Komatsu D65EX-15E0, D65PX-15E0, D65WX-15E0 Galeo Bulldozer (69001 and up) Shop Manual - SEN00046-02


This complete Service Repair Workshop Manual PDF Download for the D65EX-15E0, D65PX-15E0, D65WX-15E0 Galeo Komatsu Bulldozer (69001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Komatsu D65EX - S/N : 69001 and up
Komatsu D65PX - S/N : 69001 and up
Komatsu D65WX - S/N : 69001 and up


TABLE OF CONTENTS :

00 INDEX AND FOREWORD
01 SPECIFICATION
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
20 STANDARD VALUE TABLE
30 TESTING AND ADJUSTING
40 TROUBLESHOOTING
50 IDSASSEMBLY AND ASSEMBLY
90 DIAGRAMS AND DRAWINGS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEN00046-02
Total Pages : 1106


This (OEM) Komatsu Shop Manual has detailed illustrations as well as step by step instructions, It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic. With step by step instruction & highly detailed exploded pictures & diagrams to show you how to complete the required job correctly & efficiently Using. Provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.

This service repair workshop manual PDF download has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

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Komatsu D65EX-15E0, D65PX-15E0, D65WX-15E0 Galeo Bulldozer (69001 and up) FSM PDF Download
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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
HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT
HOW TO READ ELECTRIC WIRE CODE
METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER
STANDARD TIGHTERING 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
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, 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, HASS AND BRAKE
BRAKE VALVE
FINAL DRIVE
UNDERCARRIAGE AND FRAME
MAIN FRAME
SUSPENSION
TRACK FRAME AND IDLER CUSHION
IDLER
TRACK ROLLER
CARRIER ROLLER
SPROCKET
TRACK SHOE
HYDRAULIC SYSTEM, PART 1
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM
WORK EQUIPMENT CONTROL
HYDRAULIC TANK AND FILTER
SCAVENGING 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
PPC VALVE (BLADE LIFT, BLADE TILT)
PPC VALVE (RIPPER)
ELECTRIC LEVER (STEERING)
QUICK DROP VALVE
PPC LOCK VALVE
ACCUMULATOR
WORK EQUIPMENT
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
COOLING SYSTEM CONTROL SYSTEM
SYSTEM COMPONENTS
PALM COMMAND CONTROL SYSTEM
KOMTRAX TERMINAL SYSTEM
KOMTRAX TERMINAL
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
TESTING FUEL RETURN AND LEAK AMOUNT
BLEEDING AIR FROM FUEL CIRCUIT
TESTING FUEL CIRCUIT FOR LEAKAGE
HANDLING OF REDUCED CYLINDER MODE OPERATION
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION
ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL
MEASURING POWER TRAIN OIL PRESSURE
ADJUSTING TRANSMISSION SPEED SENSOR (REPLACEMENT PROCEDURE)
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
MEASURING INTERNAL LEAKAGE OF WORK EQUIPMENT CYLINDER
BLEEDING AIR FROM WORK EQUIPMENT CYLINDER
RELEASING RESIDUAL PRESSURE IN WORK EQUIPMENT CYLINDER
CHECKING PARTS WHICH CAUSED HYDRAULIC DRIFT OF BLADE OR RIPPER
ADJUSTING WORK EQUIPMENT LOCK LEVEL
MEASURING FAN MOTOR SPEED
MEASURING FAN PUMP CIRCUIT PRESSURE
BLEEDING AIR FROM FAN PUMP
ADJUSTING STRAIGHT TILTDOZER
TESTING AND ADJUSTING OPERATOR CAB
TESTING AND ADJUSTING, PART 2
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
TESTING AND ADJUSTING, PART 3
HANDLING OF VOLTAGE CIRCUIT OF ENGINE CONTROLLER
ADJUSTMENT METHOD WHEN CONTROLLER HAS BEEN REPLACED
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC 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 OF TROUBLESHOOTING
HOW TO DISTINGUISH WIRE CODE
WIRING TABLE FOR CONNECTOR PIN NUMBERS
T-ADAPTER BOX AND T-ADAPTER TABLE
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 1
FAILURE CODE TABLE
BEFORE TROUBLESHOOTING BY FAILURE CODES
CONTENTS OF TROUBLESHOOTING TABLE
FAILURE CODE [1500L0] TRANSMISSION CLUTCH: DUAL ENGAGEMENT
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 [AB00MA] ALTERNATOR: MALFUNCTION
FAILURE CODE [[email protected]] ENGINE OIL: OIL PRESSURE TOO LOW
FAILURE CODE [[email protected]] RADIATOR COOLANT: OVERHEAT
FAILURE CODE [[email protected]] POWER TRAIN OIL: OVERHEAT
FAILURE CODE [[email protected]] 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 TOOL HIGH: EXCESSIVELY HIGH VOLTAGE DETECTED
FAILURE CODE [CA123] CHARGE PRSSURE SENSOR TOO LOW: EXCESSIVELY LOW VOLTAGE DETECTED
FAILURE CODE [CA131] DECELERATOR PEDAL SENSOR TOOL HIGH: EXCESSIVELY HIGH VOLTAGE DETECTED
FAILURE CODE [CA132] DECELERATOR PEDAL 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 VOLTAGE DETECTED
FAILURE CODE [CA154] CHARGE TEMPERATURE SENSOR TOO LOW: EXCESSIVELY LOW VOLTAGE DETECTED
FAILURE CODE [CA155] CHARGE TEMPERATURE SENSOR TOO HIGH AND ENGINE SPEED DERATED: EXCEEDED UPPER CONTROL LIMIT OF TEMPERATURE
FAILURE CODE [CA187] SENSOR POWER SOURCE 2 TOO LOW: EXCESSIVELY 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 [CA271] IMV/PCV1 SHORT CIRCUIT: SHORT CIRCUIT
FAILURE CODE [CA272] IMV/PCV1 DISCONNECTION: DISCONNECTION
FAILURE CODE [CA281] ABNORMAL SUPPLY PUMP PRESSURE BALANCE: ABNORMAL PRESSURE FEED OF FUEL
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 2
FAILURE CODE [CA322] INJECTOR NO.1 SYSTEM DISCONNECTION OR SHORT CIRCUIT: DISCONNECTION, SHORT CIRCUIT
FAILURE CODE [CA323] INJECTOR NO.5 SYSTEM DISCONNECTION OR SHORT CIRCUIT: DISCONNECTION, SHORT CIRCUIT
FAILURE CODE [CA324] INJECTOR NO.3 SYSTEM DISCONNECTION OR SHORT CIRCUIT: DISCONNECTION, SHORT CIRCUIT
FAILURE CODE [CA325] INJECTOR NO.6 SYSTEM DISCONNECTION OR SHORT CIRCUIT: DISCONNECTION, SHORT CIRCUIT
FAILURE CODE [CA331] INJECTOR NO.2 SYSTEM DISCONNECTION OR SHORT CIRCUIT: DISCONNECTION, SHORT CIRCUIT
FAILURE CODE [CA332] INJECTOR NO.4 SYSTEM DISCONNECTION OR SHORT CIRCUIT: DISCONNECTION, SHORT CIRCUIT
FAILURE CODE [CA342] ENGINE CONTROLLER DATA MATCHING ERROR: MATCHING ERROR
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 [CA428] WATER DETECTION SENSOR TOO HIGH: EXCESSIVELY HIGH VOLTAGE DETECTED
FAILURE CODE [CA429] WATER DETECTION SENSOR TOO LOW: EXCESSIVELY LOW VOLTAGE DETECTED
FAILURE CODE [CA435] ABNORMAL ENGINE OIL PRESSURE SWITCH: ABNORMAL SIGNAL CIRCUIT
FAILURE CODE [CA441] POWER SOURCE VOLTAGE TOO LOW: EXCESSIVELY LOW VOLTAGE DETECTED
FAILURE CODE [CA442] POWER SOURCE VOLTAGE TOO HIGH: EXCESSIVELY HIGH VOLTAGE HAS OCCURRED IN THE CONTROLLER POWER SOURCE CIRCUIT
FAILURE CODE [CA449] COMMON RAIL PRESSURE TOO HIGH (2): EXCESSIVELY HIGH PRESSURE TROUBLE OCCURRED
FAILURE CODE [CA451] COMMON RAIL PRESSURE TOO HIGH: EXCESSIVELY HIGH VOLTAGE DETECTED
FAILURE CODE [CA452] COMMON RAIL PRESSURE TOO LOW: EXCESSIVELY LOW VOLTAGE DETECTED
FAILURE CODE [CA488] CHARGE TEMPERATURE TOO HIGH AND TORQUE DERATED: EXCEEDED UPPER CONTROL LIMIT OF TEMPERATURE
FAILURE CODE [CA553] COMMON RAIL PRESSURE TOO HIGH (1): EXCESSIVELY HIGH PRESSURE DETECTED
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 CONTROLLER DATA: LOSS OF ALL DATA
FAILURE CODE [CA778] ABNORMAL ENGINE BKUP SPEED SENSOR: ABNORMAL BKUP SIGNAL
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 [CA2265] ELECTRIC LIFT PUMP DISCONNECTION: DISCONNECTION
FAILURE CODE [CA2266] ELECTRIC LIFT PUMP SHORT CIRCUIT: SHORT CIRCUIT
FAILURE CODE [CA2311] ABNORMAL IMV SOLENOID: ABNORMAL RESISTANCE
FAILURE CODE [CA2555] AIR INTAKE HEATER RELAY DISCONNECTION: DISCONNECTION
FAILURE CODE [CA2556] AIR INTAKE HEATER RELAY SHORT CIRCUIT: SHORT CIRCUIT
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 3
FAILURE CODE [D110KA] BATTERY RELAY: SHORT CIRCUIT
FAILURE CODE [D110KB] BATTERY RELAY: DISCONNECTION
FAILURE CODE [D130KA] NEUTRAL SAFELY RELAY: DISCONNECTION
FAILURE CODE [D130KB] NEUTRAL SAFELY RELAY: SHORT CIRCUIT
FAILURE CODE [D161KA] BACK-UP ALARM RELAY: DISCONNECTION
FAILURE CODE [D161KB] BACK-UP ALARM RELAY: SHORT CIRCUIT
FAILURE CODE [DAFRKR] MONITOR PANEL CAN COMMUNICATION: DEFECTIVE COMMUNICATION
FAILURE CODE [DAQ1KT] [DB30KT] STEERING AND TRANSMISSION CONTROLLER: ABNORMALITY IN CONTROLLER
FAILURE CODE [DAQ1KK] [DB31KK] MAIN POWER SOURCE OF STEERING AND TRANSMISSION CONTROLLER: POWER SOURCE VOLTAGE DROP AND INPUT
FAILURE CODE [DAQ2KK] [DB32KK] LOAD POWER SOURCE OF STEERING AND TRANSMISSION CONTROLLER: POWER SOURCE VOLTAGE DROP AND INPUT
FAILURE CODE [DAQ5KK] [DB35KK] STEERING AND TRANSMISSION CONTROLLER SENSOR 5 V POWER SOURCE: POWER SOURCE VOLTAGE DROP AND INPUT
FAILURE CODE [DAQ6KK] [DB36KK] STEERING AND TRANSMISSION CONTROLLER SENSOR 24V POWER SOURCE: POWER SOURCE VOLTAGE DROP AND INPUT
FAILURE CODE [DAQ9KQ] [DB39KQ] STEERING AND TRANSMISSION CONTROLLER MODEL SELECTION: INCONSISTENCY IN MODEL SELECT SIGNAL
FAILURE CODE [DB2RKR] STEERING AND TRANSMISSION CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION
FAILURE CODE [DB30KT] [DAQ0KT] STEERING AND TRANSMISSION CONTROLLER: ABNOTMALITY IN CONTROLLER
FAILURE CODE [DB31KK] [DAQ1KK] MAIN POWER SOURCE OF STEERING AND TRANSMISSION CONTROLLER: POWER SOURCE VOLTAGE DROP AND INPUT
FAILURE CODE [DAB32KK] [DAQ2KK] LOAD POWER SOURCE OF STEERING AND TRANSMISSION CONTROLLER: POWER SOURCE VOLTAGE DROP AND INPUT
FAILURE CODE [DB35KK] [DAQ5KK] STEERING AND TRANSMISSION CONTROLLER SENSOR 5 V POWER SOURCE: 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 [DB39KQ] [DAQ9KQ] STEERING AND TRANSMISSION CONTROLLER MODEL SELECTION: INCONSISTENCY IN MODEL SELECT SIGNAL
FAILURE CODE [DD12KA] SHIFT UP SWITCH: DISCONNECTION
FAILURE CODE [DD12KB] SHIFT UP SWITCH: SHORT CIRCUIT
FAILURE CODE [DD13KA] SHIFT DOWM SWITCH: DISCONNECTION
FAILURE CODE [DD13KB] SHIFT DOWN SWITCH: SHORT CIRCUIT
FAILURE CODE [DD14KA] [DDQ2KA] PARKING BRAKE LEVER SWITCH: DISCONNECTION
FAILURE CODE [DD14KB] [DDQ2KB] PARKING BRAKE LEVER SWITCH: SHORT CIRCUIT
FAILURE CODE [DDN7KA] PITCH CONTROL SWITCH: DISCONNECTION
FAILURE CODE [DDN7KB] PITCH CONTROL SWITCH: SHORT CIRCUIT
FAILURE CODE [DDQ2KA] [DD14KA] PARKING BRAKE LEVER SWITCH: DISCONNECTION
FAILURE CODE [DDQ2KB] [DD14KB] PARKING BRAKE LEVER 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 [DK10KA] FUEL DIAL: DISCONNECTION
FAILURE CODE [DK10KB] FUEL DIAL: SHORT CIRCUIT
FAILURE CODE [DK30KA] STEERING POTENTIOMETER (1): DISCONNECTION
FAILURE CODE [DK30KB] STEERING POTENTIOMETER (1): SHORT CIRCUIT
FAILURE CODE [DK30KX] STEERING POTENTIOMETER: INPUT SIGNAL IS OUT OF NORMAL RANGE
FAILURE CODE [DK30KZ] STEERING POTENTIOMETER: DISCONNECTION OF SHORT CIRCUIT (DOUBLE FAILURE)
FAILURE CODE [DK30L8] STEERING POTENTIOMETER: INCONSISTENT ANALOG SIGNAL
FAILURE CODE [DK31KA] STEERING POTENTIOMETER (2): DISCONNECTION
FAILURE CODE [DK31KB] STEERING POTENTIOMETER (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 OF SHORT CIRCUIT (DOUBLE FAILURE)
FAILURE CODE [DK55L8] FORWARD-REVERSE POTENTIOMETER: INCONSISTENT ANALOG SIGNAL
FAILURE CODE [DK56KA] FORWARD-REVERSE POTENTIOMETER (1): SHORT CIRCUIT
FAILURE CODE [DK56KB] FORWARD-REVERSE POTENTIOMETER (1): DISCONNECTION
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 [DLT3KA] TRANSMISSION OUTPUT SPEED SENSOR: DISCONNECTION
FAILURE CODE [DLT3KB] TRANSMISSION OUTPUT SPEED SENSOR: SHORT CIRCUTI
FAILURE CODE [DV00KB] ALARM BUZZER: SHORT CIRCUIT
FAILURE CODE [DW5AKA] PITCH CONTROL SOLENOID: DISCONNECTION
FAILURE CODE [DW5AKB] PITCH CONTROL SOLENOID: SHORT CIRCUIT
FAILURE CODE [DW5AKY] PITCH CONTROL SOLENOID: SHORT CIRCUIT TO POWER SOURCE LINE
FAILURE CODE [DW7BKA] FAN REVERSE SOLENOID: DISCONNECTION
FAILURE CODE [DW7BKB] FAN REVERSE SOLENOID: 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: SHORT CIRCUIT TO POWER SOURCE LINE
FAILURE CODE [DWN2KA] HSS EPC SOLENOID LEFT: DISCONNECTION
FAILURE CODE [DWN2KB] HSS EPC SOLENOID LEFT: SHORT CIRCUIT
FAILURE CODE [DWN2KY] HSS EPC SOLENOID LEFT: SHORT CIRCUIT TO POWER SOURCE LINE
FAILURE CODE [DWN5KA] FAN PUMP TVC SOLENOID: DISCONNECTION
FAILURE CODE [DWN5KB] FAN PUMP TVC SOLENOID: SHORT CIRCUIT
FAILURE CODE [DWN5KY] FAN PUMP TVC SOLENOID: SHORT CIRCUIT TO POWER SOURCE LINE
FAILURE CODE [DXA0KA] HSS PUMP TVC SOLENOID: DISCONNECTION
FAILURE CODE [DXA0KB] HSS PUMP TVC SOLENOID: SHORT CIRCUIT
FAILURE CODE [DXA0KY] HSS PUMP TVC SOLENOID: SHORT CIRCUIT TO POWER SOURCE LINE
FAILURE CODE [DXH4KA] 1ST CLUTCH ECMV: DISCONNECTION
FAILURE CODE [DXH4KB] 1ST CLUTCH ECMV: SHORT CIRCUIT
FAILURE CODE [DXH4KY] 1ST CLUTCH ECMV: SHORT CIRCUIT TO POWER SOURCE LINE
FAILURE CODE [DXH5KA] 2ND CLUTCH ECMV: DISCONNECTION
FAILURE CODE [DXH5KB] 2ND CLUTCH ECMV: SHORT CIRCUIT
FAILURE CODE [DXH5KY] 2ND CLUTCH ECMV: SHORT CIRCUIT TO POWER SOURCE LINE
FAILURE CODE [DXH6KA] 3RD CLUTCH ECMV: DISCONNECTION
FAILURE CODE [DXH6KB] 3RD CLUTCH ECMV: SHORT CIRCUIT
FAILURE CODE [DXH6KY] 3RD CLUTCH ECMV: SHORT CIRCUIT TO POWER SOURCE LINE
FAILURE CODE [DXH7KA] REVERSE CLUTCH ECMV: DISCONNECTION
FAILURE CODE [DXH7KB] REVERSE CLUTCH ECMV: SHORT CIRCUIT
FAILURE CODE [DXH7KY] REVERSE CLUTCH ECMV: SHORT CIRCUIT TO POWER SOURCE LINE
FAILURE CODE [DXH8KA] FORWARD CLUTCH ECMV: DISCONNECTION
FAILURE CODE [DXH8KB] FORWARD CLUTCH ECMV: SHORT CIRCUIT
FAILURE CODE [DXH8KY] FORWARD CLUTCH ECMV: SHORT CIRCUIT TO POWER SOURCE LINE
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)
BEFORE TROUBLESHOOTING OF ELECTRICAL SYSTEM
CONTENTS OF TROUBLESHOOTING TABLE
E-1 THE ENGINE DOES NOT START (THE STARTING MOTOR DOES NOT TURN)
E-2 THE PREHEATER DOES NOT OPERATE
E-3 THE MONITOR PANEL DOES 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 WHILE THE ENGINE IS RUNNING, THE BATTERY CHARGE LEVEL CAUTION LAMP FLASHES.
E-6 WHILE THE ENGINE IS RUNNING, THE EMERGENCY WARNING ITEM FLASHES.
E-7 WHILE THE PREHEATER IS OPERATING, THE PREHEATING PILOT LAMP DOES NOT LIGHT UP.
E-8 THE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY.
E-9 THE POWER TRAIN OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY.
E-10 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE PROPERLY.
E-11 FUEL GAUGE DOES NOT INDICATE PROPERLY.
E-12 GEAR SPEED AND ENGINE SPEED ARE NOT INDICATE PROPERLY.
E-13 THE PRESET MODE SERVICE METER DOES NOT INDICATE NORMALLY.
E-14 THE WARNING LAMP DOES NOT FLASH OR DOES NOT GO OUT.
E-15 THE ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP.
E-16 AUTO SHIFT DOWN IS NOT POSSIBLE OR IS NOT RELEASED.
E-17 THE BUZZER CANCEL SWITCH DOES NOT WORK.
E-18 THE INFORMATION SWITCH DOES NOT WORK.
E-19 THE FAN CLEANING DOES NOT OPERATE OR CANNOT BE RESET.
E-20 THE PRESET MODE DOES NOT OPERATE OR CANNOT BE RESET.
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 DOES 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 DRAWBAR PULL).
H-2 MACHINE DOES NOT MOVE (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 IN 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 TURN LEFTWARD OR RIGHTWARD)
H-7 STEERING SPEED OR POWER IS LOW
H-8 BRAKE DOES NOT WORK
H-9 OVERHEAT OF POWER TRAIN OIL
H-10 ABNORMAL SOUND COMES OUT FROM AROUND HSS AND WORK EQUIPMENT PUMP OR HSS MOTOR
H-11 ALL WORK EQUIPMENT SPEEDS ARE SLOW
H-12 WORK EQUIPMENT DOES NOT MOVE
H-13 BLADE LIFT SPEED IS SLOW OR LACKS POWER
H-14 BLADE TILT SPEED IS SLOW OR LACKS POWER
H-15 RIPPER LIFT SPEED IS SLOW OR LACKS POWER
H-16 EXCESSIVE HYDRAULIC DRIFT OF BLADE LIFT
H-17 EXCESSIVE HYDRAULIC DRIFT 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 LACKS OUTPUT (OR LACKS POWER)
S-7 EXHAUST SMOKE IS BLACK (IMCOMPLETE 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
SKETCHES OF SPECIAL TOOLS
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
ENGINE AND COOLING SYSTEM, PART 2
REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY
REMOVAL AND INSTALLATION OF AIR AFTERCOOLER 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 TRQFLOW TRANSMISSION ASSEMBLY
POWER TRAIN, PART 2
DISASSEMBLY AND ASSEMBLY OF HSS ASSEMBLY
REMOVAL AND INSTALLATION OF FINAL DIRVE 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 WHOLE ASSEMBLY OF TRACK SHOE ASSEMBLY
FIELD DISASSEMBLY AND ASSEMBLY OF ONE LINK
REMOVAL AND INSTALLATION OF PIVOT SHAFT ASSEMBLY
REMOVAL AND INSTALLATION OF EQUALIZER BAR ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF EQUALIZER BAR SIDE BUSHING
HYDRAULIC SYSTEM
REMOVAL AND INTALLATION OF CONTROL VALVE ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY
REMOVAL AND INSTALLATION OF HSS PUMP ASSEMBLY
REMOVAL AND INSTALLATION OF POWER TRAIN AND LUBRICATING OIL PUMP ASSEMBLY
REMOVAL AND INSTALLATION OF COOLING 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 INSTALLTION OF BLADE ASSEMBLY
CAB AND ITS ATTACHMENTS
REMOVAL AND INSTALLATION OF ROPS GUARD
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 ASSEMBLY
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
CONNECTOR ARRANGEMENT DIAGRAM

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