BULLDOZER
SERIALNUMBERS
D65EX-1001
D65PX-1001
D65WX-1001 andup
Writingcompensationamountforsootaccumulationcausedbyashonengine controller.....................................................................................................................30-46
Powertrain.......................................................................................................................................30-48
Measuringpowertrainoilpressure...........................................................................................30-48
Adjustingtransmissionoutputshaftspeedsensor(replacementprocedure)...........................30-53
Simpletestprocedureforbrakeperformance..........................................................................30-54
Adjustingbrakepedal...............................................................................................................30-55
Adjustingparkingbrakelever....................................................................................................30-57
Retrievalofdisabledmachineusingbrakereleasedevice.......................................................30-59
Undercarriageandframe.................................................................................................................30-62
Adjustingidlerclearance...........................................................................................................30-62
Checkingsprocketwear............................................................................................................30-63
Testingandadjustingtracktension...........................................................................................30-64
Hydraulicsystem..............................................................................................................................30-65
Releasingremainingpressureinworkequipmentcylinder......................................................30-65
MeasuringandadjustingworkequipmentandHSSoilpressure.............................................30-66
Measuringsourcepressureofcontrolcircuit............................................................................30-69
MeasuringPPCvalveoutputpressure......................................................................................30-70
AdjustingplayofworkequipmentPPCvalve.............................................................................30-73
Isolatingthepartscausinghydraulicdriftinbladeandripper...................................................30-75
Measureinternaloilleakageofworkequipmentcylinder..........................................................30-76
Checkingfanspeed...................................................................................................................30-77
Measuringfancircuitoilpressure..............................................................................................30-78
Bleedingairfromhydrauliccircuit..............................................................................................30-79
Workequipment...............................................................................................................................30-81
Adjustingworkequipmentlocklever.........................................................................................30-81
Adjustmentofstraighttiltdozer.................................................................................................30-82
Cabanditsattachments..................................................................................................................30-84
Adjustingoperator’scab...........................................................................................................30-84
Adjustingplayofbladecenterball............................................................................................30-87
Electricalsystem..............................................................................................................................30-88
Specialfunctionsofmachinemonitor.......................................................................................30-88
Handlingvoltagecircuitofenginecontroller............................................................................30-150
Adjustmentmethodwhencontrollerhasbeenreplaced..........................................................30-151
Testingdiodes..........................................................................................................................30-153
Pmclinic..........................................................................................................................................30-154
PmClinicservice.....................................................................................................................30-154
PmClinicchecksheet..............................................................................................................30-160
40Troubleshooting.....................................................................................................................................40-1
Tableofcontents.................................................................................................................................40-2
Relatedinformationontroubleshooting.............................................................................................40-9
Troubleshootingpoints................................................................................................................40-9
Sequenceofeventsintroubleshooting......................................................................................40-11
Checkbeforetroubleshooting....................................................................................................40-13
Inspectionprocedurebeforetroubleshooting............................................................................40-15
Preparationfortroubleshootingofelectricalsystem.................................................................40-35 ....................................................................40-39 .....................................................40-41
Informationintroubleshootingtable..........................................................................................40-44
Troubleshootingmethodforopencircuitinwiringharnessofpressuresensorsystem...........40-46
Connector/electricalwiringconnectiontable............................................................................40-48
Layoutofconnector.................................................................................................................40-111 ..............................................................................................40-118
T-branchboxandT-branchadaptertable................................................................................40-157 Fuselocationstable.................................................................................................................40-162
PrecautionsforKDPF(KCSFandKDOC)CleaningandReplacement..................................40-165
Preparationofdummytemperaturesensor (forKDOCandKDPFtemperaturesensors).............................................................40-168
Preparationofshortcircuitelectricalconnector (forfailurecodes[CA1883]and[CA3135])................................................................40-169
This is the sample of the manual if you need complete manual Click Here to download
Failurecodestable...................................................................................................................40-170
Troubleshootingbyfailurecode(Displayofcode)..........................................................................40-181
Failurecode[1500L0]..............................................................................................................40-181
Failurecode[15SAL1]..............................................................................................................40-182
Failurecode[15SALH].............................................................................................................40-184
Failurecode[15SBL1]..............................................................................................................40-186
Failurecode[15SBLH].............................................................................................................40-188
Failurecode[15SEL1]..............................................................................................................40-190
Failurecode[15SELH].............................................................................................................40-192
Failurecode[15SFL1]..............................................................................................................40-194
Failurecode[15SFLH].............................................................................................................40-196
Failurecode[15SGL1]..............................................................................................................40-198
Failurecode[15SGLH]............................................................................................................40-200
Failurecode[15SJL1]...............................................................................................................40-202
Failurecode[15SJLH].............................................................................................................40-204
Failurecode[1800MW]...........................................................................................................40-206
Failurecode[879AKA]............................................................................................................40-208
Failurecode[879AKB]............................................................................................................40-209
Failurecode[879BKA].............................................................................................................40-210
Failurecode[879BKB].............................................................................................................40-211
Failurecode[879CKA].............................................................................................................40-212
Failurecode[879CKB].............................................................................................................40-213
Failurecode[879DKZ].............................................................................................................40-214
Failurecode[879EMC]............................................................................................................40-215
Failurecode[879FMC].............................................................................................................40-216
Failurecode[879GKX]............................................................................................................40-217
Failurecode[989L00]..............................................................................................................40-218
Failurecode[989M00].............................................................................................................40-219
Failurecode[989N00].............................................................................................................40-220
Failurecode[A1U0N3].............................................................................................................40-221
Failurecode[A1U0N4].............................................................................................................40-224
Failurecode[AA10NX]............................................................................................................40-227
Failurecode[AB00KE]...........................................................................................................40-229
Failurecode[B@BAZG]..........................................................................................................40-231
Failurecode[B@BCNS]..........................................................................................................40-232
Failurecode[B@CENS]..........................................................................................................40-233
Failurecode[B@HANS].........................................................................................................40-234
Failurecode[CA115]................................................................................................................40-235
Failurecode[CA122]...............................................................................................................40-236
Failurecode[CA123]................................................................................................................40-239
Failurecode[CA131]................................................................................................................40-242
Failurecode[CA132]................................................................................................................40-245
Failurecode[CA144]................................................................................................................40-248
Failurecode[CA145]................................................................................................................40-251
Failurecode[CA153]...............................................................................................................40-254
Failurecode[CA154]................................................................................................................40-257
Failurecode[CA187]...............................................................................................................40-260
Failurecode[CA221]...............................................................................................................40-263
Failurecode[CA222]...............................................................................................................40-267
Failurecode[CA227]...............................................................................................................40-270
Failurecode[CA234]...............................................................................................................40-271
Failurecode[CA238]...............................................................................................................40-273
Failurecode[CA239]...............................................................................................................40-275
Failurecode[CA271]................................................................................................................40-277
Failurecode[CA272]...............................................................................................................40-280
Failurecode[CA281]...............................................................................................................40-283
Failurecode[CA295]..............................................................................................................40-284
Failurecode[CA322]...............................................................................................................40-285
Failurecode[CA323]...............................................................................................................40-288
Failurecode[CA324]...............................................................................................................40-291 Failurecode[CA325]..............................................................................................................40-294 Failurecode[CA331]................................................................................................................40-297 Failurecode[CA332]..............................................................................................................40-300 Failurecode[CA343]..............................................................................................................40-303 Failurecode[CA351]...............................................................................................................40-304 Failurecode[CA352]..............................................................................................................40-305 Failurecode[CA356]..............................................................................................................40-307 Failurecode[CA357]...............................................................................................................40-310 Failurecode[CA386]...............................................................................................................40-314 Failurecode[CA428]...............................................................................................................40-315 Failurecode[CA429]...............................................................................................................40-317 Failurecode[CA435]..............................................................................................................40-320 Failurecode[CA441]...............................................................................................................40-322 Failurecode[CA442]..............................................................................................................40-325 Failurecode[CA449]..............................................................................................................40-326 Failurecode[CA451]...............................................................................................................40-330 Failurecode[CA452]..............................................................................................................40-333 Failurecode[CA488]..............................................................................................................40-336 Failurecode[CA515]...............................................................................................................40-337 Failurecode[CA516]...............................................................................................................40-339 Failurecode[CA553]..............................................................................................................40-342 Failurecode[CA555]..............................................................................................................40-343 Failurecode[CA556]..............................................................................................................40-344 Failurecode[CA559]..............................................................................................................40-346 Failurecode[CA595]...............................................................................................................40-351 Failurecode[CA687]..............................................................................................................40-352 Failurecode[CA689]..............................................................................................................40-355 Failurecode[CA691]................................................................................................................40-361 Failurecode[CA692]..............................................................................................................40-364 Failurecode[CA697]..............................................................................................................40-367 Failurecode[CA698]..............................................................................................................40-368 Failurecode[CA731]...............................................................................................................40-369 Failurecode[CA778]...............................................................................................................40-372 Failurecode[CA1117]..............................................................................................................40-378 Failurecode[CA1664]..............................................................................................................40-379 Failurecode[CA1691].............................................................................................................40-383 Failurecode[CA1695].............................................................................................................40-387 Failurecode[CA1696].............................................................................................................40-389 Failurecode[CA1843]..............................................................................................................40-391 Failurecode[CA1844].............................................................................................................40-394 Failurecode[CA1879].............................................................................................................40-397 Failurecode[CA1881].............................................................................................................40-400 Failurecode[CA1883].............................................................................................................40-403 Failurecode[CA1921].............................................................................................................40-409 Failurecode[CA1922]..............................................................................................................40-412 Failurecode[CA1942]..............................................................................................................40-419 Failurecode[CA1993].............................................................................................................40-421 Failurecode[CA2185]............................................................................................................40-425 Failurecode[CA2186]............................................................................................................40-427 Failurecode[CA2249]............................................................................................................40-429 Failurecode[CA2265]............................................................................................................40-430 Failurecode[CA2266]............................................................................................................40-433 Failurecode[CA2271].............................................................................................................40-436 Failurecode[CA2272]............................................................................................................40-440 Failurecode[CA2288]............................................................................................................40-445 Failurecode[CA2311].............................................................................................................40-446 Failurecode[CA2349]............................................................................................................40-447 Failurecode[CA2353].............................................................................................................40-451
Failurecode[CA2357]............................................................................................................40-454
Failurecode[CA2373]............................................................................................................40-457
Failurecode[CA2374].............................................................................................................40-460
Failurecode[CA2375]............................................................................................................40-463
Failurecode[CA2376]............................................................................................................40-466
Failurecode[CA2381]...........................................................................................................40-469
Failurecode[CA2382].............................................................................................................40-472
Failurecode[CA2383].............................................................................................................40-476
Failurecode[CA2386]............................................................................................................40-480
Failurecode[CA2387]............................................................................................................40-483
Failurecode[CA2554]............................................................................................................40-486
Failurecode[CA2555]............................................................................................................40-490
Failurecode[CA2556]............................................................................................................40-493
Failurecode[CA2637]............................................................................................................40-496
Failurecode[CA2639]............................................................................................................40-500
Failurecode[CA2961]............................................................................................................40-503
Failurecode[CA2973]............................................................................................................40-504
Failurecode[CA3133].............................................................................................................40-505
Failurecode[CA3134].............................................................................................................40-508
Failurecode[CA3135]..............................................................................................................40-511 Failurecode[CA3251]..............................................................................................................40-517 Failurecode[CA3253]............................................................................................................40-522 Failurecode[CA3254]............................................................................................................40-526 Failurecode[CA3255]............................................................................................................40-531 Failurecode[CA3256]............................................................................................................40-536 Failurecode[CA3311]..............................................................................................................40-541 Failurecode[CA3312].............................................................................................................40-546 Failurecode[CA3313]..............................................................................................................40-551 Failurecode[CA3314].............................................................................................................40-556 Failurecode[CA3315].............................................................................................................40-562 Failurecode[CA3316]............................................................................................................40-570 Failurecode[CA3317]..............................................................................................................40-575 Failurecode[CA3318].............................................................................................................40-581 Failurecode[CA3319].............................................................................................................40-589 Failurecode[CA3321].............................................................................................................40-595 Failurecode[CA3322]............................................................................................................40-600 Failurecode[CA3419].............................................................................................................40-608
Failurecode[CA3421]..............................................................................................................40-610 Failurecode[CA3741]..............................................................................................................40-613 Failurecode[D130KA].............................................................................................................40-614 Failurecode[D130KB].............................................................................................................40-617 Failurecode[D19DKA]...........................................................................................................40-620
Failurecode[D19DKB]...........................................................................................................40-623
Failurecode[D19JKZ]............................................................................................................40-625
Failurecode[D811MC]............................................................................................................40-629
Failurecode[D862KA]...........................................................................................................40-630
Failurecode[D8ALKA]...........................................................................................................40-631
Failurecode[D8ALKB]...........................................................................................................40-633
Failurecode[D8AQKR]..........................................................................................................40-635
Failurecode[DAF0MB]...........................................................................................................40-637
Failurecode[DAF0MC]..........................................................................................................40-638
Failurecode[DAF8KB]...........................................................................................................40-639
Failurecode[DAF9KQ]............................................................................................................40-641
Failurecode[DAFGMC]..........................................................................................................40-642
Failurecode[DAFLKA]...........................................................................................................40-643
Failurecode[DAFLKB]...........................................................................................................40-645
Failurecode[DAFQKR]..........................................................................................................40-647
Failurecode[DAZ9KQ]...........................................................................................................40-648
Failurecode[DAZQKR]..........................................................................................................40-649
Failurecode[DB2QKR]..........................................................................................................40-656 Failurecode[DB2RKR]...........................................................................................................40-663 Failurecode[DBE0KT]...........................................................................................................40-670 Failurecode[DBE1KK]............................................................................................................40-671 Failurecode[DBE2KK]...........................................................................................................40-675 Failurecode[DBE5KK]...........................................................................................................40-679 Failurecode[DBE6KK]...........................................................................................................40-682 Failurecode[DBE7KK]...........................................................................................................40-684 Failurecode[DBE9KQ]...........................................................................................................40-686 Failurecode[DBELKA]...........................................................................................................40-687 Failurecode[DBELKB]...........................................................................................................40-689 Failurecode[DBEQKR]..........................................................................................................40-691 Failurecode[DBERKR]..........................................................................................................40-693 Failurecode[DD12KA]...........................................................................................................40-695 Failurecode[DD12KB]...........................................................................................................40-697 Failurecode[DD13KA]...........................................................................................................40-699 Failurecode[DD13KB]............................................................................................................40-701 Failurecode[DD14KA]............................................................................................................40-703 Failurecode[DD14KB]............................................................................................................40-705 Failurecode[DDKFL4]............................................................................................................40-707 Failurecode[DDKGL4]............................................................................................................40-710 Failurecode[DDKHKA]...........................................................................................................40-713 Failurecode[DDKHKB]...........................................................................................................40-715 Failurecode[DDN7KA]...........................................................................................................40-717 Failurecode[DDN7KB]............................................................................................................40-719 Failurecode[DDNLKA]...........................................................................................................40-721 Failurecode[DDNLKB]............................................................................................................40-723 Failurecode[DGS1KA]............................................................................................................40-725 Failurecode[DGS1KX]............................................................................................................40-726 Failurecode[DGT1KA]............................................................................................................40-729 Failurecode[DGT1KX]............................................................................................................40-730 Failurecode[DH21KA]............................................................................................................40-733 Failurecode[DH21KB]............................................................................................................40-736 Failurecode[DHA4KA]............................................................................................................40-739 Failurecode[DHTDKA]...........................................................................................................40-741 Failurecode[DHTDKB]...........................................................................................................40-744 Failurecode[DK10KA].............................................................................................................40-747 Failurecode[DK10KB].............................................................................................................40-750 Failurecode[DK30KA]............................................................................................................40-753 Failurecode[DK30KB]............................................................................................................40-757 Failurecode[DK30KX]............................................................................................................40-760 Failurecode[DK30KZ]............................................................................................................40-761 Failurecode[DK30L8].............................................................................................................40-762 Failurecode[DK31KA].............................................................................................................40-763 Failurecode[DK31KB].............................................................................................................40-767 Failurecode[DK40KA]............................................................................................................40-770 Failurecode[DK40KB]............................................................................................................40-773 Failurecode[DK55KX]............................................................................................................40-776 Failurecode[DK55KZ]............................................................................................................40-777 Failurecode[DK55L8].............................................................................................................40-778 Failurecode[DK56KA]............................................................................................................40-779 Failurecode[DK56KB]............................................................................................................40-783 Failurecode[DK57KA]............................................................................................................40-786 Failurecode[DK57KB]............................................................................................................40-790 Failurecode[DKH1KA]............................................................................................................40-793 Failurecode[DKH1KB]............................................................................................................40-796 Failurecode[DLM3KA]............................................................................................................40-799 Failurecode[DLM3MB]..........................................................................................................40-801 Failurecode[DLT3KA]............................................................................................................40-802
Failurecode[DLT3KB]............................................................................................................40-805
Failurecode[DR21KX]...........................................................................................................40-807
Failurecode[DR31KX]...........................................................................................................40-808
Failurecode[DV20KB]...........................................................................................................40-809
Failurecode[DW5AKA]...........................................................................................................40-811
Failurecode[DW5AKB]...........................................................................................................40-813
Failurecode[DW5AKY]...........................................................................................................40-815
Failurecode[DW7BKA]...........................................................................................................40-818
Failurecode[DW7BKB]..........................................................................................................40-820
Failurecode[DWN1KA]..........................................................................................................40-822
Failurecode[DWN1KB]..........................................................................................................40-824
Failurecode[DWN1KY]..........................................................................................................40-826
Failurecode[DWN2KA]..........................................................................................................40-829
Failurecode[DWN2KB]..........................................................................................................40-831
Failurecode[DWN2KY].........................................................................................................40-833
Failurecode[DWN5KA]..........................................................................................................40-836
Failurecode[DWN5KB]..........................................................................................................40-838
Failurecode[DWN5KY].........................................................................................................40-840
Failurecode[DXA2KA]...........................................................................................................40-843
Failurecode[DXA2KB]...........................................................................................................40-845
Failurecode[DXA2KY]...........................................................................................................40-847
Failurecode[DXH1KA]...........................................................................................................40-850
Failurecode[DXH1KB]...........................................................................................................40-852
Failurecode[DXH1KY]...........................................................................................................40-854
Failurecode[DXH4KA]...........................................................................................................40-857
Failurecode[DXH4KB]...........................................................................................................40-859
Failurecode[DXH4KY]...........................................................................................................40-861
Failurecode[DXH5KA]...........................................................................................................40-864
Failurecode[DXH5KB]...........................................................................................................40-866
Failurecode[DXH5KY]...........................................................................................................40-868
Failurecode[DXH6KA]............................................................................................................40-871
Failurecode[DXH6KB]...........................................................................................................40-873
Failurecode[DXH6KY]...........................................................................................................40-875
Failurecode[DXH7KA]...........................................................................................................40-878
Failurecode[DXH7KB]...........................................................................................................40-880
Failurecode[DXH7KY]...........................................................................................................40-882
Failurecode[DXH8KA]...........................................................................................................40-885
Failurecode[DXH8KB]...........................................................................................................40-887
Failurecode[DXH8KY]...........................................................................................................40-889
Failurecode[DXJ4KA]............................................................................................................40-892
Failurecode[DXJ4KB]............................................................................................................40-894
Failurecode[DXJCKA]...........................................................................................................40-896
Failurecode[DXJCKB]...........................................................................................................40-898
Failurecode[DXJCKY]...........................................................................................................40-900
Failurecode[DXJDKA]...........................................................................................................40-902
Failurecode[DXJDKB]...........................................................................................................40-904
Failurecode[DXJDKY]...........................................................................................................40-906
Troubleshootingofelectricalsystem(E-mode)..............................................................................40-908
E-1Enginedoesnotstart(Enginedoesnotcrank)................................................................40-908
E-2Manualpreheatingdoesnotwork.....................................................................................40-914
E-3Automaticpreheatingdoesnotwork.................................................................................40-917
E-4Whilepreheatingisworking,preheatingmonitordoesnotlightup...................................40-919
E-5WhenstartingswitchisturnedtoONposition,machinemonitordisplaysnothing...........40-921
E-6WhenstartingswitchisturnedtoONposition(withenginestopped),basiccheck monitorlightsup.......................................................................................................40-924
E-7Aircleanercloggingmonitorlightsupinyellowwhileengineisrunning..........................40-925
E-8Chargelevelmonitorlightsupinredwhileengineisrunning..........................................40-926
E-9Enginecoolanttemperaturemonitorlightsupwhileengineisrunning............................40-928
E-10Engineoilpressuremonitorlightsupinredwhileengineisrunning..............................40-929
E-11Powertrainoiltemperaturemonitorlightsupwhileengineisrunning............................40-930
E-12Hydraulicoiltemperaturemonitorlightsupwhileengineisrunning................................40-931
E-13Enginecoolanttemperaturegaugedoesnotindicatecorrecttemparature....................40-932
E-14Fuellevelgaugedoesnotindicatecorrectlevel.............................................................40-933
E-15Powertrainoiltemperaturegaugedoesnotindicatecorrecttemperature.....................40-935
E-16Hydraulicoiltemperaturegaugedoesnotindicatecorrecttemperature........................40-936
E-17Operationmodedoesnotchange..................................................................................40-937
E-18Gearshiftmodedoesnotchange...................................................................................40-938
E-19Operatingcustomizeswitchdoesnotdisplaycustomizescreen....................................40-939
E-20Modifyingsettingoncustomizescreendoesnotchangesettingofmachine................40-940
E-21Reverseslowmodedoesnotfunctionproperly..............................................................40-941
E-22Alarmbuzzerdoesnotsoundordoesnotstopsounding..............................................40-942
E-23WhilestartingswitchisinOFFposition,servicemeterisnotdisplayed........................40-943
E-24Servicemodecannotbeselected..................................................................................40-944
E-25Horndoesnotsound......................................................................................................40-945
E-26Horndoesnotstopsounding.........................................................................................40-946
E-27Backupalarmdoesnotsound........................................................................................40-947
E-28Backupalarmdoesnotstopsounding...........................................................................40-949
E-29Headlampdoesnotlightup............................................................................................40-950
E-30Rearlampdoesnotlightup...........................................................................................40-953
E-31Nowiperoperatescontinuouslyorintermittently...........................................................40-955
E-32Frontwiperdoesnotoperate(Failureinbothcontinuousandintermittent operations)................................................................................................................40-958
E-33Rearwiperdoesnotoperate(Failureinbothcontinuousandintermittent operations)................................................................................................................40-961
E-34Leftdoorwiperdoesnotoperate(Failureofbothcontinuousandintermittent operations)................................................................................................................40-964
E-35Rightdoorwiperdoesnotoperate(Failureofbothcontinuousandintermittent operations)................................................................................................................40-967
E-36KOMTRAXsystemdoesnotoperateproperly................................................................40-970 Troubleshootingofhydraulicandmechanicalsystem(H-mode)...................................................40-972 Informationdescribedintroubleshootingtable(H-mode)........................................................40-972 Systemdiagramofhydraulicandmechanicalsystem.............................................................40-973 ListofFailureModeandCause...............................................................................................40-975 ................................................................40-978
H-2Machinecannottravel(at2ndor3rdspeed)...................................................................40-980
H-3Machinedoesnotstartatallgearspeeds.......................................................................40-981
H-4Machinetravelsonlyinonedirection,eitherforwardorinreverse.................................40-982
H-5Largetimelagatgearshiftingordirectionalselection....................................................40-983
H-6Machinecannotbesteered(machinedoesnotturnleftorright)....................................40-984 ............................................................................40-985
H-8Brakedoesnotoperate....................................................................................................40-986
H-9Torqueconverterdoesnotlockup..................................................................................40-987
H-10Powertrainoiloverheats................................................................................................40-988
H-11UnusualnoiseisheardfromaroundHSSandworkequipmentpumporHSSmotor....40-989
H-12Allworkequipmentoperatesslowly...............................................................................40-990
H-13Allworkequipmentdoesnotoperate.............................................................................40-991
H-14Bladeliftspeedorpowerislow......................................................................................40-992
H-15Bladetiltspeedorpowerislow......................................................................................40-993
H-16Bladeanglespeedorpowerislow.................................................................................40-994
H-17Ripperliftspeedorpowerislow....................................................................................40-995
H-18Hydraulicdriftofliftedbladeislarge..............................................................................40-996
H-19Hydraulicdriftoftiltedbladeislarge..............................................................................40-997
H-20Hydraulicdriftofliftedripperislarge.............................................................................40-998
H-21Fanspeedisabnormal(high,low,ornorotation)..........................................................40-999
H-22Unusualnoiseisheardfromaroundfan.......................................................................40-1001 Troubleshootingofengine(S-mode).............................................................................................40-1002
Informationmentionedintroubleshootingtable(Smode).....................................................40-1002
S-1EnginedoesnotcrankwhenstartingswitchisturnedtoSTARTposition......................40-1003
S-2Theenginecranksbutexhaustsmokedoesnotcomeout.............................................40-1004
S-3Fuelisbeinginjectedbutenginedoesnotstart(incompletecombustion:enginecranks butdoesnotstart)....................................................................................................40-1005
S-4Startabilityispoor...........................................................................................................40-1006
S-5Enginedoesnotpickupsmoothly..................................................................................40-1008
S-6Enginestopsduringoperation........................................................................................40-1010
S-7Enginerunsroughorisunstable....................................................................................40-1012
S-8Enginelackspower.........................................................................................................40-1013
S-9KDPFgetscloggedinashorttime.................................................................................40-1015
S-10Engineoilconsumptionisexcessive.............................................................................40-1017
S-11Engineoilbecomescontaminatedearly........................................................................40-1018
S-12Fuelconsumptionisexcessive......................................................................................40-1019
S-13Oilisincoolant(orcoolantspurtsorcoolantlevelgoesdown)....................................40-1020
S-14Oilpressuredrops.........................................................................................................40-1021
S-15Fuelmixesintoengineoil..............................................................................................40-1022
S-16Watermixesintoengineoil(milky)................................................................................40-1023
S-17Coolanttemperaturerisestoohigh(overheating).........................................................40-1024
S-18Unusualnoiseisheard..................................................................................................40-1025
S-19Vibrationisexcessive....................................................................................................40-1026
S-20Aircannotbebledfromfuelcircuit................................................................................40-1027
S-21Frequentactiveregeneration........................................................................................40-1028
S-22Activeregenerationtakestime......................................................................................40-1029
S-23Whitesmokeisexhaustedduringactiveregeneration..................................................40-1030
50Disassemblyandassembly...................................................................................................................50-1
Tableofcontents.................................................................................................................................50-2
Relatedinformationondisassemblyandassembly...........................................................................50-4
Howtoreadthismanual.............................................................................................................50-4
Coatingmaterialslist...................................................................................................................50-6
Specialtoollist...........................................................................................................................50-10
Sketchesofspecialtools............................................................................................................50-21
Engineandcoolingsystem..............................................................................................................50-36
Removalandinstallationoffuelsupplypumpassembly..........................................................50-36
Removalandinstallationoffuelinjectorassembly...................................................................50-46
Removalandinstallationofcylinderheadassembly................................................................50-67
Removalandinstallationofradiatorassembly..........................................................................50-98
Removalandinstallationofaftercoolerassembly...................................................................50-110
Removalandinstallationofhydraulicoilcoolerassembly.......................................................50-116
Removalandinstallationofpowertrainoilcoolerassembly...................................................50-121
Removalandinstallationofcoolingfandriveassembly..........................................................50-128
Removalandinstallationofcoolingfanmotorassembly.........................................................50-133
Removalandinstallationofengineassembly..........................................................................50-136
Removalandinstallationofdamperassembly........................................................................50-159
Removalandinstallationofenginefrontoilseal......................................................................50-165
Removalandinstallationofenginerearoilseal.......................................................................50-172
Removalandinstallationofenginehoodassembly.................................................................50-185
Removalandinstallationoffueltankassembly.......................................................................50-190
RemovalandinstallationofKDPFcover..................................................................................50-195
RemovalandinstallationofKDPFassembly...........................................................................50-198
DisassemblyandassemblyofKDPF......................................................................................50-206
RemovalandinstallationofKCCVassembly...........................................................................50-216
Removalandinstallationofaircleanerassembly....................................................................50-219
Powertrain.....................................................................................................................................50-222
Removalandinstallationofpowertrainunitassembly...........................................................50-222
Disconnectingandconnectingofpowertrainunitassembly..................................................50-233
DisassemblyandassemblyofPTO........................................................................................50-239
Disassemblyandassemblyoftorqueconverter......................................................................50-245
DisassemblyandassemblyofTORQFLOWtransmission......................................................50-258
DisassemblyandassemblyofHSS........................................................................................50-288 .....................................................................50-312 .................................................................................50-317
Undercarriageandframe...............................................................................................................50-334
Removalandinstallationoftrackframeassembly.................................................................50-334 Removalandinstallationofidlerassembly.............................................................................50-339 Disassemblyandassemblyofidler........................................................................................50-342 Removalandinstallationofrecoilspringassembly................................................................50-348 Disassemblyandassemblyofrecoilspring.............................................................................50-351 Removalandinstallationoftrackrollerassembly...................................................................50-356 Disassemblyandassemblyoftrackroller..............................................................................50-360 Removalandinstallationofcarrierrollerassembly................................................................50-366 Disassemblyandassemblyofcarrierroller............................................................................50-369
Separationandconnectionoftrackshoeassembly(normaltrackshoes)..............................50-373 Separationandconnectionoftrackshoeassembly(PLUStypetrackshoes)........................50-378
Overalldisassemblyandassemblyoftrackshoe(standardtypetrackshoe)........................50-380
Overalldisassemblyandassemblyoftrackshoe(PLUStypetrackshoe).............................50-394 .............................50-407 .................................50-416
Removalandinstallationofpivotshaftassembly...................................................................50-424 Removalandinstallationofequalizerbarassembly...............................................................50-427 Disassemblyandassemblyofequalizerbarsidebushing.....................................................50-432 Hydraulicsystem............................................................................................................................50-434
Removalandinstallationofhydraulictankassembly.............................................................50-434 Removalandinstallationofcontrolvalveassembly...............................................................50-442 Disassemblyandassemblyofcontrolvalve...........................................................................50-458 DisassemblyandassemblyofbladePPCvalve.....................................................................50-460 DisassemblyandassemblyofripperPPCvalve....................................................................50-462 RemovalandinstallationofHSSpumpandcoolingfanpumpassembly...............................50-464 Removalandinstallationofsteeringlubricationpumpandpowertrainpumpassembly.......50-469 Removalandinstallationofscavengingpumpassembly........................................................50-474 RemovalandinstallationofHSSmotorassembly..................................................................50-477
Disassemblyandassemblyofhydrauliccylinder....................................................................50-482
Workequipment.............................................................................................................................50-490
Removalandinstallationofbladeassembly(ST-TPPdozer).................................................50-490 Removalandinstallationofbladeassembly(PATdozer).......................................................50-496 Removalandinstallationofripperassembly..........................................................................50-502 Cabanditsattachments................................................................................................................50-508 RemovalandinstallationofROPScabassembly...................................................................50-508 Removalandinstallationofoperator’scabglass(adheredwindowglass).............................50-525 Removalandinstallationofoperator’sseatassembly............................................................50-532 Removalandinstallationofseatbeltassembly......................................................................50-535 Removalandinstallationofairconditionerunitassembly......................................................50-538 Removalandinstallationofairconditionercompressorassembly..........................................50-551 Electricalsystem............................................................................................................................50-555 Removalandinstallationofmachinemonitorassembly.........................................................50-555 Removalandinstallationofenginecontrollerassembly.........................................................50-560 Removalandinstallationofpowertraincontrollerassembly..................................................50-563 ........................................50-566
RemovalandinstallationofKOMTRAXterminal....................................................................50-569
Procedurefortestingandtroubleshooting.................................................................................80-24
Circuitdiagramandarrangementofconnectorpins..................................................................80-26
Systemdiagram.........................................................................................................................80-28
Inputandoutputsignalsoftheairconditionercontroller...........................................................80-29
Layoutofairconditionerrelatedpartsandconnectors..............................................................80-31
Testingairleakage(duct)..........................................................................................................80-40
Testingwithself-diagnosisfunction..........................................................................................80-43
Howtoopentheelectricalsystemabnormalityrecordscreeninservicemodeofthemachine monitor........................................................................................................................80-44
Testingvent(mode)changeover...............................................................................................80-46
TestingFRESH/RECIRCairchangeover..................................................................................80-47
Testingsunlightsensor.............................................................................................................80-48
Testing(dual)pressureswitchforrefrigerant............................................................................80-49
Testingrelays............................................................................................................................80-50
Troubleshootingchart1.............................................................................................................80-51
Troubleshootingchart2............................................................................................................80-52
Informationintroubleshootingtable..........................................................................................80-55
Failurecodelistrelatedtoairconditioner.................................................................................80-56
Failurecode[879AKA]A/CInnerSensorOpenCircuit..........................................................80-57 Failurecode[879AKB]A/CInnerSensorShortCircuit...........................................................80-58
Failurecode[879BKA]A/COutersensorOpenCircuit...........................................................80-59 Failurecode[879BKB]A/COutersensorShortCircuit............................................................80-61
Failurecode[879CKA]VentilatingSensorOpenCircuit.........................................................80-63
Failurecode[879CKB]VentilatingSensorShortCircuit..........................................................80-64
Failurecode[879DKZ]SunlightsensorOpenorShortCircuit.................................................80-65
Failurecode[879EMC]VentilationDamperAbnormality.......................................................80-67
Failurecode[879FMC]AirMixDamperAbnormality..............................................................80-68
Failurecode[879GKX]RefrigerantAbnormality.....................................................................80-69
A-1Troubleshootingforpowersupplysystem(Airconditionerdoesnotoperate)...................80-70
A-2Troubleshootingforcompressorsystem(Airisnotcooled)...............................................80-72
abnormal)..................................................................................................................80-75
A-4TroubleshootingforFRESH/RECIRCairchangeover......................................................80-77
Troubleshootingwithgaugepressure.......................................................................................80-79
Connectionofservicetool.......................................................................................................80-82
Precautionsfordisconnectingandconnectingairconditionerpiping.......................................80-84
Handlingofcompressoroil.......................................................................................................80-86
90Diagramsanddrawings........................................................................................................................90-1
Tableofcontents.................................................................................................................................90-2
Hydrauliccircuitdiagram....................................................................................................................90-3
Symbolsinhydrauliccircuitdiagram...........................................................................................90-3
Powertrainhydrauliccircuitdiagram...........................................................................................90-7
Hydrauliccircuitdiagram.............................................................................................................90-9
Electriccircuitdiagram......................................................................................................................90-21
Symbolsinelectriccircuitdiagram............................................................................................90-21
Electricalcircuitdiagram............................................................................................................90-25
Electriccircuitdiagramforairconditionerunit...........................................................................90-51
Wiringharnessdiagram............................................................................................................90-53 Index................................................................................................................................................................1
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