Komatsu D85EX-15, D85PX-15 Bulldozer Shop Manual - SEBM029105

This complete service repair workshop manual PDF download for the D85EX-15, D85PX-15 Komatsu Bulldozer 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 D85EX-15 Bulldozer
Serial Numbers : 10001 and up

Komatsu D85PX-15 Bulldozer
Serial Numbers : 1001 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 : SEBM029105
Total Pages : 924


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

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

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

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COVER
CONTENTS
01 GENERAL
SPECIFICATION DRAWING
SPECIFICATIONS
WEIGHT TABLE
TABLE OF FULE, COOLANT AND LUBRICANT

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

20 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGING
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 FORM FUEL SYSTEM
MEASURING FUEL PRESSURE
BLEEDING AIR FROM FUEL CIRCUIT
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
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
TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF BLAND AND RIPPER
MEASURING INTERNAL LEAKAGE OF WORK EQUIPMENT CYLINDER
BLEEDING AIR FROM WORK EQUIPMENT CYLINDER
RELEASING RESIDUAL PRESSURE IN WORK EQUIPMENT CYLINDER
ADJUSTING SAFETY LOCK LEVER
MEASURING FAN MOTOR SPEED
MEASURING FAN PUMP CIRCUIT PRESSURE
BLEEDING AIR FORM FAN PUMP
ADJUSTING BLADE
TESTING AND ADJUSTING OF 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 CHECK SHEET
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
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 [1500LO] (TRANSMISSION CLUTCH:SEE THE LIST.(L1))
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 CLUTCH: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 IN WIRING (KA))
ERROR CODE [AD11KB] (FUEL SUPPLY PUMP SOLENOID 1:SHORT CIRCUIT (KB))
ERROR CODE [AD51KA] (FUEL SUPPLY PUMP SOLENOID 2:DISCONNECTION IN WIRING (KA))
ERROR CODE [AD51KB] (FUEL SUPPLY PUMP SOLENOID 2:DISCONNECTION IN SHORT (KB))
ERROR CODE [ADA1KA] (NO.1 INJECTOR SOLENOID:DISCONNECTION IN WIRING (KA))
ERROR CODE [ADAZKB] (NO.1.2,AND 3 INJECTOR SOLENOIDS:SHORT(KB))
ERROR CODE [ADB1KA] (NO.2 INJECTOR SOLENOID:DISCONNECTION IN WIRING(KA))
ERROR CODE [ADC1KA] (NO.3 INJECTOR SOLENOID:DISCONNECTION IN WIRING(KA))
ERROR CODE [ADD1KA] (NO.4 INJECTOR SOLENOID:DISCONNECTION IN WIRING(KA))
ERROR CODE [ADDZKB] (NO.4.5,AND 6 INJECTOR SOLENOIDS:SHORT(KB))
ERROR CODE [ADE1KA] (NO.5 FUEL INJECTOR SOLENOID:DISCONNECTION(KA))
ERROR CODE [ADF1KA] (NO.6 FUEL 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@BCZK] (RADIATOR COOLANT:LEVEL REDUCTION (ZK))
ERROR CODE [B@CENS] (POWER TRAN OIL: OVERHEAT (NS))
ERROR CODE [B@HANS] (HYDRAULIC OIL: OVERHEAT (NS))
ERROR CODE [D110KA] (BATTERY RELAY:DISCONNECTION(KA))
ERROR CODE [D110KB] (BATTERY RELAY:SHORT CIRCUIT(KB))
ERROR CODE [D13OKA] (NEUTRAL SAFETY RELAY: DISCONNECTION (KA))
ERROR CODE [D13OKB] (NEUTRAL SAFETY RELAY: SHORT CIRCUIT (KB))
ERROR CODE [D161KA] (BACK-UP ALARM RELAY: DISCONNECTION (KA))
ERROR CODE [D161KB] (BACK-UP ALARM RELAY:SHORT CIRCUIT (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] [DB30KT] (STEERING AND TRANSMISSION CONTROLLER:ABNORMALITY IN CONTROLLER(KT))
ERROR CODE [DAQ5KK] [DB35KK] (STEERING AND TRANSMISSION CONTROLLER SENSOR 5V POWER SUPPLY:SOURCE VOLTAGE REDUCTION/INPUT (KK))
ERROR CODE [DAQ6KK] [DB36KK] (STEERING AND TRANSMISSION CONTROLLER SENSOR POWER SUPPLY:SOURCE VOLTAGE REDUCTION/INPUT (KK))
ERROR CODE [DAQ9KQ] [DB39KQ] (STEERING AND TRANSMISSION CONTROLLER TYPE COLLATION:TYPE SELECT SIGNAL INSISTENCY (KQ))
ERROR CODE [DAQRKR] [DB3RKR] (STEERING AND TRANSMISSION CONTROLLER CAN COMMUNICATION:DEFECTIVE COMMUNICATION (KR))
ERROR COED [DB20KQ] (ENGINE CONTROLLER TYPE COLLATION:TYPE SELECT CODE 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] (ENGINE CONTROLLER CAN COMMUNICATION :DEFECTIVE COMMUNICATION (KR))
ERROR CODE [DB2RMC] (STEERING AND TRANSMISSION CONTROLLER CAN COMMUNICATION:DEFECTIVE COMMUNICATION (MC))
ERROR CODE [DB30KK] [DAQ0KK] (STEERING AND TRANSMISSION CONTROLLER:SOURCE VOLTAGE REDUCTION/INPUT (KK)
ERROR CODE [DB30KT] [DAQ0KT] (STEERING AND TRANSMISSION CONTROLLER:ABNORMALITY IN CONTROLLER (KT)
ERROR CODE [DB35KK] [DAQ5KK] (STEERING AND TRANSMISSION CONTROLLER ENSOR 5V POWER SUPPLY:SOURCE VOLTAGE REDUCTION/INPUT (KK)
ERROR CODE [DB36KK] [DAQ6KK] (STEERING AND TRANSMISSION CONTROLLER SENSOR 24V POWER SUPPLY:SOURCE VOLTAGE REDUCTION/INPUT (KK)
ERROR CODE [DB39KQ] [DAQ9KQ] (STEERING AND TRANSMISSION CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ)
ERROR CODE [DB3RKR] [DAQRKR] (STEERING AND TRANSMISSION CONTROLLER CAN COMMUNICATION:DEFECTIVE COMMUNICATION (KR)
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 [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 [DH21KA] (HSS AND WORK EQUIPMENT PUMP OIL PRESSURE SENSOR:DISCONNECTION (KA))
ERROR CODE [DH21KB] (HSS AND WORK EQUIPMENT PUMP OIL PRESSURE SENSOR:SHORT CIRCUIT (KB))
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 NORMAL RANGE (KX))
ERROR CODE [DK30L8] (STEERING POTENTIOMETER 1 : SEE THE TABLE(L8))
ERROR CODE [DK31KA] (STEERING POTENTIOMETER 2 : DISCONNECTION (KA))
ERROR CODE [DK31KB] (STEERING POTENTIOMETER 2 : SHORT CIRCUIT (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 (KZ))
ERROR CODE [DK55L8] (FORWARD-REVERSE POTENTIOMETER: SEE THE TABLE (L8))
ERROR CODE [DK56KA] (FORWARD-REVERSE POTENTIOMETER 1 :DISCONNECTION (KA))
ERROR CODE [DK56KB] (FORWARD-REVERSE POTENTIOMETER 1 :SHORT CIRCUIT (KB))
ERROR CODE [DK57KA] (FORWARD-REVERSE POTENTIOMETER 2 :DISCONNECTION (KA))
ERROR CODE [DK57KB] (FORWARD-REVERSE POTENTIOMETER 2 :SHORT CIRCUIT (KB))
ERROR CODE [DKH1KA] (PITCH ANGLE SENSOR : DISCONNECTION (KA))
ERROR CODE [DKH1KB] (PITCH ANGLE SENSOR : SHORT CIRCUIT (KB))
ERROR CODE [DLE3LC] (ENGINE NE SPEED SENSOR :SEE TABLE (LC))
ERROR CODE [DLF1KA] (TRANSMISSION BEVEL SPEED SENSOR :DISCONNECTION (KA))
ERROR CODE [DLH1LC] (ENGINE G SPEED SENSOR :SEE THE TABLE (LC))
ERROR CODE [DV00KB] (CAUTION BUZZER: 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 LEFT : DISCONNECTION (KA))
ERROR CODE [DWN1KB] (HSS EPC SOLENOID LEFT : SHORT CIRCUIT (KB))
ERROR CODE [DWN2KA] (HSS EPC SOLENOID RIGHT : DISCONNECTION (KA))
ERROR CODE [DWN2KB] (HSS EPC SOLENOID RIGHT : SHORT CIRCUIT (KB))
ERROR CODE [DWN5KA] (FAN PUMP SOLENOID : DISCONNECTION (KA))
ERROR CODE [DWN5KB] (FAN PUMP SOLENOID :SHORT CIRCUIT (KB))
ERROR CODE [DXA0KA] (HSS・HYDRAULIC PUMP TVC SOLENOID: DISCONNECTION (KA))
ERROR CODE [DXA0KB] (HSS・ HYDRAULIC 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.(MANUAL PREHEATING FUNCTION)
E-3 THE MONITOR PANEL DOES NOT COME ON AT ALL WHEN THE STARTING SWITCH IS TURNED ON.
E-4 WHEN THE STARTING SWITCH IS TURNED ON,THE MONITOR PANEL COMPLETELY REMAINS LIGHTED AND DOES NOT GO OUT.
E-5 WHEN THE STARTING SWITCH IS TURNED OD,THE RADIATOR WATER LEVEL CAUTION LAMP FLASHES
E-6 WHILE THE ENGINE IS OPERATING, THE BATTERY CHARGE LEVEL CAUTION LAMP FLASHES
E-7 WHILE THE ENGINE IS OPERATING, THE EMERGENCY WARNING ITEM FLASHES
E-8 WHILE THE PREHEATER IS OPERATING , THE PREHEATING PILOT LAMP DOES NOT COME ON
E-9 THE ENGINE WATER TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY
E-10 INDICATION OF THE POWER TRAIN TEMPERATURE GAUGS IS ABNORMAL
E-11 THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY
E-12 INDICATION OF THE FUEL GAUGES IS ABNORMAL
E-13 INDICATIONS OF GAES SPEED AND ENGINE SPEED ARE ABNORMAL
E-14 INDICATION OF THE PRESET MODE SERVICE METER IS ABNORMAL
E-15 THE WARNING LAMP DOES NOT FLASH OR DOES NOT GO OUT
E-16 THE ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP
E-17 AUTO SHIFT DOWN IS NOT POSSIBLE OR IS NOT RELEASED
E-18 THE BUZZER CANCEL SWITCH DOES NOT WORK
E-19 THE INFORMATION SWITCH DOES NOT WORK
E-20 THE MANUAL MODE DOES NOT OPERATE OR CANNOT BE RESET
E-21 THE MONITOR PANEL CANNOT BE SET IN THE SERVICE MODE
E-22 THE BACK-UP ALARM DOES NOT SOUND
E-23 THE HEAD LAMP, REAR LAMP, AND RIPPER POINT LAMP DO NOT LIGHT UP
E-24 MALFUNCTION OF WIPERS
E-25 WASHING WATER DOES NOT COME OUT
E-26 THE AIR CONDITIONER DOES NOT OPERATE
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST
H-1 NO TRAVEL POWER (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 REVERES
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 BLAND LIFT SPEED IS SLOW OR LACKS POWER
H-14 BLAND TILT SPEED IS SLOW OR LACKS POWER
H-15 RIPPER LIFT SPEED IS SLOW OR LACKS POWER
H-16 EXCESSIVE HYDRAULIC DRIFT OR BLADE LIFT
H-17 EXCESSIVE HYDRAULIC DRIFT OR 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 COMBUSTION)
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE )
S-9 OIL BECOMES CONTAMINATED QUICKLY
S-10 FUEL CONSUMPTION IS EXCESSIVE
S-11 OIL IS IN 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
PRECAUTIONS WHEN PERFORMING OPERATION
SPECIAL TOOL LIST
SKETCH OF SPECIAL TOOL
FUEL SUPPLY PUMP
SPECIAL TOOLS
REMOVAL
INSTALLATION
FUEL INJECTOR
REMOVAL
INSTALLATION
NOZZLE TIP
SPECIAL TOOL
REMOVAL
INSTALLATION
ENGINE FRONT SEAL
SPECIAL TOOLS
REMOVAL
INSTALLATION
ENGINE REAR SEAL
SPECIAL TOOLS
REMOVAL AND INSTALLATION
ENGINE CYLINDER HEAD
SPECIAL TOOLS
REMOVAL
INSTALLATION
ENGINE OIL PAN
REMOVAL
INSTALLATION
FUEL TANK
REMOVAL
INSTALLATION
RADIATOR
REMOVAL
INSTALLATION
ENGINE
SPECIAL TOOLS
REMOVAL
INSTALLATION
DAMPER
REMOVAL
INSTALLATION
SPECIAL TOOLS
DISASSEMBLY
ASSEMBLY
POWER TRAIN UNIT
REMOVAL
INSTALLATION
DISCONNECTION
CONNECTION
TORQFLOW TRANSMISSION
SPECIAL TOOLS
DISASSEMBLY
ASSEMBLY
HSS
SPECIAL TOOLS
DISASSEMBLY
ASSEMBLY
PTO
DISASSEMBLY
ASSEMBLY
TORQUE CONVERTER
DISASSEMBLY
ASSEMBLY
SCAVENGING PUMP
REMOVAL AND INSTALLATION
HSS AND WORK EQUIPMENT PUMP
REMOVAL
INSTALLATION
FAN PUMP
REMOVAL AND INSTALLATION
POWER TRAIN AND LUBRICATING OIL PUMP
REMOVAL AND INSTALLATION
HSS MOTOR
REMOVAL AND INSTALLATION
FINAL DRIVE
SPECIAL TOOLS
REMOVAL
INSTALLATION
SPECIAL TOOLS
DISASSEMBLY
ASSEMBLY
TRACK FRAME
REMOVAL
INSTALLATION
IDLER
REMOVAL AND INSTALLATION
SPECIAL TOOLS
DISASSEMBLY
ASSEMBLY
RECOIL SPRING
REMOVAL
INSTALLATION
SPECIAL TOOLS
DISASSEMBLY
ASSEMBLY
TRACK ROLLER
REMOVAL AND INSTALLATION
SPECIAL TOOLS
DISASSEMBLY
ASSEMBLY
CARRIER ROLLER
REMOVAL AND INSTALLATION
SPECIAL TOOLS
DISASSEMBLY
ASSEMBLY
TRACK SHOE
CHECK BEFORE EXPANDING TRACK SHOE ASSEMBLY
EXPANSION TRACK SHOE ASSEMBLY (ORDINARY)
EXPANSION TRACK SHOE ASSEMBLY (WHEN TRACK FRAME HAS INTERNAL TROUBLE)
INSTALLATION
SPECIAL TOOLS
WHOLE DISASSEMBLY
WHOLE ASSEMBLY
DIMENSIONS TABLE OF FITTING JIG OF LINK PRESS
DISASSEMBLY OF 1 LINK IN THE FIELD
DISASSEMBLY AND ASSEMBLY OF MASTER LINK
PIVOT SHAFT
REMOVAL AND INSTALLATION
EQUALIZER BAR
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT CONTROL VALVE
REMOVAL
INSTALLATION
ASSEMBLY
HYDRAULIC CYLINDER
SPECIAL TOOLS
DISASSEMBLY
ASSEMBLY
BLADE
REMOVAL
INSTALLATION
RIPPER
DISASSEMBLY
ASSEMBLY
ROPS GUARD
REMOVAL AND INSTALLATION
OPERATOR'S CAB
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS)
SPECIAL TOOLS
REMOVAL
INSTALLATION
FLOOR FRAME
SPECIAL TOOLS
REMOVAL
INSTALLATION
ENGINE CONTROLLER
REMOVAL AND INSTALLATION
STEERING AND TRANSMISSION CONTROLLER
REMOVAL AND INSTALLATION
ENGINE HOOD
REMOVAL AND INSTALLATION
FAN DRIVE
REMOVAL
INSTALLATION
FAN MOTOR
REMOVAL AND INSTALLATION

90 OTHERS
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (1/3)
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (2/3)
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (3/3)
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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