Index

00 Index and
foreword .......................................................................................................................00-
1
Index ...................................................................................................................................
......00-2
Foreword, safety and general
information ................................................................................... 00-15
Important safety notice .......................................................................................................
00-15
How to read the shop manual..............................................................................................
00-20
Explanation of terms for maintenance
standard .................................................................... 00-22
Handling of fuel system
devices .......................................................................................... 00-24
Handling of intake system
parts........................................................................................... 00-25
Handling of hydraulic
equipment.......................................................................................... 00-26
Method of disconnecting and connecting push-pull type
coupler............................................. 00-28
Handling of electrical
equipment.......................................................................................... 00-31
How to read electric wire
code............................................................................................. 00-39
Precautions when performing
operation ............................................................................... 00-42
Standard tightening torque table..........................................................................................
00-45
List of abbreviation .............................................................................................................
00-49
Conversion table................................................................................................................
00-53
01
Specification........................................................................................................................
.........01-2
Specifications.......................................................................................................................
......01-3
Specification
drawing ...........................................................................................................01-3
Specifications ......................................................................................................................
01-6
Weight table ......................................................................................................................
01-30
Table of fuel, coolant and
lubricants ..................................................................................... 01-38
10 Structure and
function ...................................................................................................................10-3
Engine and cooling
system..........................................................................................................10-4
Engine related
parts .............................................................................................................10-4
Damper...............................................................................................................................
10-6
Cooling
system ....................................................................................................................10-8
Cooling fan pump...............................................................................................................
10-10
Cooling fan motor...............................................................................................................
10-24
Power
train............................................................................................................................... 10-
32
Power train ........................................................................................................................
10-32
HSS system ......................................................................................................................
10-35
Overall drawing of power train
unit ....................................................................................... 10-37
Power train mount ..............................................................................................................
10-39
Power train hydraulic piping
drawing.................................................................................... 10-40
Transmission, steering, and brake
control ............................................................................ 10-42
Universal joint ....................................................................................................................
10-44
Torque converter and PTO..................................................................................................
10-45
Transmission .....................................................................................................................
10-51
Transmission control valve..................................................................................................
10-64
Forward and reverse clutch ECMV and gear shift clutch
ECMV.............................................. 10-66
Lockup clutch ECMV..........................................................................................................
10-73
Main relief valve and torque converter relief
valve ................................................................. 10-77
Transmission lubricating oil relief
valve ................................................................................ 10-80
Bevel gear shaft, HSS, and brake........................................................................................
10-81
Brake valve .....................................................................................................................
10-102
Final drive .......................................................................................................................
10-106
Undercarriage and
frame......................................................................................................... 10-110
Main frame ......................................................................................................................
10-110
Suspension .....................................................................................................................
10-112
Track frame and idler cushion ...........................................................................................
10-114
Hydraulic
system .................................................................................................................... 10-116
Hydraulic piping drawing...................................................................................................
10-116
Work equipment control ....................................................................................................
10-120
Hydraulic tank..................................................................................................................
10-122
CLSS..............................................................................................................................
10-124
Scavenging pump ............................................................................................................
10-127

Steering lubricating oil pump and power train

pump............................................................. 10-128
HSS pump.......................................................................................................................
10-129
HSS motor ......................................................................................................................
10-150
Control valve ...................................................................................................................
10-159
Blade PPC valve..............................................................................................................
10-186
Ripper PPC valve.............................................................................................................
10-194
Quick drop valve ..............................................................................................................
10-198
Work equipment lock solenoid
valve .................................................................................. 10-201
Pitch selector solenoid valve .............................................................................................
10-206
Angle control EPC valve ...................................................................................................
10-207
Hydraulic oil cooler bypass valve.......................................................................................
10-212
PPC accumulator .............................................................................................................
10-213
Work
equipment ..................................................................................................................... 10-
214
Work equipment...............................................................................................................
10-214
Ripper.............................................................................................................................
10-217
Piston valve.....................................................................................................................
10-218
Cab and its
attachments.......................................................................................................... 10-220
ROPS cab .......................................................................................................................
10-220
Cab mount ......................................................................................................................
10-222
Electrical
system .................................................................................................................... 10-223
Engine control system ......................................................................................................
10-223
Cooling system control system..........................................................................................
10-226
Palm command control system..........................................................................................
10-228
Machine monitor system...................................................................................................
10-232
KOMTRAX system...........................................................................................................
10-252
System component part....................................................................................................
10-255
Sensors ..........................................................................................................................
10-270
20 Standard value
table .....................................................................................................................20-2
Standard service value
table........................................................................................................20-3
Standard value table for
engine .............................................................................................20-3
Standard value table for
machine ..........................................................................................20-5
30 Testing and
adjusting ....................................................................................................................30-3
General information on testing and
adjusting.................................................................................30-4
Tools for testing, adjusting, and
troubleshooting......................................................................30-4
Engine and cooling
system..........................................................................................................30-8
Testing engine
speed ...........................................................................................................30-8
Measuring boost pressure...................................................................................................
30-10
Measuring exhaust gas
temperature .................................................................................... 30-11
Measuring exhaust gas color...............................................................................................
30-13
Measuring and adjusting valve
clearance............................................................................. 30-15
Measuring compression pressure........................................................................................
30-17
Measuring blowby pressure ................................................................................................
30-19
Measuring engine oil pressure.............................................................................................
30-21
Measuring EGR valve and KVGToil
pressure....................................................................... 30-22
Releasing remaining pressure from fuel
system.................................................................... 30-23
Measuring fuel pressure .....................................................................................................
30-24
Measuring fuel delivery, return rate and
leakage ................................................................... 30-31
Handling cylinder cutout mode
operation.............................................................................. 30-35
Handling no injection cranking
operation .............................................................................. 30-36
Bleeding air from fuel
system .............................................................................................. 30-37
Checking fuel circuit for
leakage .......................................................................................... 30-38
Testing and adjusting air conditioner compressor belt
tension ................................................ 30-39
Replacing alternator belt .....................................................................................................
30-40
Adjusting fuel dial and decelerator
pedal .............................................................................. 30-41
Power train
system ................................................................................................................... 30-43
Measuring power train oil
pressure ...................................................................................... 30-43
Adjusting transmission output shaft speed sensor (replacement
procedure) ............................ 30-48
Simple test procedure for brake
performance ....................................................................... 30-49
Adjusting brake pedal .........................................................................................................
30-50Adjusting parking brake
lever .............................................................................................. 30-52
Retrieval of disabled machine using brake release
device ..................................................... 30-54
Undercarriage and
frame........................................................................................................... 30-57
Adjusting idler clearance.....................................................................................................
30-57
Checking sprocket wear .....................................................................................................
30-58
Checking and adjusting track shoe
tension........................................................................... 30-59
Hydraulic
system ...................................................................................................................... 30-60
Releasing remaining pressure in work equipment
cylinder ..................................................... 30-60
Measuring and adjusting work equipment and HSS oil
pressure............................................. 30-61
Measuring source pressure of control
circuit ......................................................................... 30-64
Measuring PPC valve output
pressure ................................................................................. 30-65
Adjusting play of work equipment PPC
valve ........................................................................ 30-68
Isolating the parts causing hydraulic drift in blade and
ripper .................................................. 30-70
Measure internal oil leakage of work equipment
cylinder........................................................ 30-71
Checking fan speed ...........................................................................................................
30-72
Measuring fan circuit oil
pressure ........................................................................................ 30-73
Bleeding air from hydraulic
circuit ........................................................................................ 30-74
Work
equipment .......................................................................................................................
30-76
Adjusting work equipment lock
lever .................................................................................... 30-76
Adjustment of straight tilt
dozer............................................................................................ 30-77
Cab and its
attachments............................................................................................................ 30-79
Adjusting operator's cab .....................................................................................................
30-79
Adjusting play of blade center
ball........................................................................................ 30-82
Electrical
system ...................................................................................................................... 30-83
Special functions of machine
monitor................................................................................... 30-83
Handling voltage circuit of engine
controller........................................................................ 30-143
Adjustment method when controller has been
replaced ....................................................... 30-144
Testing diodes .................................................................................................................
30-146
Pm
clinic ................................................................................................................................
30-147
Pm Clinic service .............................................................................................................
30-147
Pm Clinic check sheet ......................................................................................................
30-153
40
Troubleshooting...................................................................................................................
.........40-8
General information on
troubleshooting ........................................................................................40-9
Instruction on
troubleshooting ...............................................................................................40-9
How to proceed
troubleshooting .......................................................................................... 40-11
Check before troubleshooting..............................................................................................
40-12
Testing procedure before
troubleshooting............................................................................. 40-14
Classification and procedure for
troubleshooting................................................................... 40-23
Classification and procedures for troubleshooting
numbers.................................................... 40-25
Information mentioned in troubleshooting
table ..................................................................... 40-28
Troubleshooting method for open circuit in wiring harness of pressure sensor
system.............. 40-30
Connector list and layout ....................................................................................................
40-32
Connector contact
identification........................................................................................... 40-45
T-branch box and T-branch adapter
table ............................................................................. 40-82
Fuse locations table ...........................................................................................................
40-88
Precautions for cleaning and replacing KDPF (KCSF,
KDOC) ................................................ 40-91
Troubleshooting by failure code (Display of
code) ........................................................................ 40-93
Failure codes table.............................................................................................................
40-93
Failure code [1500L0] Transmission
clutch:Abnormal.......................................................... 40-104
Failure code [15SAL1] Forward clutch:Fill
High................................................................... 40-105
Failure code [15SALH] Forward clutch:Fill
Low................................................................... 40-107
Failure code [15SBL1] Reverse clutch:Fill
High................................................................... 40-109
Failure code [15SBLH] Reverse clutch:Fill
Low....................................................................40-111
Failure code [15SEL1] Speed 1st clutch:Fill
High ................................................................ 40-113
Failure code [15SELH] Speed 1st clutch:Fill
Low ................................................................ 40-115
Failure code [15SFL1] Speed 2nd clutch:Fill
High ............................................................... 40-117
Failure code [15SFLH] Speed 2nd clutch:Fill
Low ............................................................... 40-119
Failure code [15SGL1] Speed 3rd clutch:Fill
High ............................................................... 40-121
Failure code [15SGLH] Speed 3rd clutch:Fill
Low................................................................ 40-123Failure code [15SJL1] L/U :Fill
Hihg ................................................................................... 40-125
Failure code [15SJLH] L/U :Fill
low .................................................................................... 40-127
Failure code [1800MW] P/L
clutch:Slip ............................................................................... 40-129
Failure code [879AKA] Air Conditioner Inner Sensor
Disconnection...................................... 40-130
Failure code [879AKB] Air Conditioner Inner Sensor
Disconnection...................................... 40-131
Failure code [879BKA] Air Conditioner Outside Air Sensor
Disconnection............................. 40-132
Failure code [879BKB] Air Conditioner Outside Air Sensor
Disconnection............................. 40-133
Failure code [879CKA] Ventilating Sensor
Disconnection .................................................... 40-134
Failure code [879CKB] Ventilating Sensor Short
Circuit ....................................................... 40-135
Failure code [879DKZ] Sunlight Sensor Open Or Short
Circuit ............................................. 40-136
Failure code [879EMC] Ventilation
Abnormal...................................................................... 40-137
Failure code [879FMC] A/M Damper
Abnormal................................................................... 40-138
Failure code [879GKX] Refrigerant
Abnormality.................................................................. 40-139
Failure code [989L00] Engine Controller Lock Caution
1...................................................... 40-140
Failure code [989M00] Engine Controller Lock Caution
2..................................................... 40-141
Failure code [989N00] Engine Controller Lock Caution
3 ..................................................... 40-142
Failure code [A1U0N3]: KDPF Dry Request (HC
Release)................................................... 40-143
Failure code [A1U0N4] KDPF Dry Request (HC
Release).................................................... 40-145
Failure code [AA10NX] Air Cleaner
Clogging...................................................................... 40-147
Failure code [AB00KE] Battery Charge Voltage
Low ........................................................... 40-148
Failure code [B@BAZG] Engine Oil Pressure
Low .............................................................. 40-150
Failure code [B@BCNS] Eng Water
Overheat .................................................................... 40-151
Failure code [B@CENS] P/L Oil
Overheat.......................................................................... 40-152
Failure code [B@HANS] Hyd Oil
Overheat ......................................................................... 40-153
Failure code [CA115] Eng Ne and Bkup Speed Sens
Error .................................................. 40-154
Failure code [CA122] Chg Air Press Sensor High
Error ....................................................... 40-155
Failure code [CA123] Chg Air Press Sensor Low
Error ........................................................ 40-157
Failure code [CA131] Throttle Sensor High
Error................................................................. 40-159
Failure code [CA132] Throttle Sensor Low
Error ................................................................. 40-161
Failure code [CA144] Coolant Temp Sens High
Error .......................................................... 40-163
Failure code [CA145] Coolant Temp Sens Low
Error ........................................................... 40-165
Failure code [CA153] Chg Air Temp Sensor High
Error........................................................ 40-167
Failure code [CA154] Chg Air Temp Sensor Low
Error......................................................... 40-169
Failure code [CA187] Sensor 2 Supply Volt Low
Error ......................................................... 40-171
Failure code [CA234] Eng Overspeed................................................................................
40-173
Failure code [CA221] Ambient Press Sens High
Error ......................................................... 40-174
Failure code [CA222] Ambient Press Sens Low
Error .......................................................... 40-176
Failure code [CA227] Sens Supply 2 Volt High
Error ........................................................... 40-178
Failure code [CA238] Ne Speed Sens Supply Volt
Error ...................................................... 40-179
Failure code [CA239] Ne Speed Sens Supply Volt High
Error............................................... 40-180
Failure code [CA271] IMV/PCV1 Short
Error ...................................................................... 40-182
Failure code [CA272] IMV/PCV1 Open
Error ...................................................................... 40-184
Failure code [CA281] Pump Press Balance
Error ................................................................ 40-186
Failure code [CA295] Ambient Pressure Sensor In Range
Error ........................................... 40-187
Failure code [CA322] Inj #1(L#1) Open/Short
Error ............................................................. 40-188
Failure code [CA323] Inj #5 (L#5) Open/Short
Error ............................................................ 40-190
Failure code [CA324] Inj #3(L#3) Open/Short
Error ............................................................. 40-192
Failure code [CA325] Inj #6 (L#6) Open/Short
Error ............................................................ 40-194
Failure code [CA331] Inj #2(L#2) Open/Short
Error ............................................................. 40-196
Failure code [CA332] Inj #4 (L#4) Open/Short
Error ............................................................ 40-198
Failure code [CA343] ECM Critical Internal
Failure.............................................................. 40-200
Failure code [CA351] Injectors Drive Circuit
Error ............................................................... 40-201
Failure code [CA352] Sensor 1 Supply Volt Low
Error ......................................................... 40-202
Failure code [CA356] Mass Air Flow Sensor High
Error ....................................................... 40-204
Failure code [CA357] Mass Air Flow Sensor Low
Error........................................................ 40-206
Failure code [CA386] Sens Supply 1 Volt High
Error ........................................................... 40-208
Failure code [CA428] Water in Fuel Sensor High
Error ........................................................ 40-209
Failure code [CA429] Water in Fuel Sensor Low
Error ......................................................... 40-211
Failure code [CA435] Eng Oil Press SW
Error .................................................................... 40-213
Failure code [CA441] Battery Voltage Low
Error ................................................................. 40-214
Failure code [CA442] Battery Voltage High
Error................................................................. 40-216
Failure code [CA449] Rail Press Very High
Error................................................................. 40-217
Failure code [CA451] Rail Press Sensor High
Error............................................................. 40-219
Failure code [CA452] Rail Press Sensor Low
Error ............................................................. 40-221
Failure code [CA488] Chg Air Temp High Torque
Derate...................................................... 40-223
Failure code [CA515] Rail Press Sens Sup Volt High
Error .................................................. 40-224
Failure code [CA516] Rail Press Sens Sup Volt Low
Error ................................................... 40-226
Failure code [CA553] Rail Press High
Error ........................................................................ 40-228
Failure code [CA555] Crankcase Press High Error
2 ........................................................... 40-229
Failure code [CA556] Crankcase Pressure High Error
3 ...................................................... 40-230
Failure code [CA559] Rail Pump Press Low
Error ............................................................... 40-231
Failure code [CA595] Turbocharger Speed High Error
2 ...................................................... 40-235
Failure code [CA687] Turbo Speed Low
Error..................................................................... 40-236
Failure code [CA689] Eng Ne Speed Sensor
Error .............................................................. 40-238
Failure code [CA691] Intake Air Temp Sens High
Error........................................................ 40-242
Failure code [CA692] Intake Air Temp Sens Low
Error......................................................... 40-244
Failure code [CA697] ECM Internal Temp Sensor High
Error................................................ 40-246
Failure code [CA698] ECM Internal Temp Sensor Low
Error ................................................ 40-247
Failure code [CA731] Eng Bkup Speed Sens Phase
Error ................................................... 40-248
Failure code [CA778] Eng Bkup Speed Sensor
Error........................................................... 40-250
Failure code [CA1117] Engine Controller Partial Data Lost
Error........................................... 40-255
Failure code [CA1664] KDOC
Malfunction.......................................................................... 40-256
Failure code [CA1691] Regeneration
Ineffective ................................................................. 40-258
Failure code [CA1695] Sensor 5 Supply Volt High
Error....................................................... 40-261
Failure code [CA1696] Sensor 5 Supply Volt Low
Error ....................................................... 40-262
Failure code [CA1843] Crankcase Press Sens High
Error.................................................... 40-264
Failure code [CA1844] Crankcase Press Sens Low
Error .................................................... 40-266
Failure code [CA1879] KDPF Delta P Sensor High
Error ..................................................... 40-268
Failure code [CA1881] KDPF Delta P Sensor Low
Error ...................................................... 40-270
Failure code [CA1883] KDPF Delta P Sens In Range
Error.................................................. 40-272
Failure code [CA1921] KDPF Soot Level High Error
1 ......................................................... 40-275
Failure code [CA1922] KDPF Soot Level High Error
2 ......................................................... 40-277
Failure code [CA1942] Crankcase Press Sensor In Range
Error .......................................... 40-281
Failure code [CA1993] KDPF Delta Pressure Low
Error ...................................................... 40-282
Failure code [CA2185] Throt Sensor Sup Volt High
Error ..................................................... 40-283
Failure code [CA2186] Throt Sensor Sup Volt Low
Error...................................................... 40-285
Failure code [CA2249] Rail Press Very Low
Error ............................................................... 40-287
Failure code [CA2265] Fuel Feed Pump Open
Error............................................................ 40-288
Failure code [CA2266] Fuel Feed Pump Short
Error............................................................ 40-290
Failure code [CA2271] EGR Valve Pos Sens High
Error ...................................................... 40-292
Failure code [CA2272] EGR Valve Pos Sens Low
Error ....................................................... 40-294
Failure code [CA2288] Turbo Speed High Error
1................................................................ 40-297
Failure code [CA2311] lMV Solenoid
Error.......................................................................... 40-298
Failure code [CA2349] EGR Valve Solenoid Open
Error ...................................................... 40-299
Failure code [CA2353] EGR Valve Solenoid Short
Error ...................................................... 40-301
Failure code [CA2357] EGR Valve Servo
Error ................................................................... 40-303
Failure code [CA2373] Exhaust Manifold Press Sens High
error........................................... 40-304
Failure code [CA2374] Exhaust Manifold Press Sens Low
error ........................................... 40-306
Failure code [CA2375] EGR Orifice Temp Sens High
Error .................................................. 40-308
Failure code [CA2376] EGR Orifice Temp Sens Low
Error ................................................... 40-310
Failure code [CA2381] KVGT Pos Sens High
Error ............................................................. 40-312
Failure code [CA2382] KVGT Pos Sens Low
Error .............................................................. 40-314
Failure code [CA2383] KVGT Solenoid Open
Error ............................................................. 40-316
Failure code [CA2386] KVGT Solenoid Short
Error ............................................................. 40-318
Failure code [CA2387] KVGT Valve Servo
Error ................................................................. 40-320
Failure code [CA2554] Exh Manifold Press Sens In Range
error .......................................... 40-321
Failure code [CA2555] Grid Htr Relay Volt Low
Error........................................................... 40-322
Failure code [CA2556] Grid Htr Relay Volt High
Error .......................................................... 40-324