be bled from fuel circuit................................................................................40-1027 S-21 Frequent active regeneration ........................................................................................40-1028 S-22 Active regeneration takes time ......................................................................................40-1029 S-23 White smoke is exhausted during active regeneration..................................................40-1030 50 Disassembly and assembly ...................................................................................................................50-1 Table of contents .................................................................................................................................50-2 Related information on disassembly and assembly ........................................................................... 50-4 How to read this manual ............................................................................................................. 50-4 Coating materials list ................................................................................................................... 50-6 Special tool list ...........................................................................................................................50-10 Sketches of special tools............................................................................................................50-21 Engine and cooling system .............................................................................................................. 50-36 Removal and installation of fuel supply pump assembly .......................................................... 50-36 Removal and installation of fuel injector assembly ................................................................... 50-46 Removal and installation of cylinder head assembly ................................................................ 50-67 Removal and installation of radiator assembly.......................................................................... 50-98 Removal and installation of aftercooler assembly ................................................................... 50-110 Removal and installation of hydraulic oil cooler assembly ....................................................... 50-116 Removal and installation of power train oil cooler assembly ................................................... 50-121 Removal and installation of cooling fan drive assembly ..........................................................50-128 Removal and installation of cooling fan motor assembly .........................................................50-133 Removal and installation of engine assembly ..........................................................................50-136 Removal and installation of damper assembly ........................................................................50-159 Removal and installation of engine front oil seal ......................................................................50-165 Removal and installation of engine rear oil seal....................................................................... 50-172 Removal and installation of engine hood assembly .................................................................50-185 Removal and installation of fuel tank assembly .......................................................................50-190 Removal and installation of KDPF cover..................................................................................50-195 Removal and installation of KDPF assembly ...........................................................................50-198 Disassembly and assembly of KDPF ...................................................................................... 50-206 Removal and installation of KCCV assembly ...........................................................................50-216 Removal and installation of air cleaner assembly ....................................................................50-219 Power train ..................................................................................................................................... 50-222 Removal and installation of power train unit assembly ........................................................... 50-222 Disconnecting and connecting of power train unit assembly .................................................. 50-233 Disassembly and assembly of PTO ........................................................................................ 50-239 Disassembly and assembly of torque converter ......................................................................50-245 Disassembly and assembly of TORQFLOW transmission ......................................................50-258
Disassembly and assembly of HSS ........................................................................................ 50-288 .....................................................................50-312 .................................................................................50-317 Undercarriage and frame ............................................................................................................... 50-334 Removal and installation of track frame assembly ................................................................. 50-334 Removal and installation of idler assembly ............................................................................. 50-339 Disassembly and assembly of idler ........................................................................................ 50-342 Removal and installation of recoil spring assembly ................................................................ 50-348 Disassembly and assembly of recoil spring .............................................................................50-351 Removal and installation of track roller assembly ................................................................... 50-356 Disassembly and assembly of track roller .............................................................................. 50-360 Removal and installation of carrier roller assembly ................................................................ 50-366 Disassembly and assembly of carrier roller ............................................................................ 50-369 Separation and connection of track shoe assembly (normal track shoes) ..............................50-373 Separation and connection of track shoe assembly (PLUS type track shoes) ........................50-378 Overall disassembly and assembly of track shoe (standard type track shoe) ........................ 50-380 Overall disassembly and assembly of track shoe (PLUS type track shoe)............................. 50-394 ............................. 50-407 .................................50-416 Removal and installation of pivot shaft assembly ................................................................... 50-424 Removal and installation of equalizer bar assembly ............................................................... 50-427 Disassembly and assembly of equalizer bar side bushing ..................................................... 50-432 Hydraulic system ............................................................................................................................ 50-434 Removal and installation of hydraulic tank assembly ............................................................. 50-434 Removal and installation of control valve assembly ............................................................... 50-442 Disassembly and assembly of control valve ........................................................................... 50-458 Disassembly and assembly of blade PPC valve ..................................................................... 50-460 Disassembly and assembly of ripper PPC valve .................................................................... 50-462 Removal and installation of HSS pump and cooling fan pump assembly............................... 50-464 Removal and installation of steering lubrication pump and power train pump assembly ....... 50-469 Removal and installation of scavenging pump assembly ........................................................50-474 Removal and installation of HSS motor assembly .................................................................. 50-477 Disassembly and assembly of hydraulic cylinder.................................................................... 50-482 Work equipment ............................................................................................................................. 50-490 Removal and installation of blade assembly (ST-TPP dozer) ................................................. 50-490 Removal and installation of blade assembly (PAT dozer) ....................................................... 50-496 Removal and installation of ripper assembly .......................................................................... 50-502 Cab and its attachments ................................................................................................................ 50-508 Removal and installation of ROPS cab assembly................................................................... 50-508 Removal and installation of operator’s cab glass (adhered window glass) ............................. 50-525 Removal and installation of operator’s seat assembly ............................................................ 50-532 Removal and installation of seat belt assembly ...................................................................... 50-535 Removal and installation of air conditioner unit assembly ...................................................... 50-538 Removal and installation of air conditioner compressor assembly ..........................................50-551 Electrical system ............................................................................................................................ 50-555 Removal and installation of machine monitor assembly ......................................................... 50-555 Removal and installation of engine controller assembly ......................................................... 50-560 Removal and installation of power train controller assembly .................................................. 50-563 ........................................ 50-566 Removal and installation of KOMTRAX terminal .................................................................... 50-569 60 Maintenance standard ...........................................................................................................................60-1 Table of contents ................................................................................................................................60-2 Engine and cooling system ................................................................................................................ 60-3 Engine mount ............................................................................................................................. 60-3 Damper ....................................................................................................................................... 60-4 Cooling system .......................................................................................................................... 60-6 Cooling fan pump .........................................................................................................................60-7 Cooling fan motor ......................................................................................................................60-10 Power train .......................................................................................................................................60-12
00 Index and foreword
Index
Procedure for testing and troubleshooting .................................................................................80-24 Circuit diagram and arrangement of connector pins ..................................................................80-26 System diagram .........................................................................................................................80-28 Input and output signals of the air conditioner controller ...........................................................80-29 Layout of air conditioner related parts and connectors..............................................................80-31 Testing air leakage (duct) .......................................................................................................... 80-40 Testing with self-diagnosis function .......................................................................................... 80-43 How to open the electrical system abnormality record screen in service mode of the machine monitor ........................................................................................................................ 80-44 Testing vent (mode) changeover ............................................................................................... 80-46 Testing FRESH/RECIRC air changeover .................................................................................. 80-47 Testing sunlight sensor ............................................................................................................. 80-48 Testing (dual) pressure switch for refrigerant ............................................................................ 80-49 Testing relays ............................................................................................................................ 80-50 Troubleshooting chart 1 .............................................................................................................80-51 Troubleshooting chart 2 ............................................................................................................ 80-52 Information in troubleshooting table.......................................................................................... 80-55 Failure code list related to air conditioner ................................................................................. 80-56 Failure code [879AKA] A/C Inner Sensor Open Circuit .......................................................... 80-57 Failure code [879AKB] A/C Inner Sensor Short Circuit ........................................................... 80-58 Failure code [879BKA] A/C Outer sensor Open Circuit ........................................................... 80-59 Failure code [879BKB] A/C Outer sensor Short Circuit ............................................................ 80-61 Failure code [879CKA] Ventilating Sensor Open Circuit ......................................................... 80-63 Failure code [879CKB] Ventilating Sensor Short Circuit .......................................................... 80-64 Failure code [879DKZ] Sunlight sensor Open or Short Circuit ................................................. 80-65 Failure code [879EMC] Ventilation Damper Abnormality ....................................................... 80-67 Failure code [879FMC] Air Mix Damper Abnormality .............................................................. 80-68 Failure code [879GKX] Refrigerant Abnormality ..................................................................... 80-69 A-1 Troubleshooting for power supply system (Air conditioner does not operate) ................... 80-70 A-2 Troubleshooting for compressor system (Air is not cooled) ...............................................80-72 abnormal) .................................................................................................................. 80-75 A-4 Troubleshooting for FRESH/RECIRC air changeover ...................................................... 80-77 Troubleshooting with gauge pressure .......................................................................................80-79 Connection of service tool ....................................................................................................... 80-82 Precautions for disconnecting and connecting air conditioner piping....................................... 80-84 Handling of compressor oil ....................................................................................................... 80-86 90 Diagrams and drawings ........................................................................................................................90-1 Table of contents .................................................................................................................................90-2 Hydraulic circuit diagram .................................................................................................................... 90-3 Symbols in hydraulic circuit diagram........................................................................................... 90-3 Power train hydraulic circuit diagram ...........................................................................................90-7 Hydraulic circuit diagram ............................................................................................................. 90-9 Electric circuit diagram ......................................................................................................................90-21 Symbols in electric circuit diagram ............................................................................................90-21 Electrical circuit diagram ............................................................................................................90-25 Electric circuit diagram for air conditioner unit ...........................................................................90-51 Wiring harness diagram ............................................................................................................ 90-53 Index ................................................................................................................................................................1
00-14
D65EX,PX,WX-17
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