Komatsu D65EX-15, D65PX-15, D65WX-15 Bulldozer (67001 and up) Service Repair Shop Manual

This complete service repair workshop manual PDF download for the D65EX-15, D65PX-15, D65WX-15 Komatsu Bulldozer (SN: 67001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Komatsu D65EX-15 - S/N : 67001 and up
Komatsu D65PX-15 - S/N : 67001 and up
Komatsu D65WX-15 - S/N : 67001 and up


TABLE OF CONTENTS :

- GENERAL
- STRUCTURE AND FUNCTION
- MAINTENANCE STANDARD
- TESTING AND ADJUSTING
- DISASSEMBLY AND ASSEMBLY
- OTHERS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM029505
Total Pages : 906


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

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

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COMPLETE TABLE OF CONTENTS :

FOREWORD
GENERAL
HOW TO READ THE SHOP MANUAL
HOISTING INSTRUCTIONS
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
COATING MATERIALS
STANDARD TIGHTENING TORQUE
ELECTRIC WIRE CODE
CONVERSION TABLE
UNITS

01 GENERAL
SPECIFICATION DIMENSIONS
SPECIFICATIONS
WEIGHT TABLE
TABLE OF FUEL, COOLANT AND LUBRICANT

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
COOLING SYSTEM
ENGINE MOUNT
POWER TRAIN
OVERALL DRAWING OF POWER TRAIN UNIT
HYDRAULIC PIPING OF POWER TRAIN
DAMPER, UNIVERSAL JOINT
TRANSMISSION, STEERING, BRAKE CONTROL
TORQUE CONVERTER, PTO
TRANSMISSION
TRANSMISSION ECMV
MAIN RELIEF VALVE
LUBRICATION RELIEF VALVE
SCAVENGING PUMP
POWER TRAIN PUMP, LUBRICATION PUMP
HSS SYSTEM
HYDRAULIC, HSS PUMP
HSS MOTOR
BEVEL GEAR SHAFT, HSS, BRAKE
BRAKE VALVE
FINAL DRIVE
FRAME ASSEMBLY
SUSPENSION
TRACK FRAME, RECOIL SPRING
IDLER
TRACK ROLLER
CARRIER ROLLER
SPROCKET
TRACK SHOE
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM
WORK EQUIPMENT CONTROL
HYDRAULIC TANK
ACCUMULATOR
PPC LOCK VALVE
HYDRAULIC CYLINDER
PISTON VALVE
QUICK DROP VALVE
COOLING FAN PUMP
COOLING FAN MOTOR
PPC VALVE
PCCS LEVER
CONTROL VALVE
SELF PRESSURE REDUCING VALVE
WORK EQUIPMENT
CUTTING EDGE, END BIT
RIPPER
CAB MOUNT
CAB
AIR CONDITIONER PIPING
ENGINE CONTROL
ENGINE CONTROL SYSTEM
CRI ENGINE CONTROL SYSTEM
COOLING SYSTEM CONTROL SYSTEM
PALM COMMAND CONTROL SYSTEM
SYSTEM COMPONENTS
ENGINE CONTROLLER
TRANSMISSION AND STEERING CONTROLLER
MONITOR SYSTEM
MONITOR PANEL
SENSORS

20 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR CHASSIS
TESTING AND ADJUSTING
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
MEASURING ENGINE SPEED
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST GAS COLOR
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
MEASURING BLOW-BY PRESSURE
MEASURING ENGINE OIL PRESSURE
HANDLING OF FUEL SYSTEM DEVICES
RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM
MEASURING FUEL PRESSURE
BLEEDING AIR FROM FUEL CIRCUIT
INSPECTION OF FUEL CIRCUIT FOR LEAKAGE
REDUCED CYLINDER MODE OPERATION FOR ENGINE
TESTING AND ADJUSTING ALTERNATOR BELT TENSION
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION
ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL
MEASURING POWER TRAIN OIL PRESSURE
ADJUSTING TRANSMISSION SPEED SENSOR (REPLACEMENT PROCEDURE)
SIMPLE METHOD OF TESTING BRAKE PERFORMANCE
ADJUSTING BRAKE PEDAL
EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE
ADJUSTING CLEARANCE OF IDLER
INSPECTING WEAR OF SPROCKET
TESTING AND ADJUSTING TRACK SHOE TENSION
TESTING AND ADJUSTING WORK EQUIPMENT AND HSS OIL PRESSURE
TESTING CONTROL CIRCUIT MAIN PRESSURE
MEASURING PPC VALVE OUTPUT PRESSURE
ADJUSTING PLAY OF WORK EQUIPMENT PPC VALVE
MEASURING INTERNAL LEAKAGE OF WORK EQUIPMENT CYLINDER
BLEEDING AIR FROM WORK EQUIPMENT CYLINDER
RELEASING RESIDUAL PRESSURE IN WORK EQUIPMENT CYLINDER (IF PPC ACCUMULATOR IS INSTALLED)
RELEASING RESIDUAL PRESSURE IN WORK EQUIPMENT CYLINDER (IF PPC ACCUMULATOR IS INSTALLED)
ADJUSTING SAFETY LOCK LEVER
MEASURING FAN MOTOR SPEED
MEASURING FAN PUMP CIRCUIT PRESSURE
BLEEDING AIR FROM FAN PUMP
ADJUSTING STRAIGHT TILT DOZER
TESTING AND ADJUSTING OPERATOR'S CAB
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
HANDLING OF HIGH VOLTAGE CIRCUIT OF ENGINE CONTROLLER
ADJUSTMENT METHOD OF REPLACED CONTROLLER
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM
PM CLINIC SERVICE
UNDERCARRIAGE TROUBLESHOOTING REPORT
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
CHECKS BEFORE TROUBLESHOOTING
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING
TYPES AND LOCATIONS OF CONNECTORS (D65EX, PX-15)
CONNECTOR ARRANGEMENT DRAWING
CIRCUIT DRAWING FOR ENGINE CONTROLLER SYSTEM (E CIRCUIT)
CIRCUIT DRAWING FOR STEERING AND TRANSMISSION CONTROLLER SYSTEM (ST - TM CIRCUIT)
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
T-BRANCH BOX AND T-BRANCH TABLE
TROUBLESHOOTING WHEN ERROR CODE IS DISPLAYED (ERROR CODE)
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST
TROUBLE CODE TABLE
ERROR CODE [1500L0] (TRANSMISSION CLUTCH: SEE THE LIST. (L0))
ERROR CODE [15SAL1] (FORWARD CLUTCH: SEE THE LIST. (L1))
ERROR CODE [15SALH] (FORWARD CLUTCH: SEE THE LIST. (LH))
ERROR CODE [15SBL1] (REVERSE CLUTCH: SEE THE LIST. (L1))
ERROR CODE [15SBLH] (REVERSE CLUCTH: SEE THE LIST. (LH))
ERROR CODE [15SEL1] (1ST CLUTCH: SEE THE LIST. (L1))
ERROR CODE [15SELH] (1ST CLUTCH: SEE THE LIST. (LH))
ERROR CODE [15SFL1] (2ND CLUTCH: SEE THE LIST. (L1))
ERROR CODE [15SFLH] (2ND CLUTCH: SEE THE LIST. (LH))
ERROR CODE [15SGL1] (3RD CLUTCH: SEE THE LIST. (L1))
ERROR CODE [15SGLH] (3RD CLUTCH: SEE THE LIST. (LH))
ERROR CODE [A000N1] (ENGINE : OVERRUN (N1))
ERROR CODE [AB00MA] (ALTERNATOR : MALFUNCTION (MA))
ERROR CODE [AD00L2] (COMMON RAIL : SEE THE LIST (L2))
ERROR CODE [AD00MA] (COMMON RAIL : DEFECTIVE FUNCTION (MA))
ERROR CODE [AD10L3] (FUEL SUPPLY PUMP : SEE THE LIST (L3))
ERROR CODE [AD10MA] (FUEL SUPPLY PUMP : DEFECTIVE FUNCTION (MA))
ERROR CODE [AD10MB] (FUEL SUPPLY PUMP : FUNCTION REDUCTION (MB))
ERROR CODE [AD11KA] (FUEL SUPPLY PUMP SOLENOID 1: DISCONNECTION (KA))
ERROR CODE [AD11KB] (FUEL SUPPLY PUMP SOLENOID 1: SHORT CIRCUIT (KB))
ERROR CODE [AD51KA] (FUEL SUPPLY PUMP SOLENOID 2: DISCONNECTION (KA))
ERROR CODE [AD51KB] (FUEL SUPPLY PUMP SOLENOID 2: SHORT CIRCUIT (KB))
ERROR CODE [ADA1KA] (NO. 1 INJECTOR SOLENOID: DISCONNECTION (KA))
ERROR CODE [ADAZKB] (NO. 1, 2, AND 3 INJECTOR SOLENOIDS: SHORT CIRCUIT (KB))
ERROR CODE [ADB1KA] (NO. 2 INJECTOR SOLENOID: DISCONNECTION (KA))
ERROR CODE [ADC1KA] (NO. 3 INJECTOR SOLENOID: DISCONNECTION (KA))
ERROR CODE [ADD1KA] (NO. 4 INJECTOR SOLENOID: DISCONNECTION (KA))
ERROR CODE [ADDZKB] (NO. 4, 5, AND 6 INJECTOR SOLENOIDS: SHORT CIRCUIT (KB))
ERROR CODE [ADE1KA] (NO. 5 INJECTOR SOLENOID: DISCONNECTION (KA))
ERROR CODE [ADF1KA] (NO. 6 INJECTOR SOLENOID: DISCONNECTION (KA))
ERROR CODE [B@BAZG] ENGINE OIL: OIL PRESSURE REDUCTION (ZG))
ERROR CODE [B@BCNS] (RADIATOR COOLANT: OVERHEAT (NS))
ERROR CODE [B@CENS] (POWER TRAIN OIL: OVERHEAT (NS))
ERROR CODE [B@HANS] (HYDRAULIC OIL: OVERHEAT (NS))
ERROR CODE [D110KA] (BATTERY RELAY: SHORT CIRCUIT (KA))
ERROR CODE [D110KB] (BATTERY RELAY: DISCONNECTION (KB))
ERROR CODE [D130KA] (NEUTRAL SAFETY RELAY: SHORT CIRCUIT (KA))
ERROR CODE [D130KB] (NEUTRAL SAFETY RELAY: DISCONNECTION (KB))
ERROR CODE [D161KA] (BACK UP ALARM RELAY: SHORT CIRCUIT (KA))
ERROR CODE [D161KB] (BACK UP ALARM RELAY: DISCONNECTION (KB))
ERROR CODE [D182KZ] (PREHEATER RELAY COIL: DISCONNECTION OR SHORT CIRCUIT (KZ))
ERROR CODE [D1D0KB] (ENGINE CONTROLLER LOAD POWER SUPPLY RELAY: SHORT CIRCUIT (KB))
ERROR CODE [D5ZFKA] (TRANSMISSION NEUTRAL SIGNAL: DISCONNECTION (KA))
ERROR CODE [D5ZFKB] (TRANSMISSION NEUTRAL SIGNAL: SHORT CIRCUIT (KB))
ERROR CODE [DAFRKR] (MONITOR PANEL CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR))
ERROR CODE [DAQ0KK] [DB30KK] (STEERING AND TRANSMISSION CONTROLLER: SOURCE VOLTAGE REDUCTION/INPUT (KK))
ERROR CODE [DAQ0KT] (STEERING AND TRANSMISSION CONTROLLER: ABNORMALITY IN CONTROLLER (KT))
ERROR CODE [DAQ5KK] [DB35KK] (STEERING AND TRANSMISSION CONTROLLER SENSOR 5 V POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK))
ERROR CODE [DAQ6KK] [DB36KK] (STEERING AND TRANSMISSION CONTROLLER SENSOR 24 V POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK))
ERROR CODE [DAQ9KQ] [DB39KQ] (STEERING AND TRANSMISSION CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ))
ERROR CODE [DB3RKR] (STEERING AND TRANSMISSION CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR))
ERROR CODE [DB20KQ] (ENGINE CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ))
ERROR CODE [DB20KT] (ENGINE CONTROLLER: ABNORMALITY IN CONTROLLER (KT))
ERROR CODE [DB22KK] (ENGINE CONTROLLER LOAD POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK))
ERROR CODE [DB29KQ] (ENGINE CONTROLLER TYPE SELECT: TYPE SELECT SIGNAL INCONSISTENCY (KQ))
ERROR CODE [DB2AMA] (FUEL INJECTION AMOUNT ADJUSTMENT SWITCH SIGNAL: MALFUNCTION (MA))
ERROR CODE [DB2RKR] (STEERING AND TRANSMISSION CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR))
ERROR CODE [DB2RMC] (ENGINE CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (MC))
ERROR CODE [DB30KK] [DAQ0KK] (STEERING AND TRANSMISSION CONTROLLER: SOURCE VOLTAGE REDUCTION/INPUT (KK))
ERROR CODE [DB35KK] [DAQ5KK] (STEERING AND TRANSMISSION CONTROLLER SENSOR 5 V POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK))
ERROR CODE [DB36KK] [DAQ6KK] (STEERING AND TRANSMISSION CONTROLLER SENSOR 24 V POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK))
ERROR CODE [DB39KQ] [DAQ9KQ] (STEERING AND TRANSMISSION CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ))
ERROR CODE [DD11KB] (STARTING SWITCH: SHORT CIRCUIT (KB))
ERROR CODE [DD12KA] (SHIFT UP SWITCH: DISCONNECTION (KA))
ERROR CODE [DD12KB] (SHIFT UP SWITCH: SHORT CIRCUIT (KB))
ERROR CODE [DD13KA] (SHIFT DOWN SWITCH: DISCONNECTION (KA))
ERROR CODE [DD13KB] (SHIFT DOWN SWITCH: SHORT CIRCUIT (KB))
ERROR CODE [DD14KA] [DDQ2KA] (PARKING LEVER SWITCH: DISCONNECTION (KA))
ERROR CODE [DD14KB] [DDQ2KB] (PARKING LEVER SWITCH: SHORT CIRCUIT (KB))
ERROR CODE [DDE2L6] (ENGINE OIL PRESSURE SWITCH: REFER TO TABLE (L6))
ERROR CODE [DDN7KA] (PITCH CONTROL SWITCH: DISCONNECTION (KA))
ERROR CODE [DDN7KB] (PITCH CONTROL SWITCH: SHORT CIRCUIT (KB))
ERROR CODE [DDQ2KA] [DD14KA] (PARKING LEVER SWITCH: DISCONNECTION (KA))
ERROR CODE [DDQ2KB] [DD14KB] (PARKING LEVER SWITCH: SHORT CIRCUIT (KB))
ERROR CODE [DGE2KX] (ENGINE WATER TEMPERATURE SENSOR (FOR HIGH TEMPERATURE): INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))
ERROR CODE [DGE3L6] (ENGINE WATER TEMPERATURE SENSOR (FOR LOW TEMPERATURE): SEE TABLE (L6))
ERROR CODE [DGE4KX] (FUEL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))
ERROR CODE [DGS1KX] (HYDRAULIC OIL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))
ERROR CODE [DH30KX] (BOOST PRESSURE SENSOR: INPUT IS OUT OF NORMAL RANGE (KX))
ERROR CODE [DH40KX] (COMMON RAIL PRESSURE SENSOR: INPUT IS OUT OF NORMAL RANGE (KX))
ERROR CODE [DK10KX] (FUEL CONTROL DIAL: INPUT IS OUT OF NORMAL RANGE (KX))
ERROR CODE [DK12KX] (DECELERATION POTENTIOMETER: INPUT IS OUT OF NORMAL RANGE (KX))
ERROR CODE [DK30KA] (STEERING POTENTIOMETER 1: DISCONNECTION (KA))
ERROR CODE [DK30KB] (STEERING POTENTIOMETER 1: SHORT CIRCUIT (KB))
ERROR CODE [DK30KX] (STEERING POTENTIOMETER: INPUT SIGNAL IS OUT OF RANGE (KX))
ERROR CODE [DK30KZ] (STEERING POTENTIOMETER: DISCONNECTION OR SHORT CIRCUIT (DOUBLE TROUBLE) (KZ))
ERROR CODE [DK30L8] (STEERING POTENTIOMETER 1: SEE TABLE (L8))
ERROR CODE [DK31KA] (STEERING POTENTIOMETER 2: SHORT CIRCUIT (KA))
ERROR CODE [DK31KB] (STEERING POTENTIOMETER 2: DISCONNECTION (KB))
ERROR CODE [DK40KA] BRAKE POTENTIOMETER: DISCONNECTION (KA))
ERROR CODE [DK40KB] BRAKE POTENTIOMETER: SHORT CIRCUIT (KB))
ERROR CODE [DK55KX] (FORWARD-REVERSE POTENTIOMETER: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))
ERROR CODE [DK55KZ] (FORWARD-REVERSE POTENTIOMETER: DISCONNECTION OR SHORT CIRCUIT (DOUBLE TROUBLE) (KZ))
ERROR CODE [DK55L8] (FORWARD-REVERSE POTENTIOMETER: SEE TABLE (L8))
ERROR CODE [DK56KA] (FORWARD-REVERSE POTENTIOMETER 1: SHORT CIRCUIT (KA))
ERROR CODE [DK56KB] (FORWARD-REVERSE POTENTIOMETER 1: DISCONNECTION (KB))
ERROR CODE [DK57KA] (FORWARD-REVERSE POTENTIOMETER 2: SHORT CIRCUIT (KA))
ERROR CODE [DK57KB] (FORWARD-REVERSE POTENTIOMETER 2: DISCONNECTION (KB))
ERROR CODE [DKH1KA] (PITCH ANGLE SENSOR: SHORT CIRCUIT (KA))
ERROR CODE [DKH1KB] (PITCH ANGLE SENSOR: DISCONNECTION (KB))
ERROR CODE [DLE3LC] (ENGINE NE SPEED SENSOR: SEE TABLE (LC))
ERROR CODE [DLF1KA] (TRANSMISSION OUTPUT SPEED SENSOR: DISCONNECTION (KA))
ERROR CODE [DLH1LC] (ENGINE SPEED SENSOR: SEE TABLE (LC))
ERROR CODE [DV00KB] (CAUTION BUZZER: SHORT CIRCUIT (KB))
ERROR CODE [DW5AKA] (PITCH CONTROL SOLENOID: DISCONNECTION (KA))
ERROR CODE [DW5AKB] (PITCH CONTROL SOLENOID: SHORT CIRCUIT (KB))
ERROR CODE [DW7BKA] (FAN REVERSE SOLENOID: DISCONNECTION (KA))
ERROR CODE [DW7BKB] (FAN REVERSE SOLENOID: SHORT CIRCUIT (KB))
ERROR CODE [DWN1KA] (HSS EPC SOLENOID RIGHT: DISCONNECTION (KA))
ERROR CODE [DWN1KB] (HSS EPC SOLENOID RIGHT: SHORT CIRCUIT (KB))
ERROR CODE [DWN2KA] (HSS EPC SOLENOID LEFT: DISCONNECTION (KA))
ERROR CODE [DWN2KB] (HSS EPC SOLENOID LEFT: SHORT CIRCUIT (KB))
ERROR CODE [DWN5KA] (FAN PUMP TVC SOLENOID: DISCONNECTION (KA))
ERROR CODE [DWN5KB] (FAN PUMP TVC SOLENOID: SHORT CIRCUIT (KB))
ERROR CODE [DXH4KA] (1ST CLUTCH ECMV: DISCONNECTION (KA))
ERROR CODE [DXH4KB] (1ST CLUTCH ECMV: SHORT CIRCUIT (KB))
ERROR CODE [DXH5KA] (2ND CLUTCH ECMV: DISCONNECTION (KA))
ERROR CODE [DXH5KB] (2ND CLUTCH ECMV: SHORT CIRCUIT (KB))
ERROR CODE [DXH6KA] (3RD CLUTCH ECMV: DISCONNECTION (KA))
ERROR CODE [DXH6KB] (3RD CLUTCH ECMV: SHORT CIRCUIT (KB))
ERROR CODE [DXH7KA] (REVERSE CLUTCH ECMV: DISCONNECTION (KA))
ERROR CODE [DXH7KB] (REVERSE CLUTCH ECMV: SHORT CIRCUIT (KB))
ERROR CODE [DXH8KA] (FORWARD CLUTCH ECMV: DISCONNECTION (KA))
ERROR CODE [DXH8KB] (FORWARD CLUTCH ECMV: SHORT CIRCUIT (KB))
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST
E-1 THE ENGINE DOES NOT START
E-2 THE PREHEATER DOES NOT OPERATE
E-3 THE MONITOR PANEL DOES NOT COME ON AT ALL WHEN STARTING SWITCH IS TURNED ON
E-4 WHEN THE STARTING SWITCH IS TURNED ON, THE MONITOR PANEL COMPLETELY REMAINS LIGHTED AND DOES NOT GO OUT
E-5 WHILE THE ENGINE IS OPERATING, THE BATTERY CHARGE LEVEL CAUTION LAMP FLASHES
E-6 WHILE THE ENGINE IS OPERATING, THE EMERGENCY WARNING ITEM FLASHES
E-7 WHILE THE PREHEATER IS OPERATING, THE PREHEATER PILOT LAMP DOES NOT COME ON
E-8 THE ENGINE WATER TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY
E-9 INDICATION OF THE POWER TRAIN TEMPERATURE GAUGE IS ABNORMAL
E-10 THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY
E-11 INDICATION OF THE FUEL GAUGE IS ABNORMAL
E-12 INDICATIONS OF GEAR SPEED AND ENGINE SPEED ARE ABNORMAL
E-13 INDICATION OF THE PRESET MODE SERVICE METER IS ABNORMAL
E-14 THE WARNING LAMP DOES NOT FLASH OR DOES NOT GO OUT
E-15 THE ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP
E-16 AUTO SHIFT DOWN IS NOT POSSIBLE OR IS NOT RELEASED
E-17 THE BUZZER CANCEL SWITCH DOES NOT WORK
E-18 THE INFORMATION SWITCH DOES NOT WORK
E-19 THE PRESET MODE DOES NOT OPERATE OR CANNOT BE RESET
E-20 THE MONITOR PANEL CANNOT BE SET IN THE SERVICE MODE OR CANNOT BE SET OUT OF THE SERVICE MODE
E-21 THE BACK UP ALARM DOES NOT SOUND
E-22 THE HEAD LAMP AND REAR LAMP DO NOT LIGHT UP
E-23 MALFUNCTION OF WIPERS
E-24 WASHING WATER DOES NOT COME OUT
E-25 THE AIR CONDITIONER DOES NOT OPERATE
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST
H-1 NO TRAVEL (NO DRAWBAR PULL)
H-2 MACHINE DOES NOT MOVE (AT 2ND OR 3RD SPEED)
H-3 MACHINE DOES NOT MOVE IN ANY SPEED RANGE
H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION FORWARD OR IN REVERSE
H-5 WHEN GEAR IS SHIFTED OR TRAVEL DIRECTION IS CHANGED, LARGE TIME LAG IS MADE
H-6 MACHINE DOES NOT TURN (NOT TURNED RIGHTWARD OR LEFTWARD)
H-7 STEERING SPEED OR POWER IS LOW
H-8 BRAKE DOES NOT WORK
H-9 OVERHEAT OF POWER TRAIN OIL TEMPERATURE
H-10 ABNORMAL SOUND COMES OUT FROM AROUND HSS AND WORK EQUIPMENT PUMP OR HSS MOTOR
H-11 ALL WORK EQUIPMENT SPEEDS ARE SLOW
H-12 WORK EQUIPMENT DOES NOT MOVE
H-13 BLADE LIFT SPEED IS SLOW OR LACKS POWER
H-14 BLADE TILT SPEED IS SLOW OR LACKS POWER
H-15 RIPPER LIFT SPEED IS SLOW OR LACKS POWER
H-16 EXCESSIVE HYDRAULIC DRIFT OF BLADE LIFT
H-17 EXCESSIVE HYDRAULIC DRIFT OF BLADE TILT
H-18 EXCESSIVE HYDRAULIC DRIFT OF RIPPER LIFT
TROUBLESHOOTING OF ENGINE SYSTEM (S-MODE)
METHOD OF USING TROUBLESHOOTING CHARTS
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)
S-2 ENGINE DOES NOT START
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW UP IS POOR)
S-4 ENGINE STOPS DURING OPERATIONS
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)
S-9 OIL BECOMES CONTAMINATED QUICKLY
S-10 FUEL CONSUMPTION IS EXCESSIVE
S-11 OIL IS IN COOLING WATER (OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN)
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)
S-15 ABNORMAL NOISE IS MADE
S-16 VIBRATION IS EXCESSIVE

30 DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
REMOVAL AND INSTALLATION OF ASSEMBLIES
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES
PRECAUTIONS WHEN CARRYING OUT OPERATION
SPECIAL TOOL LIST
SKETCHES OF SPECIAL TOOLS
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY
SPECIAL TOOL
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF ENGINE HOOD ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF NOZZLE TIP
SPECIAL TOOL
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL
SPECIAL TOOL
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF DAMPER ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL
SPECIAL TOOL
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY
SPECIAL TOOL
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY
SPECIAL TOOL
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF POWER TRAIN UNIT ASSEMBLY
REMOVAL
INSTALLATION
DISCONNECTION AND CONNECTION OF POWER TRAIN UNIT ASSEMBLY
DISCONNECTION
CONNECTION
DISASSEMBLY AND ASSEMBLY OF TORQFLOW TRANSMISSION ASSEMBLY
SPECIAL TOOL
DISASSEMBLY
ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF HSS ASSEMBLY
SPECIAL TOOL
DISASSEMBLY
ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY
DISASSEMBLY
ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY
DISASSEMBLY
ASSEMBLY
REMOVAL AND INSTALLATION OF SCAVENGING PUMP ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF HSS PUMP ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF COOLING FAN PUMP ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF POWER TRAIN AND LUBRICATING OIL PUMP ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF HSS MOTOR ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY
SPECIAL TOOL
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY
SPECIAL TOOL
DISASSEMBLY
ASSEMBLY
REMOVAL AND INSTALLATION OF TRACK FRAME ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF IDLER ASSEMBLY
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY
SPECIAL TOOL
DISASSEMBLY
ASSEMBLY
REMOVAL AND INSTALLATION OF RECOIL SPRING ASSEMBLY
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY
SPECIAL TOOL
DISASSEMBLY
ASSEMBLY
REMOVAL AND INSTALLATON OF TRACK ROLLER ASSEMBLY
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY
SPECIAL TOOL
DISASSEMBLY
ASSEMBLY
REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY
SPECIAL TOOL
DISASSEMBLY
ASSEMBLY
EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY
CHECK BEFORE EXPANDING TRACK SHOE ASSEMBLY
EXPANSION OF TRACK SHOE ASSEMBLY (ORDINARY)
EXPANSION OF TRACK SHOE ASSEMBLY (WHEN TRACK FRAME HAS INTERNAL TROUBLE)
INSTALLATION
WHOLE DISASSEMBLY AND WHOLE ASSEMBLY OF TRACK SHOE ASSEMBLY
SPECIAL TOOL
WHOLE DISASSEMBLY
WHOLE ASSEMBLY
FIELD DISASSEMBLY AND ASSEMBLY OF ONE LINK
SPECIAL TOOL
DISASSEMBLY
ASSEMBLY
REMOVAL AND INSTALLATION OF PIVOT SHAFT ASSEMBLY
SPECIAL TOOL
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF EQUALIZER BAR ASSEMBLY
SPECIAL TOOL
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY OF EQUALIZER BAR SIDE BUSHING
DISASSEMBLY
ASSEMBLY
REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY
ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
SPECIAL TOOL
DISASSEMBLY
ASSEMBLY
REMOVAL AND INSTALLATION OF BLADE ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF ROPS GUARD
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS)
SPECIAL TOOL
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY
SPECIAL TOOL
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF STEERING AND TRANSMISSION CONTROLLER ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF ENGINE CONTROLLER ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF FAN DRIVE ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF FAN MOTOR ASSEMBLY
REMOVAL
INSTALLATION

90 OTHERS
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
WORK EQUIPMENT HYDRAULIC CIRUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM (1/6)
ELECTRICAL CIRCUIT DIAGRAM (2/6)
ELECTRICAL CIRCUIT DIAGRAM (3/6)
ELECTRICAL CIRCUIT DIAGRAM (4/6)
ELECTRICAL CIRCUIT DIAGRAM (5/6)
ELECTRICAL CIRCUIT DIAGRAM (6/6)
CAB ELECTRICAL CIRCUIT DIAGRAM

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