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Complete service repair manual for Komatsu Bulldozers D65E, D65EX, D65P, D65PX, D65WX, with all the technical information to maintain, diagnose, repair, service like professional mechanics.
Komatsu Bulldozers D65E, D65EX, D65P, D65PX, D65WX workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 16,613 pages (1.1 GB)
File Format: PDF
Language: English
SEBD001920 – Bulldozer D65E,P-12 & D65EX,PX-12 Shop Manual (SN60001&up).pdf
SEBM001921 – Bulldozer D65E,P-12 & D65EX,PX-12 Shop Manual (SN60001&up).pdf
SEBM001922 – Bulldozer D65E,P-12 & D65EX,PX-12 Shop Manual (SN60001&up).pdf
SEBM001923 – Bulldozer D65E,P-12 & D65EX,PX-12 Shop Manual (SN60001&up).pdf
SEBM027202 – Bulldozer D65EX-12 & D65PX-12 (EU SPEC.) Shop Manual (SN65209&up).pdf
SEBM029508 – Bulldozer D65EX,PX,WX-15 Shop Manual (SN67001&up).pdf
SEBM040800 – Bulldozer GALEO D65WX-15E0 Power Angle Power Tilt Dozer Shop Manual (SN69001&up).pdf
SEN00046-02 – Bulldozer D65EX,PX,WX-15E0 Shop Manual (SN69001&up).pdf
SEN00046-09 – Bulldozer D65EX,PX,WX-15E0 Shop Manual (SN69001&up).pdf
SEN04887-10 – Bulldozer D65EX,PX,WX-16 Shop Manual (SN80001&up).pdf
SEN04887-14 – Bulldozer D65EX,PX,WX-16 Shop Manual (SN80001&up).PDF
SEN05536-01 – Bulldozer D65EX,PX,WX-17 Shop Manual (SN1001&up).pdf
SEN05536-02 – Bulldozer D65EX,PX,WX-17 Shop Manual (SN1001&up).pdf
SRBM001910 – Бульдозер D65E,P-12 D65E,P-12 Заводская инструкция (SN60001 и выше).pdf
TABLE OF CONTENTS
Shop Manual, contents binder, binder label and tabs … SEN00046-09
00 Index and foreword … SEN00047-09
Index … SEN00055-09 q
Foreword and general information … SEN00056-04
01 Specification… SEN00048-04
Specification and technical data… SEN00057-04
10 Structure, function and maintenance standard … SEN00049-05
Engine and cooling system … SEN00281-01
Power train, Part 1 … SEN00282-02
Power train, Part 2 … SEN00283-03
Undercarriage and frame … SEN00284-04
Hydraulic system, Part 1 … SEN00285-01
Hydraulic system, Part 2 … SEN00286-01
Hydraulic system, Part 3 … SEN00287-01
Work equipment… SEN00288-00
Cab and its attachments … SEN00289-00
Electrical system … SEN00290-03
20 Standard value table … SEN00050-02
Standard service value table… SEN00584-02
30 Testing and adjusting … SEN00051-03
Testing and adjusting, Part 1… SEN00585-03
Testing and adjusting, Part 2… SEN00586-01
Testing and adjusting, Part 3… SEN00587-02
40 Troubleshooting … SEN00052-04
General information on troubleshooting… SEN00588-04 q
Troubleshooting by failure code (Display of code), Part 1 … SEN00589-03
Troubleshooting by failure code (Display of code), Part 2 … SEN00590-04 q
Troubleshooting by failure code (Display of code), Part 3 … SEN00591-01
Troubleshooting by failure code (Display of code), Part 4 … SEN00592-00
Troubleshooting of electrical system (E-mode)… SEN00593-02
Troubleshooting of hydraulic and mechanical system (H-mode) … SEN00594-00
Troubleshooting of engine (S-mode) … SEN00595-01
50 Disassembly and assembly … SEN00053-04
General information on disassembly and assembly … SEN00944-04
Engine and cooling system, Part 1 … SEN00945-03
Engine and cooling system, Part 2 … SEN00946-03
Power train, Part 1 … SEN00947-01
Power train, Part 2 … SEN00948-01
Undercarriage and frame, Part 1 … SEN00949-01
Undercarriage and frame, Part 2 … SEN00950-04
Hydraulic system … SEN00951-01
Work equipment… SEN00952-01
Cab and its attachments … SEN00953-03
Electrical system… SEN00954-00
90 Diagrams and drawings … SEN00054-03
Hydraulic diagrams and drawings… SEN00058-01
Electrical diagrams and drawings … SEN00059-02
SEBD001920 – Bulldozer D65E,P-12 & D65EX,PX-12 Shop Manual (SN60001&up)…2
COVER…2
CONTENTS…3
01 GENERAL…30
GENERAL ASSEMBLY DRAWING…31
SPECIFICATIONS…35
WEIGHT TABLE…51
TABLE OF FUEL, COOLANT AND LUBRICANTS…57
10 STRUCTURE AND FUNCTION…59
RADIATOR, OIL COOLER…60
ENGINE CONTROL…62
POWER TRAIN SYSTEM…65
POWER TRAIN SKELETON…66
POWER TRAIN UNIT…69
POWER TRAIN HYDRAULIC PIPING DIAGRAM…71
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM…76
POWER TRAIN HYDRAULIC SYSTEM DIAGRAM…77
DAMPER, UNIVERSAL JOINT…81
TORQUE CONVERTER AND PTO…83
TRANSMISSION CONTROL…85
TRANSMISSION…89
TRANSMISSION CONTROL VALVE…98
MAIN RELIEF VALVE…107
LUBRICATION RELIEF VALVE…109
STEERING, BRAKE CONTROL…110
BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE (D65E, P-12)…112
STEERING CONTROL VALVE (D65E, P-12)…125
STEERING BRAKE VALVE…132
REDUCING VALVE…136
STEERING AND BRAKE CONTROL (D65EX, PX-12)…138
BEVEL GEAR SHAFT, HSS STEERING AND BRAKE (D65EX, PX-12)…141
BEVEL GEAR SHAFT, HSS BRAKE VALVE (D65EX, PX-12)…162
SCAVENGING PUMP STRAINER…166
POWER TRAIN OIL STRAINER…167
POWER TRAIN OIL FILTER…168
FINAL DRIVE…169
MAIN FRAME…172
TRACK FRAME…173
RECOIL SPRING…175
SUSPENSION…177
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM …181
ANGLEDOZER…181
STRAIGHT TILTDOZER…183
POWER PITCH DOZER…185
RIPPER…187
PPC CONTROL PIPING DIAGRAM…188
WORK EQUIPMENT CONTROL…193
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM…195
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM…196
STEERING AND WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM…203
STEERING AND WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM…204
HYDRAULIC TANK AND FILTER…211
HYDRAULIC, HSS PUMP (D65EX, PX-12)…215
PPC VALVE (for steering) (D65EX, PX-12)…230
PPC VALVE (for steering) (D65E, P-12)…237
PPC VALVE (for blade lift, tilt and ripper)…241
PPC CHARGE VALVE…254
PPC LOCK VALVE…256
MAIN CONTROL VALVE (2-SPOOL Valve – D65E, P-12)…257
MAIN CONTROL VALVE (3-SPOOL Valve – D65EX, PX-12)…295
POWER PITCH SELECTOR VALVE…347
HSS MOTOR…350
OPERATION OF STEERING, WORK EQUIPMENT CONTROL CIRCUIT…355
SUCTION VALVE…363
PISTON VALVE…367
WORK EQUIPMENT…368
ELECTRICAL CIRCUIT DIAGRAM…372
ENGINE CONTROL…384
MACHINE MONITOR SYSTEM…385
SENSORS…388
20 TESTING AND ADJUSTING…390
STANDARD VALUE TABLE FOR ENGINE…391
STANDARD VALUE TABLE FOR CHASSIS…399
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM…424
TOOL LIST FOR TESTING AND ADJUSTING…431
ADJUSTING VALVE CLEARANCE…433
MEASURING COMPRESSION PRESSURE…434
MEASURING BLOWBY…435
ADJUSTING FUEL INJECTION TIMING…436
MEASURING EXHAUST COLOR…438
MEASURING BOOST PRESSURE…439
MEASURING EXHAUST TEMPERATURE (D65P, EX, PX-12)…440
MEASURING ENGINE OIL PRESSURE…441
MEASURING ENGINE SPEED…441
TESTING FAN BELT TENSION…442
MEASURING SPEED AT TORQUE CONVERTER STALL…443
ADJUSTING FUEL CONTROL LINKAGE…444
ADJUSTING STEERING AND DIRECTIONAL LEVER, GEAR SHIFT LEVER, PARKING BRAKE LEVER LINKAGE (D65E, P)…450
ADJUSTING DIRECTIONAL LEVER, GEAR SHIFT LEVER, PARKING BRAKE LINKAGE…457
ADJUSTING BRAKE PEDAL LINKAGE…463
D65E, P-12…463
D65EX, PX-12…465
ADJUSTING WORK EQUIPMENT CONTROL LINKAGE…466
ADJUSTING STRAIGHT TILTDOZER…468
ADJUSTING PPC VALVE…470
MEASURING POWER TRAIN OIL PRESSURE…471
D65E, P-12…471
D65EX. PX-12…478
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE…485
TESTING AND ADJUSTING WORK EQUIPMENT, STEERING HYDRAULIC PRESSURE…486
TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE…488
MEASURING OUTPUT PRESSURE OF PPC VALVE…490
MEASURING OIL LEAKAGE FROM HSS MOTOR (D65EX, PX-12)…492
MEASURING LEAKAGE INSIDE CYLINDER…492
BLEEDING AIR FROM HYDRAULIC CYLINDER…493
RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT…493
PROCEDURE FOR SIMPLE TEST OF STEERING BRAKE PERFORMANCE…494
PROCEDURE FOR TESTING SENSORS…495
TESTING AND AJUSTING "OPEN" AND "CLOSE" LOCK AND STEADY REST OF OPERATOR'S CAB DOOR…497
TROUBLESHOOTING…500
POINTS TO REMEMBER WHEN TROUBLESHOOTING…501
SEQUENCE OF EVENTS IN TROUBLESHOOTING…502
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…503
CHECKS BEFORE TROUBLESHOOTING…511
METHOD OF USING MATRIX TROUBLESHOOTING CHART…512
METHOD OF USING TROUBLESHOOTING CHARTS…516
TYPE OF CONNECTOR AND POSITION OF INSTALLATION…518
CONNECTOR POSITION DRAWING…519
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…525
ELECTICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM…548
TROUBLESHOOTING OF ENGINE (S MODE)…552
S-1 Starting performance is poor (Starting always takes time)…553
S-2 Engine does not start…554
1 Engine does not turn…554
2 Engine turns but no exhaust gas comes out (Fuel is not being injected)…555
3 Exhaust gas comes out but engine does not start (Fuel is being injected)…556
S-3 Engine does not pick up smoothly (Follow-up is poor)…557
S-4 Engine stops during operations…558
S-5 Engine does not rotate smoothly…559
S-6 Engine lacks output (no power)…560
S-7 Exhaust gas is black (incomplete combustion)…561
S-8 Oil consumption is excessive (or exhaust gas is blue)…562
S-9 Oil becomes contaminated quickly…563
S-10 Fuel consumption is excessive…564
S-11 Oil is in cooling water, or water spurts back, or water level goes down…565
S-12 Oil pressure lamp lights up (drop in oil pressure)…566
S-13 Oil level rises…567
S-14 Water temperature becomes too high (overheating)…568
S-15 Abnormal noise is made…569
S-16 Vibration is excessive…570
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)…571
Table of Failure Models and Causes (Hydraulic, Mechanical Systems)…572
H-1 Brake does not work…573
H-2 Machine does not turn. (can travel in a straight line) D65E, P-12…574
H-3 Turning speed is slow (cannot turn) or lacks power when turning. D65EX, PX-12…576
H-4 Overruns when turning D65E, P-12…578
H-5 Can turn in only one direction (when steering and directional lever is operated) D65E, P-12…579
H-6 Excessive time lag…581
H-7 Machine can travel in only one direction (forward or reverse)…581
H-8 Machine does not move (when engine is started and lever is shifted to 2nd or 3rd)…582
1) D65E, P-12…582
2) D65EX, PX-12…584
H-9 Machine does not move in any speed range…586
1) D65E, P-12…586
2) D65EX, PX-12…588
H-10 Power train oil temperature rises too…590
H-11 Drawbar pull is weak, travel speed is slow…592
1) D65E, P-12…592
2) D65EX, PX-12…594
H-13 Abnormal noise is generated from around hydraulic pump or hydraulic, HSS pump…595
H-14 Speed of all work equipment is slow…596
H-15 No work equipment moves D65E, P-12…598
H-16 All work equipment lacks power D65E, P-12…598
H-17 Turning speed and speed of all work equipment is slow D65EX, PX-12…599
H-18 Machine cannot turn and no work equipment moves D65EX, PX-12…601
H-19 Turning and all work equipment lacks power D65EX, PX-12…601
H-20 Blade lifting speed is slow or lacks power…602
1) D65E, P-12…602
2) D65EX, PX-12…602
H-21 Blade tilt speed is slow or lacks power…603
1) D65E, P-12…603
2) D65EX, PX-12…603
H-22 Hydraulic drift of blade lift is excessive…604
H-23 Hydraulic drift of blade tilt is excessive…604
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)…605
TABLE OF FAILURE MODES AND CAUSES (ELECTRICAL SYSTEM)…606
E-1 Starting motor is not cranked when starting switch is turned to ON…607
E-2 Lamps do not light up…613
a) Front lamps…613
b) Rear lamps…613
E-4 Automatic preheating is not carried out when glow switch is turned to AUTO…617
E-5 Wiper does not work…623
E-6 No washer fluid is sprayed out…625
E-7 Air conditioner has no effect…627
a) No air comes out…627
b) Does not become cool…627
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)…635
TABLE OF FAILURE MODES AND CAUSES (MACHINE MONITOR SYSTEM)…636
M-1 No display is given on monitor panel when starting switch is turned to ON…637
M-2 When starting switch is turned ON, all monitor panel lamps light up and do not go out…637
M-3 Preheating display is abnormal…638
Preheating monitor does not light up…638
Preheating monitor does not go out…638
M-4 CAUTION items light up or flash…644
CHARGE lights up or flashes…644
When starting switch is at ON and engine is started ENGINE OIL PRESSURE lights up or flashes…645
COOLANT TEMPERATURE flashes…646
POWER TRAIN OIL TEMPERATURE flashes…648
M-5 Buzzer is abnormal…650
a) Caution item flashes but buzzer does not sound…650
b) Monitor display is normal, but buzzer sounds…650
M-6 Warning lamp is abnormal…651
a) Caution item flashing but lamp does not flash…651
b) Monitor display is normal but lamp flashes…651
M-7 Gauge is abnormal…652
a) Abnormality in engine coolant temperature gauge…652
b) Abnormality in power train oil temperature gauge…653
c) Abnormality in fuel level gauge…654
M-8 Service meter does not move after engine is started…658
M-9 Monitor panel lighting does not light up (front lamps are normal)…659
30 DISASSEMBLY AND ASSEMBLY…661
METHOD OF USING MANUAL…664
PRECAUTIONS WHEN CARRYING OUT OPERATION…665
SPECIAL TOOL LIST…667
SPECIAL TOOL SKETCH…672
STARTING MOTOR…673
REMOVAL…673
INSTALLATION…673
ALTERNATOR ASSEMBLY…674
REMOVAL…674
INSTALLATION…674
ENGINE OIL COOLER CORE…676
REMOVAL…676
INSTALLATION…676
FUEL INJECTION PUMP ASSEMBLY…677
REMOVAL…677
INSTALLATION…678
WATER PUMP ASSEMBLY…679
REMOVAL…679
INSTALLATION…679
TURBOCHARGER ASSEMBLY…681
REMOVAL…681
INSTALLATION…681
NOZZLE HOLDER ASSEMBLY (D65P, EX, PX)…682
REMOVAL…682
INSTALLATION…682
NOZZLE HOLDER ASSEMBLY (D65E)…683
REMOVAL…683
INSTALLATION…683
THERMOSTAT ASSEMBLY…684
REMOVAL…684
INSTALLATION…684
CYLINDER HEAD ASSEMBLY (D65P, EX, PX)…686
REMOVAL…686
INSTALLATION…690
CYLINDER HEAD ASSEMBLY (D65E)…698
REMOVAL…698
INSTALLATION…701
ENGINE FRONT SEAL…708
REMOVAL…708
INSTALLATION…709
ENGINE REAR SEAL…710
REMOVAL…710
INSTALLATION…711
AIR CONDITIONER COMPRESSOR ASSEMBLY…714
REMOVAL…714
INSTALLATION…714
AIR CONDITIONER CONDENSER ASSEMBLY…715
REMOVAL…715
INSTALLATION…715
FUEL TANK ASSEMBLY…716
REMOVAL…716
INSTALLATION…717
RADIATOR ASSEMBLY…722
REMOVAL…722
INSTALLATION…724
HYDRAULIC OIL COOLER ASSEMBLY…724
REMOVAL…724
INSTALLATION…724
ENGINE ASSEMBLY (Cab specification)…725
REMOVAL…725
INSTALLATION…728
ENGINE ASSEMBLY (Canopy specification)…736
REMOVAL…736
INSTALLATION…738
DAMPER ASSEMBLY…739
REMOVAL…739
INSTALLATION…741
POWER TRAIN UNIT ASSEMBLY (D65E, P)…743
REMOVAL…743
INSTALLATION…748
POWER TRAIN UNIT ASSEMBLY (D65EX, PX)…749
REMOVAL…749
INSTALLATION…754
POWER TRAIN UNIT (D65E, P)…755
SEPARATION…755
CONNECTION…758
POWER TRAIN UNIT (D65EX. PX)…0
CONNECTION…760
TORQUE CONVERTER ASSEMBLY…762
DISASSEMBLY…762
ASSEMBLY…764
PTO ASSEMBLY…767
DISASSEMBLY…767
ASSEMBLY…770
TORQFLOW TRANSMISSION ASSEMBLY…774
DISASSEMBLY…774
ASSEMBLY…793
STEERING CASE ASSEMBLY (D65E, P)…821
DISASSEMBLY…821
ASSEMBLY…834
HSS ASSEMBLY (D65EX. PX)…856
DISASSEMBLY…856
ASSEMBLY…877
TORQUE CONVERTER VALVE ASSEMBLY…901
REMOVAL…901
INSTALLATION…901
DISASSEMBLY…902
ASSEMBLY…902
TRANSMISSION CONTROL VALVE ASSEMBLY…903
REMOVAL…903
INSTALLATION…903
DISASSEMBLY…905
ASSEMBLY…905
STEERING CONTROL VALVE ASSEMBLY (D65E,P)…909
REMOVAL…909
INSTALLATION…909
DISASSEMBLY…910
ASSEMBLY…912
BRAKE VALVE ASSEMBLY (D65EX. PX)…914
REMOVAL…914
INSTALLATION…914
DISASSEMBLY…915
ASSEMBLY…916
REDUCING VALVE ASSEMBLY (D65E. P)…917
REMOVAL…917
INSTALLATION…917
DISASSEMBLY…918
ASSEMBLY…918
HSS MOTOR ASSEMBLY (D65EX, PX)…919
REMOVAL…919
INSTALLATION…919
DISASSEMBLY…920
ASSEMBLY…924
SCAVENGING PUMP ASSEMBLY…931
REMOVAL…931
INSTALLATION…931
POWER TRAIN PUMP ASSEMBLY…932
REMOVAL…932
INSTALLATION…932
FINAL DRIVE ASSEMBLY…933
REMOVAL…933
INSTALLATION…934
DISASSEMBLY…935
ASSEMBLY…939
TRACK FRAME ASSEMBLY…944
REMOVAL…944
INSTALLATION…945
RECOIL SPRING ASSEMBLY…946
REMOVAL…946
INSTALLATION…946
DISASSEMBLY…948
ASSEMBLY…950
IDLER ASSEMBLY…954
REMOVAL…954
INSTALLATION…954
DISASSEMBLY…956
ASSEMBLY…957
TRACK ROLLER ASSEMBLY…962
REMOVAL…962
INSTALLATION…962
DISASSEMBLY…963
ASSEMBLY…964
CARRIER ROLLER ASSEMBLY (D65P, PX)…966
REMOVAL…966
INSTALLATION…966
CARRIER ROLLER ASSEMBLY (D65E. EX)…967
REMOVAL…967
INSTALLATION…967
DISASSEMBLY…968
ASSEMBLY…969
TRACK SHOE ASSEMBLY…970
CHECKING BEFORE REMOVAL…970
REMOVAL (NORMAL)…970
REMOVAL (WHEN THERE IS ABNORMALITY INSIDE TRACK FRAME)…971
INSTALLATION…972
OVERALL DISASSEMBLY…976
OVERALL ASSEMBLY…981
PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS…995
FIELD DISASSEMBLY OF ONE LINK…996
FIELD ASSEMBLY OF ONE LINK…997
PIVOT SHAFT ASSEMBLY…1003
REMOVAL…1003
INSTALLATION…1003
EQUALIZER BAR ASSEMBLY…1004
REMOVAL…1004
INSTALLATION…1005
EQUALIZER BAR SIDE BUSHING…1006
REMOVAL…1006
INSTALLATION…1006
SEGMENT TEETH…1007
REMOVAL…1007
INSTALLATION…1007
WORK EQUIPMENT PUMP ASSEMBLY (D65E, P)…1008
REMOVAL…1008
INSTALLATION…1008
HSS, WORK EQUIPMENT PUMP ASSEMBLY (D65EX, PX)…1009
REMOVAL…1009
INSTALLATION…1009
DISASSEMBLY…1010
ASSEMBLY…1015
PPC PUMP ASSEMBLY…1024
REMOVAL…1024
INSTALLATION…1024
MAIN CONTROL VALVE ASSEMBLY…1025
REMOVAL…1025
INSTALLATION…1025
DISASSEMBLY (3-SPOOL VALVE)…1028
ASSEMBLY…1030
MAIN RELIEF VALVE…1036
REMOVAL…1036
INSTALLATION…1036
PPC VALVE ASSEMBLY…1037
REMOVAL (FOR WORK EQUIPMENT)…1037
INSTALLATION (FOR WORK EQUIPMENT)…1037
REMOVAL (D65EX, PX, FOR STEERING)…1039
INSTALLATION (D65EX, PX, FOR STEERING)…1040
DISASSEMBLY (FOR WORK EQUIPMENT)…1043
ASSEMBLY (FOR WORK EQUIPMENT)…1044
DISASSEMBLY OF PPC VALVE ASSEMBLY (D65EX, PX FOR STEERING)…1045
ASSEMBLY (D65EX. PX FOR STEERING)…1046
PPC CHARGE RELIEF VALVE ASSEMBLY…1047
REMOVAL…1047
INSTALLATION…1047
DISASSEMBLY…1048
ASSEMBLY…1048
SUCTION VALVE ASSEMBLY…1049
REMOVAL…1049
INSTALLATION…1049
BLADE LIFT CYLINDER ASSEMBLY…1050
REMOVAL…1050
INSTALLATION…1050
BLADE TILT CYLINDER ASSEMBLY…1051
REMOVAL…1051
INSTALLATION…1051
HYDRAULIC CYLINDER ASSEMBLY (BLADE LIFT, BLADE TILT CYLINDER)…1052
DISASSEMBLY…1052
ASSEMBLY…1054
WORK EQUIPMENT ASSEMBLY…1057
REMOVAL…1057
INSTALLATION…1058
DISASSEMBLY…1059
ASSEMBLY…1061
RIPPER VALVE ASSEMBLY (OPT.)…1063
DISASSEMBLY…1063
ASSEMBLY…1064
ROPS GUARD…1065
REMOVAL…1065
INSTALLATION…1065
OPERATOR'S CAB ASSEMBLY…1066
REMOVAL…1066
INSTALLATION…1067
CANOPY ASSEMBLY…1068
REMOVAL…1068
INSTALLATION…1068
DASHBOARD ASSEMBLY …1069
REMOVAL…1069
INSTALLATION…1069
MONITOR ASSEMBLY…1070
REMOVAL…1070
INSTALLATION…1070
FLOOR FRAME ASSEMBLY (D65E-P)…1071
REMOVAL…1071
INSTALLATION…1074
FLOOR FRAME ASSEMBLY (D65EX-PX)…1079
REMOVAL…1079
INSTALLATION…1082
40 MAINTENANCE STANDARD…1087
ENGINE MOUNT…1088
POWER TRAIN UNIT MOUNT…1089
DAMPER, UNIVERSAL JOINT…1090
TORQUE CONVERTER, PTO…1091
TRANSMISSION…1093
TRANSMISSION CONTROL VALVE…1097
MAIN RELIEF VALVE…1100
BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE…1101
BEVEL GEAR SHAFT, HSS STEERING, BRAKE (1/2)…1105
BEVEL GEAR SHAFT, HSS STEERING, BRAKE (2/2)…1108
BEVEL GEAR SHAFT, HSS STEERING, BRAKE (1/2)…1110
STEERING CONTROL VALVE (D65E, P-12)…1113
BRAKE VALVE (D65EX, PX-12)…1114
POWER TRAIN, LUBRICATION PUMP…1115
PPC PUMP…1116
PPC VALVE…1118
FOR STEERING (D65EX, PX-12)…1118
FOR BLADE LIFT, BLADE TILT, RIPPER LIFT…1119
PPC CHARGE VALVE…1123
FINAL DRIVE…1124
HULL FRAME…1126
TRACK FRAME, RECOIL SPRING…1127
IDLER…1129
TRACK ROLLER…1133
CARRIER ROLLER…1135
SPROCKET TOOTH PROFILE…1136
TRACK SHOE (DRY TYPE)…1137
TRACK SHOE (LUBRICATED TYPE)…1139
SUSPENSION…1141
HYDRAULIC PUMP (D65E, P-12)…1145
HYDRAULIC, HSS PUMP (D65EX, PX-12)…1147
HSS MOTOR (D65EX-PX-12)…1148
MAIN CONTROL VALVE…1149
2 + 1-SPOOL VALVE (D65E, P-12)…1149
3 + 1-SPOOL VALVE (D65EX, PX-12)…1159
WORK EQUIPMENT CYLINDER…1169
WORK EQUIPMENT…1171
CUTTING EDGE, END BIT…1177
RIPPER…1178
90 OTHERS…1179
SPECIFICATIONS…1180
SPECIFICATION DRAWING…1180
SPECIFICATIONS…1181
WEIGHT TABLE…1187
TABLE OF FUEL, COOLANT AND LUBRICANTS…1190
STRUCTURE AND FUNCTION…1191
REAR GUARD…1191
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM…1192
STEERING AND WORK EQUIPMENT HYDRAULIC CIRCUIT…1193
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM…1195
WORK EQUIPMENT CONTROL…1196
MAIN CONTROL VALVE…1197
TRIMMING DOZER…1201
MAINTENANCE STANDARD…1202
MAIN CONTROL VALVE…1202
WORK EQUIPMENT CYLINDER…1211
TRIMMING DOZER…1213
STRUCTURE AND FUNCTION…1215
ENGINE CONTROL…1215
TRANSMISSION CONTROL…1216
STEERING AND BRAKE CONTROL…1217
PPC CONTROL PIPING DIAGRAM…1218
TESTING AND ADJUSTING…1219
STANDARD VALUE TABLE FOR CHASSIS…1219
ADJUSTING FUEL CONTROL LINKAGE…1221
ADJUSTING LINKAGES OF FORWARD-REVERSE LEVER, GEAR SHIFT LEVER AND PARKING BRAKE LEVER…1223
TROUBLESHOOTING…1225
CONNECTOR TYPES AND MOUNTING LOCATIONS…1225
CONNECTOR POSITION DRAWING…1227
ELECTRIC CIRCUIT DIAGRAM…1229
ELECTRIC CIRCUIT DIAGRAM FOR CAB…1229
CAB SPECIFICATION…1230
CANOPY SPECIFICATION…1232
SEBM001921 – Bulldozer D65E,P-12 & D65EX,PX-12 Shop Manual (SN60001&up)…1235
COVER…1235
CONTENTS…1236
01 GENERAL…1262
GENERAL ASSEMBLY DRAWING…1263
SPECIFICATIONS…1267
WEIGHT TABLE…1283
TABLE OF FUEL, COOLANT AND LUBRICANTS…1289
10 STRUCTURE AND FUNCTION…1291
RADIATOR,OIL COOLER…1292
ENGINE CONTROL…1294
POWER TRAIN SYSTEM…1297
POWER TRAIN SKELETON…1298
POWER TRAIN UNIT…1301
POWER TRAIN HYDRAULIC PIPING DIAGRAM…1303
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM…1307
POWER TRAIN HYDRAULIC SYSTEM DIAGRAM…1308
DAMPER,UNIVERSAL JOINT…1312
TORQUE CONVERTER AND PTO…1314
TRANSMISSION CONTROL…1316
TRANSMISSION…1319
TRANSMISSION CONTROL VALVE…1328
MAIN RELIEF VALVE…1337
LUBRICATION RELIEF VALVE…1339
STEERING,BRAKE CONTROL…1340
BEVEL GEAR SHAFT, STEERING CLUTCH,STEERING BRAKE (D65E,P-12)…1342
STEERING CONTROL VALVE (D65E,P-12)…1355
STEERING BRAKE VALVE (D65E,P-12)…1362
REDUCING VALVE…1366
STEERING AND BRAKE CONTROL (D65EX,PX-12)…1368
BEVEL GEAR SHAFT, HSS STEERING AND BRAKE (D65EX,PX-12)…1371
BEVEL GEAR SHAFT, HSS BRAKE VALVE (D65EX,PX-12)…1392
SCAVENGING PUMP STRAINER…1396
POWER TRAIN OIL STRAINER…1397
POWER TRAIN OIL FILTER…1398
FINAL DRIVE…1399
MAIN FRAME…1402
TRACK FRAME…1403
RECOIL SPRING…1405
SUSPENSION…1407
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM…1411
ANGLEDOZER…1411
STRAIGHT TILTDOZER…1413
POWER PITCH DOZER…1415
RIPPER…1417
PPC CONTROL PIPING DIAGRAM…1418
WORK EQUIPMENT CONTROL…1423
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM…1425
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM…1426
STEERING AND WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM…1433
STEERING AND WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM…1434
HYDRAULIC TANK AND FILTER…1441
HYDRAULIC,HSS PUMP (D65EX,PX-12)…1445
PPC VALVE (FOR STEERING) (D65EX,PX-12)…1460
PPC VALVE (FOR STEERING) (D65E,P-12)…1467
PPC VALVE (FOR BLADE LIFT, TILT AND RIPPER)…1471
PPC CHARGE VALVE…1484
PPC LOCK VALVE…1486
MAIN CONTROL VALVE (2-SPOOL VALVE) (D65E,P-12)…1487
MAIN CONTROL VALVE (2-SPOOL VALVE) (D65EX,PX-12)…1525
POWER PITCH SELECTOR VALVE…1577
HSS MOTOR…1580
OPERATION OF STEERING, WORK EQUIPMENT CONTROL CIRCUIT…1585
SUCTION VALVE…1593
PISTON VALVE…1597
WORK EQUIPMENT…1598
ELECTRICAL CIRCUIT DIAGRAM…1602
ENGINE CONTROL…1614
MACHINE MONITOR SYSTEM…1615
SENSORS…1619
20 TESTING AND ADJUSTING…1622
STANDARD VALUE TABLE FOR ENGINE…1623
STANDARD VALUE TABLE FOR CHASSIS…1631
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM…1660
TOOL LIST FOR TESTING AND ADJUSTING…1663
ADJUSTING VALVE CLEARANCE…1665
MEASURING COMPRESSION PRESSURE…1666
MEASURING BLOWBY…1667
ADJUSTING FULE INJECTION TIMING…1668
MEASURING EXHAUST COLOR…1670
MEASURING BOOST PRESSURE…1671
MEASURING EXHAUST TEMPERATURE (D65P,EX,PX-12)…1672
MEASURING ENGINE OIL PRESSURE…1673
MEASURING ENGINE SPEED…1673
TESTING FAN BELT TENSION…1674
MEASURING SPEED AT TORQUE CONVERTER STALL…1675
ADJUSTING FULE CONTROL LINKAGE…1676
ADJUSTING STEERING AND DIRECTIONAL LEVER, GEAR SHIFT LEVER, PARKING BRAKE LEVER LINKAGE (D65E,P)…1682
ADJUSTING DIRECTIONAL LEVER, GEAR SHIFT LEVER, PARKING BRAKE LINKAGE (D65EX,PX)…1689
ADJUSTING BRAKE PEDAL LINKAGE…1695
D65E,P…1695
D65EX,PX…1697
ADJUSTING WORK EQUIPMENT CONTROL LINKAGE…1698
ADJUSTING STRAIGHT TILTDOZER…1700
ADJUSTING PPC VALVE…1702
MEASURING POWER TRAIN OIL PRESSURE…1703
D65E,P…1703
D65EX,PX…1710
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE (D65E,P)…1717
TESTING AND ADJUSTING WORK EQUIPMENT, STEERING HYDRAULIC PRESSURE (D65EX,PX)…1718
TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE…1720
MEASURING OUTPUT PRESSURE OF PPC VALVE…1722
MEASURING OIL LEAKAGE FROM HSS MOTOR (D65EX,PX)…1724
MEASURING LEAKAGE INSIDE CYLINDER…1724
BLEEDING AIR FROM HYDRAULIC CYLINDER…1725
RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT…1725
PROCEDURE FOR SIMPLE TEST OF STEERING BRAKE PERFORMANCE…1726
PROCEDURE FOR TESTING SENSORS…1727
TESTING AND ADJUSTING "OPEN" AND "CLOSE" LOCK AND STEADY REST OF OPERATORS CAB DOOR…1729
TROUBLESHOOTING…1732
POINTS TO REMEMBER WHEN TROUBLESHOOTING…1733
SEQUENCE OF EVENTS IN TROUBLESHOOTING…1734
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…1735
CHECKS BEFORE TROUBLESHOOTING…1743
METHOD OF USING MATRIX TROUBLESHOOTING CHART…1744
METHOD OF USING TROUBLESHOOTING CHARTS…1748
TYPE OF CONNECTOR AND POSITION OF INSTALLATION…1750
CONNECTOR POSITION DRAWING…1755
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…1757
ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM…1780
TROUBLESHOOTING OF ENGINE (S MODE)…1784
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)…1785
S-2 ENGING DOES NOT START…1786
(1) ENGINE DOES NOT TURN…1786
(2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)…1787
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)…1788
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)…1789
S-4 ENGINE STOPS DURING OPERATIONS…1790
S-5 ENGINE DOES NO ROTATE SMOOTHLY (HUNTING)…1791
S-6 ENGINE LACKS OUTPUT (NO POWER)…1792
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)…1793
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)…1794
S-9 OIL BECOMES CONTAMINATED QUICKLY…1795
S-10 FUEL CONSUMPTION IS EXCESSIVE…1796
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN…1797
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)…1798
S-13 OIL LEVEL RISES…1799
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)…1800
S-15 ABNORMAL NOISE IS MADE…1801
S-16 VIBRATION IS EXCESSIVE…1802
TROUBLESHOOTING OF HYDRAULIC,MECHANICAL SYSTEM (H MODE)…1803
TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC,MECHANICAL SYSTEMS)…1804
H-1 BRAKE DOES NOT WORK…1805
H-2 MACHINE DOES NOT TURN (CAN TRAVEL IN A STRAIGHT LINE) (D65E,P-12)…1806
H-3 TURNING SPEED IS SLOW (CANNOT TURN) OR LACKS POWER WHEN TURNING (D65EX,PX-12)…1808
H-4 OVERRUNS WHEN TURNING (D65E,P-12)…1810
H-5 CAN TURN IN ONLY ONE DIRECTION (WHEN STEERING LEVER IS OPERATED) (D65E,P-12)…1811
H-6 EXCESSIVE TIME LAG…1813
H-7 MACHINE CAN TRAVEL IN ONLY ONE DIRECTION (FORWARD OR REVERSE)…1813
H-8 MACHINE DOES NOT MOVE (WHEN ENGINE IS STARTED AND LEVER IS SHIFTED TO 2ND OR 3RD)…1814
1) D65E,P-12…1814
2) D65EX,PX-12…1816
H-9 MACHINE DOES NOT MOVE IN ANY SPEED RANGE…1818
1) D65E,P-12…1818
2) D65EX,PX-12…1820
H-10 POWER TRAIN OIL TEMPERATURE RISES TOO HIGH…1822
H-11 DRAWBAR PULL IS WEEK,TRAVEL SPEED IS SLOW…1824
1) D65E,P-12…1824
2) D65EX,PX-12…1826
H-13 ABNORMAL NOISES IS GENERATED FROM AROUND HYDRAULIC PUMP OR HYDRAULIC,HSS PUMP…1827
H-14 SPEED OF ALL WORK EQUIPMENT IS SLOW (D65E,P-12)…1828
H-15 NO WORK EQUIPMENT MOVES (D65E,P-12)…1830
H-16 ALL WORK EQUIPMENT LACKS POWER (D65E,P-12)…1830
H-17 TURNING SPEED AND SPEED OF ALL WORK EQUIPMENT IS SLOW (D65EX,PX-12)…1831
H-18 MACHINE CANNOT TURN AND NO WORK EQUIPMENT MOVES (D65EX,PX-12)…1833
H-19 TURNING AND ALL WORK EQUIPMENT LACKS POWER (D65EX,PX-12)…1833
H-20 BLADE LIFTING SPEED IS SLOW OR LACKS POWER…1834
1) D65E,P-12…1834
2) D65EX,PX-12…1834
H-21 BLADE TILT SPEED IS SLOW OR LACKS POWER…1835
1) D65E,P-12…1835
2) D65EX,PX-12…1835
H-22 HYDRAULIC DRIFT OF BLADE LIFY IS EXCESSIVE…1836
H-23 HYDRAULIC DRIFT OF BLADE TILT IS EXCESSIVE…1836
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)…1837
TABLE OF FAILURE MODES AND CAUSES (ELECTRICAL SYSTEM)…1838
E-1 STARTING MOTOR IS NOT CRANKED WHEN STARTING SWITCH IS TURNED TO 0N…1839
E-2 LAMP DO NOT LIGHT UP…1845
a) FRONT LAMPS…1845
b) REAR LAMPS…1846
E-4 AUTOMATIC PREHEATING IS NOT CARRIED OUT WHEN GLOW SWITCH IS TURNED TO AUTO …1849
E-5 WIPER DOES NOT WORK…1855
E-6 NO WASHER FLUID IS SPRAYED OUT…1857
E-7 AIR CONDITION HAS NOT EFFECT…1859
a) NO AIR COMES OUT…1859
b) DOES NOT BECOME COOL …1863
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)…1867
TABLE OF FAILURE MODES AND CAUSES (MACHINE MONITOR SYSTEM)…1868
M-1 NO DISPLAY IS GIVEN ON MONITOR PANEL WHEN STARTING SWITCH IS TURNED TO ON…1869
M-2 WHEN STARTING SWITCH IS TURNED ON, ALL MONITOR PANEL LAMPS LIGHT UP AND DO NOT GO OUT…1869
M-3 PREHEATING DISPLAY IS ABNORMAL…1870
a) PREHEATING MONITOR DOES NOT LIGHT UP…1870
b) PREHEATING MONITOR DOES NOT GO OUT…1870
M-4 CAUTION ITEMS LIGHT UP OR FLASH…1876
a) (CHARGE) LIGHTS UP OR FLASHES…1876
b) WHEN STARTING SWITCH AT ON AND ENGINE IS STARTED (ENGINE OIL PRESSURE) LIGHTS UP OR FLASHES…1877
c) (COOLANT TEMPERATURE) FLASHES…1878
d) (POWER TRAIN OIL TEMPERATURE) FLASHES…1880
M-5 BUZZER IS ABNORMAL…1882
a) CAUTION ITEMS FLASHES BUT BUZZER DOES NOT SOUND…1882
b) MONITOR DISPLAY IS NORMAL, BUT BUZZER SOUNDS…1882
M-6 WARNING LAMP IS ABNORMAL…1883
a) CAUTION ITEM FLASHING BUT LAMP DOES NOT FLASH…1883
b) MONITOR DISPLAY IS NORMAL BUT LAMP FLASHES…1883
M-7 GAUGE IS ABNORMAL…1884
a) ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE…1884
b) ABNORMALITY IN POWER TRAIN OIL TEMPERATURE GAUGE…1885
c) ABNORMALITY IN FUEL LEVEL GAUGE…1886
M-8 SERVICE METER DOES NOT MOVE AFTER ENGINE IS STARTED…1890
M-9 MONITOR PANEL LIGHTING DOES NOT LIGHT UP (FRONT LAMPS ARE NORMAL)…1891
30 DISASSEMBLY AND ASSEMBLY…1893
METHOD OF USING MANUAL…1896
PRECAUTIONS WHEN CARRYING OUT OPERATION…1897
SPECIAL TOOL LIST…1899
SPECIAL TOOL SKETCH…1904
STARTING MOTOR…1905
REMOVAL…1905
INSTALLATION…1905
ALTERNATOR ASSEMBLY…1906
REMOVAL…1906
INSTALLATION…1906
ENGINE OIL COOLER CORE…1908
REMOVAL…1908
INSTALLATION…1908
FUEL INJECTION PUMP ASSEMBLY…1909
REMOVAL…1909
INSTALLATION…1910
WATER PUMP ASSEMBLY…1911
REMOVAL…1911
INSTALLATION…1911
TURBOCHARGER ASSEMBLY…1913
REMOVAL…1913
INSTALLATION…1913
NOZZLE HOLDER ASSEMBLY (D65P,EX,PX)…1914
REMOVAL…1914
INSTALLATION…1914
NOZZLE HOLDER ASSEMBLY (D65E)…1915
REMOVAL…1915
INSTALLATION…1915
THERMOSTAT ASSEMBLY…1916
REMOVAL…1916
INSTALLATION…1916
CYLINDER HEAD ASSEMBLY (D65P,EX,PX)…1918
REMOVAL…1918
INSTALLATION…1922
CYLINDER HEAD ASSEMBLY (D65E)…1930
REMOVAL…1930
INSTALLATION…1933
ENGINE FRONT SEAL…1940
REMOVAL…1940
INSTALLATION…1941
ENGINE REAR SEAL…1942
REMOVAL…1942
INSTALLATION…1943
AIR CONDITIONER COMPRESSOR ASSEMBLY…1946
REMOVAL…1946
INSTALLATION…1946
AIR CONDITIONER CONDENSER ASSEMBLY…1947
REMOVAL…1947
INSTALLATION…1947
FUEL TANK ASSEMBLY…1948
REMOVAL…1948
INSTALLATION…1949
RADIATOR ASSEMBLY…1954
REMOVAL…1954
INSTALLATION…1956
ENGINE ASSEMBLY (CAB SPECIFICATION)…1957
REMOVAL…1957
INSTALLATION…1960
ENGINE ASSEMBLY (CANOPY SPECIFICATION)…1965
REMOVAL…1965
INSTALLATION…1967
DAMPER ASSEMBLY…1971
REMOVAL…1971
INSTALLATION…1973
POWER TRAIN UNIT ASSEMBLY (D65E,P)…1975
REMOVAL…1975
INSTALLATION…1980
POWER TRAIN UNIT ASSEMBLY (D65EX,PX)…1981
REMOVAL…1981
INSTALLATION…1986
POWER TRAIN UNIT (D65E,P)…1987
SEPARATION…1987
CONNECTION…1990
POWER TRAIN UNIT (D65EX,PX)…1991
SEPARATION…1991
CONNECTION…1994
TORQUE CONVERTER ASSEMBLY…1995
DISASSEMBLY…1995
ASSEMBLY…1997
PTO ASSEMBLY…2000
DISASSEMBLY…2000
ASSEMBLY…2003
TORQFLOW TRANSMISSION ASSEMBLY…2007
DISASSEMBLY…2007
ASSEMBLY…2026
STEERING CASE ASSEMBLY (D65E,P)…2054
DISASSEMBLY…2054
ASSEMBLY…2067
HSS ASSEMBLY (D65EX,PX)…2089
DISASSEMBLY…2089
ASSEMBLY…2110
TORQUE CONVERTER VALVE ASSEMBLY…2134
REMOVAL…2134
INSTALLATION…2134
DISASSEMBLY…2135
ASSEMBLY…2135
TRANSMISSION CONTROL VALVE ASSEMBLY…2136
REMOVAL…2136
INSTALLATION…2136
DISASSEMBLY…2138
ASSEMBLY…2138
STEERING CONTROL VALVE ASSEMBLY (D65E,P)…2142
REMOVAL…2142
INSTALLATION…2142
DISASSEMBLY…2143
ASSEMBLY…2145
BRAKE VALVE ASSEMBLY (D65EX,PX)…2147
REMOVAL…2147
INSTALLATION…2147
DISASSEMBLY…2148
ASSEMBLY…2149
REDUCING VALVE ASSEMBLY (D65E,P)…2150
REMOVAL…2150
INSTALLATION…2150
DISASSEMBLY…2151
ASSEMBLY…2151
HSS MOTOR ASSEMBLY (D65EX,PX)…2152
REMOVAL…2152
INSTALLATION…2152
DISASSEMBLY…2153
ASSEMBLY…2157
SCAVENGING PUMP ASSEMBLY…2164
REMOVAL…2164
INSTALLATION…2164
POWER TRAIN PUMP ASSEMBLY…2165
REMOVAL…2165
INSTALLATION…2165
FINAL DRIVE ASSEMBLY…2166
REMOVAL…2166
INSTALLATION…2167
DISASSEMBLY…2168
ASSEMBLY…2172
TRACK FRAME ASSEMBLY…2177
REMOVAL…2177
INSTALLATION…2178
RECOIL SPRING ASSENBLY…2179
REMOVAL…2179
INSTALLATION…2179
DISASSEMBLY…2181
ASSEMBLY…2183
IDLER ASSEMBLY…2187
REMOVAL…2187
INSTALLATION…2187
DISASSEMBLY…2189
ASSEMBLY…2190
TRACK ROLLER ASSEMBLY…2195
REMOVAL…2195
INSTALLATION…2195
DISASSEMBLY…2196
ASSEMBLY…2197
CARRIER ROLLER ASSEMBLY (D65P,PX)…2199
REMOVAL…2199
INSTALLATION…2199
CARRIER ROLLER ASSEMBLY (D65E,EX)…2200
REMOVAL…2200
INSTALLATION…2200
DISASSEMBLY (D65E,P,EX,PX)…2201
ASSEMBLY (D65E,P,EX,PX)…2202
TRACK SHOE…2203
CHECKING BEFORE REMOVAL…2203
REMOVAL (NORMAL)…2203
REMOVAL (WHEN THERE IS ABNORMALITY INSIDE TRACK FRAME)…2204
INSTALLATION…2205
OVERALL DISASSEMBLY…2209
OVERALL ASSEMBLY…2214
PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS…2228
FIELD DISASSEMBLY OF ONE LINK…2229
FIELD ASSEMBLY OF ONE LINK…2230
PIVOT SHAFT ASSEMBLY…2236
REMOVAL…2236
INSTALLATION…2236
EQUALIZER BAR ASSEMBLY…2237
REMOVAL…2237
INSTALLATION…2238
EQUALIZER SIDE BUSHING…2239
REMOVAL…2239
INSTALLATION…2239
SEGMENT TEETH…2240
REMOVAL…2240
INSTALLATION…2240
WORK EQUIPMENT PUMP ASSEMBLY (D65E,P)…2241
REMOVAL…2241
INSTALLATION…2241
HSS, WORK EQUIPMENT PUMP ASSEMBLY (D65EX,PX)…2242
REMOVAL…2242
INSTALLATION…2242
DISASSEMBLY…2243
ASSEMBLY…2248
PPC PUMP ASSEMBLY…2257
REMOVAL…2257
INSTALLATION…2257
MAIN CONTROL VALVE ASSEMBLY…2258
REMOVAL…2258
INSTALLATION…2258
DISASSEMBLY (3-SPOOL VALVE)…2261
ASSEMBLY…2263
MAIN RELIEF VALVE…2269
REMOVAL…2269
INSTALLATION…2269
PPC VALVE ASSEMBLY…2270
REMOVAL (FOR WORK EQUIPMENT)…2270
INSTALLATION (FOR WORK EQUIPMENT)…2270
REMOVAL (D65EX,PX,FOR STEERING)…2272
INSTALLATION (D65EX,PX,FOR STEERING)…2273
DISASSEMBLY (FOR WORK EQUIPMENT)…2276
ASSEMBLY (FOR WORK EQUIPMENT)…2277
DISASSEMBLY (D65EX,PX,FOR STEERING) …2278
ASSEMBLY (D65EX,PX,FOR STEERING)…2279
PPC CHARGE RELIEF VALVE ASSEMBLY…2280
REMOVAL…2280
INSTALLATION…2280
DISASSEMBLY…2281
ASSEMBLY…2281
SUCTION VALVE ASSEMBLY…2282
REMOVAL…2282
INSTALLATION…2282
BLADE LIFT CYLINDER ASSEMBLY…2283
REMOVAL…2283
INSTALLATION…2283
BLADE TILT CYLINDER ASSEMBLY…2284
REMOVAL…2284
INSTALLATION…2284
HYDRAULIC CYLINDER ASSEMBLY (BLADE LIFT, BLADE TILT CYLINDER)…2285
DISASSEMBLY…2285
ASSEMBLY…2287
WORK EQUIPMENT ASSEMBLY…2290
REMOVAL…2290
INSTALLATION…2291
DISASSEMBLY…2292
ASSEMBLY…2294
RIPPER VALVE ASSEMBLY (OPT.)…2296
DISASSEMBLY…2296
ASSEMBLY…2297
ROPS GUARD…2298
REMOVAL…2298
INSTALLATION…2298
OPERATOR'S CAB ASSEMBLY…2299
REMOVAL…2299
INSTALLATION…2300
CANOPY ASSEMBLY…2301
REMOVAL…2301
INSTALLATION…2301
DASHBOARD ASSEMBLY…2302
REMOVAL…2302
INSTALLATION…2302
MONITOR ASSEMBLY…2303
REMOVAL…2303
INSTALLATION…2303
FLOOR FRAME ASSEMBLY (D65E,P)…2304
REMOVAL…2304
INSTALLATION…2307
FLOOR FRAME ASSEMBLY (D65EX,PX)…2312
REMOVAL…2312
INSTALLATION…2315
40 MAINTENANCE STANDARD…2320
ENGINE MOUNT…2321
POWER TRAIN UNIT MOUNT…2322
DAMPER, UNIVERSAL JOINT…2323
TORQUE CONVERTER, PTO…2324
TRANSMISSION…2326
TRANSMISSION CONTROL VALVE…2330
MAIN RELIEF VALVE…2333
BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE (D65E,P-12)…2334
BEVEL GEAR SHAFT, HSS STEERING BRAKE (1/2) (D65EX,PX-12)…2338
BEVEL GEAR SHAFT, HSS STEERING BRAKE (2/2) (D65EX,PX-12)…2340
BEVEL GEAR SHAFT, HSS STEERING BRAKE (1/2) (D65EX,PX-12)…2342
STEERING CONTROL VALVE (D65E,P-12)…2345
BEVEL GEAR SHAFT, HSS BRAKE VALVE (D65EX,PX-12)…2346
POWER TRAIN, LUBRICATION PUMP…2347
PPC PUMP…2348
PPC VALVE…2350
FOR STEERING (D65EX,PX-12)…2350
FOR BLADE LIFT, BLADE TILT, RIPPER LIFT (D65E,P-12,D65EX,PX-12)…2351
PPC CHARGE VALVE…2355
FINAL DRIVE…2356
HULL FRAME…2358
TRACK FRAME, RECOIL SPRING…2359
IDLER…2361
TRACK ROLLER…2364
CARRIER ROLLER…2366
SPROCKET TOOTH PROFILE…2367
TRACK SHOE (DRY TYPE)…2368
TRACK SHOE (LUBRICATION TYPE)…2370
SUSPENSION…2372
HYDRAULIC PUMP (D65E,P-12)…2376
HYDRAULIC, HSS PUMP (D65EX,PX-12)…2378
HSS MOTOR (D65EX,PX-12)…2379
MAIN CONTROL VALVE…2380
2+1-SPOOL VALVE (D65E,P-12)…2380
3+1-SPOOL VALVE (D65EX,PX-12)…2390
WORK EQUIPMENT CYLINDER…2400
WORK EQUIPMENT…2402
CUTTING EDGE, END BIT…2408
RIPPER…2409
90 OTHERS…2410
SPECIFICATIONS…2411
SPECIFICATION DRAWING…2411
SPECIFICATIONS…2412
WEIGHT TABLE…2418
TABLE OF FUEL, COOLANT AND LUBRICANTS…2421
STRUCTURE AND FUNCTION…2422
REAR GUARD…2422
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM…2423
STEERING AND WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM…2424
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM…2426
WORK EQUIPMENT CONTROL…2427
MAIN CONTROL VALVE…2428
TRIMMING DOZER…2432
MAINTENANCE STANDARD…2433
MAIN CONTROL VALVE…2433
WORK EQUIPMENT CYLINDER…2442
TRIMMING DOZER…2444
D65EX,PX-12 (FOR KA SPEC.)…2445
STRUCTURE AND FUNCTION…2446
ENGINE CONTROL…2446
TRANSMISSION CONTROL…2447
STEERING AND BRAKE CONTROL…2448
PPC CONTROL PIPING DIAGRAM…2449
TESTING AND ADJUSTING…2450
STANDARD VALUE TABLE FOR CHASSIS…2450
ADJUSTING FUEL CONTROL LINKAGE…2452
ADJUSTING LINKAGE OF FORWARD-REVERSE LEVER, GEAR SHIFT LEVER, AND PARKING BRAKE LEVER…2454
TROUBLESHOOTING…2456
CONNECTOR TYPES AND MOUNTING LOCATIONS…2456
CONNECTOR POSITION DRAWING…2457
ELECTRIC CIRCUIT DIAGRAM…2459
ELECTRIC CIRCUIT DIAGRAM FOR CAB…2459
CAB SPECIFICATION…2460
CANOPY SPECIFICATION…2461
SEBM001922 – Bulldozer D65E,P-12 & D65EX,PX-12 Shop Manual (SN60001&up)…2462
COVER…2462
CONTENTS…2463
01 GENERAL…2490
GENERAL ASSEMBLY DRAWING…2491
SPECIFICATIONS…2495
WEIGHT TABLE…2511
TABLE OF FUEL, COOLANT AND LUBRICANTS…2517
10 STRUCTURE AND FUNCTION…2519
RADIATOR,OIL COOLER…2520
ENGINE CONTROL…2522
POWER TRAIN SYSTEM…2525
POWER TRAIN SKELETON…2526
POWER TRAIN UNIT…2529
POWER TRAIN HYDRAULIC PIPING DIAGRAM…2531
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM…2535
POWER TRAIN HYDRAULIC SYSTEM DIAGRAM…2536
DAMPER,UNIVERSAL JOINT…2540
TORQUE CONVERTER AND PTO…2542
TRANSMISSION CONTROL…2544
TRANSMISSION…2547
TRANSMISSION CONTROL VALVE…2556
MAIN RELIEF VALVE…2565
LUBRICATION RELIEF VALVE…2567
STEERING,BRAKE CONTROL…2568
BEVEL GEAR SHAFT, STEERING CLUTCH,STEERING BRAKE (D65E,P-12)…2570
STEERING CONTROL VALVE (D65E,P-12)…2583
STEERING BRAKE VALVE (D65E,P-12)…2590
REDUCING VALVE…2594
STEERING AND BRAKE CONTROL (D65EX,PX-12)…2596
BEVEL GEAR SHAFT, HSS STEERING AND BRAKE (D65EX,PX-12)…2599
BEVEL GEAR SHAFT, HSS BRAKE VALVE (D65EX,PX-12)…2620
SCAVENGING PUMP STRAINER…2624
POWER TRAIN OIL STRAINER…2625
POWER TRAIN OIL FILTER…2626
FINAL DRIVE…2627
MAIN FRAME…2630
TRACK FRAME…2631
RECOIL SPRING…2633
SUSPENSION…2635
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM…2639
ANGLEDOZER…2639
STRAIGHT TILTDOZER…2641
POWER PITCH DOZER…2643
RIPPER…2645
PPC CONTROL PIPING DIAGRAM…2646
WORK EQUIPMENT CONTROL…2651
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM…2653
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM…2654
STEERING AND WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM…2661
STEERING AND WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM…2662
HYDRAULIC TANK AND FILTER…2669
HYDRAULIC,HSS PUMP (D65EX,PX-12)…2673
PPC VALVE (FOR STEERING) (D65EX,PX-12)…2688
PPC VALVE (FOR STEERING) (D65E,P-12)…2695
PPC VALVE (FOR BLADE LIFT, TILT AND RIPPER)…2699
PPC CHARGE VALVE…2712
PPC LOCK VALVE…2714
MAIN CONTROL VALVE (2-SPOOL VALVE) (D65E,P-12)…2715
MAIN CONTROL VALVE (2-SPOOL VALVE) (D65EX,PX-12)…2753
POWER PITCH SELECTOR VALVE…2805
HSS MOTOR…2808
OPERATION OF STEERING, WORK EQUIPMENT CONTROL CIRCUIT…2813
SUCTION VALVE…2821
PISTON VALVE…2825
WORK EQUIPMENT…2826
ELECTRICAL CIRCUIT DIAGRAM…2830
ENGINE CONTROL…2842
MACHINE MONITOR SYSTEM…2843
SENSORS…2847
20 TESTING AND ADJUSTING…2850
STANDARD VALUE TABLE FOR ENGINE…2851
STANDARD VALUE TABLE FOR CHASSIS…2859
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM…2888
TOOL LIST FOR TESTING AND ADJUSTING…2891
ADJUSTING VALVE CLEARANCE…2893
MEASURING COMPRESSION PRESSURE…2894
MEASURING BLOWBY…2895
ADJUSTING FULE INJECTION TIMING…2896
MEASURING EXHAUST COLOR…2898
MEASURING BOOST PRESSURE…2899
MEASURING EXHAUST TEMPERATURE (D65P,EX,PX-12)…2900
MEASURING ENGINE OIL PRESSURE…2901
MEASURING ENGINE SPEED…2901
TESTING FAN BELT TENSION…2902
MEASURING SPEED AT TORQUE CONVERTER STALL…2903
ADJUSTING FULE CONTROL LINKAGE…2904
ADJUSTING STEERING AND DIRECTIONAL LEVER, GEAR SHIFT LEVER, PARKING BRAKE LEVER LINKAGE (D65E,P)…2910
ADJUSTING DIRECTIONAL LEVER, GEAR SHIFT LEVER, PARKING BRAKE LINKAGE (D65EX,PX)…2917
ADJUSTING BRAKE PEDAL LINKAGE…2923
D65E,P…2923
D65EX,PX…2925
ADJUSTING WORK EQUIPMENT CONTROL LINKAGE…2926
ADJUSTING STRAIGHT TILTDOZER…2928
ADJUSTING PPC VALVE…2930
MEASURING POWER TRAIN OIL PRESSURE…2931
D65E,P…2931
D65EX,PX…2938
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE (D65E,P)…2945
TESTING AND ADJUSTING WORK EQUIPMENT, STEERING HYDRAULIC PRESSURE (D65EX,PX)…2946
TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE…2948
MEASURING OUTPUT PRESSURE OF PPC VALVE…2950
MEASURING OIL LEAKAGE FROM HSS MOTOR (D65EX,PX)…2952
MEASURING LEAKAGE INSIDE CYLINDER…2952
BLEEDING AIR FROM HYDRAULIC CYLINDER…2953
RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT…2953
PROCEDURE FOR SIMPLE TEST OF STEERING BRAKE PERFORMANCE…2954
PROCEDURE FOR TESTING SENSORS…2955
TESTING AND ADJUSTING "OPEN" AND "CLOSE" LOCK AND STEADY REST OF OPERATORS CAB DOOR…2957
TROUBLESHOOTING…2960
POINTS TO REMEMBER WHEN TROUBLESHOOTING…2961
SEQUENCE OF EVENTS IN TROUBLESHOOTING…2962
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…2963
CHECKS BEFORE TROUBLESHOOTING…2971
METHOD OF USING MATRIX TROUBLESHOOTING CHART…2972
METHOD OF USING TROUBLESHOOTING CHARTS…2976
TYPE OF CONNECTOR AND POSITION OF INSTALLATION…2978
CONNECTOR POSITION DRAWING…2983
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…2985
ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM…3008
TROUBLESHOOTING OF ENGINE (S MODE)…3012
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)…3013
S-2 ENGING DOES NOT START…3014
(1) ENGINE DOES NOT TURN…3014
(2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)…3015
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)…3016
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)…3017
S-4 ENGINE STOPS DURING OPERATIONS…3018
S-5 ENGINE DOES NO ROTATE SMOOTHLY (HUNTING)…3019
S-6 ENGINE LACKS OUTPUT (NO POWER)…3020
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)…3021
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)…3022
S-9 OIL BECOMES CONTAMINATED QUICKLY…3023
S-10 FUEL CONSUMPTION IS EXCESSIVE…3024
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN…3025
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)…3026
S-13 OIL LEVEL RISES…3027
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)…3028
S-15 ABNORMAL NOISE IS MADE…3029
S-16 VIBRATION IS EXCESSIVE…3030
TROUBLESHOOTING OF HYDRAULIC,MECHANICAL SYSTEM (H MODE)…3031
TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC,MECHANICAL SYSTEMS)…3032
H-1 BRAKE DOES NOT WORK…3033
H-2 MACHINE DOES NOT TURN (CAN TRAVEL IN A STRAIGHT LINE) (D65E,P-12)…3034
H-3 TURNING SPEED IS SLOW (CANNOT TURN) OR LACKS POWER WHEN TURNING (D65EX,PX-12)…3036
H-4 OVERRUNS WHEN TURNING (D65E,P-12)…3038
H-5 CAN TURN IN ONLY ONE DIRECTION (WHEN STEERING LEVER IS OPERATED) (D65E,P-12)…3039
H-6 EXCESSIVE TIME LAG…3041
H-7 MACHINE CAN TRAVEL IN ONLY ONE DIRECTION (FORWARD OR REVERSE)…3041
H-8 MACHINE DOES NOT MOVE (WHEN ENGINE IS STARTED AND LEVER IS SHIFTED TO 2ND OR 3RD)…3042
1) D65E,P-12…3042
2) D65EX,PX-12…3044
H-9 MACHINE DOES NOT MOVE IN ANY SPEED RANGE…3046
1) D65E,P-12…3046
2) D65EX,PX-12…3048
H-10 POWER TRAIN OIL TEMPERATURE RISES TOO HIGH…3050
H-11 DRAWBAR PULL IS WEEK,TRAVEL SPEED IS SLOW…3052
1) D65E,P-12…3052
2) D65EX,PX-12…3054
H-13 ABNORMAL NOISES IS GENERATED FROM AROUND HYDRAULIC PUMP OR HYDRAULIC,HSS PUMP…3055
H-14 SPEED OF ALL WORK EQUIPMENT IS SLOW (D65E,P-12)…3056
H-15 NO WORK EQUIPMENT MOVES (D65E,P-12)…3058
H-16 ALL WORK EQUIPMENT LACKS POWER (D65E,P-12)…3058
H-17 TURNING SPEED AND SPEED OF ALL WORK EQUIPMENT IS SLOW (D65EX,PX-12)…3059
H-18 MACHINE CANNOT TURN AND NO WORK EQUIPMENT MOVES (D65EX,PX-12)…3061
H-19 TURNING AND ALL WORK EQUIPMENT LACKS POWER (D65EX,PX-12)…3061
H-20 BLADE LIFTING SPEED IS SLOW OR LACKS POWER…3062
1) D65E,P-12…3062
2) D65EX,PX-12…3062
H-21 BLADE TILT SPEED IS SLOW OR LACKS POWER…3063
1) D65E,P-12…3063
2) D65EX,PX-12…3063
H-22 HYDRAULIC DRIFT OF BLADE LIFY IS EXCESSIVE…3064
H-23 HYDRAULIC DRIFT OF BLADE TILT IS EXCESSIVE…3064
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)…3065
TABLE OF FAILURE MODES AND CAUSES (ELECTRICAL SYSTEM)…3066
E-1 STARTING MOTOR IS NOT CRANKED WHEN STARTING SWITCH IS TURNED TO 0N…3067
E-2 LAMP DO NOT LIGHT UP…3073
a) FRONT LAMPS…3073
b) REAR LAMPS…3074
E-4 AUTOMATIC PREHEATING IS NOT CARRIED OUT WHEN GLOW SWITCH IS TURNED TO AUTO …3077
E-5 WIPER DOES NOT WORK…3083
E-6 NO WASHER FLUID IS SPRAYED OUT…3085
E-7 AIR CONDITION HAS NOT EFFECT…3087
a) NO AIR COMES OUT…3087
b) DOES NOT BECOME COOL …3091
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)…3095
TABLE OF FAILURE MODES AND CAUSES (MACHINE MONITOR SYSTEM)…3096
M-1 NO DISPLAY IS GIVEN ON MONITOR PANEL WHEN STARTING SWITCH IS TURNED TO ON…3097
M-2 WHEN STARTING SWITCH IS TURNED ON, ALL MONITOR PANEL LAMPS LIGHT UP AND DO NOT GO OUT…3097
M-3 PREHEATING DISPLAY IS ABNORMAL…3098
a) PREHEATING MONITOR DOES NOT LIGHT UP…3098
b) PREHEATING MONITOR DOES NOT GO OUT…3098
M-4 CAUTION ITEMS LIGHT UP OR FLASH…3104
a) (CHARGE) LIGHTS UP OR FLASHES…3104
b) WHEN STARTING SWITCH AT ON AND ENGINE IS STARTED (ENGINE OIL PRESSURE) LIGHTS UP OR FLASHES…3105
c) (COOLANT TEMPERATURE) FLASHES…3106
d) (POWER TRAIN OIL TEMPERATURE) FLASHES…3108
M-5 BUZZER IS ABNORMAL…3110
a) CAUTION ITEMS FLASHES BUT BUZZER DOES NOT SOUND…3110
b) MONITOR DISPLAY IS NORMAL, BUT BUZZER SOUNDS…3110
M-6 WARNING LAMP IS ABNORMAL…3111
a) CAUTION ITEM FLASHING BUT LAMP DOES NOT FLASH…3111
b) MONITOR DISPLAY IS NORMAL BUT LAMP FLASHES…3111
M-7 GAUGE IS ABNORMAL…3112
a) ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE…3112
b) ABNORMALITY IN POWER TRAIN OIL TEMPERATURE GAUGE…3113
c) ABNORMALITY IN FUEL LEVEL GAUGE…3114
M-8 SERVICE METER DOES NOT MOVE AFTER ENGINE IS STARTED…3118
M-9 MONITOR PANEL LIGHTING DOES NOT LIGHT UP (FRONT LAMPS ARE NORMAL)…3119
30 DISASSEMBLY AND ASSEMBLY…3121
METHOD OF USING MANUAL…3124
PRECAUTIONS WHEN CARRYING OUT OPERATION…3125
SPECIAL TOOL LIST…3127
SPECIAL TOOL SKETCH…3132
STARTING MOTOR…3133
REMOVAL…3133
INSTALLATION…3133
ALTERNATOR ASSEMBLY…3134
REMOVAL…3134
INSTALLATION…3134
ENGINE OIL COOLER CORE…3136
REMOVAL…3136
INSTALLATION…3136
FUEL INJECTION PUMP ASSEMBLY…3137
REMOVAL…3137
INSTALLATION…3138
WATER PUMP ASSEMBLY…3139
REMOVAL…3139
INSTALLATION…3139
TURBOCHARGER ASSEMBLY…3141
REMOVAL…3141
INSTALLATION…3141
NOZZLE HOLDER ASSEMBLY (D65P,EX,PX)…3142
REMOVAL…3142
INSTALLATION…3142
NOZZLE HOLDER ASSEMBLY (D65E)…3143
REMOVAL…3143
INSTALLATION…3143
THERMOSTAT ASSEMBLY…3144
REMOVAL…3144
INSTALLATION…3144
CYLINDER HEAD ASSEMBLY (D65P,EX,PX)…3146
REMOVAL…3146
INSTALLATION…3150
CYLINDER HEAD ASSEMBLY (D65E)…3158
REMOVAL…3158
INSTALLATION…3161
ENGINE FRONT SEAL…3168
REMOVAL…3168
INSTALLATION…3169
ENGINE REAR SEAL…3170
REMOVAL…3170
INSTALLATION…3171
AIR CONDITIONER COMPRESSOR ASSEMBLY…3174
REMOVAL…3174
INSTALLATION…3174
AIR CONDITIONER CONDENSER ASSEMBLY…3175
REMOVAL…3175
INSTALLATION…3175
FUEL TANK ASSEMBLY…3176
REMOVAL…3176
INSTALLATION…3177
RADIATOR ASSEMBLY…3182
REMOVAL…3182
INSTALLATION…3184
ENGINE ASSEMBLY (CAB SPECIFICATION)…3185
REMOVAL…3185
INSTALLATION…3188
ENGINE ASSEMBLY (CANOPY SPECIFICATION)…3193
REMOVAL…3193
INSTALLATION…3195
DAMPER ASSEMBLY…3199
REMOVAL…3199
INSTALLATION…3201
POWER TRAIN UNIT ASSEMBLY (D65E,P)…3203
REMOVAL…3203
INSTALLATION…3208
POWER TRAIN UNIT ASSEMBLY (D65EX,PX)…3209
REMOVAL…3209
INSTALLATION…3214
POWER TRAIN UNIT (D65E,P)…3215
SEPARATION…3215
CONNECTION…3218
POWER TRAIN UNIT (D65EX,PX)…3219
SEPARATION…3219
CONNECTION…3222
TORQUE CONVERTER ASSEMBLY…3223
DISASSEMBLY…3223
ASSEMBLY…3225
PTO ASSEMBLY…3228
DISASSEMBLY…3228
ASSEMBLY…3231
TORQFLOW TRANSMISSION ASSEMBLY…3235
DISASSEMBLY…3235
ASSEMBLY…3254
STEERING CASE ASSEMBLY (D65E,P)…3282
DISASSEMBLY…3282
ASSEMBLY…3295
HSS ASSEMBLY (D65EX,PX)…3317
DISASSEMBLY…3317
ASSEMBLY…3338
TORQUE CONVERTER VALVE ASSEMBLY…3362
REMOVAL…3362
INSTALLATION…3362
DISASSEMBLY…3363
ASSEMBLY…3363
TRANSMISSION CONTROL VALVE ASSEMBLY…3364
REMOVAL…3364
INSTALLATION…3364
DISASSEMBLY…3366
ASSEMBLY…3366
STEERING CONTROL VALVE ASSEMBLY (D65E,P)…3370
REMOVAL…3370
INSTALLATION…3370
DISASSEMBLY…3371
ASSEMBLY…3373
BRAKE VALVE ASSEMBLY (D65EX,PX)…3375
REMOVAL…3375
INSTALLATION…3375
DISASSEMBLY…3376
ASSEMBLY…3377
REDUCING VALVE ASSEMBLY (D65E,P)…3378
REMOVAL…3378
INSTALLATION…3378
DISASSEMBLY…3379
ASSEMBLY…3379
HSS MOTOR ASSEMBLY (D65EX,PX)…3380
REMOVAL…3380
INSTALLATION…3380
DISASSEMBLY…3381
ASSEMBLY…3385
SCAVENGING PUMP ASSEMBLY…3392
REMOVAL…3392
INSTALLATION…3392
POWER TRAIN PUMP ASSEMBLY…3393
REMOVAL…3393
INSTALLATION…3393
FINAL DRIVE ASSEMBLY…3394
REMOVAL…3394
INSTALLATION…3395
DISASSEMBLY…3396
ASSEMBLY…3400
TRACK FRAME ASSEMBLY…3405
REMOVAL…3405
INSTALLATION…3406
RECOIL SPRING ASSENBLY…3407
REMOVAL…3407
INSTALLATION…3407
DISASSEMBLY…3409
ASSEMBLY…3411
IDLER ASSEMBLY…3415
REMOVAL…3415
INSTALLATION…3415
DISASSEMBLY…3417
ASSEMBLY…3418
TRACK ROLLER ASSEMBLY…3423
REMOVAL…3423
INSTALLATION…3423
DISASSEMBLY…3424
ASSEMBLY…3425
CARRIER ROLLER ASSEMBLY (D65P,PX)…3427
REMOVAL…3427
INSTALLATION…3427
CARRIER ROLLER ASSEMBLY (D65E,EX)…3428
REMOVAL…3428
INSTALLATION…3428
DISASSEMBLY (D65E,P,EX,PX)…3429
ASSEMBLY (D65E,P,EX,PX)…3430
TRACK SHOE…3431
CHECKING BEFORE REMOVAL…3431
REMOVAL (NORMAL)…3431
REMOVAL (WHEN THERE IS ABNORMALITY INSIDE TRACK FRAME)…3432
INSTALLATION…3433
OVERALL DISASSEMBLY…3437
OVERALL ASSEMBLY…3442
PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS…3456
FIELD DISASSEMBLY OF ONE LINK…3457
FIELD ASSEMBLY OF ONE LINK…3458
PIVOT SHAFT ASSEMBLY…3464
REMOVAL…3464
INSTALLATION…3464
EQUALIZER BAR ASSEMBLY…3465
REMOVAL…3465
INSTALLATION…3466
EQUALIZER SIDE BUSHING…3467
REMOVAL…3467
INSTALLATION…3467
SEGMENT TEETH…3468
REMOVAL…3468
INSTALLATION…3468
WORK EQUIPMENT PUMP ASSEMBLY (D65E,P)…3469
REMOVAL…3469
INSTALLATION…3469
HSS, WORK EQUIPMENT PUMP ASSEMBLY (D65EX,PX)…3470
REMOVAL…3470
INSTALLATION…3470
DISASSEMBLY…3471
ASSEMBLY…3476
PPC PUMP ASSEMBLY…3485
REMOVAL…3485
INSTALLATION…3485
MAIN CONTROL VALVE ASSEMBLY…3486
REMOVAL…3486
INSTALLATION…3486
DISASSEMBLY (3-SPOOL VALVE)…3489
ASSEMBLY…3491
MAIN RELIEF VALVE…3497
REMOVAL…3497
INSTALLATION…3497
PPC VALVE ASSEMBLY…3498
REMOVAL (FOR WORK EQUIPMENT)…3498
INSTALLATION (FOR WORK EQUIPMENT)…3498
REMOVAL (D65EX,PX,FOR STEERING)…3500
INSTALLATION (D65EX,PX,FOR STEERING)…3501
DISASSEMBLY (FOR WORK EQUIPMENT)…3504
ASSEMBLY (FOR WORK EQUIPMENT)…3505
DISASSEMBLY (D65EX,PX,FOR STEERING) …3506
ASSEMBLY (D65EX,PX,FOR STEERING)…3507
PPC CHARGE RELIEF VALVE ASSEMBLY…3508
REMOVAL…3508
INSTALLATION…3508
DISASSEMBLY…3509
ASSEMBLY…3509
SUCTION VALVE ASSEMBLY…3510
REMOVAL…3510
INSTALLATION…3510
BLADE LIFT CYLINDER ASSEMBLY…3511
REMOVAL…3511
INSTALLATION…3511
BLADE TILT CYLINDER ASSEMBLY…3512
REMOVAL…3512
INSTALLATION…3512
HYDRAULIC CYLINDER ASSEMBLY (BLADE LIFT, BLADE TILT CYLINDER)…3513
DISASSEMBLY…3513
ASSEMBLY…3515
WORK EQUIPMENT ASSEMBLY…3518
REMOVAL…3518
INSTALLATION…3519
DISASSEMBLY…3520
ASSEMBLY…3522
RIPPER VALVE ASSEMBLY (OPT.)…3524
DISASSEMBLY…3524
ASSEMBLY…3525
ROPS GUARD…3526
REMOVAL…3526
INSTALLATION…3526
OPERATOR'S CAB ASSEMBLY…3527
REMOVAL…3527
INSTALLATION…3528
CANOPY ASSEMBLY…3529
REMOVAL…3529
INSTALLATION…3529
DASHBOARD ASSEMBLY…3530
REMOVAL…3530
INSTALLATION…3530
MONITOR ASSEMBLY…3531
REMOVAL…3531
INSTALLATION…3531
FLOOR FRAME ASSEMBLY (D65E,P)…3532
REMOVAL…3532
INSTALLATION…3535
FLOOR FRAME ASSEMBLY (D65EX,PX)…3540
REMOVAL…3540
INSTALLATION…3543
40 MAINTENANCE STANDARD…3548
ENGINE MOUNT…3549
POWER TRAIN UNIT MOUNT…3550
DAMPER, UNIVERSAL JOINT…3551
TORQUE CONVERTER, PTO…3552
TRANSMISSION…3554
TRANSMISSION CONTROL VALVE…3558
MAIN RELIEF VALVE…3561
BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE (D65E,P-12)…3562
BEVEL GEAR SHAFT, HSS STEERING BRAKE (1/2) (D65EX,PX-12)…3566
BEVEL GEAR SHAFT, HSS STEERING BRAKE (2/2) (D65EX,PX-12)…3568
BEVEL GEAR SHAFT, HSS STEERING BRAKE (1/2) (D65EX,PX-12)…3570
STEERING CONTROL VALVE (D65E,P-12)…3573
BEVEL GEAR SHAFT, HSS BRAKE VALVE (D65EX,PX-12)…3574
POWER TRAIN, LUBRICATION PUMP…3575
PPC PUMP…3576
PPC VALVE…3578
FOR STEERING (D65EX,PX-12)…3578
FOR BLADE LIFT, BLADE TILT, RIPPER LIFT (D65E,P-12,D65EX,PX-12)…3579
PPC CHARGE VALVE…3583
FINAL DRIVE…3584
HULL FRAME…3586
TRACK FRAME, RECOIL SPRING…3587
IDLER…3589
TRACK ROLLER…3592
CARRIER ROLLER…3594
SPROCKET TOOTH PROFILE…3595
TRACK SHOE (DRY TYPE)…3596
TRACK SHOE (LUBRICATION TYPE)…3598
SUSPENSION…3600
HYDRAULIC PUMP (D65E,P-12)…3604
HYDRAULIC, HSS PUMP (D65EX,PX-12)…3606
HSS MOTOR (D65EX,PX-12)…3607
MAIN CONTROL VALVE…3608
2+1-SPOOL VALVE (D65E,P-12)…3608
3+1-SPOOL VALVE (D65EX,PX-12)…3618
WORK EQUIPMENT CYLINDER…3628
WORK EQUIPMENT…3630
CUTTING EDGE, END BIT…3636
RIPPER…3637
90 OTHERS…3638
SPECIFICATIONS…3639
SPECIFICATION DRAWING…3639
SPECIFICATIONS…3640
WEIGHT TABLE…3646
TABLE OF FUEL, COOLANT AND LUBRICANTS…3649
STRUCTURE AND FUNCTION…3650
REAR GUARD…3650
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM…3651
STEERING AND WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM…3652
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM…3654
WORK EQUIPMENT CONTROL…3655
MAIN CONTROL VALVE…3656
TRIMMING DOZER…3660
MAINTENANCE STANDARD…3661
MAIN CONTROL VALVE…3661
WORK EQUIPMENT CYLINDER…3670
TRIMMING DOZER…3672
D65EX,PX-12 (FOR KA SPEC.)…3673
STRUCTURE AND FUNCTION…3674
ENGINE CONTROL…3674
TRANSMISSION CONTROL…3675
STEERING AND BRAKE CONTROL…3676
PPC CONTROL PIPING DIAGRAM…3677
TESTING AND ADJUSTING…3678
STANDARD VALUE TABLE FOR CHASSIS…3678
ADJUSTING FUEL CONTROL LINKAGE…3680
ADJUSTING LINKAGE OF FORWARD-REVERSE LEVER, GEAR SHIFT LEVER, AND PARKING BRAKE LEVER…3682
TROUBLESHOOTING…3684
CONNECTOR TYPES AND MOUNTING LOCATIONS…3684
CONNECTOR POSITION DRAWING…3685
ELECTRIC CIRCUIT DIAGRAM…3687
ELECTRIC CIRCUIT DIAGRAM FOR CAB…3687
CAB SPECIFICATION…3688
CANOPY SPECIFICATION…3689
SEBM001923 – Bulldozer D65E,P-12 & D65EX,PX-12 Shop Manual (SN60001&up)…3690
COVER…3690
CONTENTS…3691
01 GENERAL…3718
GENERAL ASSEMBLY DRAWING…3719
SPECIFICATIONS…3723
WEIGHT TABLE…3739
TABLE OF FUEL, COOLANT AND LUBRICANTS…3745
10 STRUCTURE AND FUNCTION…3749
RADIATOR,OIL COOLER…3750
ENGINE CONTROL…3752
POWER TRAIN SYSTEM…3755
POWER TRAIN SKELETON…3756
POWER TRAIN UNIT…3760
POWER TRAIN HYDRAULIC PIPING DIAGRAM…3762
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM…3766
POWER TRAIN HYDRAULIC SYSTEM DIAGRAM…3767
DAMPER,UNIVERSAL JOINT…3771
TORQUE CONVERTER AND PTO…3773
TRANSMISSION CONTROL…3775
TRANSMISSION…3778
TRANSMISSION CONTROL VALVE…3787
MAIN RELIEF VALVE…3796
LUBRICATION RELIEF VALVE…3798
STEERING,BRAKE CONTROL…3799
BEVEL GEAR SHAFT, STEERING CLUTCH,STEERING BRAKE (D65E,P-12)…3801
STEERING CONTROL VALVE (D65E,P-12)…3814
STEERING BRAKE VALVE (D65E,P-12)…3821
REDUCING VALVE…3825
STEERING AND BRAKE CONTROL (D65EX,PX-12)…3827
BEVEL GEAR SHAFT, HSS STEERING AND BRAKE (D65EX,PX-12)…3830
BEVEL GEAR SHAFT, HSS BRAKE VALVE (D65EX,PX-12)…3851
SCAVENGING PUMP STRAINER…3855
POWER TRAIN OIL STRAINER…3856
POWER TRAIN OIL FILTER…3857
FINAL DRIVE…3858
MAIN FRAME…3864
TRACK FRAME…3865
RECOIL SPRING…3867
SUSPENSION…3871
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM…3875
ANGLEDOZER…3875
STRAIGHT TILTDOZER…3877
POWER PITCH DOZER…3879
RIPPER…3881
PPC CONTROL PIPING DIAGRAM…3882
WORK EQUIPMENT CONTROL…3887
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM…3889
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM…3890
STEERING AND WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM…3897
STEERING AND WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM…3898
HYDRAULIC TANK AND FILTER…3905
HYDRAULIC,HSS PUMP (D65EX,PX-12)…3909
PPC VALVE (FOR STEERING) (D65EX,PX-12)…3924
PPC VALVE (FOR STEERING) (D65E,P-12)…3931
PPC VALVE (FOR BLADE LIFT, TILT AND RIPPER)…3935
PPC CHARGE VALVE…3948
PPC LOCK VALVE…3950
MAIN CONTROL VALVE (2-SPOOL VALVE) (D65E,P-12)…3951
MAIN CONTROL VALVE (2-SPOOL VALVE) (D65EX,PX-12)…3989
POWER PITCH SELECTOR VALVE…4041
HSS MOTOR…4044
OPERATION OF STEERING, WORK EQUIPMENT CONTROL CIRCUIT…4049
SUCTION VALVE…4057
PISTON VALVE…4061
WORK EQUIPMENT…4062
ELECTRICAL CIRCUIT DIAGRAM…4066
ENGINE CONTROL…4078
MACHINE MONITOR SYSTEM…4079
SENSORS…4083
20 TESTING AND ADJUSTING…4086
STANDARD VALUE TABLE FOR ENGINE…4087
STANDARD VALUE TABLE FOR CHASSIS…4095
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM…4124
TOOL LIST FOR TESTING AND ADJUSTING…4127
ADJUSTING VALVE CLEARANCE…4129
MEASURING COMPRESSION PRESSURE…4130
MEASURING BLOWBY…4131
ADJUSTING FULE INJECTION TIMING…4132
MEASURING EXHAUST COLOR…4134
MEASURING BOOST PRESSURE…4135
MEASURING EXHAUST TEMPERATURE (D65P,EX,PX-12)…4136
MEASURING ENGINE OIL PRESSURE…4137
MEASURING ENGINE SPEED…4137
TESTING FAN BELT TENSION…4138
MEASURING SPEED AT TORQUE CONVERTER STALL…4139
ADJUSTING FULE CONTROL LINKAGE…4140
ADJUSTING STEERING AND DIRECTIONAL LEVER, GEAR SHIFT LEVER, PARKING BRAKE LEVER LINKAGE (D65E,P)…4146
ADJUSTING DIRECTIONAL LEVER, GEAR SHIFT LEVER, PARKING BRAKE LINKAGE (D65EX,PX)…4153
ADJUSTING BRAKE PEDAL LINKAGE…4159
D65E,P…4159
D65EX,PX…4161
ADJUSTING WORK EQUIPMENT CONTROL LINKAGE…4162
ADJUSTING STRAIGHT TILTDOZER…4164
ADJUSTING PPC VALVE…4166
MEASURING POWER TRAIN OIL PRESSURE…4167
D65E,P…4167
D65EX,PX…4174
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE (D65E,P)…4181
TESTING AND ADJUSTING WORK EQUIPMENT, STEERING HYDRAULIC PRESSURE (D65EX,PX)…4182
TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE…4184
MEASURING OUTPUT PRESSURE OF PPC VALVE…4186
MEASURING OIL LEAKAGE FROM HSS MOTOR (D65EX,PX)…4188
MEASURING LEAKAGE INSIDE CYLINDER…4188
BLEEDING AIR FROM HYDRAULIC CYLINDER…4189
RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT…4189
PROCEDURE FOR SIMPLE TEST OF STEERING BRAKE PERFORMANCE…4190
PROCEDURE FOR TESTING SENSORS…4191
TESTING AND ADJUSTING "OPEN" AND "CLOSE" LOCK AND STEADY REST OF OPERATORS CAB DOOR…4193
TROUBLESHOOTING…4196
POINTS TO REMEMBER WHEN TROUBLESHOOTING…4197
SEQUENCE OF EVENTS IN TROUBLESHOOTING…4198
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…4199
CHECKS BEFORE TROUBLESHOOTING…4207
METHOD OF USING MATRIX TROUBLESHOOTING CHART…4208
METHOD OF USING TROUBLESHOOTING CHARTS…4212
TYPE OF CONNECTOR AND POSITION OF INSTALLATION…4214
CONNECTOR POSITION DRAWING…4219
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…4221
ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM…4244
TROUBLESHOOTING OF ENGINE (S MODE)…4248
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)…4249
S-2 ENGING DOES NOT START…4250
(1) ENGINE DOES NOT TURN…4250
(2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)…4251
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)…4252
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)…4253
S-4 ENGINE STOPS DURING OPERATIONS…4254
S-5 ENGINE DOES NO ROTATE SMOOTHLY (HUNTING)…4255
S-6 ENGINE LACKS OUTPUT (NO POWER)…4256
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)…4257
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)…4258
S-9 OIL BECOMES CONTAMINATED QUICKLY…4259
S-10 FUEL CONSUMPTION IS EXCESSIVE…4260
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN…4261
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)…4262
S-13 OIL LEVEL RISES…4263
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)…4264
S-15 ABNORMAL NOISE IS MADE…4265
S-16 VIBRATION IS EXCESSIVE…4266
TROUBLESHOOTING OF HYDRAULIC,MECHANICAL SYSTEM (H MODE)…4267
TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC,MECHANICAL SYSTEMS)…4268
H-1 BRAKE DOES NOT WORK…4269
H-2 MACHINE DOES NOT TURN (CAN TRAVEL IN A STRAIGHT LINE) (D65E,P-12)…4270
H-3 TURNING SPEED IS SLOW (CANNOT TURN) OR LACKS POWER WHEN TURNING (D65EX,PX-12)…4272
H-4 OVERRUNS WHEN TURNING (D65E,P-12)…4274
H-5 CAN TURN IN ONLY ONE DIRECTION (WHEN STEERING LEVER IS OPERATED) (D65E,P-12)…4275
H-6 EXCESSIVE TIME LAG…4277
H-7 MACHINE CAN TRAVEL IN ONLY ONE DIRECTION (FORWARD OR REVERSE)…4277
H-8 MACHINE DOES NOT MOVE (WHEN ENGINE IS STARTED AND LEVER IS SHIFTED TO 2ND OR 3RD)…4278
1) D65E,P-12…4278
2) D65EX,PX-12…4280
H-9 MACHINE DOES NOT MOVE IN ANY SPEED RANGE…4282
1) D65E,P-12…4282
2) D65EX,PX-12…4284
H-10 POWER TRAIN OIL TEMPERATURE RISES TOO HIGH…4286
H-11 DRAWBAR PULL IS WEEK,TRAVEL SPEED IS SLOW…4288
1) D65E,P-12…4288
2) D65EX,PX-12…4290
H-13 ABNORMAL NOISES IS GENERATED FROM AROUND HYDRAULIC PUMP OR HYDRAULIC,HSS PUMP…4291
H-14 SPEED OF ALL WORK EQUIPMENT IS SLOW (D65E,P-12)…4292
H-15 NO WORK EQUIPMENT MOVES (D65E,P-12)…4294
H-16 ALL WORK EQUIPMENT LACKS POWER (D65E,P-12)…4294
H-17 TURNING SPEED AND SPEED OF ALL WORK EQUIPMENT IS SLOW (D65EX,PX-12)…4295
H-18 MACHINE CANNOT TURN AND NO WORK EQUIPMENT MOVES (D65EX,PX-12)…4297
H-19 TURNING AND ALL WORK EQUIPMENT LACKS POWER (D65EX,PX-12)…4297
H-20 BLADE LIFTING SPEED IS SLOW OR LACKS POWER…4298
1) D65E,P-12…4298
2) D65EX,PX-12…4298
H-21 BLADE TILT SPEED IS SLOW OR LACKS POWER…4299
1) D65E,P-12…4299
2) D65EX,PX-12…4299
H-22 HYDRAULIC DRIFT OF BLADE LIFY IS EXCESSIVE…4300
H-23 HYDRAULIC DRIFT OF BLADE TILT IS EXCESSIVE…4300
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)…4301
TABLE OF FAILURE MODES AND CAUSES (ELECTRICAL SYSTEM)…4302
E-1 STARTING MOTOR IS NOT CRANKED WHEN STARTING SWITCH IS TURNED TO 0N…4303
E-2 LAMP DO NOT LIGHT UP…4309
a) FRONT LAMPS…4309
b) REAR LAMPS…4310
E-4 AUTOMATIC PREHEATING IS NOT CARRIED OUT WHEN GLOW SWITCH IS TURNED TO AUTO …4313
E-5 WIPER DOES NOT WORK…4319
E-6 NO WASHER FLUID IS SPRAYED OUT…4321
E-7 AIR CONDITION HAS NOT EFFECT…4323
a) NO AIR COMES OUT…4323
b) DOES NOT BECOME COOL …4327
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)…4331
TABLE OF FAILURE MODES AND CAUSES (MACHINE MONITOR SYSTEM)…4332
M-1 NO DISPLAY IS GIVEN ON MONITOR PANEL WHEN STARTING SWITCH IS TURNED TO ON…4333
M-2 WHEN STARTING SWITCH IS TURNED ON, ALL MONITOR PANEL LAMPS LIGHT UP AND DO NOT GO OUT…4333
M-3 PREHEATING DISPLAY IS ABNORMAL…4334
a) PREHEATING MONITOR DOES NOT LIGHT UP…4334
b) PREHEATING MONITOR DOES NOT GO OUT…4334
M-4 CAUTION ITEMS LIGHT UP OR FLASH…4340
a) (CHARGE) LIGHTS UP OR FLASHES…4340
b) WHEN STARTING SWITCH AT ON AND ENGINE IS STARTED (ENGINE OIL PRESSURE) LIGHTS UP OR FLASHES…4341
c) (COOLANT TEMPERATURE) FLASHES…4342
d) (POWER TRAIN OIL TEMPERATURE) FLASHES…4344
M-5 BUZZER IS ABNORMAL…4346
a) CAUTION ITEMS FLASHES BUT BUZZER DOES NOT SOUND…4346
b) MONITOR DISPLAY IS NORMAL, BUT BUZZER SOUNDS…4346
M-6 WARNING LAMP IS ABNORMAL…4347
a) CAUTION ITEM FLASHING BUT LAMP DOES NOT FLASH…4347
b) MONITOR DISPLAY IS NORMAL BUT LAMP FLASHES…4347
M-7 GAUGE IS ABNORMAL…4348
a) ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE…4348
b) ABNORMALITY IN POWER TRAIN OIL TEMPERATURE GAUGE…4349
c) ABNORMALITY IN FUEL LEVEL GAUGE…4350
M-8 SERVICE METER DOES NOT MOVE AFTER ENGINE IS STARTED…4354
M-9 MONITOR PANEL LIGHTING DOES NOT LIGHT UP (FRONT LAMPS ARE NORMAL)…4355
30 DISASSEMBLY AND ASSEMBLY…4357
METHOD OF USING MANUAL…4360
PRECAUTIONS WHEN CARRYING OUT OPERATION…4361
SPECIAL TOOL LIST…4363
SPECIAL TOOL SKETCH…4369
STARTING MOTOR…4371
REMOVAL…4371
INSTALLATION…4371
ALTERNATOR ASSEMBLY…4372
REMOVAL…4372
INSTALLATION…4372
ENGINE OIL COOLER CORE…4374
REMOVAL…4374
INSTALLATION…4374
FUEL INJECTION PUMP ASSEMBLY…4375
REMOVAL…4375
INSTALLATION…4376
WATER PUMP ASSEMBLY…4377
REMOVAL…4377
INSTALLATION…4377
TURBOCHARGER ASSEMBLY…4379
REMOVAL…4379
INSTALLATION…4379
NOZZLE HOLDER ASSEMBLY (D65P,EX,PX)…4380
REMOVAL…4380
INSTALLATION…4380
NOZZLE HOLDER ASSEMBLY (D65E)…4381
REMOVAL…4381
INSTALLATION…4381
THERMOSTAT ASSEMBLY…4382
REMOVAL…4382
INSTALLATION…4382
CYLINDER HEAD ASSEMBLY (D65P,EX,PX)…4384
REMOVAL…4384
INSTALLATION…4388
CYLINDER HEAD ASSEMBLY (D65E)…4396
REMOVAL…4396
INSTALLATION…4399
ENGINE FRONT SEAL…4406
REMOVAL…4406
INSTALLATION…4407
ENGINE REAR SEAL…4408
REMOVAL…4408
INSTALLATION…4409
AIR CONDITIONER COMPRESSOR ASSEMBLY…4412
REMOVAL…4412
INSTALLATION…4412
AIR CONDITIONER CONDENSER ASSEMBLY…4413
REMOVAL…4413
INSTALLATION…4413
FUEL TANK ASSEMBLY…4414
REMOVAL…4414
INSTALLATION…4415
RADIATOR ASSEMBLY…4420
REMOVAL…4420
INSTALLATION…4422
ENGINE ASSEMBLY (CAB SPECIFICATION)…4423
REMOVAL…4423
INSTALLATION…4426
ENGINE ASSEMBLY (CANOPY SPECIFICATION)…4431
REMOVAL…4431
INSTALLATION…4433
DAMPER ASSEMBLY…4437
REMOVAL…4437
INSTALLATION…4439
POWER TRAIN UNIT ASSEMBLY (D65E,P)…4441
REMOVAL…4441
INSTALLATION…4446
POWER TRAIN UNIT ASSEMBLY (D65EX,PX)…4447
REMOVAL…4447
INSTALLATION…4452
POWER TRAIN UNIT (D65E,P)…4453
SEPARATION…4453
CONNECTION…4456
POWER TRAIN UNIT (D65EX,PX)…4457
SEPARATION…4457
CONNECTION…4460
TORQUE CONVERTER ASSEMBLY…4461
DISASSEMBLY…4461
ASSEMBLY…4463
PTO ASSEMBLY…4466
DISASSEMBLY…4466
ASSEMBLY…4469
TORQFLOW TRANSMISSION ASSEMBLY…4473
DISASSEMBLY…4473
ASSEMBLY…4492
STEERING CASE ASSEMBLY (D65E,P)…4520
DISASSEMBLY…4520
ASSEMBLY…4533
HSS ASSEMBLY (D65EX,PX)…4555
DISASSEMBLY…4555
ASSEMBLY…4576
TORQUE CONVERTER VALVE ASSEMBLY…4600
REMOVAL…4600
INSTALLATION…4600
DISASSEMBLY…4601
ASSEMBLY…4601
TRANSMISSION CONTROL VALVE ASSEMBLY…4602
REMOVAL…4602
INSTALLATION…4602
DISASSEMBLY…4604
ASSEMBLY…4604
STEERING CONTROL VALVE ASSEMBLY (D65E,P)…4608
REMOVAL…4608
INSTALLATION…4608
DISASSEMBLY…4609
ASSEMBLY…4611
BRAKE VALVE ASSEMBLY (D65EX,PX)…4613
REMOVAL…4613
INSTALLATION…4613
DISASSEMBLY…4614
ASSEMBLY…4615
REDUCING VALVE ASSEMBLY (D65E,P)…4616
REMOVAL…4616
INSTALLATION…4616
DISASSEMBLY…4617
ASSEMBLY…4617
HSS MOTOR ASSEMBLY (D65EX,PX)…4618
REMOVAL…4618
INSTALLATION…4618
DISASSEMBLY…4619
ASSEMBLY…4623
SCAVENGING PUMP ASSEMBLY…4630
REMOVAL…4630
INSTALLATION…4630
POWER TRAIN PUMP ASSEMBLY…4631
REMOVAL…4631
INSTALLATION…4631
FINAL DRIVE ASSEMBLY…4632
REMOVAL…4632
INSTALLATION…4633
DISASSEMBLY…4636
ASSEMBLY…4641
TRACK FRAME ASSEMBLY…4660
REMOVAL…4660
INSTALLATION…4661
RECOIL SPRING ASSENBLY…4662
REMOVAL…4662
INSTALLATION…4662
DISASSEMBLY…4664
ASSEMBLY…4666
IDLER ASSEMBLY…4670
REMOVAL…4670
INSTALLATION…4670
DISASSEMBLY…4672
ASSEMBLY…4673
TRACK ROLLER ASSEMBLY…4678
REMOVAL…4678
INSTALLATION…4678
DISASSEMBLY…4679
ASSEMBLY…4680
CARRIER ROLLER ASSEMBLY (D65P,PX)…4682
REMOVAL…4682
INSTALLATION…4682
CARRIER ROLLER ASSEMBLY (D65E,EX)…4683
REMOVAL…4683
INSTALLATION…4683
DISASSEMBLY (D65E,P,EX,PX)…4684
ASSEMBLY (D65E,P,EX,PX)…4685
TRACK SHOE…4686
CHECKING BEFORE REMOVAL…4686
REMOVAL (NORMAL)…4686
REMOVAL (WHEN THERE IS ABNORMALITY INSIDE TRACK FRAME)…4687
INSTALLATION…4688
OVERALL DISASSEMBLY…4692
OVERALL ASSEMBLY…4697
PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS…4711
FIELD DISASSEMBLY OF ONE LINK…4712
FIELD ASSEMBLY OF ONE LINK…4713
PIVOT SHAFT ASSEMBLY…4719
REMOVAL…4719
INSTALLATION…4719
EQUALIZER BAR ASSEMBLY…4720
REMOVAL…4720
INSTALLATION…4721
EQUALIZER SIDE BUSHING…4722
REMOVAL…4722
INSTALLATION…4722
SEGMENT TEETH…4723
REMOVAL…4723
INSTALLATION…4723
WORK EQUIPMENT PUMP ASSEMBLY (D65E,P)…4724
REMOVAL…4724
INSTALLATION…4724
HSS, WORK EQUIPMENT PUMP ASSEMBLY (D65EX,PX)…4725
REMOVAL…4725
INSTALLATION…4725
DISASSEMBLY…4726
ASSEMBLY…4731
PPC PUMP ASSEMBLY…4740
REMOVAL…4740
INSTALLATION…4740
MAIN CONTROL VALVE ASSEMBLY…4741
REMOVAL…4741
INSTALLATION…4741
DISASSEMBLY (3-SPOOL VALVE)…4744
ASSEMBLY…4746
MAIN RELIEF VALVE…4752
REMOVAL…4752
INSTALLATION…4752
PPC VALVE ASSEMBLY…4753
REMOVAL (FOR WORK EQUIPMENT)…4753
INSTALLATION (FOR WORK EQUIPMENT)…4753
REMOVAL (D65EX,PX,FOR STEERING)…4755
INSTALLATION (D65EX,PX,FOR STEERING)…4756
DISASSEMBLY (FOR WORK EQUIPMENT)…4759
ASSEMBLY (FOR WORK EQUIPMENT)…4760
DISASSEMBLY (D65EX,PX,FOR STEERING) …4761
ASSEMBLY (D65EX,PX,FOR STEERING)…4762
PPC CHARGE RELIEF VALVE ASSEMBLY…4763
REMOVAL…4763
INSTALLATION…4763
DISASSEMBLY…4764
ASSEMBLY…4764
SUCTION VALVE ASSEMBLY…4765
REMOVAL…4765
INSTALLATION…4765
BLADE LIFT CYLINDER ASSEMBLY…4766
REMOVAL…4766
INSTALLATION…4766
BLADE TILT CYLINDER ASSEMBLY…4767
REMOVAL…4767
INSTALLATION…4767
HYDRAULIC CYLINDER ASSEMBLY (BLADE LIFT, BLADE TILT CYLINDER)…4768
DISASSEMBLY…4768
ASSEMBLY…4770
WORK EQUIPMENT ASSEMBLY…4773
REMOVAL…4773
INSTALLATION…4774
DISASSEMBLY…4775
ASSEMBLY…4777
RIPPER VALVE ASSEMBLY (OPT.)…4779
DISASSEMBLY…4779
ASSEMBLY…4780
ROPS GUARD…4781
REMOVAL…4781
INSTALLATION…4781
OPERATOR'S CAB ASSEMBLY…4782
REMOVAL…4782
INSTALLATION…4783
CANOPY ASSEMBLY…4784
REMOVAL…4784
INSTALLATION…4784
DASHBOARD ASSEMBLY…4785
REMOVAL…4785
INSTALLATION…4785
MONITOR ASSEMBLY…4786
REMOVAL…4786
INSTALLATION…4786
FLOOR FRAME ASSEMBLY (D65E,P)…4787
REMOVAL…4787
INSTALLATION…4790
FLOOR FRAME ASSEMBLY (D65EX,PX)…4795
REMOVAL…4795
INSTALLATION…4798
40 MAINTENANCE STANDARD…4803
ENGINE MOUNT…4804
POWER TRAIN UNIT MOUNT…4805
DAMPER, UNIVERSAL JOINT…4806
TORQUE CONVERTER, PTO…4807
TRANSMISSION…4809
TRANSMISSION CONTROL VALVE…4813
MAIN RELIEF VALVE…4816
BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE (D65E,P-12)…4817
BEVEL GEAR SHAFT, HSS STEERING BRAKE (1/2) (D65EX,PX-12)…4821
BEVEL GEAR SHAFT, HSS STEERING BRAKE (2/2) (D65EX,PX-12)…4823
BEVEL GEAR SHAFT, HSS STEERING BRAKE (1/2) (D65EX,PX-12)…4825
STEERING CONTROL VALVE (D65E,P-12)…4828
BEVEL GEAR SHAFT, HSS BRAKE VALVE (D65EX,PX-12)…4829
POWER TRAIN, LUBRICATION PUMP…4830
PPC PUMP…4831
PPC VALVE…4833
FOR STEERING (D65EX,PX-12)…4833
FOR BLADE LIFT, BLADE TILT, RIPPER LIFT (D65E,P-12,D65EX,PX-12)…4834
PPC CHARGE VALVE…4838
FINAL DRIVE…4839
HULL FRAME…4847
TRACK FRAME, RECOIL SPRING…4849
IDLER…4851
TRACK ROLLER…4854
CARRIER ROLLER…4856
SPROCKET TOOTH PROFILE…4857
TRACK SHOE (DRY TYPE)…4858
TRACK SHOE (LUBRICATION TYPE)…4860
SUSPENSION…4862
HYDRAULIC PUMP (D65E,P-12)…4866
HYDRAULIC, HSS PUMP (D65EX,PX-12)…4868
HSS MOTOR (D65EX,PX-12)…4869
MAIN CONTROL VALVE…4870
2+1-SPOOL VALVE (D65E,P-12)…4870
3+1-SPOOL VALVE (D65EX,PX-12)…4880
WORK EQUIPMENT CYLINDER…4890
WORK EQUIPMENT…4892
CUTTING EDGE, END BIT…4898
RIPPER…4899
90 OTHERS…4900
SPECIFICATIONS…4901
SPECIFICATION DRAWING…4901
SPECIFICATIONS…4902
WEIGHT TABLE…4908
TABLE OF FUEL, COOLANT AND LUBRICANTS…4911
STRUCTURE AND FUNCTION…4912
REAR GUARD…4912
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM…4913
STEERING AND WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM…4914
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM…4916
WORK EQUIPMENT CONTROL…4917
MAIN CONTROL VALVE…4918
TRIMMING DOZER…4922
MAINTENANCE STANDARD…4923
MAIN CONTROL VALVE…4923
WORK EQUIPMENT CYLINDER…4932
TRIMMING DOZER…4934
D65EX,PX-12 (FOR KA SPEC.)…4935
STRUCTURE AND FUNCTION…4936
ENGINE CONTROL…4936
TRANSMISSION CONTROL…4937
STEERING AND BRAKE CONTROL…4938
PPC CONTROL PIPING DIAGRAM…4939
TESTING AND ADJUSTING…4940
STANDARD VALUE TABLE FOR CHASSIS…4940
ADJUSTING FUEL CONTROL LINKAGE…4942
ADJUSTING LINKAGE OF FORWARD-REVERSE LEVER, GEAR SHIFT LEVER, AND PARKING BRAKE LEVER…4944
TROUBLESHOOTING…4946
CONNECTOR TYPES AND MOUNTING LOCATIONS…4946
CONNECTOR POSITION DRAWING…4947
ELECTRIC CIRCUIT DIAGRAM…4949
ELECTRIC CIRCUIT DIAGRAM FOR CAB…4949
CAB SPECIFICATION…4950
CANOPY SPECIFICATION…4951
SEBM027202 – Bulldozer D65EX-12 & D65PX-12 (EU SPEC.) Shop Manual (SN65209&up)…4952
COVER…4952
CONTENTS…4953
01 GENERAL…4977
GENERAL ASSEMBLY DRAWING…4978
SPECIFICATIONS…4982
WEIGHT TABLE…4987
TABLE OF FUEL, COOLANT AND LUBRICANTS…4989
10 STRUCTURE AND FUNCTION…4990
RADIATOR, OIL COOLER…4991
ENGINE CONTROL…4993
POWER TRAIN SYSTEM…4994
POWER TRAIN SKELETON…4995
POWER TRAIN UNIT…4996
POWER TRAIN HYDRAULIC PIPING DIAGRAM…4997
DAMPER, UNIVERSAL JOINT…4998
TORQUE CONVERTER AND PTO…5000
TRANSMISSION CONTROL…5002
TRANSMISSION…5003
TRANSMISSION CONTROL VALVE…5010
MAIN RELIEF VALVE…5015
LUBRICATION RELIEF VALVE…5017
STEERING AND BRAKE CONTROL…5018
BEVEL GEAR SHAFT, HSS STEERING AND BRAKE…5019
BEVEL GEAR SHIFT, HSS BRAKE VALVE…5030
FINAL DRIVE…5034
MAIN FRAME…5037
TRACK FRAME…5038
RECOIL SPRING…5039
SUSPENSION…5040
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM…5042
PPC CONTROL PIPING DIAGRAM…5046
WORK EQUIPMENT CONTROL…5047
HYDRAULIC TANK AND FILTER…5048
HYDRAULIC, HSS PUMP…5050
PPC VALVE…5065
PPC VALVE…5072
PPC CHARGE VALVE…5080
MAIN CONTROL VALVE…5082
POWER PITCH SELECTOR VALVE…5108
HSS MOTOR…5111
OPERATION OF STEERING, WORK EQUIPMENT CONTROL CIRCUIT…5116
SUCTION VALVE…5124
PISTON VALVE…5126
ENGINE CONTROL…5127
ENGINE CONTROLLER…5131
VEHICLE CONTROLLER…5133
MONITOR SYSTEM…5135
20 TESTING AND ADJUSTING…5143
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS…5144
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS…5145
STANDARD VALUE TABLE FOR ELECTRICAL PARTS…5155
TESTING AND ADJUSTING…5160
TOOL LIST FOR TESTING AND ADJUSTING…5161
MEASURING ENGINE SPEED…5163
MEASURING TORQUE CONVERTER STALL SPEED…5164
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)…5165
MEASURING EXHAUST TEMPERATURE…5166
MEASURING EXHAUST COLOR…5167
ADJUSTING VALVE CLEARANCE…5168
MEASURING COMPRESSION PRESSURE…5169
MEASURING BLOW-BY PRESSURE…5171
MEASURING ENGINE OIL PRESSURE…5172
MEASURING FUEL PRESSURE…5173
HANDLING EQUIPMENT IN FUEL SYSTEM…5174
RELEASING REMAINING PRESSURE IN FUEL SYSTEM…5174
BLEEDING AIR FROM FUEL CIRCUIT…5175
REDUCED CYLINDER MODE OPERATION FOR ENGINE…5176
CHECKING FOR LEAKAGE IN FUEL SYSTEM…5177
ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL…5178
ADJUSTING DIRECTIONAL LEVER, GEAR SHIFT LEVER, PARKING BRAKE LINKAGE…5179
ADJUSTING BRAKE PEDAL LINKAGE…5181
ADJUSTING WORK EQUIPMENT CONTROL LINKAGE…5182
ADJUSTING STRAIGHT TILTDOZER…5183
ADJUSTING PPC VALVE…5185
MEASURING POWER TRAIN OIL PRESSURE…5186
MEASURING POWER TRAIN OIL PRESSURE…5188
TESTING AND ADJUSTING WORK EQUIPMENT, STEERING HYDRAULIC PRESSURE…5191
TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE…5193
MEASURING OUTPUT PRESSURE OF PPC VALVE…5194
MEASURING OIL LEAKAGE FROM HSS MOTOR…5195
MEASURING LEAKAGE INSIDE CYLINDER…5195
BLEEDING AIR FROM HYDRAULIC CYLINDER…5195
RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT…5196
PROCEDURE FOR SIMPLE TEST OF STEERING BRAKE PERFORMANCE…5196
PROCEDURE FOR TESTING SENSORS…5197
TESTING AND ADJUSTING "OPEN" AND "CLOSE" LOCK AND STEADY REST OF OPERATOR'S CAB DOOR…5199
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)…5202
HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER…5234
ADJUSTMENT METHOD OF REPLACED CONTROLLER…5234
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM…5235
TROUBLESHOOTING…5237
POINTS TO REMEMBER WHEN TROUBLESHOOTING…5238
SEQUENCE OF EVENTS IN TROUBLESHOOTING…5239
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…5240
CHECKS BEFORE TROUBLESHOOTING…5248
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING…5249
CONNECTOR ALLOCATION DRAWING AND ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM…5252
CIRCUIT DRAWING FOR ENGINE CONTROLLER SYSTEM…5258
CIRCUIT DRAWING FOR MACHINE CONTROLLER SYSTEM…5260
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM…5262
CIRCUIT DRAWING FOR OTHERS SYSTEM…5264
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…5266
TROUBLESHOOTING WHEN ERROR CODE IS DISPLAYED (ERROR CODE)…5289
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST…5291
TROUBLE CODE TABLE…5292
ERROR CODE [A000N1] (ENGINE: OVERRUN (N1))…5293
ERROR CODE [AB00MA] (ALTERNATOR: MAIFUNCTION (MA))…5294
ERROR CODE [AD00L2] (COMMON RAIL: SEE THE LIST. (L2))…5295
ERROR CODE [AD00MA] (COMMON RAIL: DEFECTIVE FUNCTION (MA))…5296
ERROR CODE [AD10L3] (FUEL SUPPLY PUMP: SEE THE LIST. (L3))…5296
ERROR CODE [AD10MA] (FUEL SUPPLY PUMP: DEFECTIVE FUNCTION (MA))…5299
ERROR CODE [AD10MB] (FUEL SUPPLY PUMP: FUNCTION REDUCTION (MB))…5299
ERROR CODE [AD11KA] (FUEL SUPPLY PUMP SOLENOID 1: DISCONNECTION IN WIRING (KA))…5300
ERROR CODE [AD11KB] (FUEL SUPPLY PUMP SOLENOID 1: SHORT CIRCUIT (KB))…5301
ERROR CODE [AD51KA] (FUEL SUPPLY PUMP SOLENOID 2: DISCONNECTION IN WIRING (KA))…5302
ERROR CODE [AD51KB] (FUEL SUPPLY PUMP SOLENOID 2: DISCONNECTION IN SHORT (KB))…5303
ERROR CODE [ADA1KA] (NO.1 INJECTOR SOLENOID: DISCONNECTION IN WIRING (KA))…5304
ERROR CODE [ADAZKB] (NO.1, 2, AND 3 INJECTOR SOLENOIDS: SHORT (KB))…5305
ERROR CODE [ADB1KA] (NO.2 INJECTOR SOLENOID: DISCONNECTION IN WIRING (KA))…5307
ERROR CODE [ADC1KA] (NO.3 INJECTOR SOLENOID: DISCONNECTION IN WIRING (KA))…5308
ERROR CODE [ADD1KA] (NO.4 INJECTOR SOLENOID: DISCONNECTION IN WIRING (KA))…5309
ERROR CODE [ADDZKB] (NO.4, 5, AND 6 INJECTOR SOLENOIDS: SHORT (KB))…5310
ERROR CODE [ADE1KA] (NO.5 FUEL INJECTOR SOLENOID: DISCONNECTION (KA))…5312
ERROR CODE [ADF1KA] (NO.6 FUEL INJECTOR SOLENOID: DISCONNECTION (KA))…5313
ERROR CODE [B@BAZG] (ENGINE OIL: OIL PRESSURE REDUCTION (ZG))…5314
ERROR CODE [B@BCNS] (RADIATOR COOLANT: OVERHEAT (NS))…5315
ERROR CODE [B@CENS] (POWER TRAN OIL: OVERHEAT (NS))…5316
ERROR CODE [B@HANS] (HYDRAULIC OIL: OVERHEAT (NS))…5317
ERROR CODE [D110KA] (BATTERY RELAY: SHORT CIRCUIT (KA))…5318
ERROR CODE [D110KB] (BATTERY RELAY: DISCONNECTION (KB))…5319
ERROR CODE [D182KZ] (INTAKE AIR HEATER RELAY CIRCUIT: DISCONNECTION OR SHORT CIRCUIT (KZ))…5320
ERROR CODE [D1D0KB] (ENGINE CONTROLLER LOAD POWER SUPPLY: SHORT CIRCUIT (KB))…5322
ERROR CODE [D5ZFKA] (TRANSMISSION NEUTRAL SIGNAL: DISCONNECTION (KA))…5323
ERROR CODE [D5ZFKB] (TRANSMISSION NEUTRAL SIGNAL: SHORT CIRCUIT (KB))…5324
ERROR CODE [DAFRKR] (MONITOR PANEL CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR))…5325
ERROR CODE [DAQ0KK] (TRANSMISSION CONTROLLER: SOURCE VOLTAGE REDUCTION/INPUT (KK))…5327
ERROR CODE [DAQ0KT] (TRANSMISSION CONTROLLER: ABNORMALITY IN CONTROLLER (KT))…5327
ERROR CODE [DAQ5KK] (TRANSMISSION CONTROLLER POTENTIOMETER POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK))…5328
ERROR CODE [DAQ6KK] (TRANSMISSION CONTROLLER SENSOR POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK))…5328
ERROR CODE [DAQ9KQ] (TRANSMISSION CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ))…5328
ERROR CODE [DB20KT] (ENGINE CONTROLLER POWER SUPPLY: ABNORMALITY IN CONTROLLER (KT))…5329
ERROR CODE [DB22KK] (ENGINE CONTROLLER LOAD POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK))…5330
ERROR CODE [DB29KQ] (ENGINE CONTROLLER TYPE SELECT: TYPE SELECT SIGNAL INCONSISTENCY (KQ))…5332
ERROR CODE [DB2AMA] (FUEL INJECTION AMOUNT ADJUSTMENT SWITCH SIGNAL: MALFUNCTION (MA))…5333
ERROR CODE [DB2RKR] (ENGINE CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR))…5334
ERROR CODE [DB2RMC] (ENGINE CONTROLLER DETECTION: DEFECTIVE CAN COMMUNICATION (MC))…5336
ERROR CODE [DB30KK] (MACHINE CONTROLLER: SOURCE VOLTAGE REDUCTION/INPUT (KK))…5337
ERROR CODE [DB30KT] (MACHINE CONTROLLER: ABNORMALITY IN CONTROLLER (KT))…5338
ERROR CODE [DB35KK] (MACHINE CONTROLLER POTENTIOMETER POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK))…5339
ERROR CODE [DB36KK] (MACHINE CONTROLLER SENSOR POWER SUPPLY: SOURCE VOLTAGE REDUCTION INPUT (KK))…5340
ERROR CODE [DB39KQ] (MACHINE CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ))…5341
ERROR CODE [DD11KB] (STARTING SWITCH: SHORT CIRCUIT (KB))…5342
ERROR CODE [DDE2L6] (ENGINE OIL PRESSURE SWITCH: INCONSISTENT WITH MACHINE STATE (L6))…5343
ERROR CODE [DGE2KX] (ENGINE WATER TEMPERATURE SENSOR (FOR HIGH TEMPERATURE): INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))…5345
ERROR CODE [DGE3L6] (ENGINE WATER TEMPERATURE SENSOR (FOR LOW TEMPERATURE): INCONSISTENT WITH MACHINE STATE (L6))…5346
ERROR CODE [DGE4KX] (FUEL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))…5347
ERROR CODE [DGS1KX] (HYDRAULIC OIL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))…5348
ERROR CODE [DH30KX] (BOOST PRESSURE SENSOR: INPUT IS OUT OF NORMAL RANGE (KX))…5349
ERROR CODE [DH40KX] (COMMON RAIL PRESSURE SENSOR: INPUT IS OUT OF NORMAL RANGE (KX))…5351
ERROR CODE [DK10KX] (FUEL CONTROL DIAL: INPUT IS OUT OF NORMAL RANGE (KX))…5353
ERROR CODE [DK12KX] (DECELERATION POTENTIOMETER: INPUT IS OUT OF NORMAL RANGE (KX))…5355
ERROR CODE [DLE3LC] (ENGINE NE SPEED SENSOR: INPUT SIGNAL OF TWO SYSTEMS INCONSISTENCY (LC))…5357
ERROR CODE [DLH1LC] (ENGINE G SPEED SENSOR: INPUT SIGNAL OF TWO SYSTEMS INCONSISTENCY (LC))…5359
ERROR CODE [DNCAKA] (TRANSMISSION FNR DETECTION LIMIT SWITCH: DISCONNECTION (KA))…5360
ERROR CODE [DNCAKB] (TRANSMISSION FNR DETECTION LIMIT SWITCH: SHORT CIRCUIT (KB))…5362
ERROR CODE [DNCBKA] (TRANSMISSION GEAR SHIFT DETECTION LIMIT SWITCH: DISCONNECTION (KA))…5364
ERROR CODE [DNCBKB] (TRANSMISSION GEAR SHIFT DETECTION LIMIT SWITCH: SHORT CIRCUIT (KB))…5365
ERROR CODE [DV00KB] (CAUTION BUZZER: SHORT CIRCUIT (KB))…5366
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)…5367
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST…5368
E-1 THE STARTING MOTOR DOES NOT ROTATE…5369
E-2 THE INTAKE AIR HEATER DOES NOT OPERATE…5371
E-3 THE HEADLAMP DOES NOT COME ON…5374
E-4 THE REAR LAMP DOES NOT COME ON…5376
E-5 THE AIR CONDITIONER DOES NOT OPERATE…5377
E-6 THE WIPER DOES NOT OPERATE…5383
E-7 NO FLUID COMES OUT FROM WINDOW WASHER…5385
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)…5387
METHOD OF USING TROUBLESHOOTING CHARTS…5388
TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC, MECHANICAL SYSTEMS)…5389
H-1 BRAKE DOES NOT WORK…5391
H-2 TURNING SPEED IS SLOW (CANNOT TURN) OR LACKS POWER WHEN TURNING…5392
H-3 EXCESSIVE TIME LAG…5393
H-4 MACHINE CAN TRAVEL IN ONLY ONE DIRECTION (FORWARD OR REVERSE)…5393
H-5 MACHINE DOES NOT MOVE (WHEN ENGINE IS STARTED AND LEVER IS SHIFTED TO 2ND OR 3RD)…5394
M-6 MACHINE DOES NOT MOVE IN ANY SPEED RANGE…5395
H-7 POWER TRAIN OIL TEMPERATURE RISES TOO HIGH…5396
H-8 DRAWBAR PULL IS WEAK, TRAVEL SPEED IS SLOW…5397
H-9 ABNORMAL NOISE IS GENERATED FROM AROUND HYDRAULIC AND HSS PUMP…5398
H-10 TURING SPEED AND SPEED OF ALL WORK EQUIPMENT IS SLOW…5399
H-11 MACHINE CANNOT TURN AND NO WORK EQUIPMENT MOVES…5400
H-12 TURNING AND ALL WORK EQUIPMENT LACKS POWER…5401
H-13 BLADE LIFTING SPEED IS SLOW OR LACKS POWER…5402
H-14 BLADE TILT SPEED IS SLOW OR LACKS POWER…5403
H-15 HYDRAULIC DRIFT OF BLADE LIFT IS EXCESSIVE…5404
H-16 HYDRAULIC DRIFT OF BLADE TILT IS EXCESSIVE…5404
TROUBLESHOOTING OF MONITOR SYSTEM (M-MODE)…5405
METHOD OF USING TROUBLESHOOTING CHARTS…5406
TABLE OF FAILURE MODES AND CAUSES (MACHINE MONITOR SYSTEM)…5407
M-1 NO DISPLAY IS GIVEN ON MONITOR PANEL WHEN STARTING SWITCH IS TURNED TO ON …5408
M-2 WHEN STARTING SWITCH IS TURNED ON, ALL MONITOR PANEL LAMPS LIGHT UP AND DO NOT GO OUT…5408
M-3 PREHEATING DISPLAY IS ABNORMAL…5409
M-4 CAUTION ITEMS FLASH…5410
M-5 BUZZER IS ABNORMAL…5411
M-6 WARNING LAMP IS ABNORMAL…5412
M-7 GAUGE IS ABNORMAL…5413
M-8 SERVICE METER DOES NOT MOVE AFTER ENGINE IS STARTED…5417
M-9 MONITOR PANEL LIGHTING DOES NOT LIGHT UP (FRONT LAMP ARE NORMAL)…5418
30 DISASSEMBLY AND ASSEMBLY…5419
METHOD OF USING MANUAL…5421
PRECAUTIONS WHEN CARRYING OUT OPERATION…5422
SPECIAL TOOL LIST…5424
SPECIAL TOOL SKETCH…5429
FUEL SUPPLY PUMP ASSEMBLY…5431
REMOVAL…5431
INSTALLATION…5432
NOZZLE HOLDER ASSEMBLY…5434
REMOVAL…5434
INSTALLATION…5435
NOZZLE TIP…5437
REMOVAL…5437
INSTALLATION…5439
CYLINDER HEAD ASSEMBLY…5441
REMOVAL…5441
INSTALLATION…5446
FUEL TANK ASSEMBLY…5449
REMOVAL…5449
INSTALLATION…5450
RADIATOR ASSEMBLY…5451
REMOVAL…5451
INSTALLATION…5453
HYDRAULIC OIL COOLER ASSEMBLY…5453
REMOVAL…5453
INSTALLATION…5453
ENGINE ASSEMBLY (CAB SPECIFICATION)…5454
REMOVAL…5454
INSTALLATION…5457
POWER TRAIN UNIT ASSEMBLY…5458
REMOVAL…5458
INSTALLATION…5463
POWER TRAIN UNIT…5464
SEPARATION…5464
CONNECTION…5466
TORQUE CONVERTER ASSEMBLY…5467
DISASSEMBLY…5467
ASSEMBLY…5469
PTO ASSEMBLY…5472
DISASSEMBLY…5472
ASSEMBLY…5475
TORQFLOW TRANSMISSION ASSEMBLY…5479
DISASSEMBLY…5479
TORQUE TRANSMISSION ASSEMBLY…5489
ASSEMBLY…5489
HSS ASSEMBLY…5503
DISASSEMBLY…5503
ASSEMBLY…5514
TORQUE CONVERTER VALVE ASSEMBLY…5528
REMOVAL…5528
INSTALLATION…5528
DISASSEMBLY…5529
ASSEMBLY…5529
TRANSMISSION CONTROL VALVE ASSEMBLY…5530
REMOVAL…5530
TRANSMISSION CONTROL VALVE…5530
INSTALLATION …5530
TRANSMISSION CONTROL VALVE ASSEMBLY…5532
DISASSEMBLY…5532
ASSEMBLY…5532
BRAKE VALVE ASSEMBLY…5534
REMOVAL…5534
INSTALLATION…5534
DISASSEMBLY…5535
ASSEMBLY…5536
HSS MOTOR ASSEMBLY…5537
REMOVAL…5537
INSTALLATION…5537
DISASSEMBLY…5538
ASSEMBLY…5542
SCAVENGING PUMP ASSEMBLY…5549
REMOVAL…5549
INSTALLATION…5549
POWER TRAIN PUMP ASSEMBLY…5550
REMOVAL…5550
INSTALLATION…5550
FINAL DRIVE ASSEMBLY…5551
REMOVAL…5551
INSTALLATION…5552
DISASSEMBLY…5553
ASSEMBLY…5557
TRACK FRAME ASSEMBLY…5562
REMOVAL…5562
INSTALLATION…5563
RECOIL SPRING ASSEMBLY…5564
REMOVAL…5564
INSTALLATION…5564
DISASSEMBLY…5565
ASSEMBLY…5567
IDLER ASSEMBLY…5568
REMOVAL…5568
INSTALLATION…5568
DISASSEMBLY…5569
ASSEMBLY…5570
TRACK ROLLER ASSEMBLY…5575
REMOVAL…5575
INSTALLATION…5575
DISASSEMBLY…5576
ASSEMBLY…5577
CARRIER ROLLER ASSEMBLY…5579
REMOVAL…5579
INSTALLATION…5579
DISASSEMBLY…5580
ASSEMBLY…5581
TRACK SHOE ASSEMBLY…5582
CHECKING BEFORE REMOVAL…5582
REMOVAL (NORMAL)…5582
REMOVAL (WHEN THERE IS ABNORMALITY INSIDE TRACK FRAME)…5583
INSTALLATION…5584
TRACK SHOE…5585
OVERALL DISASSEMBLY…5585
OVERALL ASSEMBLY…5590
PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS…5604
ONE LINK…5605
FIELD DISASSEMBLY…5605
FIELD ASSEMBLY…5606
PIVOT SHAFT ASSEMBLY…5612
REMOVAL…5612
INSTALLATION…5612
EQUALIZER BAR ASSEMBLY…5613
REMOVAL…5613
INSTALLATION…5614
EQUALIZER BAR SIDE BUSHING…5615
REMOVAL…5615
INSTALLATION…5615
SEGMENT TEETH…5616
REMOVAL…5616
INSTALLATION…5616
HSS, WORK EQUIPMENT PUMP ASSEMBLY…5617
REMOVAL…5617
INSTALLATION…5617
DISASSEMBLY…5618
ASSEMBLY…5623
PPC PUMP ASSEMBLY…5632
REMOVAL…5632
INSTALLATION…5632
MAIN CONTROL VALVE ASSEMBLY…5633
REMOVAL (2-SPOOL: BLADE LIFT +TILT)…5633
INSTALLATION (2-SPOOL: BLADE LIFT +TILT)…5633
REMOVAL (3-SPOOL: BLADE LIFT + TILT + STEERING)…5634
INSTALLATION (3-SPOOL: BLADE LIFT +TILT +STEERING)…5634
DISASSEMBLY (3-SPOOL VALVE)…5635
ASSEMBLY (3-SPOOL VALVE)…5637
MAIN RELIEF VALVE…5639
REMOVAL…5639
INSTALLATION…5639
PPC VALVE ASSEMBLY…5640
REMOVAL (FOR WORK EQUIPMENT)…5640
INSTALLATION (FOR WORK EQUIPMENT)…5640
REMOVAL (FOR STEERING)…5641
INSTALLATION (FOR STEERING)…5642
DISASSEMBLY (FOR WORK EQUIPMENT)…5643
ASSEMBLY (FOR WORK EQUIPMENT)…5644
DISASSEMBLY (FOR STEERING)…5645
ASSEMBLY…5646
PPC CHARGE RELIEF VALVE ASSEMBLY…5647
REMOVAL…5647
INSTALLATION…5647
DISASSEMBLY…5648
ASSEMBLY…5648
SUCTION VALVE ASSEMBLY…5649
REMOVAL…5649
INSTALLATION…5649
BLADE LIFT CYLINDER ASSEMBLY…5650
REMOVAL…5650
INSTALLATION…5650
BLADE TILT CYLINDER ASSEMBLY…5651
REMOVAL…5651
INSTALLATION…5651
HYDRAULIC CYLINDER ASSEMBLY…5652
DISASSEMBLY…5652
ASSEMBLY…5654
WORK EQUIPMENT ASSEMBLY…5657
REMOVAL…5657
INSTALLATION…5658
DISASSEMBLY…5659
ASSEMBLY…5661
RIPPER VALVE ASSEMBLY (IF EQUIPPED)…5663
DISASSEMBLY…5663
ASSEMBLY…5664
ROPS GUARD …5665
REMOVAL…5665
INSTALLATION…5665
OPERATOR'S CAB ASSEMBLY…5666
REMOVAL…5666
INSTALLATION…5667
DASHBOARD ASSEMBLY…5668
REMOVAL…5668
INSTALLATION…5668
MONITOR ASSEMBLY…5669
REMOVAL…5669
INSTALLATION…5669
FLOOR FRAME ASSEMBLY…5670
REMOVAL…5670
INSTALLATION…5674
40 MAINTENANCE STANDARD…5675
ENGINE MOUNT…5676
POWER TRAIN UNIT MOUNT…5677
DAMPER, UNIVERSAL JOINT…5678
TORQUE CONVERTER, PTO…5679
TRANSMISSION…5681
TRANSMISSION CONTROL VALVE…5683
MAIN RELIEF VALVE…5684
BEVEL GEAR SHAFT, HSS STEERING, BRAKE…5685
BEVEL GEAR SHAFT, HSS BRAKE VALVE…5688
POWER TRAIN, LUBRICATION PUMP…5689
PPC PUMP…5690
PPC VALVE…5691
PPC CHARGE VALVE…5695
FINAL DRIVE…5696
HULL FRAME…5698
TRACK FRAME, RECOIL SPRING…5699
IDLER…5700
TRACK ROLLER…5702
CARRIER ROLLER…5704
SPROCKET TOOTH PROFILE…5705
TRACK SHOE (DRY TYPE)…5706
TRACK SHOE (LUBRICATED TYPE)…5708
SUSPENSION…5710
HYDRAULIC, HSS PUMP…5712
HSS MOTOR…5713
MAIN CONTROL VALVE…5714
WORK EQUIPMENT CYLINDER…5719
WORK EQUIPMENT…5721
CUTTING EDGE, END BIT…5727
RIPPER…5728
90 OTHERS…5729
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM…5730
STEERING AND WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM…5731
ELECTRICAL CIRCUIT DIAGRAM (1/3)…5732
ELECTRICAL CIRCUIT DIAGRAM (2/3)…5733
ELECTRICAL CIRCUIT DIAGRAM (3/3)…5734
ELECTRICAL CIRCUIT DIAGRAM (INSIDE CAB)…5735
SEBM029508 – Bulldozer D65EX,PX,WX-15 Shop Manual (SN67001&up)…5736
COVER…5736
CONTENTS…5737
01 GENERAL…5769
SPECIFICATION DIMENSIONS…5770
SPECIFICATIONS…5771
WEIGHT TABLE…5776
TABLE OF FUEL, COOLANT AND LUBRICANT…5778
10 STRUCTURE,FUNCTION AND MAINTENANCE STANDARD…5780
COOLING SYSTEM…5781
ENGINE MOUNT…5783
POWER TRAIN…5784
OVERALL DRAWING OF POWER TRAIN UNIT…5786
HYDRAULIC PIPING OF POWER TRAIN…5788
DAMPER,UNIVERSAL JOINT…5789
TRANSMISSION,STEERING,BRAKE CONTROL…5791
TORQUE CONVERTER,PTO…5793
TRANSMISSION…5798
TRANSMISSION ECMV…5809
MAIN RELIEF VALVE…5815
LUBRICATION RELIEF VALVE…5817
SCAVENGING PUMP…5818
POWER TRAIN PUMP,LUBRICATION PUMP…5819
HSS SYSTEM…5820
HYDRAULIC,HSS PUMP…5822
HSS MOTOR…5840
BEVEL GEAR SHAFT,HSS,BRAKE…5847
BRAKE VALVE…5862
FINAL DRIVE…5867
FRAME ASSEMBLY…5872
SUSPENSION…5874
TRACK FRAME, RECOIL SPRING…5880
IDLER…5884
TRACK ROLLER…5886
CARRIER ROLLER…5887
SPROCKET…5888
TRACK SHOE…5890
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM…5893
WORK EQUIPMENT CONTROL…5895
HYDRAULIC TANK…5897
ACCUMULATOR…5899
PPC LOCK VALVE…5900
HYDRAULIC CYLINDER…5901
PISTON VALVE…5903
QUICK DROP VALVE…5904
COOLING FAN PUMP…5906
COOLING FAN MOTOR…5914
PPC VALVE…5920
PCCS LEVER…5930
CONTROL VALVE…5933
SELF PRESSURE REDUCING VALVE…5965
WORK EQUIPMENT…5972
CUTTING EDGE,END BIT…5976
RIPPER…5977
CAB MOUNT…5978
CAB…5979
AIR CONDITIONER PIPING…5981
ENGINE CONTROL…5982
ENGINE CONTROL SYSTEM…5983
CRI ENGINE CONTROL SYSTEM…5985
COOLING SYSTEM CONTROL SYSTEM…5987
PALM COMMAND CONTROL SYSTEM…5989
SYSTEM COMPONENTS…5991
ENGINE CONTROLLER…5993
TRANSMISSION AND STEERING CONTROLLER…5995
MONITOR SYSTEM…5997
MONITOR PANEL…5999
SENSORS…6003
20 TESTING AND ADJUSTING…6008
STANDARD VALUE TABLE FOR ENGINE…6009
STANDARD VALUE TABLE FOR CHASSIS…6010
TESTING AND ADJUSTING…6018
TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING…6020
MEASURING ENGINE SPEED…6022
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)…6024
MEASURING EXHAUST TEMPERATURE…6026
MEASURING EXHAUST GAS COLOR…6027
ADJUSTING VALVE CLEARANCE…6029
MEASURING COMPRESSION PRESSURE…6031
MEASURING BLOW-BY PRESSURE…6033
MEASURING ENGINE OIL PRESSURE…6034
HANDLING OF FUEL SYSTEM DEVICES…6035
RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM…6035
MEASURING FUEL PRESSURE…6036
BLEEDING AIR FROM FUEL CIRCUIT…6037
INSPECTION OF FUEL CIRCUIT FOR LEAKAGE…6040
REDUCED CYLINDER MODE OPERATION FOR ENGINE…6041
TESTING AND ADJUSTING ALTERNATOR BELT TENSION…6042
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION…6042
ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL…6043
MEASURING POWER TRAIN OIL PRESSURE…6045
ADJUSTING TRANSMISSION SPEED SENSOR (REPLACEMENT PROCEDURE)…6050
SIMPLE METHOD OF TESTING BRAKE PERFORMANCE…6051
ADJUSTING BRAKE PEDAL…6052
EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE…6055
ADJUSTING CLEARANCE OF IDLER…6058
INSPECTING WEAR OF SPROCKET…6058
TESTING AND ADJUSTING TRACK SHOE TENSION…6059
TESTING AND ADJUSTING WORK EQUIPMENT AND HSS OIL PRESSURE…6060
TESTING CONTROL CIRCUIT MAIN PRESSURE…6063
MEASURING PPC VALVE OUTPUT PRESSURE…6064
ADJUSTING PLAY OF WORK EQUIPMENT PPC VALVE…6066
MEASURING INTERNAL LEAKAGE OF WORK EQUIPMENT CYLINDER…6067
BLEEDING AIR FROM WORK EQUIPMENT CYLINDER…6067
RELEASING RESIDUAL PRESSURE IN WORK EQUIPMENT CYLINDER (IF PPC ACCUMULATOR IS INSTALLED)…6068
RELEASING RESIDUAL PRESSURE IN WORK EQUIPMENT CYLINDER (IF PPC ACCUMULATOR IS NOT INSTALLED)…6068
ADJUSTING SAFETY LOCK LEVER…6069
MEASURING FAN MOTOR SPEED…6070
MEASURING FAN PUMP CIRCUIT PRESSURE…6071
BLEEDING AIR FROM FAN PUMP…6072
ADJUSTING STRAIGHT TILTDOZER…6073
TESTING AND ADJUSTING OPERATOR'S CAB…6075
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)…6079
HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER…6117
ADJUSTMENT METHOD OF REPLACED CONTROLLER…6117
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM …6119
PM CLINIC SERVICE…6121
UNDERCARRIAGE TROUBLESHOOTING REPORT…6128
TROUBLESHOOTING…6130
POINTS TO REMEMBER WHEN TROUBLESHOOTING…6131
SEQUENCE OF EVENTS IN TROUBLESHOOTING…6132
HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT…6133
CHECKS BEFORE TROUBLESHOOTING…6142
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING…6143
TYPES AND LOCATIONS CONNECTORS (D65EX,PX-15)…6146
CONNECTOR ARRANGEMENT DRAWING…6152
CIRCUIT DRAWING FOR ENGINE CONTROLLER SYSTEM (E CIRCUIT)…6158
CIRCUIT DRAWING FOR STEERING AND TRANSMISSION CONTROLLER SYSTEM (ST・TM CIRCUIT)…6160
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)…6162
Connection table for connector pin numbers…6164
T- BRANCH BOX AND T- BRANCH ADAPTER TABLE…6200
TROUBLESHOOTING WHEN ERROR CODE IS DISPLAYED (ERROR CODE)…6203
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST…6208
TROUBLE CODE TABLE…6209
ERROR CODE [1500L0] (TRANSMISSION CLUTCH: SEE THE LIST.(L0))…6210
ERROR CODE [15SAL1] (FORWARD CLUTCH:SEE THE LIST.(L1))…6211
ERROR CODE [15SALH] (FORWARD CLUTCH:SEE THE LIST.(LH))…6212
ERROR CODE [15SBL1] (REVERSE CLUTCH:SEE THE LIST.(L1))…6213
ERROR CODE [15SBLH] (REVERSE CLUTCH:SEE THE LIST.(LH))…6214
ERROR CODE [15SEL1] (1ST CLUTCH:SEE THE LIST.(L1))…6215
ERROR CODE [15SELH] (1ST CLUTCH:SEE THE LIST.(LH))…6216
ERROR CODE [15SFL1] (2ND CLUTCH:SEE THE LIST.(L1))…6217
ERROR CODE [15SFLH] (2ND CLUTCH:SEE THE LIST.(LH))…6218
ERROR CODE [15SGL1] (3RD CLUTCH:SEE THE LIST.(L1))…6219
ERROR CODE [15SGLH] (3RD CLUTCH:SEE THE LIST.(LH))…6220
ERROR CODE [A000N1] (ENGINE:OVERRUN (N1))…6221
ERROR CODE [AB00MA] (ALTERNATOR:MALFUNCTION (MA))…6222
ERROR CODE [AD00L2] (COMMON RAIL:SEE THE LIST.(L2))…6222
ERROR CODE [AD00MA] (COMMON RAIL:DEFECTIVE FUNCTION(MA))…6223
ERROR CODE [AD10L3] (FUEL SUPPLY PUMP:SEE THE LIST.(L3))…6223
ERROR CODE [AD10MA] (FUEL SUPPLY PUMP:DEFECTIVE FUNCTION (MA))…6225
ERROR CODE [AD10MB] (FUEL SUPPLY PUMP:FUNCTION REDUCTION (MB))…6225
ERROR CODE [AD11KA] (FUEL SUPPLY PUMP SOLENOID 1:DISCONNECTION (KA))…6226
ERROR CODE [AD11KB] (FUEL SUPPLY PUMP SOLENOID 1:SHORT CIRCUIT (KB))…6227
ERROR CODE [AD51KA] (FUEL SUPPLY PUMP SOLENOID 2:DISCONNECTION (KA))…6228
ERROR CODE [AD51KB] (FUEL SUPPLY PUMP SOLENOID 2:SHORT CIRCUIT (KB))…6229
ERROR CODE [ADA1KA] (NO.1 INJECTOR SOLENOID:DISCONNECTION (KA))…6230
ERROR CODE [ADAZKB] (NO.1.2,AND 3 INJECTOR SOLENOIDS:SHORT CIRCUIT (KB))…6231
ERROR CODE [ADB1KA] (NO.2 INJECTOR SOLENOID:DISCONNECTION (KA))…6233
ERROR CODE [ADC1KA] (NO.3 INJECTOR SOLENOID:DISCONNECTION (KA))…6234
ERROR CODE [ADD1KA] (NO.4 INJECTOR SOLENOID:DISCONNECTION (KA))…6235
ERROR CODE [ADDZKB] (NO.4.5,AND 6 INJECTOR SOLENOIDS:SHORT CIRCUIT (KB))…6236
ERROR CODE [ADE1KA] (NO.5 FUEL INJECTOR SOLENOID:DISCONNECTION(KA))…6238
ERROR CODE [ADF1KA] (NO.6 FUEL INJECTOR SOLENOID:DISCONNECTION(KA))…6239
ERROR CODE [B@BAZG] (ENGINE OIL: OIL PRESSURE REDUCTION (ZG))…6240
ERROR CODE [B@BCNS] (RADIATOR COOLANT: OVERHEAT (NS))…6240
ERROR CODE [B@CENS] (POWER TRAN OIL: OVERHEAT (NS))…6241
ERROR CODE [B@HANS] (HYDRAULIC OIL: OVERHEAT (NS))…6241
ERROR CODE [D110KA] (BATTERY RELAY:DISCONNECTION(KA))…6242
ERROR CODE [D110KB] (BATTERY RELAY:DISCONNECTION (KB))…6243
ERROR CODE [D13OKA] (NEUTRAL SAFETY RELAY: SHORT CIRCUIT (KA))…6244
ERROR CODE [D13OKB] (NEUTRAL SAFETY RELAY: DISCONNECTION (KB))…6246
ERROR CODE [D161KA] (BACK-UP ALARM RELAY: SHORT CIRCUIT (KA))…6248
ERROR CODE [D161KB] (BACK-UP ALARM RELAY:DISCONNECTION (KB))…6250
ERROR CODE [D182KZ] (PREHEATER RELAY COIL: DISCONNECTION OR SHORT CIRCUIT (KZ))…6252
ERROR CODE [D1D0KB] (ENGINE CONTROLLER LOAD POWER SUPPLY RELAY : SHORT CIRCUIT (KB))…6254
ERROR CODE [D5ZFKA] (TRANSMISSION NEUTRAL SIGNAL: DISCONNECTION (KA))…6256
ERROR CODE [D5ZFKB] (TRANSMISSION NEUTRAL SIGNAL:SHORT CIRCUIT(KB))…6257
ERROR CODE [DAFRKR] (MONITOR PANEL CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR)…6258
ERROR CODE [DAQ0KK] [DB30KK] (STEERING AND TRANSMISSION CONTROLLER:SOURCE VOLTAGE REDUCTION/INPUT (KK))…6260
ERROR CODE [DAQ0KT] (STEERING AND TRANSMISSION CONTROLLER:ABNORMALITY IN CONTROLLER(KT))…6261
ERROR CODE [DAQ5KK] [DB35KK] (STEERING AND TRANSMISSION CONTROLLER SENSOR 5V POWER SUPPLY:SOURCE VOLTAGE REDUCTION/INPUT (KK))…6262
ERROR CODE [DAQ6KK] [DB36KK] (STEERING AND TRANSMISSION CONTROLLER SENSOR 24V POWER SUPPLY:SOURCE VOLTAGE REDUCTION/INPUT (KK))…6264
ERROR CODE [DAQ9KQ] [DB39KQ] (STEERING AND TRANSMISSION CONTROLLER TYPE COLLATION:TYPE SELECT SIGNAL INSISTENCY (KQ))…6265
ERROR CODE [DB3RKR] (STEERING AND TRANSMISSION CONTROLLER CAN COMMUNICATION:DEFECTIVE COMMUNICATION (KR))…6266
ERROR COED [DB20KQ] (ENGINE CONTROLLER TYPE COLLATION:TYPE SELECT CODE INCONSISTENCY (KQ))…6268
ERROR CODE [DB20KT] (ENGINE CONTROLLER :ABNORMALITY IN CONTROLLER (KT))…6269
ERROR CODE [DB22KK] (ENGINE CONTROLLER LOAD POWER SUPPLY:SOURCE VOLTAGE REDUCTION/INPUT (KK))…6270
ERROR CODE [DB29KQ] (ENGINE CONTROLLER TYPE SELECT:TYPE SELECT SIGNAL INCONSISTENCY (KQ))…6272
ERROR CODE [DB2AMA] (FUEL INJECTION AMOUNT ADJUSTMENT SWITCH SIGNAL:MALFUNCTION (MA))…6273
ERROR CODE [DB2RKR] (STEERING AND TRANSMISSION CONTROLLER CAN COMMUNICATION :DEFECTIVE COMMUNICATION (KR))…6274
ERROR CODE [DB2RMC] (ENGINE CONTROLLER CAN COMMUNICATION:DEFECTIVE COMMUNICATION (MC))…6276
ERROR CODE [DB30KK] [DAQ0KK] (STEERING AND TRANSMISSION CONTROLLER:SOURCE VOLTAGE REDUCTION/INPUT (KK)…6278
ERROR CODE [DB35KK] [DAQ5KK] (STEERING AND TRANSMISSION CONTROLLER ENSOR 5V POWER SUPPLY:SOURCE VOLTAGE REDUCTION/INPUT (KK)…6278
ERROR CODE [DB36KK] [DAQ6KK] (STEERING AND TRANSMISSION CONTROLLER SENSOR 24V POWER SUPPLY:SOURCE VOLTAGE REDUCTION/INPUT (KK)…6278
ERROR CODE [DB39KQ] [DAQ9KQ] (STEERING AND TRANSMISSION CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ)…6278
ERROR CODE [DD11KB] (STARTING SWITCH:SHORT CIRCUIT (KB))…6279
ERROR CODE [DD12KA] (SHIFT UP SWITCH:DISCONNECTION (KA))…6280
ERROR CODE [DD12KB] (SHIFT UP SWITCH:SHORT CIRCUIT (KB))…6282
ERROR CODE [DD13KA] (SHIFT DOWN SWITCH:DISCONNECTION (KA))…6284
ERROR CODE [DD13KB] (SHIFT DOWN SWITCH:SHORT CIRCUIT (KB))…6286
ERROR CODE [DD14KA] [DDQ2KA] (PARKING LEVER SWITCH:DISCONNECTION (KA))…6288
ERROR CODE [DD14KB] [DDQ2KB] (PARKING LEVER SWITCH:SHORT CIRCUIT(KB))…6290
ERROR CODE [DDE2L6] (ENGINE OIL PRESSURE SWITCH:REFER TO TABLE (L6))…6292
ERROR CODE [DDN7KA] (PITCH CONTROL SWITCH:DISCONNECTION (KA))…6294
ERROR CODE [DDN7KB] (PITCH CONTROL SWITCH:SHORT CIRCUIT (KB))…6296
ERROR CODE [DDQ2KA] [DD14KA] (PARKING LEVER SWITCH:DISCONNECTION (KA))…6298
ERROR CODE [DDQ2KB] [DD14KB] (PARKING LEVER SWITCH:SHORT CIRCUIT (KB))…6298
ERROR CODE [DGE2KX] (ENGINE WATER TEMPERATURE SENSOR (FOR HIGH TEMPERATURE): INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))…6299
ERROR CODE [DGE3L6] (ENGINE WATER TEMPERATURE SENSOR (FOR LOW TEMPERATURE):SEE TABLE (L6))…6300
ERROR CODE (DGE4KX] (FUEL TEMPERATURE SENSOR:INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))…6301
ERROR CODE [DGS1KX] (HYDRAULIC OIL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF NORMAL RANGE(KX))…6302
ERROR CODE [DH30KX] (BOOST PRESSURE SENSOR:INPUT IS OUT OF NORMAL RANGE(KX))…6304
ERROR CODE [DH40KX] (COMMON RAIL PRESSURE SENSOR:INPUT IS OUT OF NORMAL RANGE(KX))…6306
ERROR CODE [DK10KX] (FUEL CONTROL DIAL:INPUT IS OUT OF NORMAL RANGE (KX))…6308
ERROR CODE [DK12KX] (DECELERATION POTENTIOMETER:INPUT IS OUT OF NORMAL RANGE (KX))…6310
ERROR CODE [DK30KA] (STEERING POTENTIOMETER 1: DISCONNECTION (KA))…6312
ERROR CODE [DK30KB] (STEERING POTENTIOMETER 1: SHORT CIRCUIT (KB))…6313
ERROR CODE [DK30KX] (STEERING POTENTIOMETER :INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))…6314
ERROR CODE [DK30KZ] (STEERING POTENTIOMETER :DISCONNECTION OR SHORT CIRCUIT (DOUBLE TROUBLE)(KZ))…6314
ERROR CODE [DK30L8] (STEERING POTENTIOMETER 1 : SEE TABLE(L8))…6315
ERROR CODE [DK31KA] (STEERING POTENTIOMETER 2:SHORT CIRCUIT (KA))…6316
ERROR CODE [DK31KB] (STEERING POTENTIOMETER 2:DISCONNECTION (KB))…6317
ERROR CODE [DK40KA] (BRAKE POTENTIOMETER : DISCONNECTION(KA))…6318
ERROR CODE [DK40KB] (BRAKE POTENTIOMETER : SHORT CIRCUIT(KB))…6319
ERROR CODE [DK55KX] (FORWARD-REVERSE POTENTIOMETER: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))…6320
ERROR CODE [DK55KZ] (FORWARD-REVERSE POTENTIOMETER: DISCONNECTION OR SHORT CIRCUIT (DOUBLE TROUBLE) (KZ))…6320
ERROR CODE [DK55L8] (FORWARD-REVERSE POTENTIOMETER: SEE TABLE (L8))…6321
ERROR CODE [DK56KA] (FORWARD-REVERSE POTENTIOMETER 1:SHORT CIRCUIT (KA))…6322
ERROR CODE [DK56KB] (FORWARD-REVERSE POTENTIOMETER 1:DISCONNECTION (KB))…6324
ERROR CODE [DK57KA] (FORWARD-REVERSE POTENTIOMETER 2 :SHORT CIRCUIT (KA))…6326
ERROR CODE [DK57KB] (FORWARD-REVERSE POTENTIOMETER 2 :DISCONNECTION (KB))…6328
ERROR CODE [DKH1KA] (PITCH ANGLE SENSOR : SHORT CIRCUIT (KA))…6330
ERROR CODE [DKH1KB] (PITCH ANGLE SENSOR : DISCONNECTION (KB))…6331
ERROR CODE [DLE3LC] (ENGINE NE SPEED SENSOR :SEE TABLE (LC))…6332
ERROR CODE [DLF1KA] (TRANSMISSION OUTPUT SPEED SENSOR :DISCONNECTION (KA))…6333
ERROR CODE [DLH1LC] (ENGINE G SPEED SENSOR :SEE TABLE (LC))…6334
ERROR CODE [DV00KB] (CAUTION BUZZER: SHORT CIRCUIT (KB))…6335
ERROR CODE [DW5AKA] (PITCH CONTROL SOLENOID : DISCONNECTION (KA))…6336
ERROR CODE [DW5AKB] (PITCH CONTROL SOLENOID: SHORT CIRCUIT (KB))…6337
ERROR CODE [DW7BKA] (FAN REVERSE SOLENOID : DISCONNECTION (KA))…6338
ERROR CODE [DW7BKB] (FAN REVERSE SOLENOID : SHORT CIRCUIT (KB))…6339
ERROR CODE [DWN1KA] (HSS EPC SOLENOID LEFT : DISCONNECTION (KA))…6340
ERROR CODE [DWN1KB] (HSS EPC SOLENOID LEFT : SHORT CIRCUIT (KB))…6341
ERROR CODE [DWN2KA] (HSS EPC SOLENOID LEFT: DISCONNECTION (KA))…6342
ERROR CODE [DWN2KB] (HSS EPC SOLENOID LEFT: SHORT CIRCUIT (KB))…6343
ERROR CODE [DWN5KA] (FAN PUMP TVC SOLENOID : DISCONNECTION (KA))…6344
ERROR CODE [DWN5KB] (FAN PUMP TVC SOLENOID :SHORT CIRCUIT (KB))…6345
ERROR CODE [DXH4KA] (1ST CLUTCH ECMV: DISCONNECTION (KA))…6346
ERROR CODE [DXH4KB] (1ST CLUTCH ECMV: SHORT CIRCUIT (KB))…6347
ERROR CODE [DXH5KA] (2ND CLUTCH ECMV: DISCONNECTION (KA))…6348
ERROR CODE [DXH5KB] (2ND CLUTCH ECMV:SHORT CIRCUIT (KB))…6349
ERROR CODE [DXH6KA] (3RD CLUTCH ECMV: DISCONNECTION (KA))…6350
ERROR CODE [DXH6KB] (3RD CLUTCH ECMV:SHORT CIRCUIT (KB))…6351
ERROR CODE [DXH7KA] (REVERSE CLUTCH ECMV: DISCONNECTION (KA))…6352
ERROR CODE [DXH7KB] (REVERSE CLUTCH ECMV:SHORT CIRCUIT (KB))…6353
ERROR CODE [DXH8KA] (FORWARD CLUTCH ECMV: DISCONNECTION (KA))…6354
ERROR CODE [DXH8KB] (FORWARD CLUTCH ECMV:SHORT CIRCUIT (KB))…6355
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)…6356
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST…6357
E-1 THE ENGINE DOES NOT START…6358
E-2 THE PREHEATER DOES NOT OPERATE…6361
E-3 THE MONITOR PANEL DOES NOT COME ON AT ALL WHEN THE STARTING SWITCH TURNED ON…6363
E-4 WHEN THE STARING SWITCH IS TURNED ON,THE MONITOR PANEL COMPLETELY REMAINS LIGHTED AND DOES NOT GO OUT…6364
E-5 WHILE THE ENGINE IS OPERATING,THE BATTERY CHARGE LEVEL CAUTION LAMP FLASHES…6365
E-6 WHILE THE ENGINE IS OPERATING,THE EMERGENCY WARNING ITEM FLASHES…6367
E-7 WHILE THE PREHEATER IS OPERATING,THE PREHEATING PILOT LAMP DOES NOT COME ON…6370
E-8 THE ENGINE WATER TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY…6372
E-9 INDICATION OF THE POWER TRAIN TEMPERATURE GAUGE IS ABNORMAL…6373
E-10 THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY…6374
E-11 INDICATION OF THE FUEL GAUGE IS ABNORMAL…6375
E-12 INDICATION OF GEAR SPEED AND ENGINE SPEED ARE ABNORMAL…6376
E-13 INDICATION OF THE PRESET MODE SERVICE METER IS ABNORMAL…6376
E-14 THE WARNING LAMP DOES NOT FLASH OR DOES NOT GO OUT…6376
E-15 THE ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP…6377
E-16 AUTO SHIFT DOWN IS NOT POSSIBLE OR IS NOT RELEASED…6378
E-17 THE BUZZER CANCEL SWITCH DOES NOT WORK…6379
E-18 THE INFORMATION SWITCH DOES NOT WORK…6380
E-19 THE PRESET MODE DOES NOT OPERATE OR CANNOT BE RESET…6381
E-20 THE MONITOR PANEL CANNOT BE SET IN THE SERVICE MODE OR CANNOT BE SET OUT THE SERVICE MODE…6382
E-21 THE BACK-UP ALARM DOES NOT SOUND…6384
E-22 THE HEAD LAMP AND REAR LAMP DO NOT LIGHT UP…6385
E-23 MALFUNCTION OF WIPERS…6387
E-24 WASHING WATER DOES NOT COME OUT…6403
E-25 THE AIR CONDITIONER DOES NOT OPERATE…6408
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)…6413
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST…6414
H-1 NO TRAVEL POWER (NO DRAWBAR PULL)…6415
H-2 MACHINE DOES NOT MOVE (AT 2ND OR 3RD SPEED)…6416
H-3 MACHINE DOES NOT MOVE IN ANY SPEED RANGE…6417
H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION FORWARD OR IN REVERSE…6418
H-5 WHEN GEAR IS SHIFTED OR TRAVEL DIRECTION IS CHANGED,LARGE TIME LAG IS MADE…6419
H-6 MACHINE DOES NOT TURN (NOT TURNED RIGHTWARD OR LEFTWARD)…6420
H-7 STEERING SPEED OR POWER IS LOW…6420
H-8 BRAKE DOES NOT WORK…6421
H-9 OVERHEAT OF POWER TRAIN OIL TEMPERATURE…6421
H-10 ABNORMAL SOUND COMES OUT FROM AROUND HSS AND WORK EQUIPMENT PUMP OR HSS MOTOR…6422
H-11 ALL WORK EQUIPMENT SPEEDS ARE SLOW…6422
H-12 WOEK EQUIPMENT DOES NOT MOVE …6423
H-13 BLADE LIFT SPEED IS SLOW OR LACKS POWERS…6423
H-14 BLADE TILT SPEED IS SLOW OR LACKS POWER…6424
H-15 RIPPER LIFT SPEED IS SLOW OR LACKS POWER…6424
H-16 EXCESSIVE HYDRAULIC DRIFT OF BLADE LIFT…6425
H-17 EXCESSIVE HYDRAULIC DRIFT OF BLADE TILT…6425
H-18 EXCESSIVE HYDRAULIC DRIFT OF RIPPER LIFT…6426
TROUBLESHOOTING OF ENGINE SYSTEM (S-MODE)…6427
METHOD OF USING TROUBLESHOOTING CHARTS…6428
S-1 STARING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)…6432
S-2 ENGINE DOES NOT START…6433
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) …6436
S-4 ENGINE STOPS DURING OPERATIONS…6437
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)…6438
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)…6439
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)…6440
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)…6441
S-9 OIL BECOMES CONTAMINATED QUICKLY…6442
S-10 FUEL CONSUMPTION IS EXCESSIVE…6443
S-11 OIL IS IN COOLING WATER (OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN)…6444
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) …6445
S-13 OIL LEVEL RISES (WATER,FUEL IN OIL)…6446
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)…6447
S-15 ABNORMAL NOISE IS MADE…6448
S-16 VIBRATION IS EXCESSIVE…6449
30 DISASSEMBLY AND ASSEMBLY…6450
HOW TO READ THIS MANUAL…6453
Removal and installation of assemblies…6453
Disassembly and assembly of assemblies…6454
COATING MATERIALS LIST…6455
SPECIAL TOOL LIST…6458
SKETCHES OF SPECIAL TOOLS…6462
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY…6464
SPECIAL TOOL…6464
REMOVAL…6464
INSTALLATION…6466
REMOVAL AND INSTALLATION OF ENGINE HOOD ASSEMBLY…6469
REMOVAL…6469
INSTALLATION…6469
REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY…6470
REMOVAL…6470
INSTALLATION…6471
REMOVAL AND INSTALLATION OF NOZZLE TIP…6474
SPECIAL TOOL …6474
REMOVAL…6474
INSTALLATION…6475
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL…6476
SPECIAL TOOL…6476
REMOVAL …6476
INSTALLATION…6476
REMOVAL AND INSTALLATION OF DAMPER ASSEMBLY…6477
REMOVAL…6477
INSTALLATION…6477
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL…6478
SPECIAL TOOL…6478
REMOVAL …6478
INSTALLATION…6478
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY…6481
SPECIAL TOOL…6481
REMOVAL…6481
INSTALLATION…6484
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY…6486
REMOVAL…6486
INSTALLATION…6487
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY…6488
REMOVAL…6488
INSTALLATION…6489
REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY…6490
REMOVAL…6490
INSTALLATION…6493
REMOVAL AND INSTALLATION OF POWER TRAIN UNIT ASSEMBLY…6495
REMOVAL…6495
INSTALLATION…6497
DISCONNECTION AND CONNECTION OF POWER TRAIN UNIT ASSEMBLY …6498
DISCONNECTION…6498
CONNECTION…6501
DISASSEMBLY AND ASSEMBLY OF TORQFLOW TRANSMISSION ASSEMBLY…6502
SPECIAL TOOL…6502
DISASSEMBLY…6502
ASSEMBLY…6509
DISASSEMBLY AND ASSEMBLY OF HSS ASSEMBLY…6520
SPECIAL TOOL…6520
DISASSEMBLY …6520
ASSEMBLY…6527
DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY…6538
DISASSEMBLY…6538
ASSEMBLY…6540
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY…6544
DISASSEMBLY…6544
ASSEMBLY…6546
REMOVAL AND INSTALLATION OF SCAVENGING PUMP ASSEMBLY…6549
REMOVAL…6549
INSTALLATION…6549
REMOVAL AND INSTALLATION OF HSS PUMP ASSEMBLY…6550
REMOVAL…6550
INSTALLATION…6550
REMOVAL AND INSTALLATION OF COOLING FAN PUMP ASSEMBLY…6551
REMOVAL…6551
INSTALLATION…6552
REMOVAL AND INSTALLATION OF POWER TRAIN AND LUBRICATING OIL PUMP ASSEMBLY…6553
REMOVAL…6553
INSTALLATION…6553
REMOVAL AND INSTALLATION OF MOTOR ASSEMBLY…6554
REMOVAL…6554
INSTALLATION…6554
REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY…6555
SPECIAL TOOL…6555
REMOVAL…6555
INSTALLATION…6556
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY …6557
SPECIAL TOOL…6557
DISASSEMBLY…6557
ASSEMBLY…6560
REMOVAL AND INSTALLATION OF TRACK FRAME ASSEMBLY…6564
REMOVAL…6564
INSTALLATION…6565
REMOVAL AND INSTALLATION OF IDLER ASSEMBLY…6566
REMOVAL…6566
INSTALLATION…6566
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY…6567
SPECIAL TOOL…6567
DISASSEMBLY…6567
ASSEMBLY…6568
REMOVAL AND INSTALLATION OF RECOIL SPRING ASSEMBLY…6571
REMOVAL…6571
INSTALLATION…6571
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY…6572
SPECIAL TOOL…6572
DISASSEMBLY…6572
ASSEMBLY…6574
REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY…6576
REMOVAL …6576
INSTALLATION…6576
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY …6577
SPECIAI TOOL…6577
DISASSEMBLY…6577
ASSEMBLY…6578
REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY…6581
REMOVAL…6581
INSTALLATION…6581
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY …6582
SPECIAL TOOL…6582
DISASSEMBLY…6582
ASSEMBLY…6583
EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY…6585
CHECK BEFORE EXPANDING TRACK SHOE ASSEMBLY…6585
EXPANSION OF TRACK SHOE ASSEMBLY (ORDINARY)…6585
EXPANSION TRACK SHOE ASSEMBLY (WHEN TRACK FRAME HAS INTERNAL TROUBLE)…6586
INSTALLATION…6587
WHOLE DISASSEMBLY AND WHOLE ASSEMBLY OF TRACK SHOE ASSEMBLY …6588
SPECIAL TOOL…6588
WHOLE DISASSEMBLY…6588
WHOLE ASSEMBLY…6591
FIELD DISASSEMBLY AND ASSEMBLY OF ONE LINK…6603
SPECIAL TOOL…6603
DISASSEMBLY…6603
ASSEMBLY…6604
REMOVAL AND INSTALLATION OF PIVOT SHAFT ASSEMBLY…6610
SPECIAL TOOL…6610
REMOVAL…6610
INSTALLATION…6610
REMOVAL AND INSTALLATION OF EQUALIZER BAR ASSEMBLY…6611
SPECIAL TOOL…6611
REMOVAL…6611
INSTALLATION…6612
DISASSEMBLY AND ASSEMBLY OF EQUALIZER BAR SIDE BUSHING…6613
DISASSEMBLY…6613
ASSEMBLY…6613
REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY…6614
REMOVAL…6614
INSTALLATION…6615
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY…6616
ASSEMBLY…6616
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY…6617
SPECIAL TOOL…6617
DISASSEMBLY …6617
ASSEMBLY…6619
REMOVAL AND INSTALLATION OF BLADE ASSEMBLY…6623
REMOVAL…6623
INSTALLATION…6624
REMOVAL AND INSTALLATION OF ROPS GUARD…6625
REMOVAL…6625
INSTALLATION…6625
REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY…6626
REMOVAL…6626
INSTALLATION…6628
REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS)…6631
SPECIAL TOOL…6632
REMOVAL…6632
INSTALLATION…6633
REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY…6639
REMOVAL…6639
INSTALLATION…6643
REMOVAL AND INSTALLATION OF STEERING AND TRANSMISSION CONTROLLER ASSEMBLY…6644
REMOVAL…6644
INSTALLATION…6644
REMOVAL AND INSTALLATION OF ENGINE CONTROLLER ASSEMBLY…6645
REMOVAL…6645
INSTALLATION…6645
REMOVAL AND INSTALLATION OF FAN DRIVE ASSEMBLY…6646
REMOVAL…6646
INSTALLATION…6646
REMOVAL AND INSTALLATION OF FAN MOTOR ASSEMBLY …6647
REMOVAL…6647
INSTALLATION…6647
90 OTHERS…6648
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM…6649
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM…6650
ELECTRICAL CIRCUIT DIAGRAM (1/6)…6651
ELECTRICAL CIRCUIT DIAGRAM (2/6)…6652
ELECTRICAL CIRCUIT DIAGRAM (3/6)…6653
ELECTRICAL CIRCUIT DIAGRAM (4/6)…6654
ELECTRICAL CIRCUIT DIAGRAM (5/6)…6655
ELECTRICAL CIRCUIT DIAGRAM (6/6)…6656
CAB ELECTRICAL CIRCUIT DIAGRAM…6657
SEBM040800 – Bulldozer GALEO D65WX-15E0 Power Angle Power Tilt Dozer Shop Manual (SN69001&up)…6658
COVER…6658
CONTENTS…6660
GENERAL…6661
SPECIFICATION DIMENSIONS…6661
SPECIFICATIONS…6662
WEIGHT TABLE…6667
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD…6669
FRAME ASSEMBLY…6669
TRACK FRAME, RECOIL SPRING…6671
HYDRAULIC CYLINDER…6673
RIPPER LIFT CYLINDER…6674
PPC VALVE…6675
CONTROL VALVE…6681
SELF PRESSURE REDUCING VALVE…6709
OTHERS…6717
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (For Power angle power tilt dozer)…6717
SEN00046-02 – Bulldozer D65EX,PX,WX-15E0 Shop Manual (SN69001&up)…6718
COVER…6718
00 INDEX AND FOREWORD…0
INDEX…6719
ORGANIZATION LIST OF THE SHOP MANUAL…6720
TABLE OF CONTENTS…6722
FOREWORD AND GENERAL INFORMATION…6733
SAFETY NOTICE…6734
HOW TO READ THE SHOP MANUAL…6738
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD…6740
HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT…6742
HOW TO READ ELECTRIC WIRE CODE…6750
METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER…6753
STANDARD TIGHTERING TORQUE TABLE…6756
CONVERSION TABLE…6760
01 SPECIFICATION…0
SPECIFIICATION AND TECHNICAL DATA…6766
SPECIFICATION DIMENSIONS…6767
SPECIFICATIONS…6768
WEIGHT TABLE…6773
TABLE OF FUEL, COOLANT AND LUBRICANTS…6775
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD…0
ENGINE AND COOLING SYSTEM…6779
COOLING SYSTEM…6779
COOLING FAN PUMP…6781
COOLING FAN MOTOR…6789
POWER TRAIN, PART 1…6796
POWER TRAIN…6797
HSS SYSTEM…6799
GENERAL VIEW OF POWER TRAIN UNIT…6801
POWER TRAIN HYDRAULIC PIPING DRAWING…6803
TRANSMISSION, STEERING AND BRAKE CONTROL…6804
DAMPER AND UNIVERSAL JOINT…6806
TORQUE CONVERTER AND PTO…6808
TRANSMISSION…6813
TRANSMISSION CLUTCH ECMV…6824
MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE…6830
LUBRICATION RELIEF VALVE…6832
POWER TRAIN, PART 2…6834
BEVEL GEAR SHAFT, HASS AND BRAKE…6835
BRAKE VALVE…6850
FINAL DRIVE…6855
UNDERCARRIAGE AND FRAME…6861
MAIN FRAME…6862
SUSPENSION…6864
TRACK FRAME AND IDLER CUSHION…6870
IDLER…6874
TRACK ROLLER…6876
CARRIER ROLLER…6877
SPROCKET…6878
TRACK SHOE…6880
HYDRAULIC SYSTEM, PART 1…6884
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM…6885
WORK EQUIPMENT CONTROL…6887
HYDRAULIC TANK AND FILTER…6889
SCAVENGING PUMP…6891
POWER TRAIN AND STEERING LUBRICATION PUMP…6892
HSS PUMP…6893
HSS MOTOR…6911
HYDRAULIC SYSTEM, PART 2…6919
CONTROL VALVE…6920
SELF PRESSURE REDUCING VALVE…6952
HYDRAULIC SYSTEM, PART 3…6960
PPC VALVE (BLADE LIFT, BLADE TILT)…6961
PPC VALVE (RIPPER)…6967
ELECTRIC LEVER (STEERING)…6971
QUICK DROP VALVE…6974
PPC LOCK VALVE…6976
ACCUMULATOR…6977
WORK EQUIPMENT…6979
BLADE…6980
CUTTING EDGE AND END BIT…6984
RIPPER…6985
HYDRAULIC CYLINDER…6986
PISTON VALVE…6989
CAB AND ITS ATTACHMENTS…6991
CAB MOUNT…6992
CAB…6993
AIR CONDITIONER…6995
ELECTRICAL SYSTEM…6997
MONITOR SYSTEM…6998
MONITOR PANEL…7000
ENGINE CONTROL…7004
ENGINE CONTROL SYSTEM …7005
COOLING SYSTEM CONTROL SYSTEM…7007
SYSTEM COMPONENTS…7009
PALM COMMAND CONTROL SYSTEM…7018
KOMTRAX TERMINAL SYSTEM…7020
KOMTRAX TERMINAL…7021
SENSOR …7022
20 STANDARD VALUE TABLE…0
STANDARD SERVICE VALUE TABLE…7026
STANDARD SERVICE VALUE TABLE FOR ENGINE…7027
STANDARD SERVICE VALUE TABLE FOR CHASSIS…7028
30 TESTING AND ADJUSTING …0
TESTING AND ADJUSTING, PART 1…7041
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING …7043
MEASURING ENGINE SPEED…7045
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)…7047
MEASURING EXHAUST TEMPERATURE…7049
MEASURING EXHAUST GAS COLOR…7051
ADJUSTING VALVE CLEARANCE…7052
MEASURING COMPRESSION PRESSURE…7055
MEASURING BLOW-BY PRESSURE…7059
MEASURING ENGINE OIL PRESSURE…7060
HANDLING OF FUEL SYSTEM DEVICES…7061
RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM…7061
TESTING FUEL PRESSURE…7062
TESTING FUEL RETURN AND LEAK AMOUNT…7066
BLEEDING AIR FROM FUEL CIRCUIT…7068
TESTING FUEL CIRCUIT FOR LEAKAGE…7069
HANDLING OF REDUCED CYLINDER MODE OPERATION…7070
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION…7071
ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL…7072
MEASURING POWER TRAIN OIL PRESSURE…7074
ADJUSTING TRANSMISSION SPEED SENSOR (REPLACEMENT PROCEDURE)…7078
SIMPLE METHOD TO TEST BRAKE PERFORMANCE…7079
ADJUSTING BRAKE PEDAL…7080
ADJUSTING PARKING BRAKE LEVER…7082
EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE…7083
ADJUSTING CLEARANCE OF IDLER…7086
INSPECTING WEAR OF SPROCKET…7087
TESTING AND ADJUSTING TRACK SHOE TENSION…7087
TESTING AND ADJUSTING WORK EQUIPMENT AND HSS OIL PRESSURE…7088
TESTING CONTROL CIRCUIT BASIC PRESSURE…7091
MEASURING PPC VALVE OUTPUT PRESSURE…7092
ADJUSTING PLAY OF WORK EQUIPMENT PPC VALVE…7094
MEASURING INTERNAL LEAKAGE OF WORK EQUIPMENT CYLINDER…7095
BLEEDING AIR FROM WORK EQUIPMENT CYLINDER…7095
RELEASING RESIDUAL PRESSURE IN WORK EQUIPMENT CYLINDER…7096
CHECKING PARTS WHICH CAUSED HYDRAULIC DRIFT OF BLADE OR RIPPER…7097
ADJUSTING WORK EQUIPMENT LOCK LEVEL…7098
MEASURING FAN MOTOR SPEED…7099
MEASURING FAN PUMP CIRCUIT PRESSURE…7100
BLEEDING AIR FROM FAN PUMP…7101
ADJUSTING STRAIGHT TILTDOZER…7102
TESTING AND ADJUSTING OPERATOR CAB…7104
TESTING AND ADJUSTING, PART 2…7109
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)…7110
TESTING AND ADJUSTING, PART 3…7153
HANDLING OF VOLTAGE CIRCUIT OF ENGINE CONTROLLER…7154
ADJUSTMENT METHOD WHEN CONTROLLER HAS BEEN REPLACED…7154
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM…7156
INSPECTION PROCEDURE OF DIODE…7161
PM-CLINIC SERVICE…7162
HOW TO START OPERATION OF KOMTRAX TERMINAL…7172
LAMP DISPLAY OF KOMTRAX TERMINAL…7176
40 TROUBLESHOOTING…0
GENERAL INFORMATION ON TROUBLESHOOTING…7180
POINTS TO REMEMBER WHEN TROUBLESHOOTING …7181
HOW TO PROCEED TROUBLESHOOTING…7182
CHECKS BEFORE TROUBLESHOOTING…7183
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING…7184
HOW TO DISTINGUISH WIRE CODE…7187
WIRING TABLE FOR CONNECTOR PIN NUMBERS…7191
T-ADAPTER BOX AND T-ADAPTER TABLE…7214
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 1…7219
FAILURE CODE TABLE…7221
BEFORE TROUBLESHOOTING BY FAILURE CODES…7228
CONTENTS OF TROUBLESHOOTING TABLE…7230
FAILURE CODE [1500L0] TRANSMISSION CLUTCH: DUAL ENGAGEMENT…7232
FAILURE CODE [15SAL1] FORWARD CLUTCH: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF…7233
FAILURE CODE [15SALH] FORWARD CLUTCH: FILL SIGNAL IS OFF WHEN COMMAND CURRENT IS ON…7235
FAILURE CODE [15SBL1] REVERSE CLUTCH: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF…7237
FAILURE CODE [15SBLH] REVERSE CLUTCH: FILL SIGNAL IS OFF WHEN COMMAND CURRENT IS ON…7239
FAILURE CODE [15SEL1] 1ST CLUTCH: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF…7241
FAILURE CODE [15SELH] 1ST CLUTCH: FILL SIGNAL IS OFF WHEN COMMAND CURRENT IS ON…7242
FAILURE CODE [15SFL1] 2ND CLUTCH: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF…7243
FAILURE CODE [15SFLH] 2ND CLUTCH: FILL SIGNAL IS OFF WHEN COMMAND CURRENT IS ON…7245
FAILURE CODE [15SGL1] 3RD CLUTCH: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF…7247
FAILURE CODE [15SGLH] 3RD CLUTCH: FILL SIGNAL IS OFF WHEN COMMAND CURRENT IS ON…7249
FAILURE CODE [AB00MA] ALTERNATOR: MALFUNCTION …7251
FAILURE CODE [B@BAZG] ENGINE OIL: OIL PRESSURE TOO LOW…7251
FAILURE CODE [B@BCNS] RADIATOR COOLANT: OVERHEAT…7252
FAILURE CODE [B@CENS] POWER TRAIN OIL: OVERHEAT…7252
FAILURE CODE [B@HANS] HYDRAULIC OIL: OVERHEAT…7253
FAILURE CODE [CA111] ENGINE CONTROLLER: ABNORMALITY IN CONTROLLER…7254
FAILURE CODE [CA115] ABNORMAL ENGINE NE AND BKUP SPEED SENSORS: ABNORMAL SPEED SENSOR SIGNAL…7254
FAILURE CODE [CA122] CHARGE PRESSURE SENSOR TOOL HIGH: EXCESSIVELY HIGH VOLTAGE DETECTED…7255
FAILURE CODE [CA123] CHARGE PRSSURE SENSOR TOO LOW: EXCESSIVELY LOW VOLTAGE DETECTED…7257
FAILURE CODE [CA131] DECELERATOR PEDAL SENSOR TOOL HIGH: EXCESSIVELY HIGH VOLTAGE DETECTED…7259
FAILURE CODE [CA132] DECELERATOR PEDAL SENSOR TOO LOW: EXCESSIVELY LOW VOLTAGE DETECTED…7261
FAILURE CODE [CA144] COOLANT TEMPERATURE SENSOR TOO HIGH: EXCESSIVELY HIGH VOLTAGE DETECTED…7263
FAILURE CODE [CA145] COOLANT TEMPERATURE SENSOR TOO LOW: EXCESSIVELY LOW VOLTAGE DETECTED…7265
FAILURE CODE [CA153] CHARGE TEMPERATURE SENSOR TOO HIGH: EXCESSIVELY HIGH VOLTAGE DETECTED…7267
FAILURE CODE [CA154] CHARGE TEMPERATURE SENSOR TOO LOW: EXCESSIVELY LOW VOLTAGE DETECTED…7269
FAILURE CODE [CA155] CHARGE TEMPERATURE SENSOR TOO HIGH AND ENGINE SPEED DERATED: EXCEEDED UPPER CONTROL LIMIT OF TEMPERATURE…7271
FAILURE CODE [CA187] SENSOR POWER SOURCE 2 TOO LOW: EXCESSIVELY LOW VOLTAGE DETECTED…7272
FAILURE CODE [CA221] ATMOSPHERIC PRESSURE SENSOR TOO HIGH: EXCESSIVELY HIGH VOLTAGE DETECTED…7274
FAILURE CODE [CA222] ATMOSPHERIC PRESSURE SENSOR TOO LOW: EXCESSIVELY LOW VOLTAGE DETECTED…7276
FAILURE CODE [CA227] SENSOR POWER SOURCE 2 TOO HIGH: EXCESSIVELY HIGH VOLTAGE DETECTED…7278
FAILURE CODE [CA234] ENGINE OVER SPEED: EXCESSIVELY HIGH SPEED…7280
FAILURE CODE [CA238] ABNORMAL POWER SOURCE FOR NE SPEED SENSOR: EXCESSIVELY LOW VOLTAGE DETECTED…7281
FAILURE CODE [CA271] IMV/PCV1 SHORT CIRCUIT: SHORT CIRCUIT…7282
FAILURE CODE [CA272] IMV/PCV1 DISCONNECTION: DISCONNECTION…7284
FAILURE CODE [CA281] ABNORMAL SUPPLY PUMP PRESSURE BALANCE: ABNORMAL PRESSURE FEED OF FUEL…7286
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 2…7288
FAILURE CODE [CA322] INJECTOR NO.1 SYSTEM DISCONNECTION OR SHORT CIRCUIT: DISCONNECTION, SHORT CIRCUIT…7290
FAILURE CODE [CA323] INJECTOR NO.5 SYSTEM DISCONNECTION OR SHORT CIRCUIT: DISCONNECTION, SHORT CIRCUIT…7292
FAILURE CODE [CA324] INJECTOR NO.3 SYSTEM DISCONNECTION OR SHORT CIRCUIT: DISCONNECTION, SHORT CIRCUIT…7294
FAILURE CODE [CA325] INJECTOR NO.6 SYSTEM DISCONNECTION OR SHORT CIRCUIT: DISCONNECTION, SHORT CIRCUIT…7296
FAILURE CODE [CA331] INJECTOR NO.2 SYSTEM DISCONNECTION OR SHORT CIRCUIT: DISCONNECTION, SHORT CIRCUIT…7298
FAILURE CODE [CA332] INJECTOR NO.4 SYSTEM DISCONNECTION OR SHORT CIRCUIT: DISCONNECTION, SHORT CIRCUIT…7300
FAILURE CODE [CA342] ENGINE CONTROLLER DATA MATCHING ERROR: MATCHING ERROR…7302
FAILURE CODE [CA352] SENSOR POWER SOURCE 1 TOO LOW: EXCESSIVELY LOW VOLTAGE DETECTED…7303
FAILURE CODE [CA386] SENSOR POWER SOURCE 1 TOO HIGH: EXCESSIVELY HIGH VOLTAGE DETECTED…7305
FAILURE CODE [CA428] WATER DETECTION SENSOR TOO HIGH: EXCESSIVELY HIGH VOLTAGE DETECTED…7306
FAILURE CODE [CA429] WATER DETECTION SENSOR TOO LOW: EXCESSIVELY LOW VOLTAGE DETECTED…7308
FAILURE CODE [CA435] ABNORMAL ENGINE OIL PRESSURE SWITCH: ABNORMAL SIGNAL CIRCUIT…7310
FAILURE CODE [CA441] POWER SOURCE VOLTAGE TOO LOW: EXCESSIVELY LOW VOLTAGE DETECTED…7312
FAILURE CODE [CA442] POWER SOURCE VOLTAGE TOO HIGH: EXCESSIVELY HIGH VOLTAGE HAS OCCURRED IN THE CONTROLLER POWER SOURCE CIRCUIT…7314
FAILURE CODE [CA449] COMMON RAIL PRESSURE TOO HIGH (2): EXCESSIVELY HIGH PRESSURE TROUBLE OCCURRED…7316
FAILURE CODE [CA451] COMMON RAIL PRESSURE TOO HIGH: EXCESSIVELY HIGH VOLTAGE DETECTED…7319
FAILURE CODE [CA452] COMMON RAIL PRESSURE TOO LOW: EXCESSIVELY LOW VOLTAGE DETECTED…7321
FAILURE CODE [CA488] CHARGE TEMPERATURE TOO HIGH AND TORQUE DERATED: EXCEEDED UPPER CONTROL LIMIT OF TEMPERATURE…7323
FAILURE CODE [CA553] COMMON RAIL PRESSURE TOO HIGH (1): EXCESSIVELY HIGH PRESSURE DETECTED…7324
FAILURE CODE [CA559] LOSS OF PRESSURE FEED FROM SUPPLY PUMP (1): LOSS OF PRESSURE FEED DETECTED…7325
FAILURE CODE [CA689] ABNORMAL ENGINE NE SPEED SENSOR: ABNORMAL SIGNAL …7327
FAILURE CODE [CA731] ABNORMAL ENGINE BKUP SPEED SENSOR PHASE: ABNORMAL PHASE…7329
FAILURE CODE [CA757] LOSS OF ALL ENGINE CONTROLLER DATA: LOSS OF ALL DATA…7330
FAILURE CODE [CA778] ABNORMAL ENGINE BKUP SPEED SENSOR: ABNORMAL BKUP SIGNAL…7332
FAILURE CODE [CA1633] ABNORMAL KOMNET: ABNORMAL COMMUNICATION…7334
FAILURE CODE [CA2185] DECELERATOR PEDAL SENSOR POWER SOURCE TOO HIGH: EXCESSIVELY HIGH VOLTAGE DETECTED…7336
FAILURE CODE [CA2186] DECELERATOR PEDAL SENSOR POWER SOURCE TOO LOW: EXCESSIVELY LOW VOLTAGE DETECTED…7337
FAILURE CODE [CA2249] LOSS OF PRESSURE FEED FROM SUPPLY PUMP (2): LOSS OF PRESSURE FEED DETECTED…7338
FAILURE CODE [CA2265] ELECTRIC LIFT PUMP DISCONNECTION: DISCONNECTION …7339
FAILURE CODE [CA2266] ELECTRIC LIFT PUMP SHORT CIRCUIT: SHORT CIRCUIT…7341
FAILURE CODE [CA2311] ABNORMAL IMV SOLENOID: ABNORMAL RESISTANCE…7343
FAILURE CODE [CA2555] AIR INTAKE HEATER RELAY DISCONNECTION: DISCONNECTION…7345
FAILURE CODE [CA2556] AIR INTAKE HEATER RELAY SHORT CIRCUIT: SHORT CIRCUIT…7347
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 3…7350
FAILURE CODE [D110KA] BATTERY RELAY: SHORT CIRCUIT…7352
FAILURE CODE [D110KB] BATTERY RELAY: DISCONNECTION…7354
FAILURE CODE [D130KA] NEUTRAL SAFELY RELAY: DISCONNECTION…7356
FAILURE CODE [D130KB] NEUTRAL SAFELY RELAY: SHORT CIRCUIT…7358
FAILURE CODE [D161KA] BACK-UP ALARM RELAY: DISCONNECTION…7360
FAILURE CODE [D161KB] BACK-UP ALARM RELAY: SHORT CIRCUIT…7362
FAILURE CODE [DAFRKR] MONITOR PANEL CAN COMMUNICATION: DEFECTIVE COMMUNICATION…7364
FAILURE CODE [DAQ1KT] [DB30KT] STEERING AND TRANSMISSION CONTROLLER: ABNORMALITY IN CONTROLLER…7366
FAILURE CODE [DAQ1KK] [DB31KK] MAIN POWER SOURCE OF STEERING AND TRANSMISSION CONTROLLER: POWER SOURCE VOLTAGE DROP AND INPUT…7367
FAILURE CODE [DAQ2KK] [DB32KK] LOAD POWER SOURCE OF STEERING AND TRANSMISSION CONTROLLER: POWER SOURCE VOLTAGE DROP AND INPUT…7369
FAILURE CODE [DAQ5KK] [DB35KK] STEERING AND TRANSMISSION CONTROLLER SENSOR 5 V POWER SOURCE: POWER SOURCE VOLTAGE DROP AND INPUT…7371
FAILURE CODE [DAQ6KK] [DB36KK] STEERING AND TRANSMISSION CONTROLLER SENSOR 24V POWER SOURCE: POWER SOURCE VOLTAGE DROP AND INPUT…7373
FAILURE CODE [DAQ9KQ] [DB39KQ] STEERING AND TRANSMISSION CONTROLLER MODEL SELECTION: INCONSISTENCY IN MODEL SELECT SIGNAL…7375
FAILURE CODE [DB2RKR] STEERING AND TRANSMISSION CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION…7377
FAILURE CODE [DB30KT] [DAQ0KT] STEERING AND TRANSMISSION CONTROLLER: ABNOTMALITY IN CONTROLLER…7379
FAILURE CODE [DB31KK] [DAQ1KK] MAIN POWER SOURCE OF STEERING AND TRANSMISSION CONTROLLER: POWER SOURCE VOLTAGE DROP AND INPUT…7379
FAILURE CODE [DAB32KK] [DAQ2KK] LOAD POWER SOURCE OF STEERING AND TRANSMISSION CONTROLLER: POWER SOURCE VOLTAGE DROP AND INPUT…7379
FAILURE CODE [DB35KK] [DAQ5KK] STEERING AND TRANSMISSION CONTROLLER SENSOR 5 V POWER SOURCE: POWER SOURCE VOLTAGE DROP AND INPUT…7379
FAILURE CODE [DB36KK] [DAQ6KK] STEERING AND TRANSMISSION CONTROLLER SENSOR 24 V POWER SOURCE: POWER SOURCE VOLTAGE DROP AND INPUT…7379
FAILURE CODE [DB39KQ] [DAQ9KQ] STEERING AND TRANSMISSION CONTROLLER MODEL SELECTION: INCONSISTENCY IN MODEL SELECT SIGNAL…7379
FAILURE CODE [DD12KA] SHIFT UP SWITCH: DISCONNECTION…7380
FAILURE CODE [DD12KB] SHIFT UP SWITCH: SHORT CIRCUIT…7382
FAILURE CODE [DD13KA] SHIFT DOWM SWITCH: DISCONNECTION…7384
FAILURE CODE [DD13KB] SHIFT DOWN SWITCH: SHORT CIRCUIT…7386
FAILURE CODE [DD14KA] [DDQ2KA] PARKING BRAKE LEVER SWITCH: DISCONNECTION…7388
FAILURE CODE [DD14KB] [DDQ2KB] PARKING BRAKE LEVER SWITCH: SHORT CIRCUIT…7390
FAILURE CODE [DDN7KA] PITCH CONTROL SWITCH: DISCONNECTION…7392
FAILURE CODE [DDN7KB] PITCH CONTROL SWITCH: SHORT CIRCUIT…7394
FAILURE CODE [DDQ2KA] [DD14KA] PARKING BRAKE LEVER SWITCH: DISCONNECTION…7396
FAILURE CODE [DDQ2KB] [DD14KB] PARKING BRAKE LEVER SWITCH: SHORT CIRCUIT…7396
FAILURE CODE [DGS1KX] HYDRAULIC OIL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF NORMAL RANGE…7397
FAILURE CODE [DGT1KA] POWER TRAIN OIL TEMPERATURE SENSOR: DISCONNECTION…7399
FAILURE CODE [DGT1KX] POWER TRAIN OIL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF NORMAL RANGE…7400
FAILURE CODE [DK10KA] FUEL DIAL: DISCONNECTION…7401
FAILURE CODE [DK10KB] FUEL DIAL: SHORT CIRCUIT…7403
FAILURE CODE [DK30KA] STEERING POTENTIOMETER (1): DISCONNECTION…7405
FAILURE CODE [DK30KB] STEERING POTENTIOMETER (1): SHORT CIRCUIT…7407
FAILURE CODE [DK30KX] STEERING POTENTIOMETER: INPUT SIGNAL IS OUT OF NORMAL RANGE …7409
FAILURE CODE [DK30KZ] STEERING POTENTIOMETER: DISCONNECTION OF SHORT CIRCUIT (DOUBLE FAILURE)…7410
FAILURE CODE [DK30L8] STEERING POTENTIOMETER: INCONSISTENT ANALOG SIGNAL…7410
FAILURE CODE [DK31KA] STEERING POTENTIOMETER (2): DISCONNECTION…7411
FAILURE CODE [DK31KB] STEERING POTENTIOMETER (2): SHORT CIRCUIT…7413
FAILURE CODE [DK40KA] BRAKE POTENTIOMETER: DISCONNECTION…7415
FAILURE CODE [DK40KB] BRAKE POTENTIOMETER: SHORT CIRCUIT…7416
FAILURE CODE [DK55KX] FORWARD-REVERSE POTENTIOMETER: INPUT SIGNAL IS OUT OF NORMAL RANGE…7417
FAILURE CODE [DK55KZ] FORWARD-REVERSE POTENTIOMETER: DISCONNECTION OF SHORT CIRCUIT (DOUBLE FAILURE)…7418
FAILURE CODE [DK55L8] FORWARD-REVERSE POTENTIOMETER: INCONSISTENT ANALOG SIGNAL…7419
FAILURE CODE [DK56KA] FORWARD-REVERSE POTENTIOMETER (1): SHORT CIRCUIT…7420
FAILURE CODE [DK56KB] FORWARD-REVERSE POTENTIOMETER (1): DISCONNECTION…7422
FAILURE CODE [DK57KA] FORWARD-REVERSE POTENTIOMETER (2): DISCONNECTION…7424
FAILURE CODE [DK57KB] FORWARD-REVERSE POTENTIOMETER (2): SHORT CIRCUIT…7426
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 4…7429
FAILURE CODE [DKH1KA] [DKH1KX] PITCH ANGLE SENSOR: SHORT CIRCUIT…7431
FAILURE CODE [DKH1KB] [DKH1KX] PITCH ANGLE SENSOR: DISCONNECTION…7432
FAILURE CODE [DLT3KA] TRANSMISSION OUTPUT SPEED SENSOR: DISCONNECTION…7434
FAILURE CODE [DLT3KB] TRANSMISSION OUTPUT SPEED SENSOR: SHORT CIRCUTI…7435
FAILURE CODE [DV00KB] ALARM BUZZER: SHORT CIRCUIT…7436
FAILURE CODE [DW5AKA] PITCH CONTROL SOLENOID: DISCONNECTION…7437
FAILURE CODE [DW5AKB] PITCH CONTROL SOLENOID: SHORT CIRCUIT…7438
FAILURE CODE [DW5AKY] PITCH CONTROL SOLENOID: SHORT CIRCUIT TO POWER SOURCE LINE…7439
FAILURE CODE [DW7BKA] FAN REVERSE SOLENOID: DISCONNECTION…7440
FAILURE CODE [DW7BKB] FAN REVERSE SOLENOID: SHORT CIRCUIT…7441
FAILURE CODE [DWN1KA] HSS EPC SOLENOID RIGHT: DISCONNECTION…7442
FAILURE CODE [DWN1KB] HSS EPC SOLENOID RIGHT: SHORT CIRCUIT…7443
FAILURE CODE [DWN1KY] HSS EPC SOLENOID RIGHT: SHORT CIRCUIT TO POWER SOURCE LINE…7444
FAILURE CODE [DWN2KA] HSS EPC SOLENOID LEFT: DISCONNECTION…7445
FAILURE CODE [DWN2KB] HSS EPC SOLENOID LEFT: SHORT CIRCUIT…7446
FAILURE CODE [DWN2KY] HSS EPC SOLENOID LEFT: SHORT CIRCUIT TO POWER SOURCE LINE…7447
FAILURE CODE [DWN5KA] FAN PUMP TVC SOLENOID: DISCONNECTION…7448
FAILURE CODE [DWN5KB] FAN PUMP TVC SOLENOID: SHORT CIRCUIT…7449
FAILURE CODE [DWN5KY] FAN PUMP TVC SOLENOID: SHORT CIRCUIT TO POWER SOURCE LINE …7450
FAILURE CODE [DXA0KA] HSS PUMP TVC SOLENOID: DISCONNECTION…7451
FAILURE CODE [DXA0KB] HSS PUMP TVC SOLENOID: SHORT CIRCUIT…7452
FAILURE CODE [DXA0KY] HSS PUMP TVC SOLENOID: SHORT CIRCUIT TO POWER SOURCE LINE …7453
FAILURE CODE [DXH4KA] 1ST CLUTCH ECMV: DISCONNECTION …7454
FAILURE CODE [DXH4KB] 1ST CLUTCH ECMV: SHORT CIRCUIT…7455
FAILURE CODE [DXH4KY] 1ST CLUTCH ECMV: SHORT CIRCUIT TO POWER SOURCE LINE …7456
FAILURE CODE [DXH5KA] 2ND CLUTCH ECMV: DISCONNECTION …7457
FAILURE CODE [DXH5KB] 2ND CLUTCH ECMV: SHORT CIRCUIT…7458
FAILURE CODE [DXH5KY] 2ND CLUTCH ECMV: SHORT CIRCUIT TO POWER SOURCE LINE …7459
FAILURE CODE [DXH6KA] 3RD CLUTCH ECMV: DISCONNECTION …7460
FAILURE CODE [DXH6KB] 3RD CLUTCH ECMV: SHORT CIRCUIT…7461
FAILURE CODE [DXH6KY] 3RD CLUTCH ECMV: SHORT CIRCUIT TO POWER SOURCE LINE …7462
FAILURE CODE [DXH7KA] REVERSE CLUTCH ECMV: DISCONNECTION …7463
FAILURE CODE [DXH7KB] REVERSE CLUTCH ECMV: SHORT CIRCUIT…7464
FAILURE CODE [DXH7KY] REVERSE CLUTCH ECMV: SHORT CIRCUIT TO POWER SOURCE LINE …7465
FAILURE CODE [DXH8KA] FORWARD CLUTCH ECMV: DISCONNECTION …7466
FAILURE CODE [DXH8KB] FORWARD CLUTCH ECMV: SHORT CIRCUIT…7467
FAILURE CODE [DXH8KY] FORWARD CLUTCH ECMV: SHORT CIRCUIT TO POWER SOURCE LINE …7468
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)…7470
BEFORE TROUBLESHOOTING OF ELECTRICAL SYSTEM…7472
CONTENTS OF TROUBLESHOOTING TABLE…7474
E-1 THE ENGINE DOES NOT START (THE STARTING MOTOR DOES NOT TURN)…7475
E-2 THE PREHEATER DOES NOT OPERATE…7478
E-3 THE MONITOR PANEL DOES NOT LIGHT UP AT ALL WHEN THE STARTING SWITCH IS TURNED ON…7481
E-4 WHEN THE STARTING SWITCH IS TURNED ON, THE MONITOR PANEL COMPLETELY REMAINS LIGHTED AND DOES NOT GO OUT…7482
E-5 WHILE THE ENGINE IS RUNNING, THE BATTERY CHARGE LEVEL CAUTION LAMP FLASHES…7483
E-6 WHILE THE ENGINE IS RUNNING, THE EMERGENCY WARNING ITEM FLASHES…7485
E-7 WHILE THE PREHEATER IS OPERATING, THE PREHEATING PILOT LAMP DOES NOT LIGHT UP…7488
E-8 THE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY…7490
E-9 THE POWER TRAIN OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY…7491
E-10 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE PROPERLY…7493
E-11 FUEL GAUGE DOES NOT INDICATE PROPERLY…7495
E-12 GEAR SPEED AND ENGINE SPEED ARE NOT INDICATE PROPERLY…7496
E-13 THE PRESET MODE SERVICE METER DOES NOT INDICATE NORMALLY…7496
E-14 THE WARNING LAMP DOES NOT FLASH OR DOES NOT GO OUT…7496
E-15 THE ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP…7497
E-16 AUTO SHIFT DOWN IS NOT POSSIBLE OR IS NOT RELEASED…7499
E-17 THE BUZZER CANCEL SWITCH DOES NOT WORK…7501
E-18 THE INFORMATION SWITCH DOES NOT WORK…7503
E-19 THE FAN CLEANING DOES NOT OPERATE OR CANNOT BE RESET…7505
E-20 THE PRESET MODE DOES NOT OPERATE OR CANNOT BE RESET…7507
E-21 THE MONITOR PANEL CANNOT BE SET IN THE SERVICE MODE OR CANNOT BE SET OUT OF THE SERVICE MODE…7509
E-22 THE BACK-UP ALARM DOES NOT SOUND…7511
E-23 THE HEAD LAMP AND REAR LAMP DO NOT LIGHT UP…7513
E-24 THE HORN DOES NOT SOUND OR DOES NOT STOP…7516
E-25 MALFUNCTION OF WIPERS…7517
E-26 WASHER DOES NOT SPRAY WATER…7533
E-27 THE AIR CONDITIONER DOES NOT OPERATE…7538
E-28 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY…7542
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)…7545
CONTENTS OF TROUBLESHOOTING TABLE…7547
H-1 THERE IS NO TRAVEL POWER (NO DRAWBAR PULL)…7548
H-2 MACHINE DOES NOT MOVE (AT 2ND OR 3RD SPEED)…7549
H-3 MACHINE DOES NOT MOVE AT ANY GEAR SPEED…7550
H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION, FORWARD OR IN REVERSE…7551
H-5 WHEN GEAR IS SHIFTED OR TRAVEL DIRECTION IS CHANGED, LARGE TIME LAG IS MADE…7552
H-6 MACHINE CANNOT BE STEERED (MACHINE DOES NOT TURN LEFTWARD OR RIGHTWARD)…7553
H-7 STEERING SPEED OR POWER IS LOW…7553
H-8 BRAKE DOES NOT WORK…7554
H-9 OVERHEAT OF POWER TRAIN OIL…7555
H-10 ABNORMAL SOUND COMES OUT FROM AROUND HSS AND WORK EQUIPMENT PUMP OR HSS MOTOR…7556
H-11 ALL WORK EQUIPMENT SPEEDS ARE SLOW…7556
H-12 WORK EQUIPMENT DOES NOT MOVE…7557
H-13 BLADE LIFT SPEED IS SLOW OR LACKS POWER…7557
H-14 BLADE TILT SPEED IS SLOW OR LACKS POWER…7558
H-15 RIPPER LIFT SPEED IS SLOW OR LACKS POWER…7558
H-16 EXCESSIVE HYDRAULIC DRIFT OF BLADE LIFT…7559
H-17 EXCESSIVE HYDRAULIC DRIFT OF BLADE TILT…7559
H-18 EXCESSIVE HYDRAULIC DRIFT OF RIPPER LIFT…7560
TROUBLESHOOTING OF ENGINE (S-MODE)…7562
METHOD OF USING TROUBLESHOOTING CHARTS…7564
S-1 STARTING PERFORMANCE IS POOR…7567
S-2 ENGINE DOES NOT START…7568
S-3 ENGINE DOES NOT PICK UP SMOOTHLY…7571
S-4 ENGINE STOPS DURING OPERATIONS…7572
S-5 ENGINE DOES NOT ROTATE SMOOTHLY…7573
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)…7574
S-7 EXHAUST SMOKE IS BLACK (IMCOMPLETE COMBUSTION)…7575
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)…7576
S-9 OIL BECOMES CONTAMINATED QUICKLY…7577
S-10 FUEL CONSUMPTION IS EXCESSIVE…7578
S-11 OIL IS IN COOLANT (OR COOLANT SPURTS BACK, OR COOLANT LEVEL GOES DOWN)…7579
S-12 OIL PRESSURE DROPS…7580
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)…7581
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)…7582
S-15 ABNORMAL NOISE IS MADE…7583
S-16 VIBRATION IS EXCESSIVE…7584
50 IDSASSEMBLY AND ASSEMBLY…0
GENERAL INFORMATION ON DISASSEMBLY AND ASSEMBLY…7586
HOW TO READ THIS MANUAL …7587
COATING MATERIALS LIST…7589
SPECIAL TOOL LIST…7592
SKETCHES OF SPECIAL TOOLS…7597
ENGINE AND COOLING SYSTEM, PART 1…7599
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY…7600
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY…7604
REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY…7616
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL…7618
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL…7621
ENGINE AND COOLING SYSTEM, PART 2…7626
REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY…7627
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY…7634
REMOVAL AND INSTALLATION OF AIR AFTERCOOLER ASSEMBLY…7638
REMOVAL AND INSTALLATION OF FAN DRIVE ASSEMBLY…7639
REMOVAL AND INSTALLATION OF FAN MOTOR ASSEMBLY…7640
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY…7641
REMOVAL AND INSTALLATION OF DAMPER ASSEMBLY…7643
REMOVAL AND INSTALLATION OF ENGINE HOOD ASSEMBLY…7644
POWER TRAIN, PART 1…7646
REMOVAL AND INSTALLATION OF POWER TRAIN UNIT ASSEMBLY…7647
DISCONNECTION AND CONNECTION OF POWER TRAIN UNIT ASSEMBLY…7650
DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY…7654
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY…7660
DISASSEMBLY AND ASSEMBLY OF TRQFLOW TRANSMISSION ASSEMBLY…7665
POWER TRAIN, PART 2…7684
DISASSEMBLY AND ASSEMBLY OF HSS ASSEMBLY…7685
REMOVAL AND INSTALLATION OF FINAL DIRVE ASSEMBLY…7703
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY…7705
UNDERCARRIAGE AND FRAME, PART 1…7713
REMOVAL AND INSTALLATION OF TRACK FRAME ASSEMBLY…7714
REMOVAL AND INSTALLATION OF IDLER ASSEMBLY…7716
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY…7717
REMOVAL AND INSTALLATION OF RECOIL SPRING ASSEMBLY…7721
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY…7722
REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY…7726
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY…7727
REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY…7731
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY…7732
UNDERCARRIAGE AND FRAME, PART 2…7736
EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY…7737
WHOLE DISASSEMBLY AND WHOLE ASSEMBLY OF TRACK SHOE ASSEMBLY…7740
FIELD DISASSEMBLY AND ASSEMBLY OF ONE LINK…7755
REMOVAL AND INSTALLATION OF PIVOT SHAFT ASSEMBLY…7762
REMOVAL AND INSTALLATION OF EQUALIZER BAR ASSEMBLY…7763
DISASSEMBLY AND ASSEMBLY OF EQUALIZER BAR SIDE BUSHING…7765
HYDRAULIC SYSTEM…7767
REMOVAL AND INTALLATION OF CONTROL VALVE ASSEMBLY…7768
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY…7770
REMOVAL AND INSTALLATION OF HSS PUMP ASSEMBLY…7771
REMOVAL AND INSTALLATION OF POWER TRAIN AND LUBRICATING OIL PUMP ASSEMBLY…7772
REMOVAL AND INSTALLATION OF COOLING FAN PUMP ASSEMBLY…7773
REMOVAL AND INSTALLATION OF SCAVENGING PUMP ASSEMBLY…7775
REMOVAL AND INSTALLATION OF HSS MOTOR ASSEMBLY…7776
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY…7777
WORK EQUIPMENT…7784
REMOVAL AND INSTALLTION OF BLADE ASSEMBLY…7785
CAB AND ITS ATTACHMENTS…7788
REMOVAL AND INSTALLATION OF ROPS GUARD…7789
REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY…7790
REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS)…7796
REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY…7804
ELECTRICAL SYSTEM…7811
REMOVAL AND INSTALLATION OF ENGINE CONTROLLER…7812
REMOVAL AND INSTALLATION OF STEERING AND TRANSMISSION CONTROLLER ASSEMBLY…7814
REMOVAL AND INSTALLATION OF KOMTRAX TERMINAL…7815
90 DIAGRAMS AND DRAWINGS…0
HYDRAULIC DIAGRAMS AND DRAWINGS…7817
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM…7818
HYDRAULIC CIRCUIT DIAGRAM…7819
ELECTRICAL DIAGRAMS AND DRAWINGS…7820
ELECTRICAL CIRCUIT DIAGRAM…7821
CONNECTOR ARRANGEMENT DIAGRAM…7822
SEN00046-09 – Bulldozer D65EX,PX,WX-15E0 Shop Manual (SN69001&up)…7824
COVER…7824
00 Index and foreword…0
Index…7825
Composition of shop manual…7826
Table of contents…7828
Foreword and general information…7839
Safety notice…7840
How to read the shop manual…7845
Explanation of terms for maintenance standard…7847
Handling of electric equipment and hydraulic component…7849
Handling of connectors newly used for engines…7858
How to read electric wire code…7861
Precautions when carrying out operation…7864
Method of disassembling and connecting push-pull type coupler…7867
Standard tightening torque table…7870
Conversion table…7874
01 Specification…0
Specification and technical data…7881
Specification and technical data…7882
Specification dimensions…7882
Specifications…7883
Weight table…7888
Table of fuel, coolant and lubricants…7890
10 Structure, function and maintenance standard…0
Engine and cooling system…7893
Engine and cooling system…7894
Cooling system…7894
Cooling fan pump…7896
Cooling fan motor…7904
Power train, Part 1…7911
Power train, Part 1…7912
Power train…7912
HSS system…7914
General view of power train unit…7916
Power train hydraulic piping drawing…7918
Transmission, steering and brake control…7920
Damper and universal joint…7922
Torque converter and PTO…7925
Transmission…7930
Transmission clutch ECMV…7946
Main relief valve and torque converter relief valve…7952
Lubrication relief valve…7954
Power train, Part 2…7957
Power train, Part 2…7958
Bevel gear shaft, HSS and brake…7958
Brake valve…7980
Final drive…7986
Undercarriage and frame…7993
Undercarriage and frame…7994
Main frame…7994
Suspension…7996
Track frame and idler cushion…8002
Idler…8006
Track roller…8008
Carrier roller…8012
Sprocket…8014
Track shoe…8018
Hydraulic system, Part 1…8025
Hydraulic system, Part 1…8026
Work equipment hydraulic piping diagram…8026
Work equipment control…8028
Hydraulic tank and filter…8030
Scavenging pump…8032
Power train and steering lubrication pump…8033
HSS pump…8034
HSS motor…8052
Hydraulic system, Part 2…8060
Hydraulic system, Part 2…8061
Control valve…8061
Self pressure reducing valve…8093
Hydraulic system, Part 3…8101
Hydraulic system, Part 3…8102
PPC valve (blade lift, blade tilt)…8102
PPC valve (ripper)…8108
Electric lever (steering)…8112
Quick drop valve…8115
PPC lock valve…8117
Accumulator…8118
Work equipment…8120
Work equipment…8121
Blade…8121
Cutting edge and end bit…8125
Ripper…8126
Hydraulic cylinder…8127
Piston valve…8130
Cab and its attachments…8132
Cab and its attachments…8133
Cab mount…8133
Cab…8134
Air conditioner…8136
Electrical system…8138
Electrical system…8139
Monitor system…8139
Monitor panel…8141
Engine control…8150
Engine control system…8151
Cooling system control system…8153
System components…8155
Palm command control system…8163
KOMTRAX system…8165
Sensor…8167
20 Standard value table…0
Standard service value table…8172
Standard service value table…8173
Standard service value table for engine…8173
Standard service value table for chassis…8175
30 Testing and adjusting…0
Testing and adjusting, Part 1…8188
Tools for testing, adjusting, and troubleshooting…8190
Measuring engine speed…8193
Measuring intake air pressure (boost pressure)…8195
Measuring exhaust temperature…8197
Measuring exhaust gas color…8199
Adjusting valve clearance…8200
Measuring compression pressure…8203
Measuring blow-by pressure…8207
Measuring engine oil pressure…8208
Handling of fuel system devices…8209
Releasing residual pressure from fuel system…8209
Testing fuel pressure…8210
Testing fuel return and leak amount…8215
Bleeding air from fuel circuit…8217
Testing fuel circuit for leakage…8218
Handling of reduced cylinder mode operation…8219
Testing and adjusting air conditioner compressor belt tension…8220
Adjusting fuel control dial and decelerator pedal…8221
Measuring power train oil pressure…8223
Adjusting transmission speed sensor (replacement procedure)…8227
Simple method to test brake performance…8228
Adjusting brake pedal…8229
Adjusting parking brake lever…8231
Emergency escape method when power train has trouble…8232
Adjusting clearance of idler…8235
Inspecting wear of sprocket…8236
Testing and adjusting track shoe tension…8236
Testing and adjusting work equipment and HSS oil pressure…8237
Testing control circuit basic pressure…8240
Measuring PPC valve output pressure…8241
Adjusting work equipment PPC valve play…8243
Measuring internal leakage of work equipment cylinder…8245
Bleeding air from work equipment cylinder…8245
Releasing residual pressure in work equipment cylinder…8246
Checking parts which caused hydraulic drift of blade or ripper…8247
Adjusting work equipment lock lever…8248
Measuring fan motor speed…8249
Measuring fan pump circuit pressure…8250
Bleeding air from fan pump…8251
Adjusting straight tiltdozer…8252
Testing and adjusting operator cab…8254
Testing and adjusting, Part 2…8260
Testing and adjusting, Part 2…8261
Special functions of monitor panel (EMMS)…8261
Testing and adjusting, Part 3…8304
Testing and adjusting, Part 3…8305
Adjustment method when controller has been replaced…8305
Preparation work for troubleshooting for electric system…8307
Inspection procedure of diode…8312
Pm-Clinic service…8313
How to start operation of KOMTRAX terminal…8323
Lamp display of KOMTRAX terminal…8327
Handling of voltage circuit of engine controller…8305
40 Troubleshooting…0
General information on troubleshooting…8332
Points to remember when troubleshooting…8333
How to proceed troubleshooting…8334
Checks before troubleshooting…8335
Classification and procedures of troubleshooting…8336
How to distinguish wire code…8339
Connection table for connector pin numbers…8343
T- branch box and T- branch adapter table…8379
Troubleshooting by failure code (Display of code), Part 1…8384
Failure code table…8386
Before troubleshooting by failure codes…8393
Contents of troubleshooting table…8395
Failure code [1500L0] Transmission clutch: Dual engagement…8397
Failure code [15SAL1] Forward clutch: Fill signal is ON when command current is OFF…8399
Failure code [15SALH] Forward clutch: Fill signal is OFF when command current is ON…8401
Failure code [15SBL1] Reverse clutch: Fill signal is ON when command current is OFF…8403
Failure code [15SBLH] Reverse clutch: Fill signal is OFF when command current is ON…8405
Failure code [15SEL1] 1st clutch: Fill signal is ON when command current is OFF…8407
Failure code [15SELH] 1st clutch: Fill signal is OFF when command current is ON…8408
Failure code [15SFL1] 2nd clutch: Fill signal is ON when command current is OFF…8409
Failure code [15SFLH] 2nd clutch: Fill signal is OFF when command current is ON…8411
Failure code [15SGL1] 3rd clutch: Fill signal is ON when command current is OFF…8413
Failure code [15SGLH] 3rd clutch: Fill signal is OFF when command current is ON…8415
Failure code [AB00MA] Alternator: Malfunction…8417
Failure code [B@BAZG] Engine oil: Oil pressure too low…8417
Failure code [B@BCNS] Radiator coolant: Overheat…8418
Failure code [B@CENS] Power train oil: Overheat…8418
Failure code [B@HANS] Hydraulic oil: Overheat…8419
Failure code [CA111] Engine controller: Abnormality in controller…8420
Failure code [CA115] Abnormal engine Ne and Bkup speed sensors: Abnormal speed sensor signal…8420
Failure code [CA122] Charge pressure sensor too high: Excessively high voltage detected…8421
Failure code [CA123] Charge pressure sensor too low: Excessively low voltage detected…8423
Failure code [CA131] Decelerator pedal sensor too high: Excessively high voltage detected…8425
Failure code [CA132] Decelerator pedal sensor too low: Excessively low voltage detected…8427
Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected…8429
Failure code [CA145] Coolant temperature sensor too low: Excessively low voltage detected…8431
Failure code [CA153] Charge temperature sensor too high: Excessively high voltage detected…8433
Failure code [CA154] Charge temperature sensor too low: Excessively low voltage detected…8435
Failure code [CA155] Charge temperature too high and engine speed derated: Exceeded upper control limit of temperature…8437
Failure code [CA187] Sensor power source 2 too low: Excessively low voltage detected…8439
Failure code [CA221] Atmospheric pressure sensor too high: Excessively high voltage detected…8441
Failure code [CA222] Atmospheric pressure sensor too low: Excessively low voltage detected…8443
Failure code [CA227] Sensor power source 2 too high: Excessively high voltage detected…8445
Failure code [CA234] Engine over speed: Excessively high speed…8447
Failure code [CA238] Abnormal power source for Ne speed sensor: Excessively low voltage detected…8448
Failure code [CA271] IMV/PCV1 short circuit: Short circuit…8449
Failure code [CA272] IMV/PCV1 disconnection: Disconnection…8451
Failure code [CA281] Abnormal supply pump pressure balance: Abnormal pressure feed of fuel…8453
Troubleshooting by failure code (Display of code), Part 2…8456
Failure code [CA322] Injector No. 1 system disconnection or short circuit: disconnection, short circuit…8459
Failure code [CA323] Injector No. 5 system disconnection or short circuit: disconnection, short circuit…8461
Failure code [CA324] Injector No. 3 system disconnection or short circuit: disconnection, short circuit…8463
Failure code [CA325] Injector No. 6 system disconnection or short circuit: disconnection, short circuit…8465
Failure code [CA331] Injector No. 2 system disconnection or short circuit: disconnection, short circuit…8467
Failure code [CA332] Injector No. 4 system disconnection or short circuit: disconnection, short circuit…8469
Failure code [CA342] Engine controller data matching error: matching error…8471
Failure code [CA352] Sensor power source 1 too low: Excessively low voltage detected…8473
Failure code [CA386] Sensor power source 1 too high: Excessively high voltage detected…8475
Failure code [CA428] Water detection sensor too high: Excessively high voltage detected…8477
Failure code [CA429] Water detection sensor too low: Excessively low voltage detected…8479
Failure code [CA435] Abnormal engine oil pressure switch: Abnormal signal circuit…8481
Failure code [CA441] Power source voltage too low: Excessively low voltage detected…8483
Failure code [CA442] Power source voltage too high: Excessively high voltage has occurred in the controller power source circuit…8485
Failure code [CA449] Common rail pressure too high (2): Excessively high pressure trouble occurred…8487
Failure code [CA451] Common rail pressure sensor too high: Excessively high voltage detected…8491
Failure code [CA452] Common rail pressure sensor too low: Excessively low voltage detected…8493
Failure code [CA488] Charge temperature too high and torque derated: Exceeded upper control limit of temperature…8495
Failure code [CA553] Common rail pressure too high (1): Excessively high pressure detected…8496
Failure code [CA559] Loss of pressure feed from supply pump (1): Loss of pressure feed detected…8497
Failure code [CA689] Abnormal engine Ne speed sensor: Abnormal signal…8499
Failure code [CA731] Abnormal engine Bkup speed sensor phase: Abnormal phase…8501
Failure code [CA757] Loss of all engine controller data: Loss of all data…8503
Failure code [CA778] Abnormal engine Bkup speed sensor: Abnormal Bkup signal…8505
Failure code [CA1633] Abnormal KOMNET: Abnormal communication…8507
Failure code [CA2185] Decelerator pedal sensor power source too high: Excessively high voltage detected…8509
Failure code [CA2186] Decelerator pedal sensor power source too low: Excessively low voltage detected…8510
Failure code [CA2249] Loss of pressure feed from supply pump (2): Loss of pressure feed detected…8511
Failure code [CA2265] Electric lift pump disconnection: Disconnection…8513
Failure code [CA2266] Electric lift pump short circuit: Short circuit…8515
Failure code [CA2311] Abnormal IMV solenoid: Abnormal resistance…8517
Failure code [CA2555] Air intake heater relay disconnection: Disconnection…8519
Failure code [CA2556] Air intake heater relay short circuit: Short circuit…8521
Troubleshooting by failure code (Display of code), Part 3…8524
Troubleshooting by failure code (Display of code), Part 3…8527
Failure code [D110KA] Battery relay: Short circuit…8527
Failure code [D110KB] Battery relay: Disconnection…8529
Failure code [D130KA] Neutral safety relay: Disconnection…8531
Failure code [D130KB] Neutral safety relay: Short circuit…8533
Failure code [D161KA] Back-up alarm relay: Disconnection…8535
Failure code [D161KB] Back-up alarm relay: Short circuit…8537
Failure code [DAFRKR] Monitor panel CAN communication: Defective communication…8539
Failure code [DAQ0KT] [DB30KT] Steering and transmission controller: Abnormality in controller…8541
Failure code [DAQ1KK] [DB31KK] Main power source of steering and transmission controller: Power source voltage drop and input…8543
Failure code [DAQ2KK] [DB32KK] Load power source of steering and transmission controller: Power source voltage drop and input…8545
Failure code [DAQ5KK] [DB35KK] Steering and transmission controller sensor 5 V power source: Power source voltage drop and input…8547
Failure code [DAQ6KK] [DB36KK] Steering and transmission controller sensor 24 V power source: Power source voltage drop and input…8549
Failure code [DAQ9KQ] [DB39KQ] Steering and transmission controller model selection: Inconsistency in model select signal…8551
Failure code [DB2RKR] Steering and transmission controller CAN communication: Defective communication…8553
Failure code [DB30KT] [DAQ0KT] Steering and transmission controller: Abnormality in controller…8555
Failure code [DB31KK] [DAQ1KK] Main power source of steering and transmission controller: Power source voltage drop and input…8555
Failure code [DAB32KK] [DAQ2KK] Load power source of steering and transmission controller: Power source voltage drop and input…8555
Failure code [DB35KK] [DAQ5KK] Steering and transmission controller sensor 5 V power source: Power source voltage drop and input…8555
Failure code [DB36KK] [DAQ6KK] Steering and transmission controller sensor 24 V power source: Power source voltage drop and input…8555
Failure code [DB39KQ] [DAQ9KQ] Steering and transmission controller model selection: Inconsistency in model select signal…8555
Failure code [DD12KA] Shift up switch: Disconnection…8557
Failure code [DD12KB] Shift up switch: Short circuit…8559
Failure code [DD13KA] Shift down switch: Disconnection…8561
Failure code [DD13KB] Shift down switch: Short circuit…8563
Failure code [DD14KA] [DDQ2KA] Parking brake lever switch: Disconnection…8565
Failure code [DD14KB] [DDQ2KB] Parking brake lever switch: Short circuit…8567
Failure code [DDN7KA] Pitch control switch: Disconnection…8569
Failure code [DDN7KB] Pitch control switch: Short circuit…8571
Failure code [DDQ2KA] [DD14KA] Parking brake lever switch: Disconnection…8573
Failure code [DDQ2KB] [DD14KB] Parking brake lever switch: Short circuit…8573
Failure code [DGS1KX] Hydraulic oil temperature sensor: Input signal is out of normal range…8575
Failure code [DGT1KA] Power train oil temperature sensor: Disconnection…8577
Failure code [DGT1KX] Power train oil temperature sensor: Input signal is out of normal range…8578
Failure code [DK10KA] Fuel dial: Disconnection…8579
Failure code [DK10KB] Fuel dial: Short circuit…8581
Failure code [DK30KA] Steering potentiometer (1): Disconnection…8583
Failure code [DK30KB] Steering potentiometer (1): Short circuit…8585
Failure code [DK30KX] Steering potentiometer: Input signal is out of normal range…8587
Failure code [DK30KZ] Steering potentiometer: Disconnection or short circuit (Double failure)…8588
Failure code [DK30L8] Steering potentiometer: Inconsistent analog signal…8588
Failure code [DK31KA] Steering potentiometer (2): Disconnection…8589
Failure code [DK31KB] Steering potentiometer (2): Short circuit…8591
Failure code [DK40KA] Brake potentiometer: Disconnection…8593
Failure code [DK40KB] Brake potentiometer: Short circuit…8594
Failure code [DK55KX] Forward-reverse potentiometer: Input signal is out of normal range…8595
Failure code [DK55KZ] Forward-reverse potentiometer: Disconnection or short circuit (Double failure)…8596
Failure code [DK55L8] Forward-reverse potentiometer: Inconsistent analog signal…8597
Failure code [DK56KA] Forward-reverse potentiometer (1): Short circuit…8599
Failure code [DK56KB] Forward-reverse potentiometer (1): Disconnection…8601
Failure code [DK57KA] Forward-reverse potentiometer (2): Disconnection…8603
Failure code [DK57KB] Forward-reverse potentiometer (2): Short circuit…8605
Troubleshooting by failure code (Display of code), Part 4…8608
Troubleshooting by failure code (Display of code), Part 4…8610
Failure code [DKH1KA] [DKH1KX] Pitch angle sensor: Short circuit…8610
Failure code [DKH1KB] [DKH1KX] Pitch angle sensor: Disconnection…8611
Failure code [DKH1KX], [DKH1KA] or [DKH1KB] Pitch angle sensor: Input signal out of range…8612
Failure code [DLT3KA] Transmission output speed sensor: Disconnection…8613
Failure code [DLT3KB] Transmission output speed sensor: Short circuit…8614
Failure code [DV00KB] Alarm buzzer: Short circuit…8615
Failure code [DW5AKA] Pitch control solenoid: Disconnection…8616
Failure code [DW5AKB] Pitch control solenoid: Short circuit…8617
Failure code [DW5AKY] Pitch control solenoid: Short circuit to power source line…8618
Failure code [DW7BKA] Fan reverse solenoid: Disconnection…8619
Failure code [DW7BKB] Fan reverse solenoid: Short circuit…8620
Failure code [DWN1KA] HSS EPC solenoid right: Disconnection…8621
Failure code [DWN1KB] HSS EPC solenoid right: Short circuit…8622
Failure code [DWN1KY] HSS EPC solenoid right: Short circuit to power source line…8623
Failure code [DWN2KA] HSS EPC solenoid left: Disconnection…8624
Failure code [DWN2KB] HSS EPC solenoid left: Short circuit…8625
Failure code [DWN2KY] HSS EPC solenoid left: Short circuit to power source line…8626
Failure code [DWN5KA] Fan pump TVC solenoid: Disconnection…8627
Failure code [DWN5KB] Fan pump TVC solenoid: Short circuit…8628
Failure code [DWN5KY] Fan pump TVC solenoid: Short circuit in power source line…8629
Failure code [DXA0KA] HSS pump TVC solenoid: Disconnection…8630
Failure code [DXA0KB] HSS pump TVC solenoid: Short circuit…8631
Failure code [DXA0KY] HSS pump TVC solenoid: Short circuit to power source line…8632
Failure code [DXH4KA] 1st clutch ECMV: Disconnection…8633
Failure code [DXH4KB] 1st clutch ECMV: Short circuit…8634
Failure code [DXH4KY] 1st clutch ECMV: Short circuit to power source line…8635
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection…8636
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit…8637
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit to power source line…8638
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection…8639
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit…8640
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit to power source line…8641
Failure code [DXH7KA] Reverse clutch ECMV: Disconnection…8642
Failure code [DXH7KB] Reverse clutch ECMV: Short circuit…8643
Failure code [DXH7KY] reverse clutch ECMV: Short circuit to power source line…8644
Failure code [DXH8KA] Forward clutch ECMV: Disconnection…8645
Failure code [DXH8KB] Forward clutch ECMV: Short circuit…8646
Failure code [DXH8KY] forward clutch ECMV: Short circuit to power source line…8647
Troubleshooting of electrical system (E-mode)…8649
Troubleshooting of electrical system (E-mode)…8651
Before troubleshooting of electrical system…8651
Contents of troubleshooting table…8653
E-1 The engine does not start (the starting motor does not turn)…8654
E-2 The preheater does not operate…8658
E-3 The monitor panel does not light up at all when the starting switch is turned ON…8662
E-4 When the starting switch is turned on, the monitor panel completely remains lighted and does not go out…8663
E-5 While the engine is running, the battery charge level caution lamp flashes…8664
E-6 While the engine is running, the emergency warning item flashes…8666
E-7 While the preheater is operating, the preheating pilot lamp does not light up…8670
E-8 The coolant temperature gauge does not indicate correctly…8672
E-9 The power train oil temperature gauge does not indicate correctly…8674
E-10 Hydraulic oil temperature gauge does not indicate properly…8677
E-11 Fuel gauge does not indicate properly…8680
E-12 Gear speed and engine speed are not indicated properly…8681
E-13 The preset mode service meter does not indicate normally…8681
E-14 The warning lamp does not flash or does not go out…8681
E-15 The alarm buzzer does not sound or does not stop…8682
E-16 Auto shift down is not possible or is not released…8684
E-17 The buzzer cancel switch does not work…8686
E-18 The information switch does not work…8688
E-19 The fan cleaning does not operate or cannot be reset…8690
E-20 The preset mode does not operate or cannot be reset…8692
E-21 The monitor panel cannot be set in the service mode or cannot be set out of the service mode…8694
E-22 The back-up alarm does not sound…8696
E-23 The head lamp and rear lamp do not light up…8698
E-24 The horn does not sound or does not stop…8701
E-25 Malfunction of wipers…8702
E-26 Washer does not spray water…8718
E-27 The air conditioner does not operate…8724
E-28 KOMTRAX system does not operate normally…8728
Troubleshooting of hydraulic and mechanical system (H-mode)…8731
Troubleshooting of hydraulic and mechanical system (H-mode)…8733
Contents of troubleshooting table…8733
H-1 There is no travel power (no drawbar pull)…8734
H-2 Machine does not move (at 2nd or 3rd speed)…8735
H-3 Machine does not move at any gear speed…8736
H-4 Machine travels only in one direction, forward or in reverse…8737
H-5 When gear is shifted or travel direction is changed, large time lag is made…8738
H-6 Machine cannot be steered (Machine does not turn leftward or rightward)…8739
H-7 Steering speed or power is low…8739
H- 8 Brake does not work…8740
H-9 Overheat of power train oil…8741
H-10 Abnormal sound comes out from around HSS and work equipment pump or HSS motor…8742
H-11 All work equipment speeds are slow…8742
H-12 Work equipment does not move…8743
H-13 Blade lift speed is slow or lacks power…8743
H-14 Blade tilt speed is slow or lacks power…8744
H-15 Ripper lift speed is slow or lacks power…8744
H-16 Excessive hydraulic drift of blade lift…8745
H-17 Excessive hydraulic drift of blade tilt…8745
H-18 Excessive hydraulic drift of ripper lift…8746
Troubleshooting of engine (S-mode)…8748
Troubleshooting of engine (S-mode)…8750
Method of using troubleshooting charts…8750
S-1 Starting performance is poor…8753
S-2 Engine does not start…8754
S-3 Engine does not pick up smoothly…8757
S-4 Engine stops during operations…8758
S-5 Engine does not rotate smoothly…8759
S-6 Engine lacks output (or lacks power)…8760
S-7 Exhaust smoke is black (imcomplete combustion)…8761
S-8 Oil consumption is excessive (or exhaust smoke is blue)…8762
S-9 Oil becomes contaminated quickly…8763
S-10 Fuel consumption is excessive…8764
S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down)…8765
S-12 Oil pressure drops…8766
S-13 Oil level rises (water, fuel in oil)…8767
S-14 Coolant temperature becomes too high (overheating)…8768
S-15 Abnormal noise is made…8769
S-16 Vibration is excessive…8770
50 Disassembly and assembly…0
General information on disassembly and assembly…8772
How to read this manual…8773
Coating materials list…8775
Special tool list…8778
Sketches of special tools…8784
Engine and cooling system, Part 1…8794
Engine and cooling system, Part 1…8795
Removal and installation of fuel supply pump assembly…8795
Removal and installation of cylinder head assembly…8799
Removal and installation of fuel injector assembly…8814
Removal and installation of engine front oil seal…8816
Removal and installation of engine rear oil seal…8819
Engine and cooling system, Part 2…8826
Engine and cooling system, Part 2…8827
Removal and installation of engine assembly…8827
Removal and installation of radiator assembly…8834
Removal and installation of air aftercooler assembly…8838
Removal and installation of fan drive assembly…8839
Removal and installation of fan motor assembly…8840
Removal and installation of fuel tank assembly…8841
Removal and installation of damper assembly…8843
Removal and installation of engine hood assembly…8844
Power train, Part 1…8846
Power train, Part 1…8847
Removal and installation of power train unit assembly…8847
Disconnection and connection of power train unit assembly…8850
Disassembly and assembly of PTO assembly…8854
Disassembly and assembly of torque converter assembly…8860
Disassembly and assembly of TORQFLOW transmission assembly…8865
Power train, Part 2…8884
Power train, Part 2…8885
Disassembly and assembly of HSS assembly…8885
Removal and installation of final drive assembly…8903
Disassembly and assembly of final drive assembly…8905
Undercarriage and frame, Part 1…8913
Undercarriage and frame, Part 1…8914
Removal and installation of track frame assembly…8914
Removal and installation of idler assembly…8916
Disassembly and assembly of idler assembly…8917
Removal and installation of recoil spring assembly…8921
Disassembly and assembly of recoil spring assembly…8922
Removal and installation of track roller assembly…8926
Disassembly and assembly of track roller assembly…8927
Removal and installation of carrier roller assembly…8931
Disassembly and assembly of carrier roller assembly…8932
Undercarriage and frame, Part 2…8936
Expansion and installation of track shoe assembly (Conventional type track shoe)…8937
Expansion and installation of track shoe assembly (PLUS type track shoe)…8940
Whole disassembly and whole assembly of track shoe assembly (Conventional type track shoe)…8941
Whole disassembly and whole assembly of track shoe assembly (PLUS type track shoe)…8954
Field disassembly and assembly of one link (Conventional type track shoe)…8967
Field disassembly and assembly of one link (PLUS type track shoe)…8974
Removal and installation of pivot shaft assembly…8979
Removal and installation of equalizer bar assembly…8980
Disassembly and assembly of equalizer bar side bushing…8982
Hydraulic system…8984
Hydraulic system…8985
Removal and installation of control valve assembly…8985
Disassembly and assembly of control valve assembly…8987
Removal and installation of HSS pump assembly…8988
Removal and installation of power train and lubricating oil pump assembly…8989
Removal and installation of cooling fan pump assembly…8990
Removal and installation of scavenging pump assembly…8992
Removal and installation of HSS motor assembly…8993
Disassembly and assembly of hydraulic cylinder assembly…8994
Work equipment…9001
Work equipment…9002
Removal and installation of blade assembly…9002
Cab and its attachments…9005
Cab and its attachments…9006
Removal and installation of ROPS guard…9006
Removal and installation of operator’s cab assembly…9007
Removal and installation of operator’s cab glass (Stuck glass)…9013
Removal and installation of floor frame assembly…9021
Electrical system…9029
Electrical system…9030
Removal and installation of engine controller…9030
Removal and installation of steering and transmission controller assembly…9032
Removal and installation of KOMTRAX terminal…9033
90 Diagrams and drawings…0
Hydraulic diagrams and drawings…9035
Hydraulic diagrams and drawings…9036
Power train hydraulic circuit diagram…9036
Hydraulic circuit diagram…9037
Electrical diagrams and drawings…9040
Electrical circuit diagram…9042
Connector list and stereogram…9050
SEN04887-10 – Bulldozer D65EX,PX,WX-16 Shop Manual (SN80001&up)…9053
COVER…9053
00 Index and foreword…0
100 Index…9055
Composition of shop manual…9056
Table of contents…9058
200 Foreword and general information…9069
Safety notice…9070
How to read the shop manual…9075
Explanation of terms for maintenance standard…9077
Handling of electric equipment and hydraulic component…9079
Handling of connectors newly used for engines…9088
How to read electric wire code…9091
Precautions when carrying out operation…9094
Method of disassembling and connecting push-pull type coupler…9097
Standard tightening torque table…9100
Conversion table…9104
01 General…0
100 Specification and technical data…9111
Specification dimension drawing…9112
Specifications…9118
Weight table…9130
Table of fuel, coolant and lubricants…9134
10 Structure, function and maintenance standard…0
100 Engine and cooling system…9137
Engine mount…9139
Cooling system…9140
Cooling fan pump…9142
Cooling fan motor…9156
Coolant preheater (subextremely cold weather spec.)…9162
201 Power train, Part 1…9167
Power train…9168
HSS system…9170
Overall view of power train unit…9172
Power train hydraulic piping diagram…9176
Transmission, steering and brake control…9178
Damper…9180
Universal joint…9182
Torque converter and PTO…9183
Transmission…9190
Transmission control valve…9208
ECMV…9212
Main relief and torque converter relief valve…9220
Main relief and torque converter relief valve (subextremely cold weather spec.)…9222
Transmission lubrication relief valve…9224
202 Power train, Part 2…9227
Bevel gear shaft, HSS and brake…9228
Brake valve…9250
Final drive…9256
Final drive (Planetary gear installed inside of sprocket type)…9262
300 Undercarriage and frame…9269
Main frame…9270
Suspension…9272
Track frame and idler cushion…9282
Idler…9286
Track roller…9288
Carrier roller…9294
Sprocket…9296
Track shoe…9300
401 Hydraulic system, Part 1…9307
Work equipment hydraulic system layout drawing…9308
Work equipment control…9312
Hydraulic tank and filter…9314
Scavenging pump…9316
Power train and steering lubrication pump…9317
HSS pump…9318
HSS motor…9337
402 Hydraulic system, Part 2…9347
Control valve…9348
CLSS…9357
Function and operation of each valve…9360
403 Hydraulic system, Part 3…9385
PPC valve (blade lift, blade tilt)…9386
PPC valve (ripper)…9392
Electric lever (steering)…9396
Quick drop valve…9400
Work equipment lock solenoid valve…9402
Pitch selector solenoid valve…9406
Hydraulic oil cooler bypass valve…9407
Accumulator…9408
500 Work equipment…9411
Blade…9412
Cutting edge and end bit…9420
Ripper (Multi shank)…9422
Ripper (Single shank)…9423
Hydraulic cylinder…9424
Piston valve…9428
600 Cab and its attachme…9431
Cab mount…9432
Cab…9433
Subextremely cold spec. cab (subextremely cold weather spec.)…9434
600 Cab and its attachmentsFRP canopy mountFRP canopy mount…9435
FRP canopy…9436
700 Electrical system…9439
Monitor system…9440
Engine control system…9456
Cooling system control system…9459
Electronic steering control system…9461
KOMTRAX system…9464
KOMTRAX terminal (for GPRS)…9466
System components…9467
Sensor…9475
20 Standard value table…0
100 Standard service value table…9483
Standard service value table for engine…9484
Standard service value table for chassis…9486
30 Testing and adjusting…0
101 Testing and adjusting, Part 1…9499
Tools for testing, adjusting, and troubleshooting…9500
Testing engine speed…9503
Testing intake air pressure (boost pressure)…9505
Testing exhaust temperature…9507
Testing exhaust gas color…9509
Adjusting valve clearance…9510
Testing compression pressure…9512
Testing blow-by pressure…9516
Testing engine oil pressure…9517
Handling of fuel system devices…9518
Releasing residual pressure from fuel system…9518
Testing fuel pressure…9519
Testing fuel return and leak amount…9524
Bleeding air from fuel circuit…9526
Testing fuel circuit for leakage…9527
Handling of reduced cylinder mode operation…9528
Handling of no injection cranking operation…9528
Testing and adjusting air conditioner compressor belt tension…9529
Replacing alternator belt…9530
Adjusting fuel control dial and decelerator pedal…9531
Handling controller high-voltage circuit…9532
102 Testing and adjusting, Part 2…9535
Testing power train oil pressure…9537
Adjusting transmission output shaft speed sensor (replacement procedure)…9542
Simple test procedure for brake performance…9543
Adjusting brake pedal…9544
Adjusting parking brake lever…9546
Emergency escape method when power train has trouble…9548
Adjusting clearance of idler…9551
Inspecting wear of sprocket…9552
Inspecting wear of sprocket…9553
Testing and adjusting track shoe tension…9554
Testing and adjusting work equipment and HSS oil pressure…9555
Testing control circuit basic pressure…9558
Testing PPC valve output pressure…9559
Adjusting work equipment PPC valve play…9561
Testing internal leakage of work equipment cylinder…9565
Bleeding air from work equipment cylinder…9566
Releasing residual pressure from work equipment cylinder…9566
Checking parts which caused hydraulic drift of blade or ripper…9567
Adjusting work equipment lock lever…9568
Adjusting work equipment lock lever (FRP canopy specification)…9569
Testing fan speed…9571
Testing fan circuit oil pressure…9572
Bleeding air from fan pump…9573
Bleeding air from HSS pump…9574
Adjusting straight tiltdozer…9575
Adjusting play of blade center ball1…9577
Adjusting operator’s cab…9578
103 Testing and adjusting, Part 3…9583
Special functions of machine monitor (EMMS)…9584
104 Testing and adjusting, Part 4…9641
Handling of voltage circuit of engine controller…9642
Adjustment method when controller has been replaced…9643
Preparation work for troubleshooting of electrical…9645
Inspection procedure of diode…9649
Pm-Clinic service…9650
40 Troubleshooting…0
100 Failure code table and fuse locations…9665
Failure codes table…9666
Fuse locations…9671
200 General information on troubleshooting…9675
Points to remember when troubleshooting…9676
How to proceed troubleshooting…9677
Checks before troubleshooting…9678
Classification and procedures for troubleshooting…9680
Symptom supposed to be failure and troubleshooting No…9684
Information contained in troubleshooting table…9686
Troubleshooting method for disconnecting wiring harness of pressure sensor system…9688
Connector list and stereogram…9690
Connection table for connector pin numbers…9704
T- branch box and T- branch adapter table…9740
301 Troubleshooting by failure code (Display of code), Part 1…9745
Failure code [1500L0] Transmission clutch: Abnormal…9747
Failure code [15SAL1] Forward clutch: Fill high…9748
Failure code [15SALH] Forward clutch: Fill low…9750
Failure code [15SBL1] Reverse clutch: Fill high…9752
Failure code [15SBLH] Reverse clutch: Fill low…9754
Failure code [15SEL1] Speed 1st clutch: Fill high…9756
Failure code [15SELH] Speed 1st clutch: Fill low…9758
Failure code [15SFL1] Speed 2nd clutch: Fill high…9760
Failure code [15SFLH] Speed 2nd clutch: Fill low…9762
Failure code [15SGL1] Speed 3rd clutch: Fill high…9764
Failure code [15SGLH] Speed 3rd clutch: Fill low…9766
Failure code [15SJL1] L/U: Fill high…9768
Failure code [15SJLH] L/U: Fill low…9770
Failure code [AB00MA] Battery Charge Abnormal…9772
Failure code [B@BAZG] Eng Oil Press Low…9774
Failure code [B@BCNS] Eng Water Overheat…9774
Failure code [B@CENS] T/C Oil Overheat…9775
Failure code [B@HANS] Hyd Oil Overheat…9775
302 Troubleshooting by failure code (Display of code), Part 2…9777
Failure code [CA111] ECM Critical Internal Failure…9779
Failure code [CA115] Eng Ne and Bkup Speed Sens Error…9779
Failure code [CA122] Chg Air Press Sensor High Error…9780
Failure code [CA123] Chg Air Press Sensor Low Error…9782
Failure code [CA131] Throttle Sensor High Error…9784
Failure code [CA132] Throttle Sensor Low Error…9786
Failure code [CA144] Coolant Temp Sens High Error…9788
Failure code [CA145] Coolant Temp Sens Low Error…9790
Failure code [CA153] Chg Air Temp Sensor High Error…9792
Failure code [CA154] Chg Air Temp Sensor Low Error…9794
Failure code [CA155] Chg Air Temp High Speed Derate…9796
Failure code [CA187] Sens Supply 2 Volt Low Error…9798
Failure code [CA221] Ambient Press Sens High Error…9800
Failure code [CA222] Ambient Press Sens Low Error…9802
Failure code [CA227] Sens Supply 2 Volt High Error…9804
Failure code [CA234] Eng Overspeed…9804
Failure code [CA238] Ne Speed Sens Supply Volt Error…9805
Failure code [CA271] IMV/PCV1 Short Error…9806
Failure code [CA272] IMV/PCV1 Open Error…9808
Failure code [CA281] Abnormal supply pump pressure balance…9810
Failure code [CA322] Inj #1(L#1) Open/Short Error…9812
Failure code [CA323] Inj #5(L#5) Open/Short Error…9814
Failure code [CA324] Inj #3(L#3) Open/Short Error…9816
Failure code [CA325] Inj #6(L#6) Open/Short Error…9818
Failure code [CA331] Inj #2(L#2) Open/Short Error…9820
Failure code [CA332] Inj #4(L#4) Open/Short Error…9822
303 Troubleshooting by failure code (Display of code), Part 3…9825
Failure code [CA342] Calibration Code Incompatibility…9827
Failure code [CA351] Injectors Drive Circuit Error…9827
Failure code [CA352] Sens Supply 1 Volt Low Error…9828
Failure code [CA386] Sens Supply 1 Volt High Error…9830
Failure code [CA428] Water in Fuel Sensor High Error…9832
Failure code [CA429] Water in Fuel Sensor Low Error…9834
Failure code [CA435] Eng Oil Press Sw Error…9836
Failure code [CA441] Battery Voltage Low Error…9838
Failure code [CA442] Battery Voltage High Error…9840
Failure code [CA449] Rail Press Very High Error…9842
Failure code [CA451] Rail Press Sensor High Error…9844
Failure code [CA452] Rail Press Sensor Low Error…9846
Failure code [CA488] Chg Air Temp High Torque Derate…9848
Failure code [CA553] Rail Press High Error…9849
Failure code [CA559] Rail Press Low Error…9850
Failure code [CA689] Eng Ne Speed Sensor Error…9852
Failure code [CA731] Eng Bkup Speed Sens Phase Error…9856
Failure code [CA757] All Continuous Data Lost Error…9857
Failure code [CA778] Eng Bkup Speed Sensor Error…9858
Failure code [CA1633] KOMNET Datalink Timeout Error…9861
Failure code [CA2185] Throt Sens Sup Volt High Error…9862
Failure code [CA2186] Throt Sens Sup Volt Low Error…9864
Failure code [CA2249] Rail Press Very Low Error…9866
Failure code [CA2265] Fuel Feed Pump Open Error…9868
Failure code [CA2266] Fuel Feed Pump Short Error…9870
Failure code [CA2311] IMV Solenoid Error…9871
Failure code [CA2555] Grid Htr Relay Volt High Error…9872
Failure code [CA2556] Grid Htr Relay Volt Low Error…9874
304 Troubleshooting by failure code (Display of code), Part 4…9877
Failure code [D110KB] Battery relay drive: Short circuit…9880
Failure code [D130KA] Neutral relay: Disconnection…9882
Failure code [D130KB] Neutral relay: Short circuit…9884
Failure code [D161KA] Back-up alarm relay: Disconnection…9886
Failure code [D161KB] Back-up alarm relay: Short circuit…9888
Failure code [D862KA] GPS Antenna Open Circuit…9890
Failure code [DAFRKR] CAN Disconnection…9891
Failure code [DAFRMC] CAN Discon (Monitor Detected)…9892
Failure code [DB2RKR] CAN Disconnection…9895
Failure code [DBE0KT] PT controller: Abnormality in controller…9900
Failure code [DBE1KK] Battery direct Source voltage reduction…9902
Failure code [DBE2KK] Solenoid Source voltage reduction…9904
Failure code [DBE5KK] PT cont.: Sensor voltage 5V (1) reduction…9906
Failure code [DBE6KK] PT cont.: Sensor voltage 24V reduction…9908
Failure code [DBE7KK] PT cont.: Sensor voltage 5V (2) reduction…9910
Failure code [DBE9KQ] PT controller: Type select signal…9912
Failure code [DD12KA] Shift up Sw: Disconnection…9914
Failure code [DD12KB] Shift up Sw: Short circuit…9916
Failure code [DD13KA] Shift down Sw: Disconnection…9918
Failure code [DD13KB] Shift down Sw: Short circuit…9920
Failure code [DD14KA] Parking lever Sw: Disconnection…9922
Failure code [DD14KB] Parking lever Sw: Short circuit…9924
305 Troubleshooting by failure code (Display of code), Part 5…9927
Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection…9930
Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit…9932
Failure code [DDN8KA] WEQ Knob Sw (up): Disconnection…9934
Failure code [DDN8KB] WEQ Knob Sw (up): Short circuit…9936
Failure code [DDNLKA] Weq lock Sw: Disconnection…9938
Failure code [DDNLKB] Weq lock Sw: Short circuit…9940
Failure code [DGS1KX] Hyd oil temp sensor: Abnormal…9942
Failure code [DGT1KA] T/C oil temp sensor: Disconnection…9944
Failure code [DGT1KX] T/C oil temp sensor: Short circuit…9946
Failure code [DH21KA] Weq pressure sensor: Disconnection…9948
Failure code [DH21KB] Weq pressure sensor: Short circuit…9950
Failure code [DHT5KA] T/C pressure sensor: Disconnection…9952
Failure code [DHT5KB] T/C pressure sensor: Short circuit…9954
Failure code [DK10KA] Fuel control Dial: Disconnection…9956
Failure code [DK10KB] Fuel control Dial: Short circuit…9958
Failure code [DK30KA] ST lever 1: Disconnection…9960
Failure code [DK30KB] ST lever 1: Short circuit…9962
Failure code [DK30KX] ST lever: Out of normal range…9964
Failure code [DK30KZ] ST lever: Disconnection or short circuit…9964
Failure code [DK30L8] ST lever: Signal mismatch…9965
Failure code [DK31KA] ST lever 2: Disconnection…9966
Failure code [DK31KB] ST lever 2: Short circuit…9968
Failure code [DK40KA] Brake potentiometer: Disconnection…9970
Failure code [DK40KB] Brake potentiometer: Short circuit…9972
Failure code [DK55KX] FR lever: Out of normal range…9974
Failure code [DK55KZ] FR lever: Disconnection or short circuit…9974
Failure code [DK55L8] FR lever: Signal mismatch…9975
Failure code [DK56KA] FR lever 1: Disconnection…9976
Failure code [DK56KB] FR lever 1: Short circuit…9978
Failure code [DK57KA] FR lever 2: Disconnection…9980
Failure code [DK57KB] FR lever 2: Short circuit…9982
306 Troubleshooting by failure code (Display of code), Part 6…9985
Failure code [DKH1KA] Pitch angle sensor: Disconnection…9988
Failure code [DKH1KB] Pitch angle sensor: Short circuit…9990
Failure code [DLT3KA] T/M out-speed sensor: Disconnection…9992
Failure code [DLT3KB] T/M out-speed sensor: Abnormal…9993
Failure code [DW5AKA] Pitch selector Sol.: Disconnection…9994
Failure code [DW5AKB] Pitch selector Sol.: Short circuit…9995
Failure code [DW5AKY] Pitch selector Sol.: Short circuit…9996
Failure code [DW7BKA] Fan rev EPC: Disconnection…9998
Failure code [DW7BKB] Fan rev EPC: Short circuit…9999
Failure code [DWN1KA] Hss EPC1: Disconnection…10000
Failure code [DWN1KB] Hss EPC1: Short circuit…10001
Failure code [DWN1KY] Hss EPC1: Short circuit…10002
Failure code [DWN2KA] Hss EPC2: Disconnection…10003
Failure code [DWN2KB] Hss EPC2: Short circuit…10004
Failure code [DWN2KY] Hss EPC2: Short circuit…10005
Failure code [DWN5KA] Fan pump solenoid: Disconnection…10006
Failure code [DWN5KB] Fan pump solenoid: Short circuit…10007
Failure code [DWN5KY] Fan control solenoid: Short circuit…10008
Failure code [DXA0KA] TVC Sol.: Disconnection…10010
Failure code [DXA0KB] TVC Sol.: Short circuit…10011
Failure code [DXA0KY] TVC Sol.: Short circuit…10012
Failure code [DXH1KA] Lock-up ECMV: Disconnection…10013
Failure code [DXH1KB] Lock-up ECMV: Short circuit…10014
Failure code [DXH1KY] Lock-up ECMV: Short circuit…10016
Failure code [DXH4KA] 1st clutch ECMV: Disconnection…10018
Failure code [DXH4KB] 1st clutch ECMV: Short circuit…10019
Failure code [DXH4KY] 1st clutch ECMV: Short circuit…10020
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection…10021
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit…10022
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit…10023
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection…10024
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit…10025
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit…10026
Failure code [DXH7KA] R clutch ECMV: Disconnection…10027
Failure code [DXH7KB] R clutch ECMV: Short circuit…10028
Failure code [DXH7KY] R clutch ECMV: Short circuit…10030
Failure code [DXH8KA] F clutch ECMV: Disconnection…10032
Failure code [DXH8KB] F clutch ECMV: Short circuit…10033
Failure code [DXH8KY] F clutch ECMV: Short circuit…10034
Failure code [DXJ4KA] Weq lock Sol.: Disconnection…10036
Failure code [DXJ4KB] Weq lock Sol.: Short circuit…10037
400 Troubleshooting of electrical system (E-mode)…10039
Before troubleshooting of electrical system…10041
Information in troubleshooting table…10043
E-1 Engine does not start (starting motor does not turn)…10045
E-2 Preheater does not operate…10048
E-3 When starting switch is turned ON, machine monitor displays nothing…10054
E-4 When starting switch is turned ON (before starting engine), basic check item lights up…10056
E-5 Precaution item lights up while engine is running…10058
E-6 Emergency stop item lights up while engine is running…10060
E-7 Engine coolant temperature gauge does not indicate normally…10062
E-8 Fuel gauge does not indicate properly…10064
E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally…10067
E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally…10068
E-11 Contents of display by machine monitor are different from applicable machine…10069
E-12 Machine monitor does not display some items…10069
E-13 Function switch does not work…10069
E-14 Operation mode does not change…10070
E-15 Gearshift mode does not change…10070
E-16 Customize function does not operate normally…10071
E-17 Customize memory function does not operate normally…10071
E-18 Alarm buzzer does not sound or does not stop…10072
E-19 When starting switch is turned OFF, service meter is not displayed…10072
E-20 Machine monitor cannot be set in service mode…10072
E-21 Horn does not sound or does not stop…10073
E-22 Back-up alarm does not sound or does not stop…10074
E-23 Head lamp or rear lamp does not light up…10076
E-24 Windshield wiper does not operate…10080
E-25 Window washer does not operate…10094
E-26 KOMTRAX system does not operate correctly…10099
500 Troubleshooting of hydraulic and mechanical system (H-mode)…10101
Failure mode and cause table…10102
Contents of troubleshooting table…10104
H-1 There is no travel power (no drawbar pull)…10105
H-2 Machine does not move (at 2nd or 3rd speed)…10106
H-3 Machine does not move at any gear speed…10107
H-4 Machine travels only in one direction, forward or in reverse…10108
H-5 When gear is shifted or travel direction is changed, large time lag is made…10109
H-6 Machine cannot be steered (Machine does not turn leftward or rightward)…10110
H-7 Steering speed or power is low…10110
H- 8 Brake does not work…10111
H-9 Overheat of power train oil…10112
H-10 Abnormal sound comes out from around HSS and work equipment pump or HSS motor…10113
H-11 All work equipment speeds are slow…10113
H-12 Work equipment does not move…10114
H-13 Blade lift speed is slow or lacks power…10114
H-14 Blade tilt speed is slow or lacks power…10115
H-15 Ripper lift speed is slow or lacks power…10115
H-16 Excessive hydraulic drift of blade lift…10116
H-17 Excessive hydraulic drift of blade tilt…10116
H-18 Excessive hydraulic drift of ripper lift…10117
600 Troubleshooting of engine (S-mode)…10119
Method of using troubleshooting charts…10121
S-1 Starting performance is poor…10124
S-2 Engine does not start…10125
S-3 Engine does not pick up smoothly…10128
S-4 Engine stops during operations…10129
S-5 Engine does not rotate smoothly…10130
S-6 Engine lacks output (or lacks power)…10131
S-7 Exhaust smoke is black (incomplete combustion)…10132
S-8 Oil consumption is excessive (or exhaust smoke is blue)…10133
S-9 Oil becomes contaminated quickly…10134
S-10 Fuel consumption is excessive…10135
S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down)…10136
S-12 Oil pressure drops…10137
S-13 Oil level rises (water, fuel in oil)…10138
S-14 Coolant temperature becomes too high (overheating)…10139
S-15 Abnormal noise is made…10140
S-16 Vibration is excessive…10141
50 Disassembly and assembly…0
100 General information on disassembly and assembly…10143
How to read this manual…10144
Coating materials list…10146
Special tool list…10149
Sketches of special tools…10159
200 Engine and cooling system…10175
Removal and installation of fuel supply pump assembly…10176
Removal and installation of fuel injector assembly…10181
Removal and installation of cylinder head assembly…10191
Removal and installation of radiator assembly…10206
Removal and installation of aftercooler assembly…10209
Removal and installation of hydraulic oil cooler assembly…10211
Removal and installation of power train oil cooler assembly…10213
Removal and installation of cooling fan drive assembly…10216
Removal and installation of cooling fan motor assembly…10218
Removal and installation of main body of coolant preheater (subextremely cold weather spec)…10220
Removal and installation of coolant preheater fuel tank (Subextremely cold weather spec.)…10224
Removal and installation of coolant preheater exhaust duct. (Subextremely cold weather spec.)…10226
Removal and installation of oil pan cover of coolant preheater (subextremely cold weather spec.)…10230
Removal and installation of damper assembly…10239
Removal and installation of engine front oil seal…10242
Removal and installation of engine rear oil seal…10246
Removal and installation of engine hood assembly…10254
Removal and installation of fuel tank assembly…10256
300 Power train…10259
Removal and installation of power train unit assembly…10260
Separation and connection of power train unit assembly…10264
Disassembly and assembly of PTO assembly…10269
Disassembly and assembly of torque converter assembly…10274
Disassembly and assembly of transmission assembly…10285
Disassembly and assembly of HSS assembly…10312
Removal and installation of final drive assembly…10332
Removal and installation of final drive assembly (Planetary gear installed inside of sprocket type)…10334
Disassembly and assembly of final drive assembly…10336
Disassembly and assembly of final drive assembly (Planetary gear installed inside of sprocket type)…10344
400 Undercarriage and frame…10359
Removal and installation of track frame assembly…10360
Removal and installation of idler assembly…10362
Disassembly and assembly of idler assembly…10364
Disassembly and assembly of idler assembly…10366
Disassembly and assembly of idler assembly (Without idler support automatic thrust adjustment)…10370
Removal and installation of recoil spring assembly…10375
Disassembly and assembly of recoil spring assembly…10376
Removal and installation of track roller assembly…10380
Disassembly and assembly of track roller assembly…10381
Removal and installation of carrier roller assembly…10385
Disassembly and assembly of carrier roller assembly…10386
Expansion and installation of track shoe assembly (Conventional type track shoe)…10389
Expansion and installation of track shoe assembly (PLUS type track shoe)…10392
Whole disassembly and whole assembly of track shoe assembly (Conventional type track shoe)…10393
Whole disassembly and whole assembly of track shoe assembly (PLUS type track shoe)…10407
Field disassembly and assembly of one link (Conventional type track shoe)…10419
Field disassembly and assembly of one link (PLUS type track shoe)…10426
Removal and installation of pivot shaft assembly…10431
Removal and installation of equalizer bar assembly…10432
Disassembly and assembly of equalizer bar side bushing…10434
500 Hydraulic system…10437
Removal and installation of hydraulic tank assembly…10438
Removal and installation of control valve assembly…10441
Disassembly and assembly of control valve assembly…10444
Disassembly and assembly of blade lift and tilt PPC valve assembly…10446
Disassembly and assembly of ripper PPC valve assembly…10447
Removal and installation of HSS and cooling fan pump assembly…10448
Removal and installation of power train and lubrication pump assembly…10450
Removal and installation of scavenging pump assembly…10452
Removal and installation of HSS motor assembly…10453
Disassembly and assembly of hydraulic cylinder assembly…10456
600 Work equipment…10463
Removal and installation of blade assembly (ST-TPP dozer)…10464
Removal and installation of blade assembly (PAT dozer)…10467
Removal and installation of ripper assembly…10469
700 Cab and its attachments…10473
Removal and installation of ROPS cab assembly…10474
Removal and installation of operator’s cab glass (Stuck glass)…10481
Removal and installation of floor frame assembly (FRP canopy specification)…10482
Removal and installation of operator’s cab glass (Stuck glass)…10486
Removal and installation of air conditioner unit assembly…10492
Removal and installation of air conditioner compressor assembly…10496
800 Electrical system…10499
Removal and installation of monitor panel assembly…10500
Removal and installation of engine controller assembly…10502
Removal and installation of power train controller assembly…10504
Removal and installation of KOMTRAX terminal assembly…10506
80 Appendix…0
100 Air conditioner…10509
Structure and function…10512
Air conditioner component…10512
Configuration and function of refrigerating cycle…10514
Outline of refrigerating cycle…10515
Air conditioner unit…10518
Control plate…10522
Compressor…10523
Condenser…10524
Receiver drier…10525
Testing, adjusting and troubleshooting…10526
Caution about refrigerant…10526
Troubleshooting procedure…10527
Block diagram…10528
Circuit diagram and arrangement of connector pins…10530
Detail of air conditioner unit…10532
Parts and connectors arrangement…10534
Testing air leakage (duct)…10540
Testing with self-diagnosis function…10542
Testing temperature control…10545
Testing vent (mode) changeover…10547
Testing Recirc/Fresh changeover…10550
Testing inner sensor…10551
Testing evaporator temperature sensor…10552
Testing sunlight sensor…10555
Testing (dual) pressure switch for refrigerant…10556
Testing relays and diodes…10558
Troubleshooting chart 1…10560
Troubleshooting chart 2…10561
Troubleshooting for electrical system (E mode)…10564
E-1 Power supply system (Air conditioner does not operate)…10565
E-2 Compressor and refrigerant system (Air is not cooled)…10568
E-3 Blower motor system (No air comes out or air flow is abnormal)…10571
E-4 Temperature cannot be controlled…10574
E-5 Vent (mode) cannot be changed over…10576
E-6 Recirc/Fresh air cannot be changed over…10578
Troubleshooting with gauge pressure…10580
Connection of service tool…10583
Precautions for connecting air conditioner piping…10584
Handling of compressor oil…10585
1. Control of compressor oil (Denso: ND-OIL8: For R134a)…10585
2. Adding of compressor oil…10585
3. Compressor replacement…10586
4. Applying compressor oil for O-ring…10586
90 Diagrams and drawings…0
100 Hydraulic diagrams and drawings…10589
Power train hydraulic circuit diagram…10591
Work equipment hydraulic circuit diagram…10593
200 Electrical diagrams and drawings…10599
Electrical circuit diagram…10601
Electrical circuit diagram (Sand terrain specification)…10620
Electrical circuit diagram (FRP canopy specification)…10623
SEN04887-14 – Bulldozer D65EX,PX,WX-16 Shop Manual (SN80001&up)…10631
Cover…10631
00 Index and foreword…0
100 Index…10633
Composition of shop manual…10634
Table of contents…10636
200 Foreword and general information…10647
Safety notice…10648
How to read the shop manual…10653
Explanation of terms for maintenance standard…10655
Handling of electric equipment and hydraulic component…10657
Handling of connectors newly used for engines…10666
How to read electric wire code…10669
Precautions when carrying out operation…10672
Method of disassembling and connecting push-pull type coupler…10675
Standard tightening torque table…10678
Conversion table…10682
01 General…0
100 Specification and technical data…10689
Specification dimension drawing…10690
Specifications…10696
Weight table…10708
Table of fuel, coolant and lubricants…10712
10 Structure, function and maintenance standard…0
100 Engine and cooling system…10715
Engine mount…10717
Cooling system…10718
Cooling fan pump…10720
Cooling fan motor…10734
Coolant preheater (subextremely cold weather spec.)…10740
201 Power train, Part 1…10745
Power train…10746
HSS system…10748
Overall view of power train unit…10750
Power train hydraulic piping diagram…10754
Transmission, steering and brake control…10756
Damper…10758
Universal joint…10760
Torque converter and PTO…10761
Transmission…10768
Transmission control valve…10786
ECMV…10790
Main relief and torque converter relief valve…10798
Main relief and torque converter relief valve (subextremely cold weather spec.)…10800
Transmission lubrication relief valve…10802
202 Power train, Part 2…10805
Bevel gear shaft, HSS and brake…10806
Brake valve…10828
Final drive…10834
Final drive (Planetary gear installed inside of sprocket type)…10840
300 Undercarriage and frame…10847
Main frame…10848
Suspension…10850
Track frame and idler cushion…10860
Idler…10864
Idler (Without idler support automatic thrust adjustment)…10866
Track roller…10866
Carrier roller…10872
Sprocket…10874
Track shoe…10878
401 Hydraulic system, Part 1…10885
Work equipment hydraulic system layout drawing…10886
Work equipment control…10890
Hydraulic tank and filter…10892
Scavenging pump…10894
Power train and steering lubrication pump…10895
HSS pump…10896
HSS motor…10915
402 Hydraulic system, Part 2…10925
Control valve…10926
CLSS…10935
Function and operation of each valve…10938
403 Hydraulic system, Part 3…10963
PPC valve (blade lift, blade tilt)…10964
PPC valve (ripper)…10970
Electric lever (steering)…10974
Quick drop valve…10978
Work equipment lock solenoid valve…10980
Pitch selector solenoid valve…10984
Hydraulic oil cooler bypass valve…10985
Accumulator…10986
500 Work equipment…10989
Blade…10990
Cutting edge and end bit…10998
Ripper (Multi shank)…11000
Ripper (Single shank)…11001
Hydraulic cylinder…11002
Piston valve…11006
600 Cab and its attachme…11009
Cab mount…11010
Cab…11011
Subextremely cold spec. cab (subextremely cold weather spec.)…11012
600 Cab and its attachmentsFRP canopy mountFRP canopy mount…11013
FRP canopy…11014
700 Electrical system…11017
Monitor system…11018
Engine control system…11034
Cooling system control system…11037
Electronic steering control system…11039
KOMTRAX system…11042
KOMTRAX terminal (for GPRS)…11044
System components…11045
Sensor…11053
20 Standard value table…0
100 Standard service value table…11061
Standard service value table for engine…11062
Standard service value table for chassis…11064
30 Testing and adjusting…0
101 Testing and adjusting, Part 1…11077
Tools for testing, adjusting, and troubleshooting…11078
Testing engine speed…11081
Testing intake air pressure (boost pressure)…11083
Testing exhaust temperature…11085
Testing exhaust gas color…11087
Adjusting valve clearance…11088
Testing compression pressure…11090
Testing blow-by pressure…11094
Testing engine oil pressure…11095
Handling of fuel system devices…11096
Releasing residual pressure from fuel system…11096
Testing fuel pressure…11097
Testing fuel return and leak amount…11102
Bleeding air from fuel circuit…11104
Testing fuel circuit for leakage…11105
Handling of reduced cylinder mode operation…11106
Handling of no injection cranking operation…11106
Testing and adjusting air conditioner compressor belt tension…11107
Replacing alternator belt…11108
Adjusting fuel control dial and decelerator pedal…11109
Handling controller high-voltage circuit…11110
102 Testing and adjusting, Part 2…11113
Testing power train oil pressure…11115
Adjusting transmission output shaft speed sensor (replacement procedure)…11120
Simple test procedure for brake performance…11121
Adjusting brake pedal…11122
Adjusting parking brake lever…11124
Emergency escape method when power train has trouble…11126
Adjusting clearance of idler…11129
Inspecting wear of sprocket…11130
Inspecting wear of sprocket…11131
Testing and adjusting track shoe tension…11132
Testing and adjusting work equipment and HSS oil pressure…11133
Testing control circuit basic pressure…11136
Testing PPC valve output pressure…11137
Adjusting work equipment PPC valve play…11139
Testing internal leakage of work equipment cylinder…11143
Bleeding air from work equipment cylinder…11144
Releasing residual pressure from work equipment cylinder…11144
Checking parts which caused hydraulic drift of blade or ripper…11145
Adjusting work equipment lock lever…11146
Adjusting work equipment lock lever (FRP canopy specification)…11147
Testing fan speed…11149
Testing fan circuit oil pressure…11150
Bleeding air from fan pump…11151
Bleeding air from HSS pump…11152
Adjusting straight tiltdozer…11153
Adjusting play of blade center ball1…11155
Adjusting operator’s cab…11156
103 Testing and adjusting, Part 3…11161
Special functions of machine monitor (EMMS)…11162
104 Testing and adjusting, Part 4…11219
Handling of voltage circuit of engine controller…11220
Adjustment method when controller has been replaced…11221
Preparation work for troubleshooting of electrical…11223
Inspection procedure of diode…11227
Pm-Clinic service…11228
40 Troubleshooting…0
100 Failure code table and fuse locations…11243
Failure codes table…11244
Fuse locations…11249
200 General information on troubleshooting…11253
Points to remember when troubleshooting…11254
How to proceed troubleshooting…11255
Checks before troubleshooting…11256
Classification and procedures for troubleshooting…11258
Symptom supposed to be failure and troubleshooting No…11262
Information contained in troubleshooting table…11264
Troubleshooting method for disconnecting wiring harness of pressure sensor system…11266
Connector list and stereogram…11268
Connection table for connector pin numbers…11282
T- branch box and T- branch adapter table…11318
301 Troubleshooting by failure code (Display of code), Part 1…11323
Failure code [1500L0] Transmission clutch: Abnormal…11325
Failure code [15SAL1] Forward clutch: Fill high…11326
Failure code [15SALH] Forward clutch: Fill low…11328
Failure code [15SBL1] Reverse clutch: Fill high…11330
Failure code [15SBLH] Reverse clutch: Fill low…11332
Failure code [15SEL1] Speed 1st clutch: Fill high…11334
Failure code [15SELH] Speed 1st clutch: Fill low…11336
Failure code [15SFL1] Speed 2nd clutch: Fill high…11338
Failure code [15SFLH] Speed 2nd clutch: Fill low…11340
Failure code [15SGL1] Speed 3rd clutch: Fill high…11342
Failure code [15SGLH] Speed 3rd clutch: Fill low…11344
Failure code [15SJL1] L/U: Fill high…11346
Failure code [15SJLH] L/U: Fill low…11348
Failure code [AB00MA] Battery Charge Abnormal…11350
Failure code [B@BAZG] Eng Oil Press Low…11352
Failure code [B@BCNS] Eng Water Overheat…11352
Failure code [B@CENS] T/C Oil Overheat…11353
Failure code [B@HANS] Hyd Oil Overheat…11353
302 Troubleshooting by failure code (Display of code), Part 2…11355
Failure code [CA111] ECM Critical Internal Failure…11357
Failure code [CA115] Eng Ne and Bkup Speed Sens Error…11357
Failure code [CA122] Chg Air Press Sensor High Error…11358
Failure code [CA123] Chg Air Press Sensor Low Error…11360
Failure code [CA131] Throttle Sensor High Error…11362
Failure code [CA132] Throttle Sensor Low Error…11364
Failure code [CA144] Coolant Temp Sens High Error…11366
Failure code [CA145] Coolant Temp Sens Low Error…11368
Failure code [CA153] Chg Air Temp Sensor High Error…11370
Failure code [CA154] Chg Air Temp Sensor Low Error…11372
Failure code [CA155] Chg Air Temp High Speed Derate…11374
Failure code [CA187] Sens Supply 2 Volt Low Error…11376
Failure code [CA221] Ambient Press Sens High Error…11378
Failure code [CA222] Ambient Press Sens Low Error…11380
Failure code [CA227] Sens Supply 2 Volt High Error…11382
Failure code [CA234] Eng Overspeed…11382
Failure code [CA238] Ne Speed Sens Supply Volt Error…11383
Failure code [CA271] IMV/PCV1 Short Error…11384
Failure code [CA272] IMV/PCV1 Open Error…11386
Failure code [CA281] Abnormal supply pump pressure balance…11388
Failure code [CA322] Inj #1(L#1) Open/Short Error…11390
Failure code [CA323] Inj #5(L#5) Open/Short Error…11392
Failure code [CA324] Inj #3(L#3) Open/Short Error…11394
Failure code [CA325] Inj #6(L#6) Open/Short Error…11396
Failure code [CA331] Inj #2(L#2) Open/Short Error…11398
Failure code [CA332] Inj #4(L#4) Open/Short Error…11400
303 Troubleshooting by failure code (Display of code), Part 3…11403
Failure code [CA342] Calibration Code Incompatibility…11405
Failure code [CA351] Injectors Drive Circuit Error…11405
Failure code [CA352] Sens Supply 1 Volt Low Error…11406
Failure code [CA386] Sens Supply 1 Volt High Error…11408
Failure code [CA428] Water in Fuel Sensor High Error…11410
Failure code [CA429] Water in Fuel Sensor Low Error…11412
Failure code [CA435] Eng Oil Press Sw Error…11414
Failure code [CA441] Battery Voltage Low Error…11416
Failure code [CA442] Battery Voltage High Error…11418
Failure code [CA449] Rail Press Very High Error…11420
Failure code [CA451] Rail Press Sensor High Error…11422
Failure code [CA452] Rail Press Sensor Low Error…11424
Failure code [CA488] Chg Air Temp High Torque Derate…11426
Failure code [CA553] Rail Press High Error…11427
Failure code [CA559] Rail Press Low Error…11428
Failure code [CA689] Eng Ne Speed Sensor Error…11430
Failure code [CA731] Eng Bkup Speed Sens Phase Error…11434
Failure code [CA757] All Continuous Data Lost Error…11435
Failure code [CA778] Eng Bkup Speed Sensor Error…11436
Failure code [CA1633] KOMNET Datalink Timeout Error…11439
Failure code [CA2185] Throt Sens Sup Volt High Error…11440
Failure code [CA2186] Throt Sens Sup Volt Low Error…11442
Failure code [CA2249] Rail Press Very Low Error…11444
Failure code [CA2265] Fuel Feed Pump Open Error…11446
Failure code [CA2266] Fuel Feed Pump Short Error…11448
Failure code [CA2311] IMV Solenoid Error…11449
Failure code [CA2555] Grid Htr Relay Volt High Error…11450
Failure code [CA2556] Grid Htr Relay Volt Low Error…11452
304 Troubleshooting by failure code (Display of code), Part 4…11455
Failure code [D110KB] Battery relay drive: Short circuit…11458
Failure code [D130KA] Neutral relay: Disconnection…11460
Failure code [D130KB] Neutral relay: Short circuit…11462
Failure code [D161KA] Back-up alarm relay: Disconnection…11464
Failure code [D161KB] Back-up alarm relay: Short circuit…11466
Failure code [D862KA] GPS Antenna Open Circuit…11468
Failure code [DAFRKR] CAN Disconnection…11469
Failure code [DAFRMC] CAN Discon (Monitor Detected)…11470
Failure code [DB2RKR] CAN Disconnection…11473
Failure code [DBE0KT] PT controller: Abnormality in controller…11478
Failure code [DBE1KK] Battery direct Source voltage reduction…11480
Failure code [DBE2KK] Solenoid Source voltage reduction…11482
Failure code [DBE5KK] PT cont.: Sensor voltage 5V (1) reduction…11484
Failure code [DBE6KK] PT cont.: Sensor voltage 24V reduction…11486
Failure code [DBE7KK] PT cont.: Sensor voltage 5V (2) reduction…11488
Failure code [DBE9KQ] PT controller: Type select signal…11490
Failure code [DD12KA] Shift up Sw: Disconnection…11492
Failure code [DD12KB] Shift up Sw: Short circuit…11494
Failure code [DD13KA] Shift down Sw: Disconnection…11496
Failure code [DD13KB] Shift down Sw: Short circuit…11498
Failure code [DD14KA] Parking lever Sw: Disconnection…11500
Failure code [DD14KB] Parking lever Sw: Short circuit…11502
305 Troubleshooting by failure code (Display of code), Part 5…11505
Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection…11508
Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit…11510
Failure code [DDN8KA] WEQ Knob Sw (up): Disconnection…11512
Failure code [DDN8KB] WEQ Knob Sw (up): Short circuit…11514
Failure code [DDNLKA] Weq lock Sw: Disconnection…11516
Failure code [DDNLKB] Weq lock Sw: Short circuit…11518
Failure code [DGS1KX] Hyd oil temp sensor: Abnormal…11520
Failure code [DGT1KA] T/C oil temp sensor: Disconnection…11522
Failure code [DGT1KX] T/C oil temp sensor: Short circuit…11524
Failure code [DH21KA] Weq pressure sensor: Disconnection…11526
Failure code [DH21KB] Weq pressure sensor: Short circuit…11528
Failure code [DHT5KA] T/C pressure sensor: Disconnection…11530
Failure code [DHT5KB] T/C pressure sensor: Short circuit…11532
Failure code [DK10KA] Fuel control Dial: Disconnection…11534
Failure code [DK10KB] Fuel control Dial: Short circuit…11536
Failure code [DK30KA] ST lever 1: Disconnection…11538
Failure code [DK30KB] ST lever 1: Short circuit…11540
Failure code [DK30KX] ST lever: Out of normal range…11542
Failure code [DK30KZ] ST lever: Disconnection or short circuit…11542
Failure code [DK30L8] ST lever: Signal mismatch…11543
Failure code [DK31KA] ST lever 2: Disconnection…11544
Failure code [DK31KB] ST lever 2: Short circuit…11546
Failure code [DK40KA] Brake potentiometer: Disconnection…11548
Failure code [DK40KB] Brake potentiometer: Short circuit…11550
Failure code [DK55KX] FR lever: Out of normal range…11552
Failure code [DK55KZ] FR lever: Disconnection or short circuit…11552
Failure code [DK55L8] FR lever: Signal mismatch…11553
Failure code [DK56KA] FR lever 1: Disconnection…11554
Failure code [DK56KB] FR lever 1: Short circuit…11556
Failure code [DK57KA] FR lever 2: Disconnection…11558
Failure code [DK57KB] FR lever 2: Short circuit…11560
306 Troubleshooting by failure code (Display of code), Part 6…11563
Failure code [DKH1KA] Pitch angle sensor: Disconnection…11566
Failure code [DKH1KB] Pitch angle sensor: Short circuit…11568
Failure code [DLT3KA] T/M out-speed sensor: Disconnection…11570
Failure code [DLT3KB] T/M out-speed sensor: Abnormal…11571
Failure code [DW5AKA] Pitch selector Sol.: Disconnection…11572
Failure code [DW5AKB] Pitch selector Sol.: Short circuit…11573
Failure code [DW5AKY] Pitch selector Sol.: Short circuit…11574
Failure code [DW7BKA] Fan rev EPC: Disconnection…11576
Failure code [DW7BKB] Fan rev EPC: Short circuit…11577
Failure code [DWN1KA] Hss EPC1: Disconnection…11578
Failure code [DWN1KB] Hss EPC1: Short circuit…11579
Failure code [DWN1KY] Hss EPC1: Short circuit…11580
Failure code [DWN2KA] Hss EPC2: Disconnection…11581
Failure code [DWN2KB] Hss EPC2: Short circuit…11582
Failure code [DWN2KY] Hss EPC2: Short circuit…11583
Failure code [DWN5KA] Fan pump solenoid: Disconnection…11584
Failure code [DWN5KB] Fan pump solenoid: Short circuit…11585
Failure code [DWN5KY] Fan control solenoid: Short circuit…11586
Failure code [DXA0KA] TVC Sol.: Disconnection…11588
Failure code [DXA0KB] TVC Sol.: Short circuit…11589
Failure code [DXA0KY] TVC Sol.: Short circuit…11590
Failure code [DXH1KA] Lock-up ECMV: Disconnection…11591
Failure code [DXH1KB] Lock-up ECMV: Short circuit…11592
Failure code [DXH1KY] Lock-up ECMV: Short circuit…11594
Failure code [DXH4KA] 1st clutch ECMV: Disconnection…11596
Failure code [DXH4KB] 1st clutch ECMV: Short circuit…11597
Failure code [DXH4KY] 1st clutch ECMV: Short circuit…11598
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection…11599
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit…11600
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit…11601
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection…11602
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit…11603
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit…11604
Failure code [DXH7KA] R clutch ECMV: Disconnection…11605
Failure code [DXH7KB] R clutch ECMV: Short circuit…11606
Failure code [DXH7KY] R clutch ECMV: Short circuit…11608
Failure code [DXH8KA] F clutch ECMV: Disconnection…11610
Failure code [DXH8KB] F clutch ECMV: Short circuit…11611
Failure code [DXH8KY] F clutch ECMV: Short circuit…11612
Failure code [DXJ4KA] Weq lock Sol.: Disconnection…11614
Failure code [DXJ4KB] Weq lock Sol.: Short circuit…11615
400 Troubleshooting of electrical system (E-mode)…11617
Before troubleshooting of electrical system…11619
Information in troubleshooting table…11621
E-1 Engine does not start (starting motor does not turn)…11623
E-2 Preheater does not operate…11626
E-3 When starting switch is turned ON, machine monitor displays nothing…11632
E-4 When starting switch is turned ON (before starting engine), basic check item lights up…11634
E-5 Precaution item lights up while engine is running…11636
E-6 Emergency stop item lights up while engine is running…11638
E-7 Engine coolant temperature gauge does not indicate normally…11640
E-8 Fuel gauge does not indicate properly…11642
E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally…11645
E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally…11646
E-11 Contents of display by machine monitor are different from applicable machine…11647
E-12 Machine monitor does not display some items…11647
E-13 Function switch does not work…11647
E-14 Operation mode does not change…11648
E-15 Gearshift mode does not change…11648
E-16 Customize function does not operate normally…11649
E-17 Customize memory function does not operate normally…11649
E-18 Alarm buzzer does not sound or does not stop…11650
E-19 When starting switch is turned OFF, service meter is not displayed…11650
E-20 Machine monitor cannot be set in service mode…11650
E-21 Horn does not sound or does not stop…11651
E-22 Back-up alarm does not sound or does not stop…11652
E-23 Head lamp or rear lamp does not light up…11654
E-24 Windshield wiper does not operate…11658
E-25 Window washer does not operate…11672
E-26 KOMTRAX system does not operate correctly…11677
500 Troubleshooting of hydraulic and mechanical system (H-mode)…11679
Failure mode and cause table…11680
Contents of troubleshooting table…11682
H-1 There is no travel power (no drawbar pull)…11683
H-2 Machine does not move (at 2nd or 3rd speed)…11684
H-3 Machine does not move at any gear speed…11685
H-4 Machine travels only in one direction, forward or in reverse…11686
H-5 When gear is shifted or travel direction is changed, large time lag is made…11687
H-6 Machine cannot be steered (Machine does not turn leftward or rightward)…11688
H-7 Steering speed or power is low…11688
H- 8 Brake does not work…11689
H-9 Overheat of power train oil…11690
H-10 Abnormal sound comes out from around HSS and work equipment pump or HSS motor…11691
H-11 All work equipment speeds are slow…11691
H-12 Work equipment does not move…11692
H-13 Blade lift speed is slow or lacks power…11692
H-14 Blade tilt speed is slow or lacks power…11693
H-15 Ripper lift speed is slow or lacks power…11693
H-16 Excessive hydraulic drift of blade lift…11694
H-17 Excessive hydraulic drift of blade tilt…11694
H-18 Excessive hydraulic drift of ripper lift…11695
600 Troubleshooting of engine (S-mode)…11697
Method of using troubleshooting charts…11699
S-1 Starting performance is poor…11702
S-2 Engine does not start…11703
S-3 Engine does not pick up smoothly…11706
S-4 Engine stops during operations…11707
S-5 Engine does not rotate smoothly…11708
S-6 Engine lacks output (or lacks power)…11709
S-7 Exhaust smoke is black (incomplete combustion)…11710
S-8 Oil consumption is excessive (or exhaust smoke is blue)…11711
S-9 Oil becomes contaminated quickly…11712
S-10 Fuel consumption is excessive…11713
S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down)…11714
S-12 Oil pressure drops…11715
S-13 Oil level rises (water, fuel in oil)…11716
S-14 Coolant temperature becomes too high (overheating)…11717
S-15 Abnormal noise is made…11718
S-16 Vibration is excessive…11719
50 Disassembly and assembly…0
100 General information on disassembly and assembly…11721
How to read this manual…11722
Coating materials list…11724
Special tool list…11727
Sketches of special tools…11737
200 Engine and cooling system…11753
Removal and installation of fuel supply pump assembly…11754
Removal and installation of fuel injector assembly…11759
Removal and installation of cylinder head assembly…11769
Removal and installation of radiator assembly…11784
Removal and installation of aftercooler assembly…11787
Removal and installation of hydraulic oil cooler assembly…11789
Removal and installation of power train oil cooler assembly…11791
Removal and installation of cooling fan drive assembly…11794
Removal and installation of cooling fan motor assembly…11796
Removal and installation of main body of coolant preheater (subextremely cold weather spec)…11798
Removal and installation of coolant preheater fuel tank (Subextremely cold weather spec.)…11802
Removal and installation of coolant preheater exhaust duct. (Subextremely cold weather spec.)…11804
Removal and installation of oil pan cover of coolant preheater (subextremely cold weather spec.)…11808
Removal and installation of damper assembly…11817
Removal and installation of engine front oil seal…11820
Removal and installation of engine rear oil seal…11824
Removal and installation of engine hood assembly…11832
Removal and installation of fuel tank assembly…11834
300 Power train…11837
Removal and installation of power train unit assembly…11838
Separation and connection of power train unit assembly…11842
Disassembly and assembly of PTO assembly…11847
Disassembly and assembly of torque converter assembly…11852
Disassembly and assembly of transmission assembly…11863
Disassembly and assembly of HSS assembly…11890
Removal and installation of final drive assembly…11910
Removal and installation of final drive assembly (Planetary gear installed inside of sprocket type)…11912
Disassembly and assembly of final drive assembly…11914
Disassembly and assembly of final drive assembly (Planetary gear installed inside of sprocket type)…11922
400 Undercarriage and frame…11937
Removal and installation of track frame assembly…11938
Removal and installation of idler assembly…11940
Removal and installation of idler assembly (Without idler support automatic thrust adjustment)…11942
Disassembly and assembly of idler assembly…11944
Disassembly and assembly of idler assembly (Without idler support automatic thrust adjustment)…11948
Removal and installation of recoil spring assembly…11953
Disassembly and assembly of recoil spring assembly…11954
Removal and installation of track roller assembly…11958
Disassembly and assembly of track roller assembly…11959
Removal and installation of carrier roller assembly…11963
Disassembly and assembly of carrier roller assembly…11964
Expansion and installation of track shoe assembly (Conventional type track shoe)…11967
Expansion and installation of track shoe assembly (PLUS type track shoe)…11970
Whole disassembly and whole assembly of track shoe assembly (Conventional type track shoe)…11971
Whole disassembly and whole assembly of track shoe assembly (PLUS type track shoe)…11985
Field disassembly and assembly of one link (Conventional type track shoe)…11997
Field disassembly and assembly of one link (PLUS type track shoe)…12004
Removal and installation of pivot shaft assembly…12009
Removal and installation of equalizer bar assembly…12010
Disassembly and assembly of equalizer bar side bushing…12012
500 Hydraulic system…12015
Removal and installation of hydraulic tank assembly…12016
Removal and installation of control valve assembly…12019
Disassembly and assembly of control valve assembly…12022
Disassembly and assembly of blade lift and tilt PPC valve assembly…12024
Disassembly and assembly of ripper PPC valve assembly…12025
Removal and installation of HSS and cooling fan pump assembly…12026
Removal and installation of power train and lubrication pump assembly…12028
Removal and installation of scavenging pump assembly…12030
Removal and installation of HSS motor assembly…12031
Disassembly and assembly of hydraulic cylinder assembly…12034
600 Work equipment…12041
Removal and installation of blade assembly (ST-TPP dozer)…12042
Removal and installation of blade assembly (PAT dozer)…12045
Removal and installation of ripper assembly…12048
700 Cab and its attachments…12053
Removal and installation of ROPS cab assembly…12054
Removal and installation of operator’s cab glass (Stuck glass)…12061
Removal and installation of floor frame assembly (FRP canopy specification)…12062
Removal and installation of operator’s cab glass (Stuck glass)…12066
Removal and installation of air conditioner unit assembly…12072
Removal and installation of air conditioner compressor assembly…12076
800 Electrical system…12079
Removal and installation of monitor panel assembly…12080
Removal and installation of engine controller assembly…12082
Removal and installation of power train controller assembly…12084
Removal and installation of KOMTRAX terminal assembly…12086
80 Appendix…0
100 Air conditioner…12089
Structure and function…12092
Air conditioner component…12092
Configuration and function of refrigerating cycle…12094
Outline of refrigerating cycle…12095
Air conditioner unit…12098
Control plate…12102
Compressor…12103
Condenser…12104
Receiver drier…12105
Testing, adjusting and troubleshooting…12106
Caution about refrigerant…12106
Troubleshooting procedure…12107
Block diagram…12108
Circuit diagram and arrangement of connector pins…12110
Detail of air conditioner unit…12112
Parts and connectors arrangement…12114
Testing air leakage (duct)…12120
Testing with self-diagnosis function…12122
Testing temperature control…12125
Testing vent (mode) changeover…12127
Testing Recirc/Fresh changeover…12130
Testing inner sensor…12131
Testing evaporator temperature sensor…12132
Testing sunlight sensor…12135
Testing (dual) pressure switch for refrigerant…12136
Testing relays and diodes…12138
Troubleshooting chart 1…12140
Troubleshooting chart 2…12141
Troubleshooting for electrical system (E mode)…12144
E-1 Power supply system (Air conditioner does not operate)…12145
E-2 Compressor and refrigerant system (Air is not cooled)…12148
E-3 Blower motor system (No air comes out or air flow is abnormal)…12151
E-4 Temperature cannot be controlled…12154
E-5 Vent (mode) cannot be changed over…12156
E-6 Recirc/Fresh air cannot be changed over…12158
Troubleshooting with gauge pressure…12160
Connection of service tool…12163
Precautions for connecting air conditioner piping…12164
Handling of compressor oil…12165
1. Control of compressor oil (Denso: ND-OIL8: For R134a)…12165
2. Adding of compressor oil…12165
3. Compressor replacement…12166
4. Applying compressor oil for O-ring…12166
90 Diagrams and drawings…0
100 Hydraulic diagrams and drawings…12169
Power train hydraulic circuit diagram…12171
Work equipment hydraulic circuit diagram…12173
200 Electrical diagrams and drawings…12179
Electrical circuit diagram…12181
Electrical circuit diagram (Sand terrain specification)…12200
Electrical circuit diagram (FRP canopy specification)…12203
SEN05536-01 – Bulldozer D65EX,PX,WX-17 Shop Manual (SN1001&up)…12211
COVER…12211
00 Index and foreword…12212
Index…12213
Foreword, safety and general information…12226
Important safety notice…12226
How to read the shop manual…12231
Explanation of terms for maintenance standard…12233
Handling of fuel system devices…12235
Handling of intake system parts…12236
Handling of hydraulic equipment…12237
Method of disconnecting and connecting push-pull type coupler…12239
Handling of electrical equipment…12242
How to read electric wire code…12250
Precautions when performing operation…12253
Standard tightening torque table…12256
List of abbreviation…12260
Conversion table…12264
01 Specification…12270
Specifications…12272
Specification drawing…12272
Speciiffiicattiions…12275
Weight table…12299
Table of fuel, coolant and lubricants…12307
10 Structure and function…12308
Engine and cooling system…12311
Engine related parts…12311
Damper…12313
Cooling system…12315
Cooling fan pump…12317
Cooling fan motor…12331
Power train…12339
Power train…12339
HSS system…12342
Overall drawing of power train unit…12344
Power train mount…12346
Power train hydraulic piping drawing…12347
Transmission, steering, and brake control…12349
Universal joint…12351
Torque converter and PTO…12352
Transmission…12358
Transmission control valve…12371
Forward and reverse clutch ECMV and gear shift clutch ECMV…12373
Lockup clutch ECMV…12380
Main relief valve and torque converter relief valve…12384
Transmission lubricating oil relief valve…12387
Bevel gear shaft, HSS, and brake…12388
Brake valve…12409
Final drive…12413
Undercarriage and frame…12417
Main frame…12417
Suspension…12419
Track frame and idler cushion…12421
Hydraulic system…12423
Hydraulic piping drawing…12423
Work equipment control…12427
Hydraulic tank…12429
CLSS…12431
Scavenging pump…12434
Steering lubricating oil pump and power train pump…12435
HSS pump…12436
HSS motor…12457
Control valve…12466
Blade PPC valve…12493
Ripper PPC valve…12501
Quick drop valve…12505
Work equipment lock solenoid valve…12508
Pitch selector solenoid valve…12513
Angle control EPC valve…12514
Hydraulic oil cooler bypass valve…12519
PPC accumulator…12520
Work equipment…12521
Work equipment…12521
Ripper…12524
Piston valve…12525
Cab and its attachments…12527
ROPS cab…12527
Cab mount…12529
Electrical system…12530
Cooling system control system…12533
Palm command control system…12535
Machine monitor system…12539
KOMTRAX system…12559
System component part…12562
Sensors…12577
20 Standard value table…12592
Standard service value table…12594
Standard value table for engine…12594
Standard value table for machine…12596
30 Testing and adjusting…12620
General information on testing and adjusting…12623
Tools for testing, adjusting, and troubleshooting…12623
Engine and cooling system…12627
Testing engine speed…12627
Measuring boost pressure…12629
Measuring exhaust gas temperature…12630
Measuring exhaust gas color…12632
Measuring and adjusting valve clearance…12634
Measuring compression pressure…12636
Measuring blowby pressure…12638
Measuring engine oil pressure…12640
Measuring EGR valve and KVGT oil pressure…12641
Releasing remaining pressure from fuel system…12642
Measuring fuel pressure…12643
Measuring fuel delivery, return rate and leakage…12650
Handling cylinder cutout mode operation…12654
Handling no injection cranking operation…12655
Bleeding air from fuel system…12656
Checking fuel circuit for leakage…12657
Testing and adjusting air conditioner compressor belt tension…12658
Replacing alternator belt…12659
Adjusting fuel dial and decelerator pedal…12660
Power train system…12662
Measuring power train oil pressure…12662
Adjusting transmission output shaft speed sensor (replacement procedure)…12667
Simple test procedure for brake performance…12668
Adjusting brake pedal…12669
Adjusting parking brake lever…12671
Retrieval of disabled machine using brake release device…12673
Undercarriage and frame…12676
Adjusting idler clearance…12676
Checking sprocket wear…12677
Checking and adjusting track shoe tension…12678
Hydraulic system…12679
Releasing remaining pressure in work equipment cylinder…12679
Measuring and adjusting work equipment and HSS oil pressure…12680
Measuring source pressure of control circuit…12683
Measuring PPC valve output pressure…12684
Adjusting play of work equipment PPC valve…12687
Isolating the parts causing hydraulic drift in blade and ripper…12689
Measure internal oil leakage of work equipment cylinder…12690
Checking fan speed…12691
Measuring fan circuit oil pressure…12692
Bleeding air from hydraulic circuit…12693
Work equipment…12695
Adjusting work equipment lock lever…12695
Adjustment of straight tilt dozer…12696
Cab and its attachments…12698
Adjusting operator's cab…12698
Adjusting play of blade center ball…12701
Electrical system…12702
Special functions of machine monitor…12702
Handling voltage circuit of engine controller…12762
Adjustment method when controller has been replaced…12763
Testing diodes…12765
Pm clinic…12766
Pm Clinic service…12766
Pm Clinic check sheet…12772
40 Troubleshooting…12782
General information on troubleshooting…12790
Instruction on troubleshooting…12790
How to proceed troubleshooting…12792
Check before troubleshooting…12793
Testing procedure before troubleshooting…12795
Classification and procedure for troubleshooting…12804
Classification and procedures for troubleshooting numbers…12806
Information mentioned in troubleshooting table…12809
Troubleshooting method for open circuit in wiring harness of pressure sensor system…12811
Connector list and layout…12813
Connector contact identification…12826
T-branch box and T-branch adapter table…12863
Fuse locations table…12869
Precautions for cleaning and replacing KDPF (KCSF, KDOC)…12872
Troubleshooting by failure code (Display of code)…12874
Failure codes table…12874
Failure code [1500L0] Transmission clutch:Abnormal…12885
Failure code [15SAL1] Forward clutch:Fill High…12886
Failure code [15SALH] Forward clutch:Fill Low…12888
Failure code [15SBL1] Reverse clutch:Fill High…12890
Failure code [15SBLH] Reverse clutch:Fill Low…12892
Failure code [15SEL1] Speed 1st clutch:Fill High…12894
Failure code [15SELH] Speed 1st clutch:Fill Low…12896
Failure code [15SFL1] Speed 2nd clutch:Fill High…12898
Failure code [15SFLH] Speed 2nd clutch:Fill Low…12900
Failure code [15SGL1] Speed 3rd clutch:Fill High…12902
Failure code [15SGLH] Speed 3rd clutch:Fill Low…12904
Failure code [15SJL1] L/U :Fill Hihg…12906
Failure code [15SJLH] L/U :Fill low…12908
Failure code [1800MW] P/L clutch:Slip…12910
Failure code [879AKA] Air Conditioner Inner Sensor Disconnection…12911
Failure code [879AKB] Air Conditioner Inner Sensor Disconnection…12912
Failure code [879BKA] Air Conditioner Outside Air Sensor Disconnection…12913
Failure code [879BKB] Air Conditioner Outside Air Sensor Disconnection…12914
Failure code [879CKA] Ventilating Sensor Disconnection…12915
Failure code [879CKB] Ventilating Sensor Short Circuit…12916
Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit…12917
Failure code [879EMC] Ventilation Abnormal…12918
Failure code [879FMC] A/M Damper Abnormal…12919
Failure code [879GKX] Refrigerant Abnormality…12920
Failure code [989L00] Engine Controller Lock Caution 1…12921
Failure code [989M00] Engine Controller Lock Caution 2…12922
Failure code [989N00] Engine Controller Lock Caution 3…12923
Failure code [A1U0N3]: KDPF Dry Request (HC Release)…12924
Failure code [A1U0N4] KDPF Dry Request (HC Release)…12926
Failure code [AA10NX] Air Cleaner Clogging…12928
Failure code [AB00KE] Battery Charge Voltage Low…12929
Failure code [B@BAZG] Engine Oil Pressure Low…12931
Failure code [B@BCNS] Eng Water Overheat…12932
Failure code [B@CENS] P/L Oil Overheat…12933
Failure code [B@HANS] Hyd Oil Overheat…12934
Failure code [CA115] Eng Ne and Bkup Speed Sens Error…12935
Failure code [CA122] Chg Air Press Sensor High Error…12936
Failure code [CA123] Chg Air Press Sensor Low Error…12938
Failure code [CA131] Throttle Sensor High Error…12940
Failure code [CA132] Throttle Sensor Low Error…12942
Failure code [CA144] Coolant Temp Sens High Error…12944
Failure code [CA145] Coolant Temp Sens Low Error…12946
Failure code [CA153] Chg Air Temp Sensor High Error…12948
Failure code [CA154] Chg Air Temp Sensor Low Error…12950
Failure code [CA187] Sensor 2 Supply Volt Low Error…12952
Failure code [CA234] Eng Overspeed…12954
Failure code [CA221] Ambient Press Sens High Error…12955
Failure code [CA222] Ambient Press Sens Low Error…12957
Failure code [CA227] Sens Supply 2 Volt High Error…12959
Failure code [CA238] Ne Speed Sens Supply Volt Error…12960
Failure code [CA239] Ne Speed Sens Supply Volt High Error…12961
Failure code [CA271] IMV/PCV1 Short Error…12963
Failure code [CA272] IMV/PCV1 Open Error…12965
Failure code [CA281] Pump Press Balance Error…12967
Failure code [CA295] Ambient Pressure Sensor In Range Error…12968
Failure code [CA322] Inj #1(L#1) Open/Short Error…12969
Failure code [CA323] Inj #5 (L#5) Open/Short Error…12971
Failure code [CA324] Inj #3(L#3) Open/Short Error…12973
Failure code [CA325] Inj #6 (L#6) Open/Short Error…12975
Failure code [CA331] Inj #2(L#2) Open/Short Error…12977
Failure code [CA332] Inj #4 (L#4) Open/Short Error…12979
Failure code [CA343] ECM Critical Internal Failure…12981
Failure code [CA351] Injectors Drive Circuit Error…12982
Failure code [CA352] Sensor 1 Supply Volt Low Error…12983
Failure code [CA356] Mass Air Flow Sensor High Error…12985
Failure code [CA357] Mass Air Flow Sensor Low Error…12987
Failure code [CA386] Sens Supply 1 Volt High Error…12989
Failure code [CA428] Water in Fuel Sensor High Error…12990
Failure code [CA429] Water in Fuel Sensor Low Error…12992
Failure code [CA435] Eng Oil Press SW Error…12994
Failure code [CA441] Battery Voltage Low Error…12995
Failure code [CA442] Battery Voltage High Error…12997
Failure code [CA449] Rail Press Very High Error…12998
Failure code [CA451] Rail Press Sensor High Error…13000
Failure code [CA452] Rail Press Sensor Low Error…13002
Failure code [CA488] Chg Air Temp High Torque Derate…13004
Failure code [CA515] Rail Press Sens Sup Volt High Error…13005
Failure code [CA516] Rail Press Sens Sup Volt Low Error…13007
Failure code [CA553] Rail Press High Error…13009
Failure code [CA555] Crankcase Press High Error 2…13010
Failure code [CA556] Crankcase Pressure High Error 3…13011
Failure code [CA559] Rail Pump Press Low Error…13012
Failure code [CA595] Turbocharger Speed High Error 2…13016
Failure code [CA687] Turbo Speed Low Error…13017
Failure code [CA689] Eng Ne Speed Sensor Error…13019
Failure code [CA691] Intake Air Temp Sens High Error…13023
Failure code [CA692] Intake Air Temp Sens Low Error…13025
Failure code [CA697] ECM Internal Temp Sensor High Error…13027
Failure code [CA698] ECM Internal Temp Sensor Low Error…13028
Failure code [CA731] Eng Bkup Speed Sens Phase Error…13029
Failure code [CA778] Eng Bkup Speed Sensor Error…13031
Failure code [CA1117] Engine Controller Partial Data Lost Error…13036
Failure code [CA1664] KDOC Malfunction…13037
Failure code [CA1691] Regeneration Ineffective…13039
Failure code [CA1695] Sensor 5 Supply Volt High Error…13042
Failure code [CA1696] Sensor 5 Supply Volt Low Error…13043
Failure code [CA1843] Crankcase Press Sens High Error…13045
Failure code [CA1844] Crankcase Press Sens Low Error…13047
Failure code [CA1879] KDPF Delta P Sensor High Error…13049
Failure code [CA1881] KDPF Delta P Sensor Low Error…13051
Failure code [CA1883] KDPF Delta P Sens In Range Error…13053
Failure code [CA1921] KDPF Soot Level High Error 1…13056
Failure code [CA1922] KDPF Soot Level High Error 2…13058
Failure code [CA1942] Crankcase Press Sensor In Range Error…13062
Failure code [CA1993] KDPF Delta Pressure Low Error…13063
Failure code [CA2185] Throt Sensor Sup Volt High Error…13064
Failure code [CA2186] Throt Sensor Sup Volt Low Error…13066
Failure code [CA2249] Rail Press Very Low Error…13068
Failure code [CA2265] Fuel Feed Pump Open Error…13069
Failure code [CA2266] Fuel Feed Pump Short Error…13071
Failure code [CA2271] EGR Valve Pos Sens High Error…13073
Failure code [CA2272] EGR Valve Pos Sens Low Error…13075
Failure code [CA2288] Turbo Speed High Error 1…13078
Failure code [CA2311] lMV Solenoid Error…13079
Failure code [CA2349] EGR Valve Solenoid Open Error…13080
Failure code [CA2353] EGR Valve Solenoid Short Error…13082
Failure code [CA2357] EGR Valve Servo Error…13084
Failure code [CA2373] Exhaust Manifold Press Sens High error…13085
Failure code [CA2374] Exhaust Manifold Press Sens Low error…13087
Failure code [CA2375] EGR Orifice Temp Sens High Error…13089
Failure code [CA2376] EGR Orifice Temp Sens Low Error…13091
Failure code [CA2381] KVGT Pos Sens High Error…13093
Failure code [CA2382] KVGT Pos Sens Low Error…13095
Failure code [CA2383] KVGT Solenoid Open Error…13097
Failure code [CA2386] KVGT Solenoid Short Error…13099
Failure code [CA2387] KVGT Valve Servo Error…13101
Failure code [CA2554] Exh Manifold Press Sens In Range error…13102
Failure code [CA2555] Grid Htr Relay Volt Low Error…13103
Failure code [CA2556] Grid Htr Relay Volt High Error…13105
Failure code [CA2637] KDOC Blocked…13107
Failure code [CA2639] Manual Stationary Regeneration Request…13109
Failure code [CA2961] EGR Orifice Temp High Error 1…13112
Failure code [CA2973] Chg Air Press Sensor In Range Error…13113
Failure code [CA3133] KDPF Outlet Press Sens High Error…13114
Failure code [CA3134] KDPF Outlet Press Sens Low Error…13116
Failure code [CA3135] KDPF Outlet Press Sens In Range Error…13118
Failure code [CA3251] KDOC Inlet Temp High Error…13121
Failure code [CA3253] KDOC Temp Error – Non Regeneration…13124
Failure code [CA3254] KDOC Outlet Temp High Error 1…13125
Failure code [CA3255] KDPF Temp Error – Non Regeneration…13128
Failure code [CA3256] KDPF Outlet Temp High Error 1…13129
Failure code [CA3311] KDOC Outlet Temp High Error 2…13130
Failure code [CA3312] KDPF Outlet Temp High Error 2…13131
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error…13134
Failure code [CA3314] KDOC Inlet Temp Sens High Error…13137
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error…13141
Failure code [CA3316] KDOC Outlet Temp Sens Low Error…13145
Failure code [CA3317] KDOC Outlet Temp Sens High Error…13148
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error…13152
Failure code [CA3319] KDPF Outlet Temp Sens High Error…13156
Failure code [CA3321] KDPF Outlet Temp Sens Low Error…13160
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error…13163
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error…13167
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error…13169
Failure code [CA3741] Rail Press Valve Trip Error…13171
Failure code [D130KA] Neutral relay:Open…13172
Failure code [D130KB] Neutral relay:Short circuit…13174
Failure code [D19DKA] Amber light relay:Open…13176
Failure code [D19DKB] Amber light relay:Short circuit…13178
Failure code [D19JKZ] Personal Code Relay Abnormality…13180
Failure code [D811MC] KOMTRAX Error…13183
Failure code [D862KA] GPS Antenna Open Circuit…13184
Failure code [D8ALKA] Operating Lamp Open Circuit(KOMTRAX)…13185
Failure code [D8ALKB] Operating Lamp Short Circuit(KOMTRAX)…13187
Failure code [D8AQKR] CAN2 Discon(KOMTRAX)…13188
Failure code [DAF0MB] Monitor Memory Error…13189
Failure code [DAF0MC] Monitor Malfunction…13190
Failure code [DAF8KB] Camera Power Supply Short Circuit…13191
Failure code [DAF9KQ] Model Selection Abnormality…13193
Failure code [DAFGMC] GPS Module Error…13194
Failure code [DAFLKA] Operating Lamp Open Circuit(Monitor)…13195
Failure code [DAFLKB] Operating Lamp Short Circuit(Monitor)…13197
Failure code [DAFQKR] CAN2 Discon…13198
Failure code [DAZ9KQ] A/C Model Selection Abnormality…13199
Failure code [DAZQKR] CAN2 Discon (Aircon ECU)…13200
Failure code [DB2QKR] CAN2 Discon (Engine Con)…13204
Failure code [DB2RKR] CAN1 Discon (Engine Con)…13209
Failure code [DBE0KT] PT controller:Abnormality in controller…13214
Failure code [DBE1KK] PT controller:Source voltage low…13215
Failure code [DBE2KK] PT controller:Output voltage low…13217
Failure code [DBE5KK] PT:Sensor volt 5V (0) Out of normal range…13219
Failure code [DBE6KK] PT:Sensor volt 24V Out of normal range…13221
Failure code [DBE7KK] PT:Sensor volt 5V (1) Out of normal range…13223
Failure code [DBE9KQ] PT controller:Type select signal…13225
Failure code [DBELKA] Operating Lamp Open Circuit(PT Con)…13226
Failure code [DBELKB] Operating Lamp Short Circuit(PT Con)…13228
Failure code [DBEQKR] CAN2 Discon (PT Con)…13229
Failure code [DBERKR] CAN1 Discon (PT Con)…13230
Failure code [DD12KA] Shift up Sw:Open…13231
Failure code [DD12KB] Shift up Sw:Short circuit…13233
Failure code [DD13KA] Shift down Sw:Open…13235
Failure code [DD13KB] Shift down Sw:Short circuit…13237
Failure code [DD14KA] Parking lever Sw:Open…13239
Failure code [DD14KB] Parking lever Sw:Short circuit…13241
Failure code [DDKFL4] Left Angle Sw:Signal mismatch…13243
Failure code [DDKGL4] Right Angle Sw:Signal mismatch…13245
Failure code [DDKHKA] iB Sw:Open…13247
Failure code [DDKHKB] iB Sw:Short circuit…13249
Failure code [DDN7KA] Weq pitch SW: Open…13251
Failure code [DDN7KB] Pitch select solenoid:Short circuit…13253
Failure code [DDNLKA] Weq lock Sw:Open…13255
Failure code [DDNLKB] Weq lock Sw:Short circuit…13257
Failure code [DGS1KA] Hyd oil temp sensor:Open…13259
Failure code [DGS1KX] Hyd oil temp: signal abnormal…13260
Failure code [DGT1KA] T/C oil temp sensor:Open…13262
Failure code [DGT1KX] T/C oil temp sensor:Out of normal range…13263
Failure code [DH21KA] Weq pressure sensor:Open…13265
Failure code [DH21KB] Work equipment pressure sensor:Hot Short…13267
Failure code [DHA4KA] Air Cleaner Clogging Sensor Open Circuit…13269
Failure code [DHTDKA] T/C pressure sensor:Open…13270
Failure code [DHTDKB] T/C pressure sensor:Hot Short…13272
Failure code [DK10KA] Fuel control Dial:Open…13274
Failure code [DK10KB] Fuel control Dial:Short circuit…13276
Failure code [DK30KA] ST lever1:Open…13278
Failure code [DK30KB] ST lever:Hot Short…13280
Failure code [DK30KX] ST lever:Main and Sub Error…13282
Failure code [DK30KZ] ST lever:Main and Sub Error…13283
Failure code [DK30L8] ST lever:Signal mismatch…13284
Failure code [DK31KA] ST lever2:Open…13285
Failure code [DK31KB] ST lever2:Hot Short…13287
Failure code [DK40KA] Brake potentiometer:Open…13289
Failure code [DK40KB] Brake potentiometer:Hot Short…13291
Failure code [DK55KX] FR lever:Main and Sub Error…13293
Failure code [DK55KZ] FR lever:Main and Sub Error…13294
Failure code [DK55L8] FR lever:Signal mismatch…13295
Failure code [DK56KA] FR lever1:Open…13296
Failure code [DK56KB] FR lever1:Hot Short…13298
Failure code [DK57KA] FR lever2:Open…13300
Failure code [DK57KB] FR lever2:Hot Short…13302
Failure code [DKH1KA] Pitch angle sensor:Open…13304
Failure code [DKH1KB] Pitch angle sensor:Hot Short…13306
Failure code [DLM3KA] Fan rev. sensor:Open…13308
Failure code [DLM3MB] Fan control:Mismatch…13310
Failure code [DLT3KA] T/M out-speed sensor:Open…13311
Failure code [DLT3KB] T/M out-speed sensor:Short circuit…13313
Failure code [DV20KB] Back-up alarm :Short Circuit…13314
Failure code [DW5AKA] Pitch select solenoid:Disconnection…13316
Failure code [DW5AKB] Pitch select solenoid:Short circuit…13317
Failure code [DW5AKY] Pitch select solenoid:Hot short…13318
Failure code [DW7BKA] Fan reverse solenoid:Open…13320
Failure code [DW7BKB] Fan reverse solenoid:Short circuit…13322
Failure code [DWN1KB] Hss EPC RH:Short circuit…13324
Failure code [DWN1KY] Hss EPC RH:Hot short…13325
Failure code [DWN2KA] Hss EPC LH:Open…13327
Failure code [DWN2KB] Hss EPC LH:Short circuit…13328
Failure code [DWN2KY] Hss EPC LH:Hot short…13329
Failure code [DWN5KA] Fan pump solenoid 1 :Open…13331
Failure code [DWN5KB] Fan pump solenoid 1 :Short circuit…13332
Failure code [DWN5KY] Fan pump solenoid 1: Hot short…13333
Failure code [DXA2KA] TVC solenoid 1: Open…13335
Failure code [DXA2KB] TVC solenoid 1: Short circuit…13336
Failure code [DXA2KY] TVC solenoid 1: Hot short…13337
Failure code [DXH1KA] Lock-up ECMV:Open…13339
Failure code [DXH1KB] Lock-up ECMV: Short circuit…13341
Failure code [DXH1KY] Lock-up ECMV: Hot short…13342
Failure code [DXH4KA] 1st clutch ECMV:Open…13344
Failure code [DXH4KB] 1st clutch ECMV:Short circuit…13345
Failure code [DXH4KY] 1st clutch ECMV:Hot short…13346
Failure code [DXH5KA] 2nd clutch ECMV:Open…13348
Failure code [DXH5KB] 2nd clutch ECMV:Short circuit…13349
Failure code [DXH5KY] 2nd clutch ECMV:Hot short…13350
Failure code [DXH5KY] 2nd clutch ECMV:Hot short…13350
Failure code [DXH5KY] 2nd clutch ECMV:Hot short…13350
Failure code [DXH5KY] 2nd clutch ECMV:Hot short…13350
Failure code [DXH5KY] 2nd clutch ECMV:Hot short…13350
Failure code [DXH5KY] 2nd clutch ECMV:Hot short…13350
Failure code [DXH5KY] 2nd clutch ECMV:Hot short…13350
Failure code [DXH5KY] 2nd clutch ECMV:Hot short…13350
Failure code [DXH5KY] 2nd clutch ECMV:Hot short…13350
Failure code [DXH5KY] 2nd clutch ECMV:Hot short…13350
Failure code [DXH5KY] 2nd clutch ECMV:Hot short…13350
Failure code [DXH5KY] 2nd clutch ECMV:Hot short…13350
Failure code [DXH5KY] 2nd clutch ECMV:Hot short…13350
Failure code [DXH5KY] 2nd clutch ECMV:Hot short…13350
Failure code [DXH5KY] 2nd clutch ECMV:Hot short…13350
Failure code [DXH5KY] 2nd clutch ECMV:Hot short…13350
Failure code [DXH5KY] 2nd clutch ECMV:Hot short…13350
Failure code [DXH6KA] 3rd clutch ECMV:Open…13352
Failure code [DXH6KB] 3rd clutch ECMV:Short circuit…13353
Failure code [DXH6KY] 3rd clutch ECMV:Hot short…13354
Failure code [DXH7KA] R clutch ECMV:Open…13356
Failure code [DXH7KB] R clutch ECMV:Short circuit…13357
Failure code [DXH7KY] R clutch ECMV:Hot short…13358
Failure code [DXH8KA] F clutch ECMV:Open…13360
Failure code [DXH8KB] F clutch ECMV:Short circuit…13361
Failure code [DXH8KY] F clutch ECMV:Hot short…13362
Failure code [DXJ4KA] Weq lock Sol.:Open…13364
Failure code [DXJ4KB] Weq lock Sol.:Short circuit…13366
Failure code [DXJCKA] Blade angle left EPC:Open…13367
Failure code [DXJCKB] Blade angle left EPC:Short circuit…13368
Failure code [DXJCKY] Blade angle left EPC:Hot short…13369
Failure code [DXJDKA] Blade angle right EPC:Open…13371
Failure code [DXJDKB] Blade angle right EPC:Short circuit…13372
Failure code [DXJDKY] Blade angle right EPC:Hot short…13373
Troubleshooting of electrical system (E-mode)…13375
E-1 Engine does not start (Engine does not crank)…13375
E-2 Manual preheating does not work…13381
E-3 Automatic preheating does not work…13384
E-4 While preheating is working, preheating monitor does not light up…13386
E-5 When starting switch is turned to ON position, machine monitor displays nothing…13388
E-6 When starting switch is turned to ON position (with engine stopped), basic check monitor lights up…13391
E-7 Air cleaner clogging monitor lights up in yellow while engine is running…13392
E-8 Charge level monitor lights up while engine is running…13393
E-9 Engine coolant temperature monitor lights up while engine is running…13395
E-10 Engine oil pressure monitor lights up while engine is running…13396
E-11 Power train oil temperature monitor lights up while engine is running…13397
E-12 Hydraulic oil temperature monitor lights up while engine is running…13398
E-13 Engine coolant temperature gauge does not indicate correct temparature…13399
E-14 Fuel level gauge does not indicate correct level…13400
E-15 Power train oil temperature gauge (multi-gauge) does not indicate correct temperature…13402
E-16 Hydraulic oil temperature gauge (multi-gauge) does not indicate correct temperature…13403
E-17 Operation mode does not change…13404
E-18 Gearshift mode does not change…13405
E-19 Operating customize switch does not display customize screen…13406
E-20 Modifying setting on customize screen does not change setting of machine…13407
E-21 Reverse slow mode does not function properly…13408
E-22 Alarm buzzer does not sound or does not stop sounding…13409
E-23 While starting switch is in OFF position, service meter is not displayed…13410
E-24 Service mode cannot be selected…13411
E-25 Horn does not sound…13412
E-26 Horn does not stop sounding…13413
E-27 Backup alarm does not sound…13414
E-28 Backup alarm does not stop sounding…13416
E-29 Headlamp does not light up…13417
E-30 Rear lamp does not light up…13420
E-31 No wiper operates continuously or intermittently…13422
E-32 Front wiper does not operate (Failure in both continuous and intermittent operations)…13425
E-33 Rear wiper does not operate (Failure in both continuous and intermittent operations)…13428
E-34 Left door wiper does not operate (Failure of both continuous and intermittent operations)…13431
E-35 Right door wiper does not operate (Failure of both continuous and intermittent operations)…13434
E-36 KOMTRAX system does not operate properly…13437
Troubleshooting of hydraulic and mechanical system (H-mode)…13439
Information mentioned in troubleshooting table (H mode)…13439
System diagram of hydraulic and mechanical system…13440
List of Failure Mode and Cause…13442
H-1 Machine lacks power (insufficient drawbar pull)…13445
H-2 Machine cannot travel (at 2nd or 3rd speed)…13447
H-3 Machine does not start at all gear speeds…13448
H-4 Machine travels only in one direction, either forward or in reverse…13449
H-5 Large time lag at gear shifting or directional selection…13450
H-6 Machine cannot be steered (machine does not turn left or right)…13451
H-7 Steering speed or power is insufficient…13452
H-8 Brake does not operate…13453
H-9 Torque converter does not lock up…13454
H-10 Power train oil overheats…13455
H-11 Unusual noise is heard from around HSS and work equipment pump or HSS motor …13456
H-12 All work equipment operates slowly…13457
H-13 All work equipment does not operate…13458
H-14 Blade lift speed or power is low…13459
H-15 Blade tilt speed or power is low…13460
H-16 Blade angle speed or power is low…13461
H-17 Ripper lift speed or power is low…13462
H-18 Hydraulic drift of lifted blade is large…13463
H-19 Hydraulic drift of tilted blade is large…13464
H-20 Hydraulic drift of lifted ripper is large…13465
H-21 Fans speed is abnormal (high, low, or no rotation)…13466
H-22 Unusual noise is heard from around fan…13468
Troubleshooting of engine (S-mode)…13469
Information contained in troubleshooting table (S mode)…13469
S-1 When starting switch is turned to START position, engine is not cranked…13470
S-2 The engine cranks but exhaust smoke does not come out…13471
S-3 Fuel is being injected but engine does not start (incomplete combustion: engine cranks but does not start)…13472
S-4 Startability is poor…13473
S-5 Engine does not pick up smoothly…13475
S-6 Engine stops during operation…13477
S-7 Engine runs rough or is unstable…13479
S-8 Engine lacks power…13480
S-9 Exhaust gas is black (KDPF gets clogged in a short time)…13482
S-10 Engine oil consumption is excessive…13484
S-11 Engine oil becomes contaminated early…13485
S-12 Fuel consumption is excessive…13486
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)…13487
S-14 Oil pressure drops…13488
S-15 Fuel mixes into engine oil…13489
S-16 Water mixes into engine oil (milky)…13490
S-17 Coolant temperature rises too high (overheating)…13491
S-18 Unusual noise is made…13492
S-19 Vibration is excessive…13493
S-20 Air cannot be bled from fuel circuit…13494
S-21 Frequent active regeneration…13495
S-22 Active regeneration is long…13496
S-23 White smoke is exhausted during active regeneration…13497
50 Disassembly and assembly…13498
General information on disassembly and assembly…13501
How to read this manual…13501
Coating materials list…13503
Special tool list…13507
Sketches of special tools…13517
Engine and cooling system…13532
Removal and installation of supply pump assembly…13532
Removal and installation of fuel injector assembly…13537
Removal and installation of cylinder head assembly…13551
Removal and installation of radiator assembly…13569
Removal and installation of aftercooler and assembly…13574
Removal and installation of hydraulic oil cooler assembly…13577
Removal and installation of power train oil cooler assembly…13579
Removal and installation of cooling fan drive assembly…13581
Removal and installation of cooling fan motor assembly…13583
Removal and installation of engine assembly…13585
Removal and installation of damper assembly…13592
Removal and installation of engine front seal…13595
Removal and installation of engine rear seal…13598
Removal and installation of engine hood assembly…13606
Removal and installation of fuel tank assembly…13608
Removal and installation of KDPF assembly…13610
Disassembly and assembly of KDPF…13614
Removal and installation of KCCV assembly…13622
Removal and installation of air cleaner assembly…13626
Power train…13627
Removal and installation of power train unit assembly…13627
Disconnecting and connecting of power train unit assembly…13632
Disassembly and assembly of PTO…13637
Disassembly and assembly of torque converter…13641
Disassembly and assembly of TORQFLOW transmission…13650
Disassembly and assembly of HSS…13674
Removal and installation of final drive assembly…13693
Disassembly and assembly of final drive…13695
Undercarriage and frame…13708
Removal and installation of track frame assembly…13708
Removal and installation of idler assembly…13710
Disassembly and assembly of idler…13712
Removal and installation of recoil spring assembly…13716
Disassembly and assembly of recoil spring…13717
Removal and installation of track roller assembly…13721
Disassembly and assembly of track roller…13722
Removal and installation of carrier roller assembly…13725
Disassembly and assembly of carrier roller…13726
Separation and connection of track shoe assembly (Standard type track shoe)…13729
Separation and connection of track shoe assembly (PLUS type track shoe)…13732
Overall disassembly and assembly of track shoe (standard type track shoe)…13733
Overall disassembly and assembly of track shoe (PLUS type track shoe)…13746
Disassembly and assembly of one link in field (standard type track shoe)…13758
Disassembly and assembly of one link in field (PLUS type track shoe)…13765
Removal and installation of pivot shaft assembly…13770
Removal and installation of equalizer bar assembly…13771
Disassembly and assembly of equalizer bar side bushing…13773
Hydraulic system…13774
Removal and installation of hydraulic tank assembly…13774
Removal and installation of control valve assembly…13777
Disassembly and assembly of control valve…13781
Disassembly and assembly of blade PPC valve…13782
Disassembly and assembly of ripper PPC valve…13783
Removal and installation of HSS pump and cooling fan pump assembly…13784
Removal and installation of steering lubrication pump and power train pump assembly…13786
Removal and installation of cooling scavenging pump assembly…13788
Removal and installation of HSS motor assembly…13789
Disassembly and assembly of hydraulic cylinder…13791
Work equipment…13797
Removal and installation of blade assembly (ST-TPP dozer)…13797
Removal and installation of blade assembly (PAT dozer)…13799
Removal and installation of ripper assembly…13801
Cab and its attachments…13804
Removal and installation of ROPS cab assembly…13804
Removal and installation of operator's cab glass (adhesion glass)…13810
Removal and installation of operator's sea…13815
Removal and installation of seat belt…13816
Removal and installation of air conditioner unit assembly…13817
Removal and installation of air conditioner compressor assembly…13821
Electric system…13822
Removal and installation of engine controller assembly…13823
Removal and installation of power train controller assembly…13824
Removal and installation of mass air flow and temperature sensor…13826
Removal and installation of KOMTRAX terminal…13827
60 Maintenance standard…13830
Engine and cooling system…13832
Engine mount…13832
Damper…13833
Cooling system…13835
Cooling fan pump…13836
Cooling fan motor…13839
Power train…13841
Power train mount…13841
Universal joint…13843
Torque converter and PTO…13844
Transmission…13847
Transmission control valve…13851
Forward-reverse clutch ECMV and gear shift clutch ECMV…13852
Lockup clutch ECMV…13853
Main relief valve and torque converter relief valve…13854
Transmission lubricating oil relief valve…13855
Bevel gear shaft, HSS, and brake…13856
Brake valve…13861
Final drive…13862
Sprocket…13865
Undercarriage and frame…13869
Main frame…13870
Suspension…13872
Track frame and idler cushion…13874
Idler…13876
Track roller…13878
Carrier roller…13882
Track shoe…13884
Hydraulic system…13889
Hydraulic tank…13889
Scavenging pump…13890
Steering lubricating pump and power train pump…13891
HSS pump…13892
LS(PC)-EPC valve…13893
HSS motor…13894
Control valve…13896
Blade PPC valve…13903
Ripper PPC valve…13905
Quick drop valve…13907
Work equipment lock solenoid valve…13909
Angle control EPC valve…13912
Work equipment…13913
Work equipment…13913
Cutting edge and end bit…13921
Ripper…13923
Lift cylinder…13924
Tilt cylinder…13925
Pitch cylinder…13926
Angle cylinder…13927
Ripper cylinder…13928
Cab and its attachments…13929
Cab mount…13929
80 Appendix…13930
Air conditioner…13932
Precautions for refrigerant…13932
Air conditioner component…13933
Configuration and function of refrigeration cycle…13936
Outline of refrigeration cycle…13937
Air conditioner unit…13939
Dual pressure switch…13945
Air conditioner controller…13946
Air conditioner compressor…13947
Condenser…13948
Receiver drier…13949
Sunlight sensor…13950
Outside air temperature sensor…13951
Procedure for testing and troubleshooting…13952
Circuit diagram and arrangement of connector pins…13954
System diagram…13956
Input and output signals of the air conditioner controller…13957
Layout of air conditioner related parts and connectors…13959
Testing air leakage (duct)…13968
Testing with self-diagnosis function…13971
How to enter the electrical system abnormality record screen in service mode of machine monitor…13972
Testing vent (mode) changeover…13974
Testing FRESH/RECIRC air changeover…13975
Testing sunlight sensor…13976
Testing (dual) pressure switch for refrigerant…13977
Testing relays…13978
Troubleshooting chart 1…13979
Troubleshooting chart 2…13980
Information mentioned in troubleshooting table…13983
Failure code list related to air conditioner…13984
Failure code [879AKA] A/C Inner sensor Open Circuit…13985
Failure code [879AKB] A/C Inner sensor Short Circuit…13986
Failure code [879BKA] A/C Outer sensor Open Circuit…13987
Failure code [879BKB] A/C Outer sensor Short Circuit…13989
Failure code [879CKA] Ventilating sensor Open Circuit…13991
Failure code [879CKB] Ventilating sensor Short Circuit…13992
Failure code [879DKZ] Sunlight sensor Open or Short Circuit…13993
Failure code [879EMC] Ventilating Damper Abnormality…13995
Failure code [879FMC] Air Mix Damper Abnormality…13996
Failure code [879GKX] Refrigerant Abnormality…13997
A-1 Troubleshooting for power supply system (Air conditioner does not operate)…13998
A-2 Troubleshooting for compressor system (Air is not cooled)…14000
A-3 Troubleshooting for blower motor system (Air does not come out or air flow is abnormal)…14003
A-4 Troubleshooting for FRESH/RECIRC air changeover…14005
Troubleshooting with gauge pressure…14007
Connection of service tool…14010
Precautions for disconnecting and connecting air conditioner piping…14011
Handling of compressor oil…14013
90 Diagrams and drawings…14016
Hydraulic circuit diagram…14018
Symbols in hydraulic circuit diagram…14018
Power train hydraulic circuit diagram…14022
Hydraulic circuit diagram…14024
Electric circuit diagram…14029
Symbols in electric circuit diagram…14029
Electrical circuit diagram…14033
Electrical circuit diagram for air conditioner unit…14046
Index…14047
SEN05536-02 – Bulldozer D65EX,PX,WX-17 Shop Manual (SN1001&up)…14059
COVER…14059
00 Index and foreword …14061
Index …14062
Foreword, safety and general information …14075
Important safety notice …14075
How to read the shop manual …14080
Explanation of terms for maintenance standard …14082
Handling equipment of fuel system devices …14084
Handling of intake system parts …14085
Handling of hydraulic equipment …14086
Method of disconnecting and connecting of push-pull type coupler …14088
Handling of electrical equipment …14091
How to read electric wire code …14099
Precautions when performing operation …14102
Standard tightening torque table …14107
List of abbreviation …14113
Conversion table …14118
01 Specification …14123
Table of contents …14124
Specifications …14125
Specification drawing …14125
Specifications …14128
Weight table …14152
Table of fuel, coolant and lubricants …14160
10 Structure and function …14161
Table of contents …14162
Engine and cooling system …14164
Engine related parts …14164
Damper …14166
Cooling system …14168
Cooling fan pump …14170
Cooling fan motor …14184
Power train …14192
Power train …14192
HSS system …14195
Overall drawing of power train unit …14197
Power train mount …14199
Power train hydraulic piping drawing …14200
Transmission, steering, and brake control …14202
Universal joint …14204
Torque converter and PTO …14205
Transmission …14211
Transmission control valve …14224
Forward and reverse clutch ECMV and gear shift clutch ECMV …14226
Lockup clutch ECMV …14233
Main relief valve and torque converter relief valve …14237
Transmission lubricating oil relief valve …14240
Bevel gear shaft, HSS, and brake …14241
Brake valve …14262
Final drive …14266
Undercarriage and frame …14270
Main frame …14270
Suspension …14272
Track frame and idler cushion …14274
Hydraulic system …14276
Hydraulic component layout …14276
Work equipment control …14280
Hydraulic tank …14282
CLSS …14284
Scavenging pump …14288
Steering lubricating oil pump and power train pump …14289
HSS pump …14290
HSS motor …14310
Control valve …14319
Blade PPC valve …14346
Ripper PPC valve …14354
Quick drop valve …14359
Work equipment lock solenoid valve …14362
Pitch selector solenoid valve …14367
Angle control EPC valve …14368
Hydraulic oil cooler bypass valve …14373
PPC accumulator …14374
Work equipment …14375
Work equipment …14375
Ripper …14378
Piston valve …14379
Cab and its attachments …14381
ROPS cab …14381
Cab mount …14383
Electrical system …14384
Engine control system …14384
Cooling system control system …14387
Palm command control system …14389
Machine monitor system …14393
KOMTRAX system …14413
System component parts …14416
Sensor …14431
20 Standard value table …14447
Table of contents …14448
Standard service value table …14449
Standard value table for engine …14449
Standard value table for machine …14451
30 Testing and adjusting …14475
Table of contents …14476
Related information on testing and adjusting …14478
Tools for testing, adjusting, and troubleshooting …14478
Engine and cooling system …14483
Testing engine speed …14483
Measuring boost pressure …14485
Measuring exhaust gas temperature …14486
Measuring exhaust gas color …14488
Measuring and adjusting valve clearance …14490
Measuring compression pressure …14492
Measuring blowby pressure …14494
Measuring engine oil pressure …14496
Measuring EGR valve and KVGT oil pressure …14497
Releasing remaining pressure from fuel system …14498
Measuring fuel pressure …14499
Measuring fuel delivery, return rate and leakage …14506
Handling cylinder cutout mode operation …14510
Handling no-injection cranking operation …14511
Bleeding air from fuel system …14512
Testing fuel circuit for leakage …14513
Testing and adjusting air conditioner compressor belt tension …14514
Replacing alternator belt …14515
Adjusting fuel dial and decelerator pedal …14516
Power train …14518
Measuring power train oil pressure …14518
Adjusting transmission output shaft speed sensor (replacement procedure) …14523
Simple test procedure for brake performance …14524
Adjusting brake pedal …14525
Adjusting parking brake lever …14527
Retrieval of disabled machine using brake release device …14529
Undercarriage and frame …14532
Adjusting idler clearance …14532
Checking sprocket wear …14533
Testing and adjusting track tension …14534
Hydraulic system …14535
Releasing remaining pressure in work equipment cylinder …14535
Measuring and adjusting work equipment and HSS oil pressure …14536
Measuring source pressure of control circuit …14539
Measuring PPC valve output pressure …14540
Adjusting play of work equipment PPC valve …14543
Isolating the parts causing hydraulic drift in blade and ripper …14545
Measure internal oil leakage of work equipment cylinder …14546
Checking fan speed …14547
Measuring fan circuit oil pressure …14548
Bleeding air from hydraulic circuit …14549
Work equipment …14551
Adjusting work equipment lock lever …14551
Adjustment of straight tilt dozer …14552
Cab and its attachments …14554
Adjusting operator's cab …14554
Adjusting play of blade center ball …14557
Electrical system …14558
Special functions of machine monitor …14558
Handling voltage circuit of engine controller …14621
Adjustment method when controller has been replaced …14622
Testing diodes …14624
Pm clinic …14625
Pm Clinic service …14625
Pm Clinic check sheet …14631
40 Troubleshooting …14641
Table of contents …14642
Related information on troubleshooting …14649
Troubleshooting points …14649
Sequence of events in troubleshooting …14651
Check before troubleshooting …14653
Inspection procedure before troubleshooting …14655
Preparation for troubleshooting of electrical system …14675
Classification and procedures for troubleshooting …14679
Classification and procedures for troubleshooting numbers …14681
Information in troubleshooting table …14684
Troubleshooting method for open circuit in wiring harness of pressure sensor system …14686
Connector list and layout …14688
Connector contact identification …14701
T-branch box and T-branch adapter table …14739
Fuse locations table …14744
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement …14747
Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) …14750
Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) …14751
Failure codes table …14752
Troubleshooting by failure code (Display of code) …14763
Failure code [1500L0] Transmission clutch:Abnormal …14763
Failure code [15SAL1] Forward clutch:Fill High …14764
Failure code [15SALH] Forward clutch:Fill Low …14766
Failure code [15SBL1] Reverse clutch:Fill High …14768
Failure code [15SBLH] Reverse clutch:Fill Low …14770
Failure code [15SEL1] Speed 1st clutch:Fill High …14772
Failure code [15SELH] Speed 1st clutch:Fill Low …14774
Failure code [15SFL1] Speed 2nd clutch:Fill High …14776
Failure code [15SFLH] Speed 2nd clutch:Fill Low …14778
Failure code [15SGL1] Speed 3rd clutch:Fill High …14780
Failure code [15SGLH] Speed 3rd clutch:Fill Low …14782
Failure code [15SJL1] L/U :Fill Hihg …14784
Failure code [15SJLH] L/U :Fill low …14786
Failure code [1800MW] P/L clutch:Slip …14788
Failure code [879AKA] A/C Inner Sensor Open Circuit …14789
Failure code [879AKB] A/C Inner Sensor Short Circuit …14790
Failure code [879BKA] A/C Outer Sensor Open Circuit …14791
Failure code [879BKB] A/C Outer Sensor Short Circuit …14792
Failure code [879CKA] Ventilating Sensor Open Circuit …14793
Failure code [879CKB] Ventilating Sensor Short Circuit …14794
Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit …14795
Failure code [879EMC] Ventilation Damper Abnormality …14796
Failure code [879FMC] Air Mix Damper Abnormality …14797
Failure code [879GKX] Refrigerant Abnormality …14798
Failure code [989L00] Engine Controller Lock Caution 1 …14799
Failure code [989M00] Engine Controller Lock Caution 2 …14800
Failure code [989N00] Engine Controller Lock Caution 3 …14801
Failure code [A1U0N3] HC Desorb Request 1 …14802
Failure code [A1U0N4] HC Desorb Request 2 …14804
Failure code [AA10NX] Air Cleaner Clogging …14806
Failure code [AB00KE] Charge Voltage Low …14807
Failure code [B@BAZG] Eng Oil Press Low …14809
Failure code [B@BCNS] Eng Water Overheat …14810
Failure code [B@CENS] P/L Oil Overheat …14811
Failure code [B@HANS] Hyd Oil Overheat …14812
Failure code [CA115] Eng Ne and Bkup Speed Sens Error …14813
Failure code [CA122] Chg Air Press Sensor High Error …14814
Failure code [CA123] Chg Air Press Sensor Low Error …14816
Failure code [CA131] Throttle Sensor High Error …14818
Failure code [CA132] Throttle Sensor Low Error …14820
Failure code [CA144] Coolant Temp Sens High Error …14822
Failure code [CA145] Coolant Temp Sens Low Error …14824
Failure code [CA153] Chg Air Temp Sensor High Error …14826
Failure code [CA154] Chg Air Temp Sensor Low Error …14828
Failure code [CA187] Sensor 2 Supply Volt Low Error …14830
Failure code [CA234] Eng Overspeed …14832
Failure code [CA221] Ambient Press Sensor High Error …14833
Failure code [CA222] Ambient Press Sensor Low Error …14835
Failure code [CA227] Sensor 2 Supply Volt High Error …14837
Failure code [CA238] Ne Speed Sensor Supply Volt Error …14838
Failure code [CA239] Ne Speed Sens Supply Volt High Error …14839
Failure code [CA271] IMV/PCV1 Short Error …14840
Failure code [CA272] IMV/PCV1 Open Error …14842
Failure code [CA281] Pump Press Balance Error …14844
Failure code [CA295] Ambient Pressure Sensor In Range Error …14845
Failure code [CA322] Inj #1(L#1) Open/Short Error …14846
Failure code [CA323] Inj #5(L#5) Open/Short Error …14848
Failure code [CA324] Inj #3(L#3) Open/Short Error …14850
Failure code [CA325] Inj #6(L#6) Open/Short Error …14852
Failure code [CA331] Inj #2(L#2) Open/Short Error …14854
Failure code [CA332] Inj #4(L#4) Open/Short Error …14856
Failure code [CA343] ECM Critical Internal Failure …14858
Failure code [CA351] Injectors Drive Circuit Error …14859
Failure code [CA352] Sensor 1 Supply Volt Low Error …14860
Failure code [CA356] Mass Air Flow Sensor High Error …14862
Failure code [CA357] Mass Air Flow Sensor Low Error …14864
Failure code [CA386] Sensor 1 Supply Volt High Error …14866
Failure code [CA428] Water in Fuel Sensor High Error …14867
Failure code [CA429] Water in Fuel Sensor Low Error …14869
Failure code [CA435] Eng Oil Press Sw Error …14871
Failure code [CA441] Battery Voltage Low Error …14872
Failure code [CA442] Battery Voltage High Error …14874
Failure code [CA449] Rail Press Very High Error …14875
Failure code [CA451] Rail Press Sensor High Error …14877
Failure code [CA452] Rail Press Sensor Low Error …14879
Failure code [CA488] Chg Air Temp High Torque Derate …14881
Failure code [CA515] Rail Press Sens Sup Volt High Error …14882
Failure code [CA516] Rail Press Sens Sup Volt Low Error …14884
Failure code [CA553] Rail Press High Error …14886
Failure code [CA555] Crankcase Press High Error 2 …14887
Failure code [CA556] Crankcase Press High Error 2 …14888
Failure code [CA559] Rail Pump Press Low Error …14889
Failure code [CA595] Turbo Speed High Error 2 …14893
Failure code [CA687] Turbo Speed Low Error …14894
Failure code [CA689] Eng Ne Speed Sensor Error …14896
Failure code [CA691] Intake Air Temp Sens High Error …14900
Failure code [CA692] Intake Air Temp Sens Low Error …14902
Failure code [CA697] ECM Internal Temp Sensor High Error …14904
Failure code [CA698] ECM Int Temp Sensor Low Error …14905
Failure code [CA731] Eng Bkup Speed Sens Phase Error …14906
Failure code [CA778] Eng Bkup Speed Sensor Error …14908
Failure code [CA1117] Persistent Data Lost Error …14913
Failure code [CA1664] KDOC Malfunction …14914
Failure code [CA1691] Regeneration Ineffective …14918
Failure code [CA1695] Sensor 5 Supply Volt High Error …14921
Failure code [CA1696] Sensor 5 Supply Volt Low Error …14922
Failure code [CA1843] Crankcase Press Sens High Error …14924
Failure code [CA1844] Crankcase Press Sens Low Error …14926
Failure code [CA1879] KDPF Delta P Sensor High Error …14928
Failure code [CA1881] KDPF Delta P Sensor Low Error …14930
Failure code [CA1883] KDPF Delta P Sens In Range Error …14932
Failure code [CA1921] KDPF Soot Load High Error 1 …14936
Failure code [CA1922] KDPF Soot Load High Error 2 …14939
Failure code [CA1942] Crankcase Press Sens In Range Error …14944
Failure code [CA1993] KDPF Delta Pressure Low Error …14945
Failure code [CA2185] Throt Sensor Sup Volt High Error …14949
Failure code [CA2186] Throt Sensor Sup Volt Low Error …14951
Failure code [CA2249] Rail Press Very Low Error …14953
Failure code [CA2265] Fuel Feed Pump Open Error …14954
Failure code [CA2266] Fuel Feed Pump Short Error …14956
Failure code [CA2271] EGR Valve Pos Sens High Error …14958
Failure code [CA2272] EGR Valve Pos Sens Low Error …14960
Failure code [CA2288] Turbo Speed High Error 1 …14963
Failure code [CA2311] IMV Solenoid Error …14964
Failure code [CA2349] EGR Valve Solenoid Open Error …14965
Failure code [CA2353] EGR Valve Solenoid Short Error …14967
Failure code [CA2357] EGR Valve Servo Error …14969
Failure code [CA2373] Exhaust Manifold Press Sens High error …14970
Failure code [CA2374] Exhaust Manifold Press Sens Low error …14972
Failure code [CA2375] EGR Orifice Temp Sens High Error …14974
Failure code [CA2376] EGR Orifice Temp Sens Low Error …14976
Failure code [CA2381] KVGT Pos Sens High Error …14978
Failure code [CA2382] KVGT Pos Sens Low Error …14980
Failure code [CA2383] KVGT Solenoid Open Error …14983
Failure code [CA2386] KVGT Solenoid Short Error …14985
Failure code [CA2387] KVGT Servo Error …14987
Failure code [CA2554] Exh Manifold Press Sens In Range Error …14988
Failure code [CA2555] Grid Htr Relay Volt Low Error …14989
Failure code [CA2556] Grid Htr Relay Volt High Error …14991
Failure code [CA2637] KDOC Blocked …14993
Failure code [CA2639] Manual Stationary Regeneration Request …14995
Failure code [CA2961] EGR Orifice Temp High Error 1 …14998
Failure code [CA2973] Chg Air Press Sensor In Range Error …14999
Failure code [CA3133] KDPF Outlet Press Sens High Error …15000
Failure code [CA3134] KDPF Outlet Press Sens Low Error …15002
Failure code [CA3135] KDPF Outlet Press Sens In Range Error …15004
Failure code [CA3251] KDOC Inlet Temp High Error …15008
Failure code [CA3253] KDOC Temp Error – Non Regeneration …15011
Failure code [CA3254] KDOC Outlet Temp High Error 1 …15014
Failure code [CA3255] KDPF Temp Error – Non Regeneration …15017
Failure code [CA3256] KDPF Outlet Temp High Error 1 …15020
Failure code [CA3311] KDOC Outlet Temp High Error 2 …15023
Failure code [CA3312] KDPF Outlet Temp High Error 2 …15026
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error …15029
Failure code [CA3314] KDOC Inlet Temp Sens High Error …15032
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error …15036
Failure code [CA3316] KDOC Outlet Temp Sens Low Error …15040
Failure code [CA3317] KDOC Outlet Temp Sens High Error …15043
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error …15046
Failure code [CA3319] KDPF Outlet Temp Sens High Error …15050
Failure code [CA3321] KDPF Outlet Temp Sens Low Error …15054
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error …15057
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error …15061
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error …15063
Failure code [CA3741] Rail Press Valve Trip Error …15065
Failure code [D130KA] Neutral relay: Open …15066
Failure code [D130KB] Neutral relay: Short circuit …15068
Failure code [D19DKA] Amber light relay:Open …15070
Failure code [D19DKB] Amber light relay:Short circuit …15072
Failure code [D19JKZ] Personal Code Relay Abnormality …15074
Failure code [D811MC] KOMTRAX Error …15077
Failure code [D862KA] GPS Antenna Open Circuit …15078
Failure code [D8ALKA] Operating Lamp Open Circuit(KOMTRAX) …15079
Failure code [D8ALKB] Operating Lamp Short Circuit(KOMTRAX) …15081
Failure code [D8AQKR] CAN2 Discon(KOMTRAX) …15082
Failure code [DAF0MB] Monitor ROM Abnormality …15083
Failure code [DAF0MC] Monitor Error …15084
Failure code [DAF8KB] Camera Power Supply Short Circuit …15085
Failure code [DAF9KQ] Model Selection Abnormality …15087
Failure code [DAFGMC] GPS Module Error …15088
Failure code [DAFLKA] Operating Lamp Open Circuit(Monitor) …15089
Failure code [DAFLKB] Operating Lamp Short Circuit(Monitor) …15091
Failure code [DAFQKR] CAN2 Discon …15092
Failure code [DAZ9KQ] A/C Model Selection Abnormality …15093
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) …15094
Failure code [DB2QKR] CAN2 Discon (Engine Con) …15098
Failure code [DB2RKR] CAN1 Discon (Engine Con) …15103
Failure code [DBE0KT] PT controller: Abnormality in controller …15108
Failure code [DBE1KK] PT controller: Source voltage low …15109
Failure code [DBE2KK] PT controller: Output voltage low …15111
Failure code [DBE5KK] PT:Sensor volt 5V (0) Out of normal range …15113
Failure code [DBE6KK] PT:Sensor volt 24V Out of normal range …15115
Failure code [DBE7KK] PT:Sensor volt 5V (1) Out of normal range …15117
Failure code [DBE9KQ] PT controller:Type select signal …15119
Failure code [DBELKA] Operating Lamp Open Circuit(PT Con) …15120
Failure code [DBELKB] Operating Lamp Short Circuit(PT Con) …15122
Failure code [DBEQKR] CAN2 Discon (PT Con) …15123
Failure code [DBERKR] CAN1 Discon (PT Con) …15124
Failure code [DD12KA] Shift up Sw:Open …15125
Failure code [DD12KB] Shift up Sw:Short circuit …15127
Failure code [DD13KA] Shift down Sw:Open …15129
Failure code [DD13KB] Shift down Sw:Short circuit …15131
Failure code [DD14KA] Parking lever Sw: Open …15133
Failure code [DD14KB] Parking lever Sw: Short circuit …15135
Failure code [DDKFL4] Left Angle Sw:Signal mismatch …15137
Failure code [DDKGL4] Right Angle Sw:Signal mismatch …15139
Failure code [DDKHKA] iB Sw:Open …15141
Failure code [DDKHKB] iB Sw:Short circuit …15143
Failure code [DDN7KA] Weq pitch Sw: Open …15145
Failure code [DDN7KB] Weq pitch Sw: Short circuit …15147
Failure code [DDNLKA] Weq lock Sw: Open …15149
Failure code [DDNLKB] Weq lock Sw: Short circuit …15151
Failure code [DGS1KA] Hyd oil temp sensor:Open …15153
Failure code [DGS1KX] Hyd oil temp: signal abnormal …15154
Failure code [DGT1KA] T/C oil temp sensor:Open …15156
Failure code [DGT1KX] T/C oil temp sensor:Out of normal range …15157
Failure code [DH21KA] Weq pressure sensor:Open …15159
Failure code [DH21KB] Work equipment pressure sensor: Hot Short …15161
Failure code [DHA4KA] Air Cleaner Clogging Sensor Open Circuit …15163
Failure code [DHTDKA] T/C pressure sensor: Open …15164
Failure code [DHTDKB] T/C pressure sensor:Hot Short …15166
Failure code [DK10KA] Fuel control Dial: Open …15168
Failure code [DK10KB] Fuel control Dial:Short circuit …15170
Failure code [DK30KA] ST lever1: Open …15172
Failure code [DK30KB] ST lever: Hot Short …15174
Failure code [DK30KX] ST lever: Main and Sub Error …15176
Failure code [DK30KZ] ST lever: Main and Sub Error …15177
Failure code [DK30L8] ST lever:Signal mismatch …15178
Failure code [DK31KA] ST lever2: Open …15179
Failure code [DK31KB] ST lever2: Hot Short …15181
Failure code [DK40KA] Brake potentiometer: Open …15183
Failure code [DK40KB] Brake potentiometer:Hot Short …15185
Failure code [DK55KX] FR lever:Main and Sub Error …15187
Failure code [DK55KZ] FR lever:Main and Sub Error …15188
Failure code [DK55L8] FR lever:Signal mismatch …15189
Failure code [DK56KA] FR lever1:Open …15190
Failure code [DK56KB] FR lever1:Hot Short …15192
Failure code [DK57KA] FR lever2:Open …15194
Failure code [DK57KB] FR lever2:Hot Short …15196
Failure code [DKH1KA] Pitch angle sensor: Open …15198
Failure code [DKH1KB] Pitch angle sensor: Hot Short …15200
Failure code [DLM3KA] Fan rev. sensor:Open …15202
Failure code [DLM3MB] Fan control:Mismatch …15204
Failure code [DLT3KA] T/M out-speed sensor:Open …15205
Failure code [DLT3KB] T/M out-speed sensor:Short circuit …15207
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality …15208
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality …15209
Failure code [DV20KB] Back-up alarm :Short Circuit …15210
Failure code [DW5AKA] Pitch select solenoid:Disconnection …15212
Failure code [DW5AKB] Pitch select solenoid:Short circuit …15213
Failure code [DW5AKY] Pitch select solenoid:Hot short …15214
Failure code [DW7BKA] Fan reverse solenoid:Open …15216
Failure code [DW7BKB] Fan reverse solenoid:Short circuit …15218
Failure code [DWN1KA] Hss EPC RH:Open …15219
Failure code [DWN1KB] Hss EPC RH:Short circuit …15220
Failure code [DWN1KY] Hss EPC RH:Hot short …15221
Failure code [DWN2KA] Hss EPC LH:Open …15223
Failure code [DWN2KB] Hss EPC LH:Short circuit …15224
Failure code [DWN2KY] Hss EPC LH:Hot short …15225
Failure code [DWN5KA] Fan pump solenoid 1 :Open …15227
Failure code [DWN5KB] Fan pump solenoid 1 :Short circuit …15228
Failure code [DWN5KY] Fan pump solenoid 1: Hot short …15229
Failure code [DXA2KA] TVC solenoid 1: Open …15231
Failure code [DXA2KB] TVC solenoid 1: Short circuit …15232
Failure code [DXA2KY] TVC solenoid 1: Hot short …15233
Failure code [DXH1KA] Lock-up ECMV:Open …15235
Failure code [DXH1KB] Lock-up ECMV: Short circuit …15237
Failure code [DXH1KY] Lock-up ECMV: Hot short …15238
Failure code [DXH4KA] 1st clutch ECMV:Open …15240
Failure code [DXH4KB] 1st clutch ECMV:Short circuit …15241
Failure code [DXH4KY] 1st clutch ECMV:Hot short …15242
Failure code [DXH5KA] 2nd clutch ECMV:Open …15244
Failure code [DXH5KB] 2nd clutch ECMV:Short circuit …15245
Failure code [DXH5KY] 2nd clutch ECMV:Hot short …15246
Failure code [DXH6KA] 3rd clutch ECMV:Open …15248
Failure code [DXH6KB] 3rd clutch ECMV:Short circuit …15249
Failure code [DXH6KY] 3rd clutch ECMV:Hot short …15250
Failure code [DXH7KA] R clutch ECMV:Open …15252
Failure code [DXH7KB] R clutch ECMV:Short circuit …15253
Failure code [DXH7KY] R clutch ECMV:Hot short …15254
Failure code [DXH8KA] F clutch ECMV:Open …15256
Failure code [DXH8KB] F clutch ECMV:Short circuit …15257
Failure code [DXH8KY] F clutch ECMV:Hot short …15258
Failure code [DXJ4KA] Weq lock Sol.:Open …15260
Failure code [DXJ4KB] Weq lock Sol.:Short circuit …15262
Failure code [DXJCKA] Blade angle left EPC:Open …15263
Failure code [DXJCKB] Blade angle left EPC:Short circuit …15264
Failure code [DXJCKY] Blade angle left EPC:Hot short …15265
Failure code [DXJDKA] Blade angle right EPC:Open …15267
Failure code [DXJDKB] Blade angle right EPC:Short circuit …15268
Failure code [DXJDKY] Blade angle right EPC:Hot short …15269
Troubleshooting of electrical system (E-mode) …15271
E-1 Engine does not start (Engine does not crank) …15271
E-2 Manual preheating does not work …15277
E-3 Automatic preheating does not work …15280
E-4 While preheating is working, preheating monitor does not light up …15282
E-5 When starting switch is turned to ON position, machine monitor displays nothing …15284
E-6 When starting switch is turned to ON position (with engine stopped), basic check monitor lights up …15287
E-7 Air cleaner clogging monitor lights up in yellow while engine is running …15288
E-8 Charge level monitor lights up in red while engine is running …15289
E-9 Engine coolant temperature monitor lights up while engine is running …15291
E-10 Engine oil pressure monitor lights up in red while engine is running …15292
E-11 Power train oil temperature monitor lights up while engine is running …15293
E-12 Hydraulic oil temperature monitor lights up while engine is running …15294
E-13 Engine coolant temperature gauge does not indicate correct temparature …15295
E-14 Fuel level gauge does not indicate correct level …15296
E-15 Power train oil temperature gauge does not indicate correct temperature …15298
E-16 Hydraulic oil temperature gauge does not indicate correct temperature …15299
E-17 Operation mode does not change …15300
E-18 Gearshift mode does not change …15301
E-19 Operating customize switch does not display customize screen …15302
E-20 Modifying setting on customize screen does not change setting of machine …15303
E-21 Reverse slow mode does not function properly …15304
E-22 Alarm buzzer does not sound or does not stop sounding …15305
E-23 While starting switch is in OFF position, service meter is not displayed …15306
E-24 Service mode cannot be selected …15307
E-25 Horn does not sound …15308
E-26 Horn does not stop sounding …15309
E-27 Backup alarm does not sound …15310
E-28 Backup alarm does not stop sounding …15312
E-29 Headlamp does not light up …15313
E-30 Rear lamp does not light up …15316
E-31 No wiper operates continuously or intermittently …15318
E-32 Front wiper does not operate (Failure in both continuous and intermittent operations) …15321
E-33 Rear wiper does not operate (Failure in both continuous and intermittent operations) …15324
E-34 Left door wiper does not operate (Failure of both continuous and intermittent operations) …15327
E-35 Right door wiper does not operate (Failure of both continuous and intermittent operations) …15330
E-36 KOMTRAX system does not operate properly …15333
Troubleshooting of hydraulic and mechanical system (H-mode) …15335
Information described in troubleshooting table (H-mode) …15335
System diagram of hydraulic and mechanical system …15336
List of Failure Mode and Cause …15338
H-1 Machine lacks power (insufficient drawbar pull) …15341
H-2 Machine cannot travel (at 2nd or 3rd speed) …15343
H-3 Machine does not start at all gear speeds …15344
H-4 Machine travels only in one direction, either forward or in reverse …15345
H-5 Large time lag at gear shifting or directional selection …15346
H-6 Machine cannot be steered (machine does not turn left or right) …15347
H-7 Steering speed or power is insufficient …15348
H-8 Brake does not operate …15349
H-9 Torque converter does not lock up …15350
H-10 Power train oil overheats …15351
H-11 Unusual noise is heard from around HSS and work equipment pump or HSS motor …15352
H-12 All work equipment operates slowly …15353
H-13 All work equipment does not operate …15354
H-14 Blade lift speed or power is low …15355
H-15 Blade tilt speed or power is low …15356
H-16 Blade angle speed or power is low …15357
H-17 Ripper lift speed or power is low …15358
H-18 Hydraulic drift of lifted blade is large …15359
H-19 Hydraulic drift of tilted blade is large …15360
H-20 Hydraulic drift of lifted ripper is large …15361
H-21 Fan speed is abnormal (high, low, or no rotation) …15362
H-22 Unusual noise is heard from around fan …15364
Troubleshooting of engine (S-mode) …15365
Information contained in troubleshooting table (S mode) …15365
S-1 Engine does not crank when starting switch is turned to START position …15366
S-2 The engine cranks but exhaust smoke does not come out …15367
S-3 Fuel is being injected but engine does not start (incomplete combustion: engine cranks but does not start) …15368
S-4 Startability is poor …15369
S-5 Engine does not pick up smoothly …15371
S-6 Engine stops during operation …15373
S-7 Engine runs rough or is unstable …15375
S-8 Engine lacks power …15376
S-9 KDPF gets clogged in a short time …15378
S-10 Engine oil consumption is excessive …15380
S-11 Engine oil becomes contaminated early …15381
S-12 Fuel consumption is excessive …15382
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) …15383
S-14 Oil pressure drops …15384
S-15 Fuel mixes into engine oil …15385
S-16 Water mixes into engine oil (milky) …15386
S-17 Coolant temperature rises too high (overheating) …15387
S-18 Unusual noise is heard …15388
S-19 Vibration is excessive …15389
S-20 Air cannot be bled from fuel circuit …15390
S-21 Frequent active regeneration …15391
S-22 Active regeneration takes time …15392
S-23 White smoke is exhausted during active regeneration …15393
50 Disassembly and assembly …15395
Table of contents …15396
Related information on disassembly and assembly …15398
How to read this manual …15398
Coating materials list …15400
Special tool list …15404
Sketches of special tools …15416
Engine and cooling system …15431
Removal and installation of supply pump assembly …15431
Removal and installation of fuel injector assembly …15435
Removal and installation of cylinder head assembly …15449
Removal and installation of radiator assembly …15467
Removal and installation of aftercooler …15472
Removal and installation of hydraulic oil cooler assembly …15475
Removal and installation of power train oil cooler assembly …15477
Removal and installation of cooling fan drive assembly …15479
Removal and installation of cooling fan motor assembly …15481
Removal and installation of engine assembly …15483
Removal and installation of damper assembly …15490
Removal and installation of engine front seal …15493
Removal and installation of engine rear seal …15496
Removal and installation of engine hood assembly …15504
Removal and installation of fuel tank assembly …15506
Removal and installation of KDPF assembly …15508
Disassembly and assembly of KDPF …15512
Removal and installation of KCCV assembly …15520
Removal and installation of air cleaner assembly …15524
Power train …15525
Removal and installation of power train unit assembly …15525
Disconnecting and connecting of power train unit assembly …15530
Disassembly and assembly of PTO …15535
Disassembly and assembly of torque converter …15539
Disassembly and assembly of TORQFLOW transmission …15548
Disassembly and assembly of HSS …15572
Removal and installation of final drive assembly …15591
Disassembly and assembly of final drive …15593
Undercarriage and frame …15606
Removal and installation of track frame assembly …15606
Removal and installation of idler assembly …15608
Disassembly and assembly of idler …15610
Removal and installation of recoil spring assembly …15614
Disassembly and assembly of recoil spring …15615
Removal and installation of track roller assembly …15619
Disassembly and assembly of track roller …15620
Removal and installation of carrier roller assembly …15624
Disassembly and assembly of carrier roller …15625
Separation and connection of track shoe assembly (Standard type track shoe) …15628
Separation and connection of track shoe assembly (PLUS type track shoe) …15631
Overall disassembly and assembly of track shoe (standard type track shoe) …15632
Overall disassembly and assembly of track shoe (PLUS type track shoe) …15645
Disassembly and assembly of one link in field (standard type track shoe) …15657
Disassembly and assembly of one link in field (PLUS type track shoe) …15664
Removal and installation of pivot shaft assembly …15669
Removal and installation of equalizer bar assembly …15670
Disassembly and assembly of equalizer bar side bushing …15672
Hydraulic system …15673
Removal and installation of hydraulic tank assembly …15673
Removal and installation of control valve assembly …15676
Disassembly and assembly of control valve …15680
Disassembly and assembly of blade PPC valve …15681
Disassembly and assembly of ripper PPC valve …15682
Removal and installation of HSS pump and cooling fan pump assembly …15683
Removal and installation of steering lubrication pump and power train pump assembly …15685
Removal and installation of cooling scavenging pump assembly …15687
Removal and installation of HSS motor assembly …15688
Disassembly and assembly of hydraulic cylinder …15690
Work equipment …15696
Removal and installation of blade assembly (ST-TPP dozer) …15696
Removal and installation of blade assembly (PAT dozer) …15698
Removal and installation of ripper assembly …15700
Cab and its attachments …15703
Removal and installation of ROPS cab assembly …15703
Removal and installation of operator's cab glass (adhesion glass) …15709
Removal and installation of operator's seat …15717
Removal and installation of seat belt …15718
Removal and installation of air conditioner unit assembly …15719
Removal and installation of air conditioner compressor assembly …15723
Electrical system …15724
Removal and installation of machine monitor assembly …15724
Removal and installation of engine controller assembly …15725
Removal and installation of power train controller assembly …15726
Removal and installation of mass air flow and temperature sensor …15728
Removal and installation of KOMTRAX terminal …15729
60 Maintenance standard …15731
Table of contents …15732
Engine and cooling system …15733
Engine mount …15733
Damper …15734
Cooling system …15736
Cooling fan pump …15737
Cooling fan motor …15740
Power train …15742
Power train mount …15742
Universal joint …15744
Torque converter and PTO …15745
Transmission …15748
Transmission control valve …15752
Forward and reverse clutch ECMV and gear shift clutch ECMV …15753
Lockup clutch ECMV …15754
Main relief valve and torque converter relief valve …15755
Transmission lubricating oil relief valve …15756
Bevel gear shaft, HSS, and brake …15757
Brake valve …15762
Final drive …15763
Sprocket …15766
Undercarriage and frame …15770
Main frame …15770
Suspension …15772
Track frame and idler cushion …15774
Idler …15776
Track roller …15778
Carrier roller …15782
Track shoe …15784
Hydraulic system …15789
Hydraulic tank …15789
Scavenging pump …15790
Steering lubricating oil pump and power train pump …15791
HSS pump …15792
HSS motor …15794
Control valve …15796
Blade PPC valve …15803
Ripper PPC valve …15805
Quick drop valve …15807
Work equipment lock solenoid valve …15809
Angle control EPC valve …15812
Work equipment …15813
Work equipment …15813
Cutting edge and end bit …15820
Ripper …15822
Lift cylinder …15823
Tilt cylinder …15824
Pitch cylinder …15825
Angle cylinder …15826
Ripper cylinder …15827
Cab and its attachments …15828
Cab mount …15828
80 Appendix …15829
Table of contents …15830
Air conditioner components …15831
Precautions for refrigerant …15831
Air conditioner component …15832
Configuration and function of refrigeration cycle …15835
Outline of refrigeration cycle …15836
Air conditioner unit …15838
Dual pressure switch …15845
Air conditioner controller …15846
Compressor …15847
Condenser …15848
Receiver drier …15849
Sunlight sensor …15850
Outside air temperature sensor …15851
Procedure for testing and troubleshooting …15852
Circuit diagram and arrangement of connector pins …15854
System diagram …15856
Input and output signals of the air conditioner controller …15857
Layout of air conditioner related parts and connectors …15859
Testing air leakage (duct) …15868
Testing with self-diagnosis function …15871
How to open the electrical system abnormality record screen in service mode of the machine monitor …15872
Testing vent (mode) changeover …15874
Testing FRESH/RECIRC air changeover …15875
Testing sunlight sensor …15876
Testing (dual) pressure switch for refrigerant …15877
Testing relays …15878
Troubleshooting chart 1 …15879
Troubleshooting chart 2 …15880
Information in troubleshooting table …15883
Failure code list related to air conditioner …15884
Failure code [879AKA] A/C Inner Sensor Open Circuit …15885
Failure code [879AKB] A/C Inner Sensor Short Circuit …15886
Failure code [879BKA] A/C Outer sensor Open Circuit …15887
Failure code [879BKB] A/C Outer sensor Short Circuit …15889
Failure code [879CKA] Ventilating Sensor Open Circuit …15891
Failure code [879CKB] Ventilating Sensor Short Circuit …15892
Failure code [879DKZ] Sunlight sensor Open or Short Circuit …15893
Failure code [879EMC] Ventilation Damper Abnormality …15895
Failure code [879FMC] Air Mix Damper Abnormality …15896
Failure code [879GKX] Refrigerant Abnormality …15897
A-1 Troubleshooting for power supply system (Air conditioner does not operate) …15898
A-2 Troubleshooting for compressor system (Air is not cooled) …15900
A-3 Troubleshooting for blower motor system (Air does not come out or air flow is abnormal) …15903
A-4 Troubleshooting for FRESH/RECIRC air changeover …15905
Troubleshooting with gauge pressure …15907
Connection of service tool …15910
Precautions for disconnecting and connecting air conditioner piping …15912
Handling of compressor oil …15914
90 Diagrams and drawings …15917
Table of contents …15918
Hydraulic circuit diagram …15919
Symbols in hydraulic circuit diagram …15919
Power train hydraulic circuit diagram …15923
Hydraulic circuit diagram …15924
Electric circuit diagram …15930
Symbols in electric circuit diagram …15930
Electric circuit diagram …15934
Electric circuit diagram for air conditioner unit …15947
INDEX…15948
SRBM001910 – Бульдозер D65E,P-12 D65E,P-12 Заводская инструкция (SN60001 и выше)…15960
Заводская инструкция D65E,P-12 БУЛЬДОЗЕР…15960
СОДЕРЖАНИЕ…15961
БЕЗОПАСНОСТЬ…15966
ПРЕДИСЛОВИЕ…15968
КАК ПОЛЬЗОВАТЬСЯ ДАННОЙ ИНСТРУКЦИЕЙ…15969
ИНСТРУКЦИИ ПО ПОДЪЕМУ ДЕТАЛЕЙ…15970
МАТЕРИАЛЫ ПОКРЫТИЙ…15971
НОРМАТИВНЫ НА МОМЕНТ ЗАТЯЖКИ…15972
УСЛОВНЫЕ ОБОЗНАЧЕНИЯ ЭЛЕМЕНТОВ ЭЛЕКТРИЧЕСКИХ СХЕМ…15974
ТАБЛИЦЫ ПЕРЕВОДА…15975
ТАБЛИЦЫ КОЛИЧЕСТВА МАСЛА И ОХЛАЖДАЮЩЕЙ ЖИДКОСТИ…15981
01 ОБЩЕЕ…15983
ОБЩИЙ СБОРОЧНЫЙ ЧЕРТЕЖ…15984
ТЕХНИЧЕСКИЕ ХАРАКТЕРИСТИКИ…15988
ТАБЛИЦА МАСС…15998
ТАБЛИЦА КОЛИЧЕСТВА МАСЛА И ОХЛАЖДАЮЩЕЙ ЖИДКОСТИ…16002
10 УСТРОЙСТВО И РАБОТА…16005
РАДИАТОР, МАСЛООХЛАДИТЕЛЬ…16006
УПРАВЛЕНИЕ ДВИГАТЕЛЕМ…16008
СИСТЕМА СИЛОВОЙ ПЕРЕДАЧИ…16010
КИНЕМАТИЧЕСКАЯ СХЕМА СИЛОВОЙ ПЕРЕДАЧИ…16011
СИЛОВАЯ ПЕРЕДАЧА…16012
СХЕМА ГИДРАВЛИЧЕСКИХ ТРУБОПРОВОДОВ СИЛОВОЙ ПЕРЕДАЧИ…16013
ПРИНЦИПИАЛЬНАЯ ГИДРАВЛИЧЕСКАЯ СХЕМА СИЛОВОЙ ПЕРЕДАЧИ…16015
СХЕМА ГИДРОСИСТЕМЫ СИЛОВОЙ ПЕРЕДАЧИ…16016
ДЕМПФЕР, КАРДАННЫЙ ВАЛ…16018
ГИДРОТРАНСФОРМАТОР И МЕХАНИЗМ ОТБОРА МОЩНОСТИ…16020
УПРАВЛЕНИЕ КОРОБКОЙ ПЕРЕДАЧ…16023
КОРОБКА ПЕРЕДАЧ…16025
РАСПРЕДЕЛИТЕЛЬНЫЙ КЛАПАН КОРОБКИ ПЕРЕДАЧ…16032
ГЛАВНЫЙ РАЗГРУЗОЧНЫЙ КЛАПАН…16039
РАЗГРУЗОЧНЫЙ КЛАПАН СМАЗКИ…16041
РУЛЕВОЕ УПРАВЛЕНИЕ, УПРАВЛЕНИЕ ТОРМОЗАМИ…16042
ВАЛ ВЕДОМОЙ КОНИЧЕСКОЙ ШЕСТЕРНИ, МУФТА ПОВОРОТА, ТОРМОЗ ПОВОРОТА (D65Е, Р-12)…16043
РАСПРЕДЕЛИТЕЛЬНЫЙ КЛАПАН РУЛЕВОГО МЕХАНИЗМА (D65Е, Р-12)…16050
РЕДУКЦИОННЫЙ КЛАПАН…16057
СЕТЧАТЫЙ ФИЛЬТР ОТКАЧИВАЮЩЕГО НАСОСА СЕТЧАТЫЙ ФИЛЬТР СИЛОВОЙ ПЕРЕДАЧИ…16058
СЕТЧАТЫЙ ФИЛЬТР СИЛОВОЙ ПЕРЕДАЧИ…16059
МАСЛЯНЫЙ ФИЛЬТР СИЛОВОЙ ПЕРЕДАЧИ…16060
КОНЕЧНАЯ ПЕРЕДАЧА…16061
ОСНОВНАЯ РАМА…16064
РАМА ГУСЕНИЧНОЙ ТЕЛЕЖКИ…16065
НАТЯЖНАЯ ПРУЖИНА…16067
ПОДВЕСКА…16069
ГИДРАВЛИЧЕСКАЯ СХЕМА РАБОЧЕГО ОБОРУДОВАНИЯ…16073
СХЕМА СИСТЕМЫ ПРОПОРЦИОНАЛЬНОГО КОНТРОЛЯ (РРС)…16077
УПРАВЛЕНИЕ РАБОЧИМ ОБОРУДОВАНИЕМ…16079
ПРИНЦИПИАЛЬНАЯ ГИДРАВЛИЧЕСКАЯ СХЕМА РАБОЧЕГО ОБОРУДОВАНИЯ…16081
СХЕМА ГИДРОСИСТЕМЫ РАБОЧЕГО ОБОРУДОВАНИЯ…16082
ГИДРОБАК И ФИЛЬТР…16090
КЛАПАН РРС (Для подъема и перекоса отвала и для рыхлителя)…16095
РЕДУКЦИОННЫЙ КЛАПАН РРС…16108
СТОПОРНЫЙ КЛАПАН РРС…16110
ГЛАВНЫЙ РАСПРЕДЕЛИТЕЛЬНЫЙ КЛАПАН…16111
СХЕМА ГИДРОСИСТЕМЫ РУЛЕВОГО УПРАВЛЕНИЯ УПРАВЛЕНИЯ РАБОЧИМ ОБОРУДОВАНИЕМ…16155
ВСАСЫВАЮЩИЙ КЛАПАН…16164
ПОРШНЕВОЙ КЛАПАН…16167
РАБОЧЕЕ ОБОРУДОВАНИЕ…16168
СХЕМА ЭЛЕКТРООБОРУДОВАНИЯ…16174
УПРАВЛЕНИЕ ДВИГАТЕЛЕМ…16189
СИСТЕМА КОНТРОЛЯ МАШИНЫ…16190
ДАТЧИКИ…16193
20 ПРОВЕРКА И РЕГУЛИРОВКА…16195
Таблица нормативных значений для двигателя…16196
Таблица нормативных значений для шасси…16200
Таблица нормативных значений для электрооборудования…16210
Перечень инструментов для проверки и регулировки…16213
Регулировка клапанного зазора…16215
Измерение давления компрессии…16216
Измерение давления прорыва картерных газов…16217
Регулировка момента впрыска топлива…16218
Определение цвета выхлопных газов…16220
Измерение давления наддува…16221
Измерение температуры выхлопных газов (D65Р)…16222
Измерение давления масла в двигателе…16223
Измерение частоты вращения двигателя…16223
Проверка натяжения ремня вентилятора…16224
Измерение частоты вращения двигателя при пробуксовке гидротрансформатора…16225
Регулировка рычажного механизма управления подачей топлива…16226
Регулировка рычага рулевого управления и направления движения, рычага переключения передач, рычажного механизма стояночного тормоза (D65Е, Р)…16228
Регулировка рычажного механизма тормозной педали (D65Е, Р)…16230
Регулировка рычажного механизма управления рабочим оборудованием…16231
Регулировка прямого отвала с регулируемым перекосом…16233
Регулировка клапана РРС…16236
Измерение давления масла силовой передачи (D65Е, Р)…16237
Проверка и регулировка давления гидравлики рабочего оборудования (D65Е, Р)…16240
Проверка и регулировка давления контура управления…16241
Измерение выходного давления клапана РРС…16242
Измерение утечки внутри цилиндра…16243
Выпуск воздуха из гидроцилиндра…16244
Сброс остаточного давления из гидравлического контура…16244
Порядок проведения простой проверки работы тормоза рулевого управления…16245
Процедура проверки датчиков…16246
ДИАГНОСТИКА НЕИСПРАВНОСТЕЙ…16249
МОМЕНТЫ, О КОТОРЫХ НУЖНО ПОМНИТЬ ПРИ ДИАГНОСТИКЕ НЕИСПРАВНОСТЕЙ…16250
ПОСЛЕДОВАТЕЛЬНОСТЬ ДЕЙСТВИЙ ПРИ ДИАГНОСТИКЕ НЕИСПРАВНОСТЕЙ…16251
МЕРЫ ПРЕДОСТОРОЖНОСТИ ПРИ ПРОВЕДЕНИИ ТЕХНИЧЕСКОГО ОБСЛУЖИВАНИЯ…16252
ОБСЛУЖИВАНИЕ РАЗЪЕМОВ…16259
ПРОВЕРКИ ПЕРЕД ДИАГНОСТИКОЙ НЕИСПРАВНОСТЕЙ…16260
ТИПЫ РАЗЪЕМОВ И МЕСТА ИХ УСТАНОВКИ…16268
СХЕМА РАСПОЛОЖЕНИЯ РАЗЪЕМОВ…16269
ТАБЛИЦА РАЗЪЕМОВ ПО КОЛИЧЕСТВУ ШТЫРЕЙ…16271
ЭЛЕКТРИЧЕСКИЕ СХЕМЫ ДЛЯ КАЖДОЙ СИСТЕМЫ…16276
ДИАГНОСТИКА НЕИСПРАВНОСТЕЙ ДВИГАТЕЛЯ (РАЗДЕЛ S)…16277
ДИАГНОСТИКА НЕИСПРАВНОСТЕЙ ГИДРОСИСТЕМЫ, МЕХАНИЧЕСКОЙ СИСТЕМЫ (РАЗДЕЛ H)…16297
ДИАГНОСТИКА НЕИСПРАВНОСТЕЙ ЭЛЕКТРООБОРУДОВАНИЯ (РАЗДЕЛ E)…16322
ДИАГНОСТИКА НЕИСПРАВНОСТЕЙ СИСТЕМЫ КОНТРОЛЯ МАШИНЫ (РАЗДЕЛ M)…16344
30 РАЗБОРКА И СБОРКА…16360
Как пользоваться данной инструкцией…16362
Меры предосторожности при выполнении операции…16363
Перечень специальных инструментов…16365
СТАРТЕР В СБОРЕ…16372
ГЕНЕРАТОР В СБОРЕ…16372
СЕРДЕЧНИК МАСЛООХЛАДИТЕЛЯ ДВИГАТЕЛЯ…16373
ТОПЛИВНЫЙ НАСОС ВЫСОКОГО ДАВЛЕНИЯ В СБОРЕ…16374
ВОДЯНОЙ НАСОС В СБОРЕ…16376
ТУРБОНАГНЕТАТЕЛЬ В СБОРЕ…16377
ФОРСУНКА В СБОРЕ (D65Е)…16379
ТЕРМОСТАТ В СБОРЕ…16380
ГОЛОВКА ЦИЛИНДРА В СБОРЕ (D65Е)…16381
ПЕРЕДНЕЕ УПЛОТНЕНИЕ ДВИГАТЕЛЯ…16386
ЗАДНЕЕ УПЛОТНЕНИЕ ДВИГАТЕЛЯ…16388
КОМПРЕССОР КОНДИЦИОНЕРА В СБОРЕ…16392
КОНДЕНСАТОР КОНДИЦИОНЕРА В СБОРЕ…16393
ТОПЛИВНЫЙ БАК В СБОРЕ…16394
РАДИАТОР В СБОРЕ…16398
ОХЛАДИТЕЛЬ ГИДРАВЛИЧЕСКОГО МАСЛА В СБОРЕ…16400
ДВИГАТЕЛЬ В СБОРЕ (Спецификация предусматривает наличие кабины)…16401
ДВИГАТЕЛЬ В СБОРЕ (Спецификация предусматривает наличие навеса)…16404
ДЕМПФЕР В СБОРЕ…16408
УЗЕЛ СИЛОВОЙ ПЕРЕДАЧИ В СБОРЕ (D56Е, Р)…16412
УЗЕЛ СИЛОВОЙ ПЕРЕДАЧИ (D56Е, Р)…16416
ГИДРОТРАНСФОРМАТОР В СБОРЕ…16419
PTO В СБОРЕ…16424
КОРОБКА ПЕРЕДАЧ «ТОРКФЛОУ» В СБОРЕ…16431
КАРТЕР РУЛЕВОГО МЕХАНИЗМА В СБОРЕ (D65Е, Р)…16454
КЛАПАН ГИДРОТРАНСФОРМАТОРА В СБОРЕ…16471
РАСПРЕДЕЛИТЕЛЬНЫЙ КЛАПАН КОРОБКИ ПЕРЕДАЧ В СБОРЕ…16473
КЛАПАН РУЛЕВОГО УПРАВЛЕНИЯ В СБОРЕ (D65Е, Р)…16478
РЕДУКЦИОННЫЙ КЛАПАН В СБОРЕ (D65Е, Р)…16484
ОТКАЧИВАЮЩИЙ НАСОС В СБОРЕ…16486
НАСОС СИЛОВОЙ ПЕРЕДАЧИ В СБОРЕ…16487
КОНЕЧНАЯ ПЕРЕДАЧА В СБОРЕ…16488
РАМА ГУСЕНИЧНОЙ ТЕЛЕЖКИ В СБОРЕ…16499
НАТЯЖНАЯ ПРУЖИНА В СБОРЕ…16501
НАПРАВЛЯЮЩЕЕ КОЛЕСО В СБОРЕ…16508
ОПОРНЫЙ КАТОК В СБОРЕ…16516
ПОДДЕРЖИВАЮЩИЙ КАТОК В СБОРЕ (D65Р)…16520
ПОДДЕРЖИВАЮЩИЙ КАТОК В СБОРЕ (D65Е)…16521
ГУСЕНИЧНАЯ ЦЕПЬ…16524
ПОВОРОТНЫЙ ШКВОРЕНЬ В СБОРЕ…16559
БАЛАНСИРНАЯ БАЛКА В СБОРЕ…16560
БОКОВАЯ ВТУЛКА БАЛАНСИРНОЙ БАЛКИ…16562
СЕГМЕНТЫ ЗВЕЗДОЧКИ…16563
НАСОС РАБОЧЕГО ОБОРУДОВАНИЯ В СБОРЕ (065Е, Р)…16564
НАСОС РРС В СБОРЕ…16566
ГЛАВНЫЙ РАСПРЕДЕЛИТЕЛЬНЫЙ КЛАПАН В СБОРЕ…16567
ГЛАВНЫЙ РАЗГРУЗОЧНЫЙ КЛАПАН…16572
КЛАПАН РРС В СБОРЕ…16573
РАЗГРУЗОЧНЫЙ КЛАПАН РРС В СБОРЕ…16576
ЦИЛИНДР ПОДЪЕМА ОТВАЛА В СБОРЕ…16578
ЦИЛИНДР ПЕРЕКОСА ОТВАЛА В СБОРЕ…16579
ГИДРАВЛИЧЕСКИЙ ЦИЛИНДР В СБОРЕ (ЦИЛИНДРЫ ПОДЪЕМА И ПЕРЕКОСА ОТВАЛА)…16580
РАБОЧЕЕ ОБОРУДОВАНИЕ В СБОРЕ…16585
КЛАПАН РЫХЛИТЕЛЯ В СБОРЕ (ПРИОБРЕТАЕТСЯ ДОПОЛНИТЕЛЬНО)…16591
ОГРАЖДЕНИЕ ROPS…16593
КАБИНА ВОДИТЕЛЯ В СБОРЕ…16594
НАВЕС В СБОРЕ…16595
ПАНЕЛЬ ПРИБОРОВ В СБОРЕ…16596
КОНТРОЛЬНАЯ ПАНЕЛЬ В СБОРЕ…16597
РАМА ПОЛА В СБОРЕ (D65Е, Р)…16598
40 НОРМАТИВЫ ТЕХОБСЛУЖИВАНИЯ…16602
ДЕТАЛИ КРЕПЛЕНИЯ ДВИГАТЕЛЯ…16603
ДЕТАЛИ КРЕПЛЕНИЯ СИЛОВОЙ ПЕРЕДАЧИ…16604
ДЕМПФЕР, УНИВЕРСАЛЬНЫЙ ШАРНИР…16605
ГИДРОТРАНСФОРМАТОР, МЕХАНИЗМ ОТБОРА МОЩНОСТИ…16607
КОРОБКА ПЕРЕДАЧ…16609
РАСПРЕДЕЛИТЕЛЬНЫЙ КЛАПАН КОРОБКИ ПЕРЕДАЧ…16611
ГЛАВНЫЙ РАЗГРУЗОЧНЫЙ КЛАПАН…16614
ВАЛ КОНИЧЕСКОЙ ШЕСТЕРНИ, МУФТА РУЛЕВОГО УПРАВЛЕНИЯ, ТОРМОЗ РУЛЕВОГО УПРАВЛЕНИЯ (D65Е, Р12)…16616
РАСПРЕДЕЛИТЕЛЬНЫЙ КЛАПАН РУЛЕВОГО УПРАВЛЕНИЯ (D65Е, Р12)…16620
СМАЗОЧНЫЙ НАСОС СИЛОВОЙ ПЕРЕДАЧИ…16621
НАСОС РРС…16622
КЛАПАН РРС…16625
РЕДУКЦИОННЫЙ КЛАПАН РРС…16630
КОНЕЧНАЯ ПЕРЕДАЧА…16631
РАМА КОРПУСА…16633
РАМА ГУСЕНИЧНОЙ ТЕЛЕЖКИ, НАТЯЖНАЯ ПРУЖИНА…16634
НАПРАВЛЯЮЩЕЕ КОЛЕСО…16636
ОПОРНЫЙ КАТОК…16639
ПОДДЕРЖИВАЮЩИЙ КАТОК…16640
ГУСЕНИЦА (СУХОГО ТИПА)…16641
ГУСЕНИЦА (СМАЗЫВАЕМОГО ТИПА)…16643
ПОДВЕСКА…16645
ГИДРОНАСОС (D65Е, Р-12)…16649
ГЛАВНЫЙ РАСПРЕДЕЛИТЕЛЬНЫЙ КЛАПАН…16652
ЦИЛИНДР РАБОЧЕГО ОБОРУДОВАНИЯ…16664
РАБОЧЕЕ ОБОРУДОВАНИЕ…16666
ЦЕНТРАЛЬНЫЙ НОЖ, УГЛОВОЙ НОЖ ОТВАЛА…16670
РЫХЛИТЕЛЬ…16671
90 ПРОЧЕЕ…16673
ТАБЛИЦА КОЛИЧЕСТВА МАСЛА И ОХЛАЖДАЮЩЕЙ ЖИДКОСТИ…16674
УСТРОЙСТВО И РАБОТА…16675
СХЕМА ГИДРАВЛИЧЕСКИХ ТРУБОПРОВОДОВ РАБОЧЕГО ОБОРУДОВАНИЯ…16676
СХЕМА ГИДРАВЛИЧЕСКИХ КОНТУРОВ РУЛЕВОГО УПРАВЛЕНИЯ И РАБОЧЕГО ОБОРУДОВАНИЯ…16677
УПРАВЛЕНИЕ РАБОЧИМ ОБОРУДОВАНИЕМ…16679
ГЛАВНЫЙ РАСПРЕДЕЛИТЕЛЬНЫЙ КЛАПАН…16680
ОБОРУДОВАНИЕ БУЛЬДОЗЕРА-ПЛАНИРОВЩИК…16683
НОРМАТИВЫ ТЕХОБСЛУЖИВАНИЯ…16684
ГЛАВНЫЙ РАСПРЕДЕЛИТЕЛЬНЫЙ КЛАПАН…16684
ГИДРОЦИЛИНДР РАБОЧЕГО ОБОРУДОВАНИЯ…16689
ОБОРУДОВАНИЕ БУЛЬДОЗЕРА-ПЛАНИРОВЩИКА…16691
Komatsu Bulldozers D65E, D65EX, D65P, D65PX, D65WX Repair Service Manuals
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