Service manual Komatsu D85EX-15E0, D85PX-15E0 | SEN00060-02

Komatsu D85EX-15E0, D85PX-15E0 SEN00060-02 (Preview)

COVER
00 INDEX AND FOREWORD
INDEX
ORGANIZATION LIST OF THE SHOP MANUAL
TABLE OF CONTENTS
FOREWORD AND GENERAL INFORMATION
SAFETY NOTICE
HOW TO READ THE SHOP MANUAL
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
HANDING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT
HOW TO READ ELECTRIC WIRE CODE
METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER
STANDARD TIGHTENING TORQUE TABLE
CONVERSION TABLE
01 SPECIFICATION
SPECIFIICATION AND TECHNICAL DATA
SPECIFICATION DIMENSIONS
SPECIFICATIONS
WEIGHT TABLE
TABLE OF FUEL, COOLANT AND LUBRICANTS
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE AND COOLING SYSTEM
ENGINE MOUNT
COOLING SYSTEM
COOLING FAN PUMP
COOLING FAN MOTOR
POWER TRAIN, PART 1
POWER TRAIN
HSS SYSTEM
GENERAL VIEW OF POWER TRAIN UNIT
POWER TRAIN HYDRAULIC PIPING DRAWING
TRANSMISSION CONTROL
STEERING AND BRAKE CONTROL
DAMPER AND UNIVERSAL JOINT
TORQUE CONVERTER AND PTO
TRANSMISSION
TRANSMISSION CLUTCH ECMV
MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE
LUBRICATION RELIEF VALVE
POWER TRAIN, PART 2
BEVEL GEAR SHAFT, HSS AND BRAKE
BRAKE VALVE
FINAL DRIVE
UNDERCARRIAGE AND FRAME
MAIN FRAME
SUSPENSION
TRACK FRAME
LDLER CUSHION
LDLER
TRACK ROLLER
CARRIER ROLLER
SPROCKET
TRACK SHOE
HYDRAULIC SYSTEM, PART 1
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM
WORK EQUIPMENT CONTROL
HYDRAULIC TANK AND FILTER
SCAVENGINE PUMP
POWER TRAIN AND STEERING LUBRICATION PUMP
HSS PUMP
HSS MOTOR
HYDRAULIC SYSTEM, PART 2
CONTROL VALVE
SELF PRESSURE REDUCING VALVE
HYDRAULIC SYSTEM, PART 3
OIL COOLER BYPASS VALVE
PPC VALVE
ELEVTRIC LEVER (STRREING)
QUICK DROP VALVE
PPC LOCK VALVE
ACCUMULATOR
WORK EQUIPMENT
CYLINDER STAY
BLADE
CUTTING EDGE AND END BIT
RIPPER
HYDRAULIC CYLINDER
PISTON VALVE
CAB AND ITS ATTACHMENTS
CAB MOUNT
CAB
AIR CONDITIONER
ELECTRICAL SYSTEM
MONITOR SYSTEM
MONITOR PANEL
ENGINE CONTROL
ENGINE CONTROL SYSTEM
SYSTEM COMPONENTS
CRI ENGINE CONTROL SYSTEM
PLAM COMMAND CONTROL SYSTEM
KOMTRAX TERMINAL SYSTEM
SENSOR
20 STANDARD VALUE TABLE
STANDARD SERVICE VALUE TABLE
STANDARD SERVICE VALUE TABLE FOR ENGINE
STANDARD SERVICE VALUE TABLE FOR CHASSIS
30 TESTING AND ADJUSTING
TESTING AND ADJUSTING, PART 1
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
MEASURING ENGINE SPEED
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST GAS COLOR
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
MEASURING BLOW-BY PRESSURE
MEASURING ENGINE OIL PRESSURE
HANDLING OF FUEL SYSTEM DEVICES
RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM
TESTING FUEL PRESSURE
HANDLING OF RESUCED CYLINDER MODE OPERATION
HANDLING OF NO INJECTION CRANKING OPERATION
TESTING FUEL RETURN AND LEAK AMOUNT
BLEEDING AIR FROM FUEL CIRCUIT
TESTING FUEL CIRCUIT FOR LEAKAGE
TESTING AND ADJUSTING ALTERNATOR BELT TENSION
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION
ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL
MEASURING POWER TRAIN OIL PRESSURE
ASJUDTING TRANSMISSION SPEED SENSOR
SIMPLE METHOD TO TEST BRAKE PERFORMANCE
ADJUSTING BRAKE PEDAL
ADJUSTING PARKING BRAKE LEVER
EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE
ADJUSTING CLEARANCE OF IDLER
INSPECTING WEAR OF SPROCKET
TESTING AND ADJUSTING TRACK SHOE TENSION
TESTING AND ADJUSTING WORK EQUIPMENT AND HSS OIL PRESSURE
TESTING CONTROL CIRCUIT BASIC PRESSURE
MEASURING PPC VALVE OUTPUT PRESSURE
ADJUSTING PLAY OF WORK EQUIPMENT PPC VALVE
SHECKING PARTS WHICH CAUSED HYDRAULIC DRIFT OF BLADE AND RIPPER
MEASURING INTERNAL LEAKAGE OF WORK EQUIPMENT CYLINDER
BLEEDING AIR FROM WORK EQUIPMENT CYLINDER
RELESAING RESIDUAL PRESSURE IN WORK EQUIPMENT CYLINDER
ADJUSTING WORK EQUIPMENT LOCK LEVER
MESAURING FAN MOTOE SPEED
MEASURING FAN PUMP CIRCUIT PRESSURE
BLEEDING AIR FROM FAN PUMP
ADJUSTING BLADE
TESTING AND ADJUSTING OPERATOR CAB
TESTING AND ADJUSTING, PART 2
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
TESTING AND ADJUSTING, PART 3
HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER
ADJUSTMENT METHOD WHEN CONTROLLER HAS BEEN REPLACED
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL SYSTEM
INSPECTION PROCEDURE OF DIODE
PM CLINIC SERVICE
HOW TO START OPERATION OF KOMTRAX TERMINAL
LAMP DISPLAY OF KOMTRAX TERMINAL
40 TROUBLESHOOTING
GENERAL INFORMATION ON TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
HOW TO PROCEED TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
CLASSIFICATION AND PROCEDURES FOR TROUBLESHOOTING
HOW TO DISTINGUISH WIRE CODE
WIRING TABLE FOR CONECTOR PIN NUMBERS
T-ADAPTER BOX AND T-ADAPTER TABLE
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 1
FAILURE CODES TABLE
BEFORE TROUBLESHOOTING BY FAILURE CODES
CONTENS OF TROUBLESHOOTING TABLE
FAILURE CODE [1500L0] TRANSMISSION CLUTCH: DUAL ENGAGENMENT
FAILURE CODE [15SAL1] FORWARD CLUTCH: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF
FAILURE CODE [15SALH] FORWARD CLUTCH: FILL SIGNAL IS OFF WHEN COMMAND CURRENT IS ON
FAILURE CODE [15SBL1] REVERSE CLUTCH: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF
FAILURE CODE [15SBLH] REVERSE CLUTCH: FILL SIGNAL IS OFF WHEN COMMAND CURRENT IS ON
FAILURE CODE [15SEL1] 1ST CLUTCH: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF
FAILURE CODE [15SELH] 1ST CLUTCH: FILL SIGNAL IS OFF WHEN COMMAND CURRENT IS ON
FAILURE CODE [15SFL1] 2ND CLUTCH: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF
FAILURE CODE [15SFLH] 2ND CLUTCH: FILL SIGNAL IS OFF WHEN COMMAND CURRENT IS ON
FAILURE CODE [15SGL1] 3RD CLUTCH: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF
FAILURE CODE [15SGLH] 3RD CLUTCH: FILL SIGNAL IS OFF WHEN COMMAND CURRENT IS ON
FAILURE CODE [AA10NX] AIR CLEANER: CLOGGED
FAILURE CODE [AB00MA] ABNORMAL BATTERY CHARGE: MALFUNCTION
FAILURE CODE [B@BCNS] RADIATOR COOLANT: OVERHEAT
FAILURE CODE [B@BCZK] RADIATOR COOLANT: LEVEL TOO LOW
FAILURE CODE [B@CENS] POWER TRAIN OIL: OVERHEAT
FAILURE CODE [B@HANS] HYDRAULIC OIL: OVERHEAT
FAILURE CODE [CA111] ENGINE CONTROLLER: ABNORMALITY IN CONTROLLER
FAILURE CODE [CA115] ABNORMAL ENGINE NE AND BKUP SPEED SENSORS: ABNORMAL SPEED SENSOR SIGNAL
FAILURE CODE [CA122] CHARGE PRESSURE SENSOR TOO HIGH: EXCESSIVELY HIGH VOLTAGE DETECTED
FAILURE CODE [CA123] CHARGE PRESSURE SENSOR TOO LOW: EXCESSIVELY LOW VOLTAGE DETECTED
FAILURE CODE [CA131] DECELERATOR PEDAL SENSOR TOO HIGH: EXCESSIVELY HIGH VOLTAGE DETECTED
FAILURE CODE [CA132] DECELERATOR PEDAL SENSOR TOO LOW: EXCESSIVELY LOW VOLTAGE DETECTED
FAILURE CODE [CA135] OIL PRESSURE SENSOR TOO HIGH: EXCESSIVELY HIGH VOLTAGE DETECTED
FAILURE CODE [CA141] OIL PRESSURE SENSOR TOO LOW: EXCESSIVELY LOW VOLTAGE DETECTED
FAILURE CODE [CA144] COOLANT TEMPERATURE SENSOR TOO HIGH: EXCESSIVELY HIGH VOLTAGE DETECTED
FAILURE CODE [CA145] COOLANT TEMPERATURE SENSOR TOO LOW: EXCESSIVELY LOW VOLTAGE DETECTED
FAILURE CODE [CA153] CHARGE TEMPERATURE SENSOR TOO HIGH: EXCESSIVELY HIGH VOTAGE DETECTED
FAILURE CODE [CA154] CHARGE TEMPERATURE SENSOR TOO LOW: EXCESSIVELY LOW VOTAGE DETECTED
FAILURE CODE [CA187] SENSOR POWER SOURCE 2 TOO LOW: LOW VOLTAGE DETECTED
FAILURE CODE [CA221] ATMOSPHERIC PRESSURE SENSOR TOO HIGH: EXCESSIVELY HIGH VOLTAGE DETECTED
FAILURE CODE [CA222] ATMOSPHERIC PRESSURE SENSOR TOO LOW: EXCESSIVELY LOW VOLTAGE DETECTED
FAILURE CODE [CA227] SENSOR POWER SOURCE 2 TOO HIGH: EXCESSIVELY HIGH VOLTAGE DETECTED
FAILURE CODE [CA234] ENGINE OVER SPEED: EXCESSIVELY HIGH SPEED
FAILURE CODE [CA238] ABNORMAL POWER SOURCE FOR NE SPEED SENSOR: EXCESSIVELY LOW VOLTAGE DETECTED
FAILURE CODE [CA263] FUEL TEMPERATURE SENSOR TOO HIGH: EXCESSIVELY HIGH VOLTAGE DETECTED
FAILURE CODE [CA265] FUEL TEMPERATURE SENSOR TOO LOW: EXCESSIVELY LOW VOLTAGE DETECTED
FAILURE CODE [CA271] PCV1 SHORT CIRCUIT: SHORT CIRCUIT
FAILURE CODE [CA272] PCV1 DISCONNECTION: DISCONNECTION
FAILURE CODE [CA273] PCV2 SHORT CIRCUIT: SHORT CIRCUIT
FAILURE CODE [CA274] PCV2 DISCONNECTION: DISCONNECTION
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 2
FAILURE CODE [CA322] INJECTOR NO.1 SYSTEM DISCONNECTION OR SHORT CIRCUIT: DISCONNECTION, SHORT CITCUIT
FAILURE CODE [CA323] INJECTOR NO.5 SYSTEM DISCONNECTION OR SHORT CIRCUIT: DISCONNECTION, SHORT CITCUIT
FAILURE CODE [CA324] INJECTOR NO.3 SYSTEM DISCONNECTION OR SHORT CIRCUIT: DISCONNECTION, SHORT CITCUIT
FAILURE CODE [CA325] INJECTOR NO.6 SYSTEM DISCONNECTION OR SHORT CIRCUIT: DISCONNECTION, SHORT CITCUIT
FAILURE CODE [CA331] INJECTOR NO.2 SYSTEM DISCONNECTION OR SHORT CIRCUIT: DISCONNECTION, SHORT CITCUIT
FAILURE CODE [CA332] INJECTOR NO.4 SYSTEM DISCONNECTION OR SHORT CIRCUIT: DISCONNECTION, SHORT CITCUIT
FAILURE CODE [CA342] ENGINE CONTROLLER DATA MATCHING ERROR: MATCHING ERROR
FAILURE CODE [CA351] ABNORMAL INJECTOR DRIVE CIRCUIT: ABNORMAL CIRCUIT
FAILURE CODE [CA352] SENSOR POWER SOURCE (1) TOO LOW: EXCESSIVELY LOW VOLTAGE DETECTED
FAILURE CODE [CA386] SENSOR POWER SOURCE (1) TOO HIGH: EXCESSIVELY HIGH VOLTAGE DETECTED
FAILURE CODE [CA441] POWER SOURCE VOLAGE TOO LOW: EXCESSIVELY LOW VOLTAGE DETECTED
FAILURE CODE [CA442] POWER SOURCE VOLAGE TOO HIGH: EXCESSIVELY HIGH VOLTAGE DETECTED
FAILURE CODE [CA449] COMMON RAIL PRESSURE TOO HIGH (2): EXCESSIVELY HIGH PRESSURE TROUBLE OCCURRED
FAILURE CODE [CA451] COMMON RAIL PRESSURE SENSOR TOO HIGH: EXCESSIVELY HIGH VOLTAGE DETECTED
FAILURE CODE [CA452] COMMON RAIL PRESSURE SENSOR TOO LOW: EXCESSIVELY LOW VOLTAGE DETECTED
FAILURE CODE [CA553] COMMON RAIL PRESSURE TOO HIGH (1): EXCESSIVELY HIGH PRESSURE DETECTED
FAILURE CODE [CA554] IN-RANGE ERROR IN COMMON RAIL PRESSURE SENSOR: IN-RANGE ERROR
FAILURE CODE [CA559] LOSS OF PRESSURE FEED FROM SUPPLY PUMP (1): LOSS OF PRESSURE FEED DETECTED
FAILURE CODE [CA689] ABNORMAL ENGINE NE SPEED SENSOR: ABNORMAL SIGNAL
FAILURE CODE [CA731] ABNORMAL ENGINE BKUP SPEED SENSOR PHASE: ABNORMAL PHASE
FAILURE CODE [CA757] LOSS OF ALL ENGINE CINREILLER DATA: LOSS OF ALL DATA
FAILURE CODE [CA778] ABNORMAL ENGINE BKUP SPEED SENSOR: ABNORMAL BKUP SIGNAL
FAILURE CODE [CA1228] ABNORMAL EGR VALVE SERVO (1): EGR OUT OF CONTROL
FAILURE CODE [CA1625] ABNORMAL EGR VALVE SERVO (2): EGR OUT OF CONTROL
FAILURE CODE [CA1633] ABNORMAL KOMNET: ABNORMAL COMMUNICATION
FAILURE CODE [CA2185] DECELERATOR PEDAL SENSOR POWER SOURCE TOO HIGH: EXCESSIVELY HIGH VOLTAGE DETECTED
FAILURE CODE [CA2186] DECELERATOR PEDAL SENSOR POWER SOURCE TOO LOW: EXCESSIVELY LOW VOLTAGE DETECTED
FAILURE CODE [CA2249] LOSS OF PRESSURE FEED FROM SUPPLY PUMP (2): LOSS OF PRESSURE FEED DETECTED
FAILURE CODE [CA2271] EGR VALVE LIFT SENSOR TOO HIHG: EXCESSIVELY HIGH VOLTAGE DETECTED
FAILURE CODE [CA2272] EGR VALVE LIFT SENSOR TOO LOW: EXCESSIVELY LOW VOLTAGE DETECTED
FAILURE CODE [CA2351] EGR VALVE SOLENOID DRIVE SHORT CIRCUIT: SHORT CIRCUIT
FAILURE CODE [CA2352] EGR VALVE SOLENOID DRIVE DISCONNECTION: DISCONNECTION
FAILURE CODE [CA2555] INTAKE AIR HEATER RELAY DISCONNECTION: DISCONNECTION
FAILURE CODE [CA2556] INTAKE AIR HEATER RELAY SHORT CIRCUIT: SHORT CIRCUIT
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 3
FAILURE CODE [D110KA] BATTERY RELAY: DISCINNECTION
FAILURE CODE [D110KB] BATTERY RELAY: SHORT CIRCUIT
FAILURE CODE [D130KA] NEUTRAL SAFETY RELAY: DISCONNECTION
FAILURE CODE [D130KB] NEUTRAL SAFETY RELAY: SHORT CIRCUIT
FAILURE CODE [D161KA] BACK-UP ALARM RELAY: DISCONNECTION
FAILURE CODE [D161KB] BACK-UP ALARM RELAY: SHORT CIRCUIT
FAILURE CODE [D190KA] ENGINE CONTROLLER ACC SIGNAL CUTOUT RELAY: DISCONNECTION
FAILURE CODE [D190KB] ENGINE CONTROLLER ACC SIGNAL CUTOUT RELAY: SHORT CIRCUIT
FAILURE CODE [D811KR] KOMTRAX CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION
FAILURE CODE [DAFRKR] MONITOR PANEL CAN COMMUNICATION: DEFECTIVE COMMUNICATION
FAILURE CODE [DAQ0KT] AND [DB30KT] STEERING AND TRANSMINNION CINTROLLER: ABNORMAL CONTROLLER MEMORY INFORMATION
FAILURE CODE [DAQ1KK] AND [DB31KK] MAIN POWER SOURCE OF STEERING AND TRANSMISSION CONTROLLER: POWER SOURCE VOLTAGE DROP AND INPUT
FAILURE CODE [DAQ2KK] AND [DB32KK] LOAD POWER SOURCE OF STEERING AND TRANSMISSION CONTROLLER: POWER SOURCE VOLTAGE DROP AND INPUT
FAILURE CODE [DAQ5KK] AND [DB35KK] STEERING AND TRANSMISSION CONTROLLER SENSOR 5 V POWER SOURCE (1): POWER SOURCE VOLTAGE DROP AND INPUT
FAILURE CODE [DAQ6KK] [DB36KK] STEERING AND TRANSMISSION CONTROLLER SENSOR 24 V POWER SOURCE: POWER SOURCE VOLTAGE DROP AND INPUT
FAILURE CODE [DAQ7KK] AND [DB37KK] STEERING AND TRANSMISSION CONTROLLER SENSOR 5 V POWER SOURCE (2): POWER SOURCE VOLTAGE DROP AND INPUT
FAILURE CODE [DAQ9KQ] AND [DB39KQ] STEERING AND TRANSMISSION CONTROLLER MODEL SELECTION: INCONSISTENCY IN MODEL SELECT SIGNAL
FAILURE CODE [DAQRKR] AND [DB3RKR] STEERING AND TRANSMISSION CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION
FAILURE CODE [DB2RKR] ENGINE CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION
FAILURE CODE [DB30KT] [DAQ0KT] STEERING AND TRANSMISSION CONTROLLER: ABNORMAL CONTROLLER MEMORY INFORMAION
FAILURE CODE [DB31KK] [DAQ1KK] MAIN POWER SOURCE OF STEERING AND TRANSMISSION CONTROLLER: POWER SOURCE VOLTAGE DROP AND INPUT
FAILURE CODE [DB32KK] [DAQ2KK] LOAD POWER SOURCE OF STEERING AND TRANSMISSION CONTROLLER: POWER SOURCE VOLTAGE DROP AND INPUT
FAILURE CODE [DB35KK] AND [DAQ5KK] STEERING AND TRANSMISSION CONTROLLER SENSOR 5 V POWER SOURCE (1): POWER SOURCE VOLTAGE DROP AND INPUT
FAILURE CODE [DB36KK] [DAQ6KK] STEERING AND TRANSMISSION CONTROLLER SENSOR 24 V POWER SOURCE: POWER SOURCE VOLTAGE DROP AND INPUT
FAILURE CODE [DB37KK] AND [DAQ7KK] STEERING AND TRANSMISSION CONTROLLER SENSOR 5 V POWER SOURCE (2): POWER SOURCE VOLTAGE DROP AND INPUT
FAILURE CODE [DB39KQ] AND [DAQ9KQ] STEERING AND TRANSMISSION CONTROLLER MODEL SELECTION: INCONSISTEN MODEL SELECTION SIGNAL
FAILURE CODE [DB3RKR] AND [DAQRKR] STEERING AND TRANSMISSION CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION
FAILURE CODE [DD12KA] SHIFT UP SWITCH : DISCONNECTION
FAILURE CODE [DD12KB] SHIFT UP SWITCH : SHORT CIRCUIT
FAILURE CODE [DD13KA] SHIFT DOWN SWITCH : DISCONNECTION
FAILURE CODE [DD13KB] SHIFT DOWN SWITCH : SHORT CIRCUIT
FAILURE CODE [DD14KA] AND [DDQ2KA] PARKING LOCK SWITCH: DISCONNECTION
FAILURE CODE [DD14KB] AND [DDQ2KB] PARKING LOCK SWITCH: SHORT CIRCUIT
FAILURE CODE [DDQ2KA] AND [DD14KA] PARKING LOCK SWITCH: DISCONNECTION
FAILURE CODE [DDQ2KB] AND [DD14KB] PARKING LOCK SWITCH: SHORT CIRCUIT
FAILURE CODE [DGS1KX] HYDRAULIC OIL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF NORMAL RANGE
FAILURE CODE [DGT1KA] POWER TRAIN OIL TEMPERATURE SENSOR: DISCONNECTION
FAILURE CODE [DGT1KX] POWER TRAIN OIL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF NORMAL RANGE
FAILURE CODE [DH22KA] HSS AND WORK EQUIPMENT PUMP OIL PRESSURE SENSOR: DISCONNECTION
FAILURE CODE [DH22KB] HSS AND WORK EQUIPMENT PUMP OIL PRESSURE SENSOR: SHORT CIRCUIT
FAILURE CODE [DK10KA] FUEL DIAL: DISCONNECTION
FAILURE CODE [DK10KB] FUEL DIAL: SHORT CIRCUIT
FAILURE CODE [DK30KA] STEERING POTENTIOMENTER (1): DISCONNECTION
FAILURE CODE [DK30KB] STEERING POTENTIOMENTER (1): SHORT CIRCUIT
FAILURE CODE [DK30KX] STEERING POTENTIOMRTER: INPUT SIGNAL IS OUT OF NORMAL RANGE
FAILURE CODE [DK30KZ] STEERING POTENTIOMRTER: DISCONNECTION OR SHORT CIRCUIT (DOUBLE FAILURE)
FAILURE CODE [DK30L8] STEERING POTENTIOMRTER: INCONSISTENT ANALOG SIGNAL
FAILURE CODE [DK31KA] STEERING POTENTIOMENTER (2): DISCONNECTION
FAILURE CODE [DK31KB] STEERING POTENTIOMENTER (2): SHORT CIRCUIT
FAILURE CODE [DK40KA] BRAKE POTENTIOMETER: DISCONNECTION
FAILURE CODE [DK40KB] BRAKE POTENTIOMETER: SHORT CIRCUIT
FAILURE CODE [DK55KX] FORWARD-REVERSE POTENTIOMETER: INPUT SIGNAL IS OUT OF NORMAL RANGE
FAILURE CODE [DK55KZ] FORWARD-REVERSE POTENTIOMETER: DISCONNECTION OR SHORT CIRCUIT (DOUBLE FAILURE)
FAILURE CODE [DK55L8] FORWARD-REVERSE POTENTIOMETER: INCONSISTENT ANALOG SIGNAL
FAILURE CODE [DK56KA] FORWARD-REVERSE POTENTIOMETER (1): DISCONNECTION
FAILURE CODE [DK56KB] FORWARD-REVERSE POTENTIOMETER (1): SHORT CIRCUIT
FAILURE CODE [DK57KA] FORWARD-REVERSE POTENTIOMETER (2): DISCONNECTION
FAILURE CODE [DK57KB] FORWARD-REVERSE POTENTIOMETER (2): SHORT CIRCUIT
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 4
FAILURE CODE [DKH1KA] [DKH1KX] PITCH ANGLE SENSOR: SHORT CIRCUIT
FAILURE CODE [DKH1KB] [DKH1KX] PITCH ANGLE SENSOR: DISCONNECTION
FAILURE CODE [DKH1KX], [DKH1KA] OR [DKH1KB] PITCH ANGLE SENSOR: INPUT SIGNAL OUT OF RANGE
FAILURE CODE [DLT3KA] TANSMISSION PUTPUT SPEED SENSOR: DISCONNECTION
FAILURE CODE [DLT3KB] TANSMISSION PUTPUT SPEED SENSOR: SHORT CIRCUIT
FAILURE CODE [DV00KB] ALARM BUZZER: SHORT CIRCUIT
FAILURE CODE [DW7BKA] FAN REVERSE SOLENOID: DISCONNECTION
FAILURE CODE [DW7BKB] FAN REVERSE SOLENOID: SHORT CIRCUIT
FAILURE CODE [DW7BKY] FAN REVERSE SOLENOID: HOT SHORT CIRCUIT
FAILURE CODE [DWN1KA] HSS EPC SOLENOID RIGHT: DISCONNECTION
FAILURE CODE [DWN1KB] HSS EPC SOLENOID RIGHT: SHORT CIRCUIT
FAILURE CODE [DWN1KY] HSS EPC SOLENOID RIGHT: HOT SHOTR CIRCUIR
FAILURE CODE [DWN2KA] HSS EPC SOLENOID LEFT: DISCONNECTION
FAILURE CODE [DWN2KB] HSS EPC SOLENOID LEFT: SHORT CIRCUIT
FAILURE CODE [DWN2KY] HSS EPC SOLENOID LEFT: HOT SHOTR CIRCUIR
FAILURE CODE [DWN5KA] FAN PUMP EPC SOLENOID: DISCONNECTION
FAILURE CODE [DWN5KB] FAN PUMP EPC SOLENOID: SHORT CIRCUIT
FAILURE CODE [DWN5KY] FAN PUMP EPC SOLENOID: HOT SHORT CIRCUIT
FAILURE CODE [DXA0KA] HSS AND WORK EQUIPMENT PUMP TVC SOLENOID: DISCONNECTION
FAILURE CODE [DXA0KB] HSS AND WORK EQUIPMENT PUMP TVC SOLENOID: SHORT CIRCUIT
FAILURE CODE [DXA0KY] HSS AND WORK EQUIPMENT PUMP TVC SOLENOID: HOT SHORT CIRCUIT
FAILURE CODE [DXH4KA] 1ST CLUTCH ECMV: DISCONNECTION
FAILURE CODE [DXH4KB] 1ST CLUTCH ECMV: SHORT CIRCUIT
FAILURE CODE [DXH4KY] 1ST CLUTCH ECMV: HOT SHORT CIRCUIT
FAILURE CODE [DXH5KA] 2ND CLUTCH ECMV: DISCONNECTION
FAILURE CODE [DXH5KB] 2ND CLUTCH ECMV: SHORT CIRCUIT
FAILURE CODE [DXH5KY] 2ND CLUTCH ECMV: HOT SHORT CIRCUIT
FAILURE CODE [DXH6KA] 3RD CLUTCH ECMV: DISCONNECTION
FAILURE CODE [DXH6KB] 3ED CLUTCH ECMV: SHORT CIRCUIT
FAILURE CODE [DXH6KY] 3RD CLUTCH ECMV: HOT SHORT CIRCUIT
FAILURE CODE [DXH7KA] REVERSE CLUTCH ECMV: DISCONNECTION
FAILURE CODE [DXH7KB] REVERSE CLUTCH ECMV: SHORT CIRCUIT
FAILURE CODE [DXH7KY] REVERSE CLUTCH ECMV: HOT SHORT CIRCUIT
FAILURE CODE [DXH8KA] FORWARD CLUTCH ECMV: DISCONNECTION
FAILURE CODE [DXH8KB] FORWARD CLUTCH ECMV: SHORT CIRCUIT
FAILURE CODE [DXH8KY] FORWARD CLUTCH ECMV: HOT SHORT CIRCUIT
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)
BEFORE TROUBLESHOOTING OF ELECTRICAL SYSTEM
CONTENTS OF TROUBLESHOOTING TABLE
E-1 ENGINE DOES NOT START.
E-2 THE PREHEATER DOSE NOT OPERATE.
E-3 THE MONITOR PANEL DOSE NOT LIGHT UP AT ALL WHEN THE STARTING SWITCH IS TURNED ON.
E-4 WHEN THE STARTING SWITCH IS TURNED ON, THE MONITOR PANEL COMPLETELY REMAINS LIGHTED AND DOES NOT GO OUT.
E-5 WHEN THE STARTING SWITCH IS TURNED ON, THE RADIATOR COOLANT LEVEL CAUTION LAMP FLASHES.
E-6 WHILE THE ENGINE IS RUNNING, THE BATTERY LEVEL CAUTION LAMP FLASHES.
E-7 WHILE THE ENGINE IS RUNNING, THE EMERGENCY WARNING ITEM FLASHES.
E-8 WHILE THE PREHEATER IS OPERATING, THE PREHEATING PILOT LAMP DOES NOT LIGHT UP.
E-9 THE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY.
E-10 POWER TRAIN OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY.
E-11 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE PROPERLY.
E-12 FUEL GAUGE DOES NOT INDICATE PROPERLY.
E-13 GEAR SPEED AND ENGINE SPEED ARE NOT INDICATED PROPERLY.
E-14 THE PRESET MODE AND SERVICE METER DO NO INDICATE PROPERLY.
E-15 THE WARNING LAMP DOES NOT FLASH OR DOES NOT GO OUT.
E-16 THE ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP.
E-17 AUTO SHIFT DOWN DOES NOT OPERATE OR DOES NOT RELEASE.
E-18 BUZZER CANCEL SWITCH DOES NOT WORK.
E-19 THE INFORMATION SWITCH DOES NOT WORK.
E-20 THE MANUAL MODE DOES NOT OPERATE OR DOES NOT RELEASE.
E-21 THE MONITOR PANEL CANNOT BE SET IN THE SERVICE MODE OR CANNOT BE SET OUT OF THE SERVICE MODE.
E-22 THE BACK-UP ALARM DOES NOT SOUND.
E-23 THE HEAD LAMP AND REAR LAMP DO NOT LIGHT UP.
E-24 THE HORN NOT SOUND OR DOES NOT STOP.
E-25 MALFUNCTION OF WIPERS
E-26 WASHER DOES NOT SPRAY WATER
E-27 THE AIR CONDITIONER DOES NOT OPERATE
E-28 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY.
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)
CONTENTS OF TROUBLESHOOTING TABLE
H-1 THERE IS NO TRAVEL POWER (NO DRAWBER PULL)
H-2 MACHINE DOES NOT WOVE (AT 2ND OR 3RD SPEED)
H-3 MACHINE DOES NOT MOVE AT ANY GEAR SPEED
H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION, FORWARD OR REVERSE
H-5 WHEN GEAR IS SHIFTED OR TRAVEL DIRECTION IS CHANGED, LARGE TIME LAG IS MADE
H-6 MACHINE CANNOT BE STEERED (MACHINE DOES NOT TUEN LEFTWARD OR RIGHTWARD)
H-7 STEERING SPEED OR POWER IS LOW
H-8 BRAKE ODES NOT WORK
H-9 OVERHEAT OF POWER TRAIN OIL
H-10 ABNORMAL SOUND COMES OUT FROM AROUD HSS AND WORK EQUIPMENT PUMP OR HSS MOTOR
H-11 ALL WORK EQUIPMENT SPEEDS ARE SLOW
H-12 ALL WORK EQUIPMENTS DO NOT MOVE
H-13 BLADE LIFT SPEED IS SLOW OR LACKS POWER
H-14 BLADE LILT SPEED IS SLOW OR LACKS POWER
H-15 RIPPER LIFT SPEED IS SLOW OR LACKS POWER
H-16 EXCESSIVE HYDRAULIC DIRFT OF BLADE LIFT
H-17 EXCESSIVE HYDRAULIC DIRIFT OF BLADE TILT
H-18 EXCESSIVE HYDRAULIC DRIFT OF RIPPER LIFT
TROUBLESHOOTING OF ENGINE (S-MODE)
METHOD OF USING TROUBLESHOOTING CHARTS
S-1 STARTING PERFORMANCE IS POOR.
S-2 ENGINE DOES NOT START
S-3 ENGINE DOES NOT PICK UP SMOOTHLY
S-4 ENGINE STOPS DURING OPERATIONS
S-5 ENGINE DOES NOT ROTATE SMOOTHLY
S-6 ENGINE LACK OUTPUT (OR LACKS POWER)
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)
S-9 OIL BECOMES CONTAMINATED QUICKLY
S-10 FUEL CONSUMPTION IS EXCESSIVE
S-11 OIL IS IN COOLANT (OR COOLANT SPURTS BACK, OR COOLANT LEVEL GOES DOWN)
S-12 OIL PRESSURE DROPS
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)
S-15 ABNORMAL NOISE IS MADE.
S-16 VIBRATION IS EXCESSIVE
50 DISASSEMBLY AND ASSEMBLY
GENERAL INFORMATION ON DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
COATING MATERIALS LIST
SPECIAL TOOL LIST
SKETCH OF SPECIAL TOOL
ENGINE AND COOLING SYSTEM, PART 1
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY
REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL
REMOVAL AND INSTALLATION OF ENGINE OIL PAN
ENGINE AND COOLING SYSTEM, PART 2
REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY
REMOVAL AND INSTALLATION OF FAN DRIVE ASSEMBLY
REMOVAL AND INSTALLATION OF FAN MOTOR ASSEMBLY
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY
REMOVAL AND INSTALLATION OF DAMPER ASSEMBLY
REMOVAL AND INSTALLATION OF ENGINE HOOD ASSEMBLY
POWER TRAIN, PART 1
REMOVAL AND INSTALLATION OF POWER TRAIN UNIT ASSEMBLY
DISCONNECTION AND CONNECTION OF POWER TRAIN UNIT ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF TORQFLOW TRANSMISSION ASSEMBLY
POWER TRAIN, PART 2
DISASSEMBLY AND ASSEMBLY OF HSS ASSEMBLY
REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY
UNDERCARRIAGE AND FRAME, PART 1
REMOVAL AND INSTALLATION OF TRACK FRAME ASSEMBLY
REMOVAL AND INSTALLATION OF IDLER ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY
REMOVAL AND INSTALLATION OF RECOIL SPRING ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY
REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY
REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY
UNDERCARRIAGE AND FRAME, PART 2
EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY
WHOLE DISASSEMBLY AND ASSEMBLY OF TRACK SHOE
REMOVAL AND INSTALLATION OF PIVOT SHAFT ASSEMBLY
REMOVAL AND INSTALLATION OF EQUALIZER BAR ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF EQUALIZER BAR ASSEMBLY
HYDRAULIC SYSTEM
REMOVAL AND INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY
REMOVAL AND INSTALLATION OF HSS AND WORK EQUIPMENT PUMP ASSEMBLY
REMOVAL AND INSTALLATION OF POWER TRAIN AND LUBRICATING OIL PUMP ASSEMBLY
REMOVAL AND INSTALLATION OF FAN PUMP ASSEMBLY
REMOVAL AND INSTALLATION OF SCAVENGING PUMP ASSEMBLY
REMOVAL AND INSTALLATION OF HSS MOTOR ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
WORK EQUIPMENT
REMOVAL AND INSTALLATION OF BLADE ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF RIPPER ASSEMBLY
CAB AND ITS ATTACHMENTS
REMOVAL AND INSTALLATION OF ROPS GUARD ASSEMBLY
REMOVAL AND INSTALLATION OF OPERATOR ’ S CAB ASSEMBLY
REMOVAL AND INSTALLATION OF OPERATOR ’ S CAB GLASS (STUCK GLASS)
REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY
ELECTRICAL SYSTEM
REMOVAL AND INSTALLATION OF ENGINE CONTROLLER
REMOVAL AND INSTALLATION OF STEERING AND TRANSMISSION CONTROLLER
REMOVAL AND INSTALLATION OF KOMTRAX TERMINAL
90 DIAGRAMS AND DRAWINGS
HYDRAULIC DIAGRAMS AND DRAWINGS
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC CIRCUIT DIAGRAM
ELECTRICAL DIAGRAMS AND DRAWINGS
ELECTRICAL CIRCUIT DIAGRAM