Komatsu D155AX-8E0 Bulldozer Shop Manual SEN06762-01 PDF

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Komatsu D155AX-8E0 Bulldozer Shop Manual SEN06762-01 – PDF DOWNLOAD

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Komatsu D155AX-8E0 Bulldozer Shop Manual SEN06762-01 – PDF DOWNLOAD 

Language : English
Pages : 3472
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu D155AX-8E0 Bulldozer Shop Manual SEN06762-01 – PDF DOWNLOAD 

SERIAL NUMBERS 100358 and up

Cover 1
00 Index and Foreword 3
Index 4
Abbreviation List 24
Foreword, Safety, Basic Information 27
How to Read the Shop Manual 27
Safety Notice for Operation 29
Precautions to Prevent Fire 37
Procedures If Fire Occurs 39
Precautions When You Discard Waste Materials 40
Procedures for Exhaust Gas Regulations 41
Precautions for DEF 42
General Character and Precautions for Handling 42
Precautions When You Add 42
Precautions for Storage 42
Precautions for Fire Hazard and Leakage 42
Other Precautions 42
Store DEF 43
Precautions When You Handle Hydraulic Equipment 44
Precautions When You Disconnect and Connect Pipings 47
Precautions When You Handle Electrical Equipment 54
Precautions When You Handle Fuel System Equipment 56
Precautions When You Handle Intake System Equipment 57
Practical Use of KOMTRAX 58
Disconnect and Connect Push-Pull Type Coupler 59
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 59
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 60
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 61
Precautions for Disconnection and Connection of Connectors 63
Disconnect and Connect Deutsch Connector 67
How to Disconnect and Connect Slide Lock Type Connector 68
Disconnect and Connect Connector with Lock to Pull 70
Disconnect and Connect Connector with Lock to Push 71
Disconnect and Connect Connector with Housing to Rotate 73
How to Read the Codes for Electric Cable 74
Explanation of Terms for Maintenance Standard 78
Standard Tightening Torque Table 81
Conversion Table 88
01 Specification 93
Table of Contents 94
Specifications 95
Specification Drawing 95
Specification Drawing: D155AX-8E0 95
Specifications 97
Specifications: D155AX-8E0 97
Weight Table 105
Weight Table: D155AX-8E0 105
Table of Fuel, Coolant, and Lubricants 108
10 Structure and Function 111
Table of Contents 112
Urea SCR System 115
Layout Drawing of Urea SCR System 115
Urea SCR System Diagram 117
Function of Urea SCR System 118
Function of DEF System 118
Inducement Strategy 121
Component Parts of Urea SCR System 135
DEF Mixing Tube 135
SCR Assembly 135
DEF Tank 138
DEF Pump 140
DEF Injector 141
DEF Hose 142
DEF Tank Heating Valve 143
Boot-up System 144
Layout Drawing of Boot-up System (Machine with Gateway Function Controller) 144
System Operating Lamp System 145
System Diagram of System Operating Lamp System (Machine with KOMTRAX Terminal) 145
System Diagram of System Operating Lamp System (Machine with Gateway Function Controller) 145
Function of System Operating Lamp System (Machine with KOMTRAX Terminal) 145
Function of System Operating Lamp System (Machine with Gateway Function Controller) 146
Battery Disconnect Switch 148
Layout Drawing of Battery Disconnect Switch 148
Function of Battery Disconnect Switch 148
Engine System 150
Layout Drawing of Engine System 150
Engine Control System 152
Layout of Engine Control System (Machine with KOMTRAX Terminal) 152
Layout of Engine Control System (Machine with Gateway Function Controller) 153
System Diagram of Engine Control System (Machine with KOMTRAX Terminal) 154
System Diagram of Engine Control System (Machine with Gateway Function Controller) 156
Function of Engine Control System 157
Automatic Idle Stop System 158
Automatic Idle Stop System Diagram (Machine with KOMTRAX Terminal) 158
System Diagram of Automatic Idle Stop System (Machine with Gateway Function Controller) 159
Function of Automatic Idle Stop System 159
Component Parts of Engine System 162
Damper 162
VGT 163
EGR System 167
EGR Valve 169
EGR Cooler 171
KCCV System 173
KCCV Ventilator 175
KDPF 178
Cooling System 182
Layout Drawing of Cooling System 182
Specifications of Cooling System 183
Component Parts of Cooling System 184
Cooling Fan Pump 184
Cooling Fan Motor 192
Hydraulic Oil Cooler Bypass Valve 199
Control System 200
Layout Drawing of Control System (Machine with KOMTRAX Terminal) 200
Layout Drawing of Control System (Machine with Gateway Function Controller) 201
Machine Monitor System 202
System Diagram of Machine Monitor System (Machine with KOMTRAX Terminal) 202
System Diagram of Machine Monitor System (Machine with Gateway Function Controller) 203
Function of Machine Monitor System 203
KOMTRAX System 206
System Diagram of KOMTRAX System (Machine with KOMTRAX Terminal) 206
System Diagram of KOMTRAX System (Machine with Gateway Function Controller) 206
Function of KOMTRAX System 207
Component Parts of Control System 208
Machine Monitor 208
KOMTRAX Terminal 224
Gateway Function Controller 226
Communication Terminal 229
Power Train Controller 231
Work Equipment Controller 235
Engine Controller 239
Fuel Feed Pump 245
Fuel Feed Pump Switch 246
Hydraulic System 247
Layout Drawing of Hydraulic System 247
CLSS 248
Structure of CLSS 248
Function of CLSS 249
Component Parts of Hydraulic System 251
Hydraulic Tank 251
Work Equipment and HSS Pump 252
LS Valve 257
PC Valve 262
PC-EPC Valve 268
Control Valve 272
Power Train System 314
Layout Drawing of Power Train System 314
Operation of Power Train System 317
Transmission, Steering, and Brake Control 319
Layout Drawing of Transmission, Steering, and Brake Control System 319
Function of Transmission, Steering, and Brake Control System 320
Palm Command Control System 322
Palm Command Control System Diagram 322
HSS System 326
HSS System Diagram 326
Function of HSS System 327
Centralized Pressure Pickup Port 329
Layout Drawing of Centralized Pressure Pickup Port 329
Function of Centralized Pressure Pickup Port 330
Component Parts of Power Train System 331
Universal Joint 331
Power Train Mount 332
Torque Converter and PTO 333
Torque Converter Control Valve 340
Lockup Clutch ECMV 341
Stator Clutch ECMV 344
Transmission 348
Transmission ECMV 358
Main Relief Valve and Torque Converter Relief Valve 365
Transmission Lubrication Relief Valve 367
Bevel Gear Shaft, HSS, and Brake 367
Final Drive 394
Scavenging Pump 397
Steering Lubrication Pump and Power Train Pump 398
HSS Motor 399
Electric Steering Electric Lever 406
Work Equipment System 411
Work Equipment Control 411
Layout Drawing of Work Equipment Control 411
Function of Work Equipment Control 412
Layout Drawing of Front Work Equipment 413
Layout Drawing of Variable Giant Ripper 414
Layout Drawing of Variable Multi-Shank Ripper 415
Component Parts of Work Equipment System 416
Self-Pressure Reducing Valve 416
Work Equipment Lock Solenoid Valve 422
Pilot Circuit Accumulator 424
Quick Drop Valve 425
Piston Valve 430
Electric Blade Control Lever 430
Ripper Electric Lever 432
Undercarriage and Frame 433
Main Frame 433
Structure of Main Frame 433
Suspension 434
Structure of Suspension 434
Function of Suspension 436
Track Frame and Idler Cushion 437
Structure of Track Frame and Idler Cushion 437
Specifications of Track Frame and Idler Cushion 438
Function of Track Frame and Idler Cushion 438
Work Equipment 439
Structure of Front Work Equipment 439
Structure of Cylinder Stay 441
Structure of Variable Giant Ripper 442
Structure of Variable Multi-Shank Ripper 443
CAB Related Parts 444
ROPS CAB 444
Structure of ROPS CAB 444
Function of ROPS CAB 444
CAB Mount 445
Structure of CAB Mount 445
20 Standard Value Table 447
Table of Contents 448
Standard Value Table for Engine 449
Standard Value Table for Engine: D155AX-8E0 449
Standard Value Table for Machine 454
Standard Value Table for Machine: D155AX-8E0 454
Machine Posture and Procedures to Measure Performance 471
Standard Value Table for Electricity 473
Standard Value Table for Electricity 473
30 Testing and Adjusting 483
Table of Contents 484
Precautions Before Work 487
Related Information on Testing and Adjusting 488
Tools for Testing and Adjusting 488
Sketch of Tools for Testing and Adjusting 496
Engine and Cooling System 499
Examine Engine Speed 499
How to Examine Engine Speed 499
Examine Boost Pressure 504
How to Examine Boost Pressure 504
Examine Exhaust Gas Temperature 506
How to Examine Exhaust Gas Temperature 506
Examine Exhaust Gas Color 509
How to Examine Exhaust Gas Color with the Handy Smoke Checker 509
How to Examine Exhaust Gas Color with Smoke Meter 510
Examine Mass Air Flow and Temperature Sensor 511
How to Examine Mass Air Flow and Temperature Sensor 511
Examine and Adjust Valve Clearance 513
Check Valve Clearance 513
Adjust Valve Clearance 514
Examine Compression Pressure 516
How to Examine Compression Pressure 516
Examine Blowby Pressure 519
How to Examine Blowby Pressure 519
Examine Engine Oil Pressure 521
Examine Engine Oil Pressure on Machine Monitor 521
Examine Engine Oil Pressure by Testing Tool 521
Examine EGR Valve and VGT Oil Pressure 523
How to Examine EGR Valve and VGT Oil Pressure 523
Examine Fuel Pressure 525
How to Examine Fuel Pressure 525
Examine Fuel Return Rate and Leakage 527
How to Examine Fuel Return Rate and Leakage 528
Bleed Air from Fuel System 532
How to Bleed Air from Fuel System 532
Examine Fuel Circuit for Leakage 534
How to Examine Fuel System for Leakage 534
Handle Cylinder Cut-out Mode Operation 536
Handle No-Injection Cranking Operation 537
Clean Fuel Doser 538
How to Clean Fuel Doser 538
Write Injector Compensation Value to Engine Controller 540
Write Injector Compensation Value 540
Write Correction for Ash in Soot Accumulation to Engine Controller 546
How to Write Correction for Ash in Soot Accumulation to Engine Controller 546
Examine SCR Related Functions 547
Examine DEF Pump Raised Pressure 551
Examine Injection Volume from DEF Injector 554
Examine DEF Line Heater Relay 1 559
Examine DEF Line Heater Relay 2 562
Examine DEF Pump Heater Relay 565
Examine DEF Tank Heater Valve 568
Examine SCR Denitration Efficiency 571
Clean DEF Tank 574
How to Clean DEF Tank 575
Clean DEF Pump 580
How to Clean DEF Pump 580
Adjust Decelerator Pedal 587
How to Adjust Decelerator Pedal 587
Power Train 590
Examine Power Train Oil Pressure 590
How to Examine Power Train Oil Pressure 591
Adjust Transmission Output Shaft Speed Sensor 601
How to Adjust Transmission Output Shaft Speed Sensor 601
Examine Brake Performance Simply 602
How to Examine Brake Performance Simply 602
Examine and Adjust Brake Pedal 603
How to Examine Brake Pedal 603
How to Adjust Brake Pedal 604
Adjust Parking Brake Lever 607
How to Adjust Parking Brake Lever 607
Move Machine by Parking Brake Release When Machine Does Not Travel 609
Move Machine with Hydraulic Type Parking Brake Release System 609
Move Machine with Electric Type Parking Brake Release System 610
Undercarriage and Frame 613
Adjust Idler Clearance 613
How to Adjust Idler Clearance 613
Examine and Adjust Track Tension 615
How to Examine Track Tension 615
How to Adjust Track Tension 615
Hydraulic System 616
Release Remained Pressure in Hydraulic Circuit 616
How to Release Remained Pressure in Hydraulic System 616
Examine and Adjust Work Equipment and HSS Oil Pressure 617
How to Examine Work Equipment and HSS Oil Pressure 617
Adjust Oil Pressure of Work Equipment and HSS 620
Examine Oil Pressure of Control Circuit 622
Examine Oil Pressure in Control Circuit 622
Examine Work Equipment Lock Solenoid Valve Outlet Pressure 624
How to Examine Work Equipment Lock Solenoid Valve Outlet Pressure 624
Examine Ripper Pin Puller Solenoid Valve Outlet Pressure 626
How to Examine Ripper Pin Puller Solenoid Valve Outlet Pressure 626
Bleed Air from Work Equipment and HSS Pump 628
How to Bleed Air from Work Equipment and HSS Pump 628
Examine Cooling Fan Speed 629
How to Examine Cooling Fan Speed 629
Examine Cooling Fan Circuit Oil Pressure 630
How to Examine Cooling Fan Circuit Oil Pressure 630
Bleed Air in Cooling Fan Pump 632
How to Bleed Air in Cooling Fan Pump 632
Examine Parts Which Cause Hydraulic Drift of Work Equipment 633
How to Examine Parts Which Cause Hydraulic Drift of Blade Lift Cylinder 633
How to Examine the Parts Which Cause Hydraulic Drift of Blade Tilt Cylinder 633
How to Examine the Parts Which Cause Hydraulic Drift of Ripper Lift Cylinder 634
Examine Oil Leakage from Work Equipment Cylinder 635
How to Examine Internal Oil Leakage of Work Equipment Cylinder 635
Bleed Air from Work Equipment Cylinders 637
Bleed Air from Work Equipment Cylinder 637
Operation When Work Equipment is Disabled 638
Operate When Work Equipment is Disabled 638
Work Equipment 640
Adjust Work Equipment Lock Lever 640
How to Adjust Work Equipment Lock Lever 640
Examine and Adjust Play of Blade Electric Lever 642
How to Examine Play of Blade Electric Lever 644
Adjust Play of Blade Electric Lever 644
Replace Universal Joint 645
CAB Related Parts 652
Examine and Adjust Operator Cab 652
Examine Operator Cab 652
Adjust Operator Cab 655
Electrical System 657
Set and Operate Machine Monitor 657
Operator Mode 661
Function to Show Technician Identification Status Screen 661
Function to Show Operator Identification Input Screen 661
Examine Function by LCD (Liquid Crystal Display) 662
Examine Function of Service Meter 662
Usage Limitation and Change Maintenance Password 662
Service Mode 665
How to Operate Service Mode 665
How to See Pre-defined Monitoring Information 667
How to Examine Self-Define Monitor Information 672
Abnormality Record Menu 684
How to See Maintenance Record 688
Maintenance Mode Setting 689
Set Phone Number Entry 693
Default Menu 694
Diagnostic Tests Menu 703
Adjustment Menu 712
No-Injection Cranking Operation 777
KOMTRAX Settings Menu 779
Show Service Message 781
Start Up KOMTRAX Terminal (Machine with KOMTRAX Terminal) 783
Stop Use of KOMTRAX Terminal (Machine with KOMTRAX Terminal) 787
Start Up KOMTRAX System (Machine with Gateway Function Controller) 789
Stop Use of KOMTRAX System (Machine with Gateway Function Controller) 794
How to Start Up KOMTRAX Terminal 796
Adjust Rearview Camera Angle 801
How to Adjust Rearview Camera Angle 801
Handle Voltage Circuit of Engine Controller 802
Handle Battery Disconnect Switch 803
Examine Diodes 804
Examine Diodes by Digital Tester 804
How to Examine Diodes by Analog Tester 804
Pm Clinic 805
Pm Clinic Service 805
Pm Clinic Check Sheet 807
Pm Clinic Check Sheet for Undercarriage 821
40 Troubleshooting 825
Table of Contents 826
Precautions Before Work 838
Related Information to Troubleshooting 839
General Troubleshooting Points 839
Troubleshooting Points for Urea SCR System 840
Sequence of Events in Troubleshooting 854
Checks Before Troubleshooting 856
Inspection Procedure Before Troubleshooting 858
Walk-Around Check 858
Test in Accordance with Testing Procedure 860
Examine Fuel Level and Type 860
Examine for Impure Ingredient in Fuel 860
Examine DEF Level and Type 861
Examine Fuel Prefilter 861
Examine Fuel Main Filter 863
Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type 864
Examine Coolant Level (Reservoir Tank) 865
Examine Air Cleaner Clogging 866
Clean Outer Element 867
Replace Element 869
Examine Hydraulic Oil Level 869
Examine Hydraulic Oil Strainer 871
Examine Hydraulic Oil Filter 872
Examine Oil Level in Power Train Case 872
Examine Power Train Strainer 874
Examine Power Train Filter 875
Examine Oil Level in Damper Case 875
Examine Oil Level in Final Drive Case 876
How to Examine Electric Equipment 878
Procedure for Troubleshooting 885
Symptom and Troubleshooting Numbers 888
Information Shown in Troubleshooting Table 891
Connector List and Layout (Machine with KOMTRAX Terminal) 893
Connectors List (Machine with Gateway Function Controller) 909
Connector Layout (Machine with Gateway Function Controller) 918
Connector Contact Connection Table 925
T-Branch Box and T-Branch Adapter Table 965
Fuse Location Table 971
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 974
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 978
Failure Code Table (Machine with KOMTRAX Terminal) 980
Failure Codes Table (Machine with Gateway Function Controller) 1002
Troubleshooting by Failure Code (Display of Code) 1026
Failure Code [1500L0] 1026
Failure Code [15SAL1] 1027
Failure Code [15SALH] 1029
Failure Code [15SBL1] 1031
Failure Code [15SBLH] 1033
Failure Code [15SEL1] 1035
Failure Code [15SELH] 1037
Failure Code [15SFL1] 1039
Failure Code [15SFLH] 1041
Failure Code [15SGL1] 1043
Failure Code [15SGLH] 1045
Failure Code [15SJL1] 1047
Failure Code [15SJLH] 1049
Failure Code [1800MW] 1051
Failure Code [2300NR] 1052
Failure Code [2301L1] 1053
Failure Code [2301LH] 1055
Failure Code [2302L1] 1057
Failure Code [2302LH] 1059
Failure Code [879AKA] 1061
Failure Code [879AKB] 1062
Failure Code [879BKA] 1063
Failure Code [879BKB] 1065
Failure Code [879CKA] 1067
Failure Code [879CKB] 1068
Failure Code [879DKZ] 1069
Failure Code [879EMC] 1071
Failure Code [879FMC] 1072
Failure Code [879GKX] 1073
Failure Code [989L00] 1075
Failure Code [989M00] 1076
Failure Code [989N00] 1077
Failure Code [A1U0N3] 1078
Failure Code [A1U0N4] 1080
Failure Code [AA10NX] 1082
Failure Code [AB00KE] 1084
Failure Code [AQ10N3] 1086
Failure Code [AS00N3] 1088
Failure Code [AS00R2] 1090
Failure Code [AS00R3] 1091
Failure Code [AS00R4] 1092
Failure Code [AS00R5] 1093
Failure Code [AS00R6] 1094
Failure Code [AS00ZK] 1095
Failure Code [AS10KM] 1096
Failure Code [AS10NR] 1097
Failure Code [AS10NT] 1098
Failure Code [B@BAZG] 1099
Failure Code [B@BCNS] 1100
Failure Code [B@BCQA] 1101
Failure Code [B@BCZK] 1103
Failure Code [B@CENS] 1105
Failure Code [B@HANS] 1106
Failure Code [CA115] 1107
Failure Code [CA122] 1108
Failure Code [CA123] 1110
Failure Code [CA131] 1112
Failure Code [CA132] 1114
Failure Code [CA135] 1116
Failure Code [CA141] 1118
Failure Code [CA144] 1120
Failure Code [CA145] 1122
Failure Code [CA153] 1124
Failure Code [CA154] 1127
Failure Code [CA187] 1130
Failure Code [CA221] 1132
Failure Code [CA222] 1134
Failure Code [CA227] 1136
Failure Code [CA234] 1137
Failure Code [CA238] 1138
Failure Code [CA239] 1140
Failure Code [CA249] 1142
Failure Code [CA256] 1144
Failure Code [CA271] 1146
Failure Code [CA272] 1148
Failure Code [CA273] 1149
Failure Code [CA274] 1151
Failure Code [CA322] 1152
Failure Code [CA323] 1154
Failure Code [CA324] 1156
Failure Code [CA325] 1158
Failure Code [CA331] 1160
Failure Code [CA332] 1162
Failure Code [CA343] 1164
Failure Code [CA351] 1165
Failure Code [CA352] 1166
Failure Code [CA356] 1169
Failure Code [CA357] 1171
Failure Code [CA386] 1174
Failure Code [CA441] 1175
Failure Code [CA442] 1178
Failure Code [CA449] 1179
Failure Code [CA451] 1180
Failure Code [CA452] 1182
Failure Code [CA515] 1184
Failure Code [CA516] 1186
Failure Code [CA553] 1188
Failure Code [CA555] 1189
Failure Code [CA556] 1190
Failure Code [CA559] 1191
Failure Code [CA595] 1196
Failure Code [CA687] 1197
Failure Code [CA689] 1199
Failure Code [CA691] 1201
Failure Code [CA692] 1203
Failure Code [CA697] 1205
Failure Code [CA698] 1206
Failure Code [CA731] 1207
Failure Code [CA778] 1208
Failure Code [CA1117] 1211
Failure Code [CA1664] 1212
Failure Code [CA1669] 1215
Failure Code [CA1673] 1216
Failure Code [CA1677] 1217
Failure Code [CA1678] 1218
Failure Code [CA1682] 1219
Failure Code [CA1683] 1221
Failure Code [CA1684] 1223
Failure Code [CA1686] 1225
Failure Code [CA1691] 1226
Failure Code [CA1694] 1229
Failure Code [CA1695] 1231
Failure Code [CA1696] 1232
Failure Code [CA1712] 1234
Failure Code [CA1713] 1237
Failure Code [CA1714] 1239
Failure Code [CA1715] 1240
Failure Code [CA1776] 1241
Failure Code [CA1777] 1244
Failure Code [CA1843] 1247
Failure Code [CA1844] 1249
Failure Code [CA1879] 1252
Failure Code [CA1881] 1255
Failure Code [CA1883] 1257
Failure Code [CA1885] 1261
Failure Code [CA1887] 1263
Failure Code [CA1921] 1265
Failure Code [CA1922] 1268
Failure Code [CA1923] 1273
Failure Code [CA1924] 1275
Failure Code [CA1925] 1277
Failure Code [CA1927] 1279
Failure Code [CA1928] 1281
Failure Code [CA1942] 1283
Failure Code [CA1963] 1284
Failure Code [CA1977] 1287
Failure Code [CA1993] 1290
Failure Code [CA2185] 1293
Failure Code [CA2186] 1295
Failure Code [CA2249] 1297
Failure Code [CA2265] 1298
Failure Code [CA2266] 1300
Failure Code [CA2271] 1303
Failure Code [CA2272] 1305
Failure Code [CA2349] 1307
Failure Code [CA2353] 1309
Failure Code [CA2357] 1311
Failure Code [CA2381] 1312
Failure Code [CA2382] 1314
Failure Code [CA2383] 1316
Failure Code [CA2386] 1318
Failure Code [CA2387] 1320
Troubleshooting Flowchart 1324
Failure Code [CA2555] 1325
Failure Code [CA2556] 1328
Failure Code [CA2637] 1330
Failure Code [CA2639] 1332
Failure Code [CA2732] 1335
Failure Code [CA2733] 1337
Failure Code [CA2741] 1339
Failure Code [CA2765] 1340
Failure Code [CA2771] 1341
Failure Code [CA2777] 1347
Failure Code [CA2878] 1350
Failure Code [CA2881] 1353
Failure Code [CA2976] 1356
Failure Code [CA3133] 1358
Failure Code [CA3134] 1360
Failure Code [CA3135] 1362
Failure Code [CA3142] 1366
Failure Code [CA3143] 1367
Failure Code [CA3144] 1368
Failure Code [CA3146] 1370
Failure Code [CA3147] 1371
Failure Code [CA3148] 1372
Failure Code [CA3151] 1374
Failure Code [CA3165] 1380
Failure Code [CA3167] 1382
Failure Code [CA3229] 1385
Failure Code [CA3231] 1387
Failure Code [CA3232] 1389
Failure Code [CA3235] 1393
Failure Code [CA3239] 1395
Failure Code [CA3241] 1398
Failure Code [CA3242] 1401
Failure Code [CA3251] 1404
Failure Code [CA3253] 1407
Failure Code [CA3254] 1411
Failure Code [CA3255] 1414
Failure Code [CA3256] 1418
Failure Code [CA3311] 1420
Failure Code [CA3312] 1422
Failure Code [CA3313] 1425
Failure Code [CA3314] 1426
Failure Code [CA3315] 1427
Failure Code [CA3316] 1430
Failure Code [CA3317] 1431
Failure Code [CA3318] 1432
Failure Code [CA3319] 1435
Failure Code [CA3321] 1436
Failure Code [CA3322] 1438
Failure Code [CA3419] 1441
Failure Code [CA3421] 1443
Failure Code [CA3497] 1445
Failure Code [CA3498] 1446
Failure Code [CA3543] 1447
Failure Code [CA3545] 1454
Failure Code [CA3547] 1456
Failure Code [CA3558] 1457
Failure Code [CA3559] 1459
Failure Code [CA3562] 1461
Failure Code [CA3563] 1463
Failure Code [CA3567] 1466
Failure Code [CA3568] 1469
Failure Code [CA3571] 1473
Failure Code [CA3572] 1475
Failure Code [CA3574] 1477
Failure Code [CA3575] 1479
Failure Code [CA3577] 1481
Failure Code [CA3578] 1483
Failure Code [CA3582] 1485
Failure Code [CA3583] 1492
Failure Code [CA3596] 1494
Failure Code [CA3649] 1496
Failure Code [CA3681] 1498
Failure Code [CA3682] 1503
Failure Code [CA3713] 1509
Failure Code [CA3717] 1512
Failure Code [CA3718] 1513
Failure Code [CA3725] 1514
Failure Code [CA3748] 1517
Failure Code [CA3751] 1520
Failure Code [CA3755] 1522
Failure Code [CA3866] 1524
Failure Code [CA3867] 1528
Failure Code [CA3868] 1531
Failure Code [CA3899] 1535
Failure Code [CA3911] 1537
Failure Code [CA3912] 1541
Failure Code [CA3932] 1543
Failure Code [CA3933] 1545
Failure Code [CA3934] 1547
Failure Code [CA3935] 1550
Failure Code [CA3936] 1552
Failure Code [CA4151] 1554
Failure Code [CA4152] 1558
Failure Code [CA4155] 1562
Failure Code [CA4156] 1564
Failure Code [CA4157] 1567
Failure Code [CA4158] 1569
Failure Code [CA4159] 1570
Failure Code [CA4161] 1571
Failure Code [CA4162] 1574
Failure Code [CA4163] 1577
Failure Code [CA4164] 1579
Failure Code [CA4165] 1581
Failure Code [CA4166] 1583
Failure Code [CA4168] 1585
Failure Code [CA4169] 1588
Failure Code [CA4171] 1590
Failure Code [CA4249] 1593
Failure Code [CA4251] 1595
Failure Code [CA4259] 1597
Failure Code [CA4261] 1600
Failure Code [CA4277] 1603
Failure Code [CA4281] 1607
Failure Code [CA4459] 1611
Failure Code [CA4461] 1614
Failure Code [CA4658] 1617
Failure Code [CA4731] 1621
Failure Code [CA4732] 1622
Failure Code [CA4739] 1623
Failure Code [CA4768] 1624
Failure Code [CA4769] 1626
Failure Code [CA4842] 1629
Failure Code [CA4952] 1633
Failure Code [CA5115] 1635
Failure Code [CA5383] 1638
Failure Code [D130KA] 1640
Failure Code [D130KB] 1643
Failure Code [D190KA] 1645
Failure Code [D190KB] 1647
Failure Code [D19JKZ] 1649
Failure Code [D811MC] (Machine with KOMTRAX Terminal) 1652
Failure Code [D811MC] (Machine with Gateway Function Controller) 1653
Failure Code [D862KA] (Machine with KOMTRAX Terminal) 1654
Failure Code [D862KA] (Machine with Gateway Function Controller) 1655
Failure Code [D8ALKA] (Machine with KOMTRAX Terminal) 1656
Failure Code [D8ALKA] (Machine with Gateway Function Controller) 1658
Failure Code [D8ALKB] (Machine with KOMTRAX Terminal) 1660
Failure Code [D8ALKB] (Machine with Gateway Function Controller) 1663
Failure Code [D8AQKR] 1666
Failure Code [D8ARKR] (Machine with Gateway Function Controller) 1667
Failure Code [D8G1KT] (Machine with Gateway Function Controller) 1669
Failure Code [D8G6KT] (Machine with Gateway Function Controller) 1670
Failure Code [DAF0MB] 1671
Failure Code [DAF0MC] 1672
Failure Code [DAF8KB] 1673
Failure Code [DAF9KQ] 1674
Failure Code [DAFGMC] 1675
Failure Code [DAFLKA] 1676
Failure Code [DAFLKB] 1678
Failure Code [DAFQKR] 1681
Failure Code [DAZ9KQ] 1682
Failure Code [DAZQKR] 1683
Failure Code [DB2QKR] 1684
Failure Code [DB2RKR] 1690
Failure Code [DB90KT] 1696
Failure Code [DB90MC] 1697
Failure Code [DB91KK] 1698
Failure Code [DB92KK] 1701
Failure Code [DB95KK] 1703
Failure Code [DB97KK] 1706
Failure Code [DB99KQ] 1708
Failure Code [DB9LKA] 1710
Failure Code [DB9LKB] 1712
Failure Code [DB9QKR] 1714
Failure Code [DB9RKR] 1715
Failure Code [DBE0KT] 1717
Failure Code [DBE0MC] 1718
Failure Code [DBE1KK] 1719
Failure Code [DBE2KK] 1722
Failure Code [DBE5KK] 1725
Failure Code [DBE6KK] 1727
Failure Code [DBE9KQ] 1729
Failure Code [DBELKA] 1730
Failure Code [DBELKB] 1732
Failure Code [DBEQKR] 1734
Failure Code [DBERKR] 1735
Failure Code [DD12KA] 1737
Failure Code [DD12KB] 1739
Failure Code [DD13KA] 1741
Failure Code [DD13KB] 1743
Failure Code [DD14KA] 1745
Failure Code [DD14KB] 1748
Failure Code [DDDDKA] 1750
Failure Code [DDDDKB] 1753
Failure Code [DDDDKX] 1756
Failure Code [DDKAKA] 1757
Failure Code [DDKAKB] 1759
Failure Code [DDKBKA] 1761
Failure Code [DDKBKB] 1763
Failure Code [DDKCL4] 1765
Failure Code [DDKEL4] 1768
Failure Code [DDN7L4] 1771
Failure Code [DDN8L4] 1774
Failure Code [DDNLKA] 1777
Failure Code [DDNLKB] 1779
Failure Code [DDTSL1] 1781
Failure Code [DDTSLH] 1783
Failure Code [DFA4KX] 1785
Failure Code [DFA4KZ] 1786
Failure Code [DFA4L8] 1787
Failure Code [DFA5KA] 1788
Failure Code [DFA5KY] 1791
Failure Code [DFA6KA] 1793
Failure Code [DFA6KY] 1796
Failure Code [DFA7KX] 1798
Failure Code [DFA7KZ] 1799
Failure Code [DFA7L8] 1800
Failure Code [DFA8KA] 1801
Failure Code [DFA8KY] 1804
Failure Code [DFA9KA] 1806
Failure Code [DFA9KY] 1809
Failure Code [DFAAKX] 1811
Failure Code [DFAAKZ] 1812
Failure Code [DFAAL8] 1813
Failure Code [DFABKA] 1814
Failure Code [DFABKY] 1817
Failure Code [DFACKA] 1819
Failure Code [DFACKY] 1822
Failure Code [DGS1KA] 1824
Failure Code [DGS1KX] 1826
Failure Code [DGT1KA] 1828
Failure Code [DGT1KX] 1831
Failure Code [DH21KA] 1833
Failure Code [DH21KY] 1836
Failure Code [DHA4KA] 1838
Failure Code [DHAAMA] 1840
Failure Code [DHACMA] 1842
Failure Code [DHT5KA] 1844
Failure Code [DHT5KY] 1847
Failure Code [DHT7KA] 1849
Failure Code [DHT7KY] 1852
Failure Code [DK10KA] 1854
Failure Code [DK10KB] 1857
Failure Code [DK30KA] 1859
Failure Code [DK30KX] 1862
Failure Code [DK30KY] 1863
Failure Code [DK30KZ] 1865
Failure Code [DK30L8] 1866
Failure Code [DK31KA] 1867
Failure Code [DK31KY] 1870
Failure Code [DK40KA] 1872
Failure Code [DK40KY] 1875
Failure Code [DK55KX] 1877
Failure Code [DK55KZ] 1878
Failure Code [DK55L8] 1879
Failure Code [DK56KA] 1880
Failure Code [DK56KY] 1883
Failure Code [DK57KA] 1885
Failure Code [DK57KY] 1888
Failure Code [DKH1KA] 1890
Failure Code [DKH1KY] 1893
Failure Code [DLM3KA] 1895
Failure Code [DLM3KB] 1897
Failure Code [DLM3MB] 1898
Failure Code [DLT3KA] 1899
Failure Code [DLT3KB] 1901
Failure Code [DR21KX] 1903
Failure Code [DR31KX] 1904
Failure Code [DV20KB] 1905
Failure Code [DW7BKA] 1907
Failure Code [DW7BKB] 1909
Failure Code [DWN1KA] 1911
Failure Code [DWN1KB] 1913
Failure Code [DWN1KY] 1915
Failure Code [DWN2KA] 1916
Failure Code [DWN2KB] 1918
Failure Code [DWN2KY] 1919
Failure Code [DWN3KA] 1920
Failure Code [DWN3KB] 1922
Failure Code [DWN3KY] 1924
Failure Code [DWN5KA] 1926
Failure Code [DWN5KB] 1928
Failure Code [DWN5KY] 1930
Failure Code [DXA2KA] 1932
Failure Code [DXA2KB] 1934
Failure Code [DXA2KY] 1936
Failure Code [DXH1KA] 1938
Failure Code [DXH1KB] 1940
Failure Code [DXH1KY] 1942
Failure Code [DXH4KA] 1944
Failure Code [DXH4KB] 1946
Failure Code [DXH4KY] 1948
Failure Code [DXH5KA] 1950
Failure Code [DXH5KB] 1952
Failure Code [DXH5KY] 1954
Failure Code [DXH6KA] 1956
Failure Code [DXH6KB] 1958
Failure Code [DXH6KY] 1959
Failure Code [DXH7KA] 1961
Failure Code [DXH7KB] 1963
Failure Code [DXH7KY] 1965
Failure Code [DXH8KA] 1967
Failure Code [DXH8KB] 1969
Failure Code [DXH8KY] 1971
Failure Code [DXHBKA] 1973
Failure Code [DXHBKB] 1975
Failure Code [DXHBKY] 1977
Failure Code [DXHCKA] 1979
Failure Code [DXHCKB] 1981
Failure Code [DXHCKY] 1983
Failure Code [DXHRKA] 1985
Failure Code [DXHRKB] 1987
Failure Code [DXHRKY] 1988
Failure Code [DXHSKA] 1990
Failure Code [DXHSKB] 1992
Failure Code [DXHSKY] 1993
Failure Code [DXHTKA] 1995
Failure Code [DXHTKB] 1997
Failure Code [DXHTKY] 1999
Failure Code [DXHUKA] 2001
Failure Code [DXHUKB] 2003
Failure Code [DXHUKY] 2005
Failure Code [DXHWKA] 2007
Failure Code [DXHWKB] 2009
Failure Code [DXHWKY] 2010
Failure Code [DXHXKA] 2012
Failure Code [DXHXKB] 2014
Failure Code [DXHXKY] 2015
Failure Code [DXHYKA] 2017
Failure Code [DXHYKB] 2019
Failure Code [DXHYKY] 2020
Failure Code [DXHZKA] 2022
Failure Code [DXHZKB] 2024
Failure Code [DXHZKY] 2025
Failure Code [DXJ4KA] 2027
Failure Code [DXJ4KB] 2029
Failure Code [DXJ8KA] 2030
Failure Code [DXJ8KB] 2032
Failure Code [DXJ8KY] 2034
Failure Code [DXJ9KA] 2036
Failure Code [DXJ9KB] 2038
Failure Code [DXJ9KY] 2040
Failure Code [DXJAKA] 2042
Failure Code [DXJAKB] 2044
Failure Code [DXJAKY] 2046
Failure Code [DXJBKA] 2048
Failure Code [DXJBKB] 2050
Failure Code [DXJBKY] 2052
Failure Code [F311KA] 2054
Failure Code [F311KB] 2056
Failure Code [F312KA] 2058
Failure Code [F312KB] 2060
Failure Code [F313KA] 2062
Failure Code [F313KB] 2064
Failure Code [F314KA] 2067
Failure Code [F314KB] 2069
Failure Code [F315KB] 2071
Failure Code [F315KY] 2073
Failure Code [F316KB] 2075
Failure Code [F316KY] 2077
Failure Code [F318KB] 2079
Failure Code [F318KY] 2082
Failure Code [F31AKB] 2084
Failure Code [F31AKY] 2086
Failure Code [F31BKB] 2088
Failure Code [F31BKY] 2090
Failure Code [F31CKB] 2092
Failure Code [F31CKY] 2094
Failure Code [F31DKB] 2096
Failure Code [F31DKY] 2098
Failure Code [F31EKB] 2100
Failure Code [F31EKY] 2102
Failure Code [F7FQKR] 2104
Failure Code [F7G0MC] 2107
Troubleshooting of Electrical System (E-Mode) 2108
E-1 Engine Does Not Start (Engine Does Not Crank) 2108
E-2 Manual Preheating System Does Not Operate 2115
E-3 Automatic Preheating System Does Not Operate 2118
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On 2120
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 2122
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow 2126
E-7 Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation 2128
E-8 Charge Level Monitor Comes On in Red While Engine is in Operation 2129
E-9 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 2131
E-10 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation 2132
E-11 Power Train Oil Temperature Monitor Comes On in Red While Engine is in Operation 2133
E-12 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 2134
E-13 Engine Coolant Temperature Gauge Does Not Show Correct Temperature 2135
E-14 Fuel Gauge Does Not Show Normally 2136
E-15 Power Train Oil Temperature Gauge Does Not Show Correct Temperature 2138
E-16 Hydraulic Oil Temperature Gauge Does Not Show Correct Temperature 2139
E-17 Operation Mode Does Not Change 2140
E-18 Gear Shift Mode Does Not Change 2141
E-19 Operating Customize Switch Does Not Display Customize Screen 2142
E-20 Modifying Setting on Customize Screen Does Not Change Setting of Machine 2143
E-21 Some Areas of Machine Monitor Screen are Not Shown 2144
E-22 Alarm Buzzer Does Not Sound or Cannot be Stopped 2145
E-23 Service Meter is Not Shown, While Starting Switch is in OFF Position 2146
E-24 Machine Does Not Change to Service Mode 2147
E-25 Horn Does Not Sound 2148
E-26 Horn Does Not Stop 2150
E-27 Backup Alarm Does Not Sound 2151
E-28 Backup Alarm Does Not Stop 2152
E-29 Headlamp Does Not Come On 2153
E-30 Rear Lamp and Ripper Point Lamp Do Not Come On 2157
E-31 No Wiper Operates 2161
E-32 Front Wiper Does Not Operate 2166
E-33 Rear Wiper Does Not Operate 2170
E-34 Left Door Wiper Does Not Operate 2174
E-35 Right Door Wiper Does Not Operate 2178
E-36 Fuel Feed Pump Does Not Operate or Stop Automatically 2182
E-37 Fan Does Not Rotate in Reverse 2183
E-38 Gear Cannot be Shifted 2184
E-39 Front Washer Does Not Operate 2185
E-40 Rear Washer Does Not Operate 2188
E-41 Left Door Washer Does Not Operate 2191
E-42 Right Door Washer Does Not Operate 2194
E-43 Ripper Pin Puller Does Not Work 2197
E-44 KOMTRAX System Does Not Operate Correctly 2199
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 2200
Information Shown in Troubleshooting Table (H-Mode) 2200
System Chart of Hydraulic and Mechanical Systems 2201
Failure Mode and Cause Table 2205
H-1 Machine Power is Not Sufficient (Not Sufficient Drawbar Pull) 2213
H-2 Machine Does Not Travel (at 2nd or 3rd Gear Speed) 2216
H-3 Machine Does Not Move Off at All Gear Speeds 2218
H-4 Machine Travels Only in One Direction, Forward or in Reverse 2221
H-5 Large Time Lag is in Gear Shifting or Directional Change 2222
H-6 Brake Does Not Work 2224
H-7 Power Train Oil Overheats 2225
H-8 Unusual Noise is Heard from Around Work Equipment and HSS Pump or HSS Motor 2227
H-9 Torque Converter Lockup Clutch Does Not Engage 2228
H-10 Machine Cannot be Steered (Machine Does Not Turn Left or Right) 2229
H-11 Steering Speed or Power is Not Sufficient 2231
H-12 All Work Equipment Operate Slowly 2233
H-13 All Work Equipment Do Not Operate 2235
H-14 Blade Lift Speed or Power is Low 2237
H-15 Blade Tilt Speed or Power is Low 2239
H-16 Ripper Lift Speed or Power is Low 2241
H-17 Ripper Tilt Speed or Power is Low 2243
H-18 Hydraulic Drift of Blade Lift is Large 2245
H-19 Hydraulic Drift of Tilted Blade is Large 2246
H-20 Hydraulic Drift of Lifted Ripper is Large 2247
H-21 Ripper Pin Puller Cylinder Does Not Operate 2248
H-22 Blade Pitch Cylinder Does Not Operate 2249
H-23 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) 2250
H-24 Unusual Noise is Heard from Around Fan 2251
Troubleshooting of Engine (S-Mode) 2252
Information Shown in Troubleshooting Table (S-Mode) 2252
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position 2253
S-2 Engine Cranks but No Exhaust Smoke Comes Out 2254
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 2255
S-4 Engine Startability is Unsatisfactory 2256
S-5 Engine Does Not Pick Up Smoothly 2258
S-6 Engine Stops During Operation 2260
S-7 Engine Runs Rough or is Not Stable 2262
S-8 Engine Lacks Power 2263
S-9 KDPF Becomes Clogged in a Short Time 2265
S-10 Engine Oil Consumption is Excessive 2267
S-11 Oil Becomes Dirty Quickly 2268
S-12 Fuel Consumption is Excessive 2269
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant 2270
S-14 Oil Pressure Drops 2271
S-15 Fuel Mixes Into Engine Oil 2273
S-16 Water Mixes Into Engine Oil (Milky) 2274
S-17 Coolant Temperature Increases Too High (Overheating) 2275
S-18 Unusual Noise is Heard 2276
S-19 Vibration is Excessive 2277
S-20 Air Cannot be Bled from Fuel Circuit 2278
S-21 Active Regeneration is Done Frequently 2279
S-22 Active Regeneration Continues Long 2281
S-23 White Smoke is Exhausted During Active Regeneration 2282
S-24 DEF Consumption is Excessive 2283
S-25 There is Unusual Smell (Irritating Odor) 2285
S-26 Foreign Materials Enter DEF (DEF Increases) 2286
50 Disassembly and Assembly 2287
Table of Contents 2288
Precautions Before Work 2294
Related Information on Disassembly and Assembly 2295
How to Read This Manual 2295
Coating Materials List 2297
Special Tool List 2302
Sketches of Special Tools 2330
Engine and Cooling System 2358
Remove and Install Supply Pump Assembly 2358
How to Remove Supply Pump Assembly 2358
How to Install Supply Pump Assembly 2365
Remove and Install Injector Assembly 2374
How to Remove Injector Assembly 2374
How to Install Injector Assembly 2382
Remove and Install Fuel Doser Assembly 2393
How to Remove Fuel Doser Assembly 2393
How to Install Fuel Doser Assembly 2394
Remove and Install Cylinder Head Assembly 2395
How to Remove Cylinder Head Assembly 2396
How to Install Cylinder Head Assembly 2407
Remove and Install EGR Valve Assembly 2425
How to Remove EGR Valve Assembly 2425
How to Install EGR Valve Assembly 2426
Remove and Install EGR Cooler Assembly 2428
How to Remove EGR Cooler Assembly 2428
How to Install EGR Cooler Assembly 2431
Remove and Install Starter Assembly 2435
How to Remove Starting Motor Assembly 2435
How to Install Starting Motor Assembly 2436
Remove and Install Alternator Belt 2439
How to Remove Alternator Belt 2439
How to Install Alternator Belt 2440
Remove and Install Radiator Assembly 2442
How to Remove Radiator Assembly 2442
How to Install Radiator Assembly 2447
Remove and Install Hydraulic Oil Cooler Assembly 2455
How to Remove Hydraulic Oil Cooler Assembly 2455
How to Install Hydraulic Oil Cooler Assembly 2457
Remove and Install Aftercooler Assembly 2459
How to Remove Aftercooler Assembly 2459
How to Install Aftercooler Assembly 2460
Remove and Install Cooling Fan Drive Assembly 2463
Remove Cooling Fan Drive Assembly 2463
Install Cooling Fan Drive Assembly 2465
Remove and Install Cooling Fan Motor Assembly 2468
How to Remove Cooling Fan Motor Assembly 2468
How to Install Cooling Fan Motor Assembly 2469
Remove and Install Engine Assembly 2471
How to Remove Engine Assembly 2472
How to Install Engine Assembly 2482
Remove and Install Engine Front Oil Seal 2492
How to Remove Engine Front Oil Seal 2492
How to Install Engine Front Oil Seal 2494
Remove and Install Engine Rear Oil Seal 2497
How to Remove Engine Rear Oil Seal 2497
How to Install Engine Rear Oil Seal 2498
Remove and Install Engine Hood Assembly 2502
How to Remove Engine Hood Assembly 2502
How to Install Engine Hood Assembly 2505
Remove and Install Fuel Tank Assembly 2509
How to Remove Fuel Tank Assembly 2509
How to Install Fuel Tank Assembly 2512
Remove and Install DEF Tank Assembly 2516
How to Remove DEF Tank Assembly 2516
How to Install DEF Tank Assembly 2522
Remove and Install DEF Tank Sensor Flange Assembly 2527
How to Remove DEF Tank Sensor Flange Assembly 2527
How to Install DEF Tank Sensor Flange Assembly 2533
Remove and Install DEF Tank Sensor 2539
Remove DEF Tank Sensor 2539
Install DEF Tank Sensor 2539
Remove and Install DEF Tank Strainer 2546
How to Remove DEF Tank Strainer 2546
How to Install DEF Tank Strainer 2546
Remove and Install DEF Tank Filler Port Filter 2547
How to Remove DEF Tank Filler Port Filter 2547
Install DEF Tank Filler Port Filter 2548
Remove and Install KDPF Assembly 2551
How to Remove KDPF Assembly 2551
How to Install KDPF Assembly 2556
Disassemble and Assemble KDPF Assembly 2561
How to Disassemble KDPF Assembly 2561
How to Assemble KDPF Assembly 2565
Remove and Install SCR Assembly 2570
How to Remove SCR Assembly 2570
How to Install SCR Assembly 2574
Remove and Install KDPF and SCR Assembly 2578
How to Remove KDPF and SCR Assembly 2578
How to Install KDPF and SCR Assembly 2584
Remove and Install KCCV Assembly 2591
How to Remove KCCV Assembly 2591
How to Install KCCV Assembly 2593
Remove and Install DEF Mixing Tube 2597
How to Remove DEF Mixing Tube 2597
How to Install DEF Mixing Tube 2602
Remove and Install DEF Injector 2609
How to Remove DEF Injector 2609
How to Install DEF Injector 2612
Remove and Install DEF Pump 2616
How to Remove DEF Pump 2616
How to Install DEF Pump 2620
Remove and Install DEF Hose 2625
How to Remove DEF Hose 2625
Install DEF Hose 2633
Remove and Install Air Cleaner Assembly 2642
How to Remove Air Cleaner Assembly 2642
How to Install Air Cleaner Assembly 2643
Remove and Install Air Conditioner Compressor Assembly 2645
How to Remove Air Conditioner Compressor Assembly 2645
How to Install Air Conditioner Compressor Assembly 2646
Remove and Install Air Conditioner Condenser Assembly 2648
How to Remove Air Conditioner Condenser Assembly 2648
How to Install Air Conditioner Condenser Assembly 2650
Power Train 2652
Remove and Install Damper Assembly 2652
How to Remove Damper Assembly 2652
How to Install Damper Assembly 2654
Disassemble and Assemble Damper Assembly 2657
Disassemble Damper Assembly 2657
How to Assemble Damper Assembly 2659
Remove and Install Power Train Unit Assembly 2662
Remove Power Train Unit Assembly 2662
How to Install Power Train Unit Assembly 2669
Disconnect and Connect Power Train Unit Assembly 2676
How to Disconnect Power Train Unit Assembly 2676
How to Connect Power Train Unit Assembly 2684
Disassemble and Assemble PTO Assembly 2692
How to Disassemble PTO Assembly 2692
How to Assemble PTO Assembly 2696
Disassemble and Assemble Torque Converter Assembly 2701
How to Disassemble Torque Converter Assembly 2701
How to Assemble Torque Converter Assembly 2707
Disassemble and Assemble Transmission Assembly 2714
How to Disassemble Transmission Assembly 2714
How to Assemble Transmission Assembly 2724
Disassemble and Assemble HSS Assembly 2736
Disassemble HSS Assembly 2737
How to Assemble HSS Assembly 2745
Remove and Install HSS Motor Assembly 2759
Remove HSS Motor Assembly 2759
How to Install HSS Motor Assembly 2760
Remove and Install Final Drive Assembly 2762
Remove Final Drive Assembly 2762
How to Install Final Drive Assembly 2764
Disassemble and Assemble Final Drive Assembly 2767
How to Disassemble Final Drive Assembly 2768
How to Assemble Final Drive Assembly 2774
Undercarriage and Frame 2785
Remove and Install Track Frame Assembly (Applicable Machine: 100001 to 100616) 2785
Remove Track Frame Assembly 2786
How to Install Track Frame Assembly 2790
Remove and Install Track Frame Assembly (Applicable Machine: 100617 and up) 2795
How to Remove Track Frame Assembly (Applicable Machine: 100617 and up) 2795
How to Install Track Frame Assembly (Applicable Machine: 100617 and up) 2800
Remove and Install Idler Assembly 2804
How to Remove Idler Assembly 2804
How to Install Idler Assembly 2806
Disassemble and Assemble Idler Assembly 2808
How to Disassemble Idler Assembly 2808
How to Assemble Idler Assembly 2810
Remove and Install Recoil Spring Assembly 2814
Remove Recoil Spring Assembly 2814
Install Recoil Spring Assembly 2814
Disassemble and Assemble Recoil Spring Assembly 2815
Disassemble Recoil Spring Assembly 2815
How to Assemble Recoil Spring Assembly 2819
Remove and Install Track Roller Assembly 2822
Remove Track Roller Assembly 2822
Install Track Roller Assembly 2824
Disassemble and Assemble Track Roller Assembly 2827
How to Disassemble Track Roller Assembly 2827
How to Assemble Track Roller Assembly 2829
Remove and Install No 1 Bogie Assembly 2832
Remove No 1 Bogie Assembly 2833
Install No 1 Bogie Assembly 2836
Remove and Install No 2, 3, 4 Bogie Assemblies 2841
How to Remove No 2, 3, 4 Bogie Assemblies 2842
Install No 2, 3, 4 Bogie Assemblies 2845
Disassemble and Assemble Bogie Assembly 2850
Disassemble Bogie Assembly 2850
How to Assemble Bogie Assembly 2851
Remove and Install Carrier Roller Assembly 2854
How to Remove Carrier Roller Assembly 2854
How to Install Carrier Roller Assembly 2855
Disassemble and Assemble Carrier Roller Assembly 2857
How to Disassemble Carrier Roller Assembly 2858
Assemble Carrier Roller Assembly 2860
Remove and Install Pivot Shaft Assembly 2863
How to Remove Pivot Shaft Assembly 2863
How to Install Pivot Shaft Assembly 2864
Separate and Connect Track Assembly 2866
Examine Before Separation of Track Assembly 2866
Separate Track Assembly (Standard) 2867
How to Separate Track Assembly (When Track Frame Has Internal Defect) 2868
How to Install Track Assembly 2869
Separate and Connect PLUS Type Track Assembly 2871
Separate PLUS Type Track Assembly Generally 2871
Install PLUS Type Track Assembly 2871
Disassemble and Assemble Track Assembly Generally 2873
How to Disassemble Full Track Shoe Assembly 2874
How to Assemble Full Track Shoe Assembly 2876
Disassemble and Assemble PLUS Type Track Assembly Generally 2888
Disassemble PLUS Type Track Assembly Generally 2889
How to Assemble PLUS Type Track Shoe Assembly Generally 2890
Disassemble and Assemble One Track Link Assembly in Field 2898
Disassemble One Track Link Assembly in Field 2899
Assemble One Track Link Assembly in Field 2900
Disassemble and Assemble Master Link 2902
Disassemble Master Link 2902
Assemble Master Link 2903
Remove and Install Equalizer Bar Assembly 2906
How to Remove Equalizer Bar Assembly 2907
How to Install Equalizer Bar Assembly 2909
Disassemble and Assemble Equalizer Bar Bushing 2911
Disassemble Equalizer Bar Bushing 2911
How to Assemble Equalizer Bar Bushing 2912
Remove and Install Sprocket 2913
Remove Sprocket 2913
Install Sprocket 2913
Remove and Install Center Under Guard Assembly 2915
How to Remove Underguard Assembly 2915
How to Install Underguard Assembly 2922
Hydraulic System 2930
Remove and Install Hydraulic Tank Assembly 2930
How to Remove Hydraulic Tank Assembly 2930
How to Install Hydraulic Tank Assembly 2932
Remove and Install Work Equipment Pump and HSS Pump Assembly 2934
Remove Work Equipment Pump and HSS Pump Assembly 2935
How to Install Work Equipment Pump and HSS Pump Assembly 2937
Remove and Install Power Train Pump and Steering Lubrication Pump Assembly 2939
Remove Power Train Pump and Steering Lubrication Pump Assembly 2940
How to Install Power Train Pump and Steering Lubrication Pump Assembly 2942
Remove and Install Cooling Fan Pump Assembly 2945
Remove Cooling Fan Pump Assembly 2945
How to Install Cooling Fan Pump Assembly 2948
Remove and Install Scavenging Pump Assembly 2951
Remove Scavenging Pump Assembly 2951
How to Install Scavenging Pump Assembly 2952
Remove and Install Control Valve Assembly 2954
How to Remove Control Valve Assembly 2955
How to Install Control Valve Assembly 2957
Work Equipment 2960
Remove and Install Blade Assembly 2960
How to Remove Blade Assembly 2960
How to Install Blade Assembly 2962
Remove and Install Blade Lift Cylinder Assembly 2965
Remove Blade Lift Cylinder Assembly 2966
Install Blade Lift Cylinder Assembly 2969
Disassemble and Assemble Blade Assembly 2973
Disassemble Blade Assembly 2973
Assemble Blade Assembly 2977
Method of Blade Angling 2983
Disassemble and Assemble Multi-Shank Ripper Assembly 2986
Disassemble Multi-Shank Ripper Assembly 2986
Assemble Multi-Shank Ripper Assembly 2990
Disassemble and Assemble Giant Ripper Assembly 2995
Disassemble Giant Ripper Assembly 2995
Assemble Giant Ripper Assembly 2999
Disassemble and Assemble Blade Lift Cylinder Assembly 3004
Disassemble Blade Lift Cylinder Assembly 3004
Assemble Blade Lift Cylinder Assembly 3007
Disassemble and Assemble Blade Tilt Cylinder Assembly 3011
Disassemble Blade Tilt Cylinder Assembly 3011
Assemble Blade Tilt Cylinder Assembly 3013
Disassemble and Assemble Ripper Cylinder Assembly 3017
How to Disassemble Ripper Cylinder Assembly 3017
How to Assemble Ripper Cylinder Assembly 3019
CAB Related Parts 3024
Remove and Install Operator Cab Assembly 3024
How to Remove Operator Cab Assembly 3025
How to Install Operator Cab Assembly 3032
Remove and Install Operator Cab Glass (Adhered Glass) 3041
How to Remove Operator Cab Glass (Adhered Glass) 3042
How to Install Operator Cab Glass (Adhered Glass) 3042
Remove and Install Air Conditioner Unit Assembly 3047
How to Remove Air Conditioner Unit Assembly 3047
How to Install Air Conditioner Unit Assembly 3053
Remove and Install Operator Seat 3061
How to Remove Operator Seat 3061
How to Install Operator Seat 3062
How to Remove and Install Seat Belt 3064
How to Remove Seat Belt 3064
How to Install Seatbelt 3064
Electrical System 3066
Remove and Install Engine Controller Assembly 3066
How to Remove Engine Controller Assembly 3066
How to Install Engine Controller Assembly 3069
Remove and Install Power Train Controller Assembly 3074
Remove Power Train Controller Assembly 3074
Install Power Train Controller Assembly 3075
Remove and Install Work Equipment Controller Assembly 3077
How to Remove Work Equipment Controller Assembly 3077
How to Install Work Equipment Controller Assembly 3078
Remove and Install Machine Monitor Assembly 3080
How to Remove Machine Monitor Assembly 3080
How to Install Machine Monitor Assembly 3081
Remove and Install Mass Air Flow and Temperature Sensor 3083
How to Remove Mass Air Flow and Temperature Sensor 3083
How to Install Mass Air Flow and Temperature Sensor 3084
Remove and Install KCCV Crankcase Pressure Sensor 3086
How to Remove KCCV Crankcase Pressure Sensor 3086
How to Install KCCV Crankcase Pressure Sensor 3087
Remove and Install SCR Temperature Sensor 3088
How to Remove SCR Temperature Sensor 3088
How to Install SCR Temperature Sensor 3090
Remove and Install Battery Relay 3092
How to Remove Battery Relay 3092
How to Install Battery Relay 3099
Remove and Install KOMTRAX Terminal Assembly 3105
How to Remove KOMTRAX Terminal Assembly 3105
How to Install KOMTRAX Terminal Assembly 3107
Remove and Install Gateway Controller Assembly 3110
Remove Gateway Controller Assembly 3110
Install Gateway Controller Assembly 3114
Remove and Install Communication Terminal 3119
How to Remove Communication Terminal 3119
How to Install Communication Terminal 3125
Remove and Install Communication Terminal Wiring Harness 3131
How to Remove Communication Terminal Wiring Harness 3132
How to Install Communication Terminal Wiring Harness 3144
60 Maintenance Standard 3157
Table of Contents 3158
Engine and Cooling System 3160
Maintenance Standard for Engine Mount 3160
Maintenance Standard for Damper 3162
Maintenance Standard for Cooling System 3164
Maintenance Standard for Cooling Fan Pump 3166
Maintenance Standard for Servo Valve 3168
Maintenance Standard for Cooling Fan Motor 3170
Power Train 3172
Maintenance Standard for Universal Joint 3172
Maintenance Standard for Power Train Mount 3173
Maintenance Standard for Torque Converter and PTO 3175
Maintenance Standard for Torque Converter Control Valve 3180
Maintenance Standard for Lockup Clutch ECMV 3181
Maintenance Standard for Stator Clutch ECMV 3182
Maintenance Standard for Transmission 3183
Maintenance Standard for Transmission ECMV 3188
Maintenance Standard for Main Relief Valve and Torque Converter Relief Valve 3189
Maintenance Standard for Transmission Lubrication Relief Valve 3190
Maintenance Standard for Bevel Gear Shaft, HSS, and Brake 3191
Maintenance Standard for Brake Control Valve 3197
Maintenance Standard for Brake ECMV 3199
Maintenance Standard for Brake Solenoid Valve 3200
Maintenance Standard for Sudden Stop Prevention Valve 3201
Maintenance Standard for Final Drive 3202
Maintenance Standard for Sprocket for Conventional Type Track Shoes 3205
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for Conventional Type Track Shoes 3206
Maintenance Standard for Sprocket for PLUS Type Track Shoes 3208
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for PLUS Type Track Shoes 3209
Undercarriage and Frame 3211
Maintenance Standard for Main Frame 3211
Maintenance Standard for Suspension 3213
Maintenance Standard for Track Frame and Idler Cushion 3215
Maintenance Standard for Idler 3217
Maintenance Standard for Track Roller for Conventional Type Track Shoes 3219
Maintenance Standard for Track Roller for PLUS Type Track Shoes 3221
Maintenance Standard for Carrier Roller for Conventional Type Track Shoes 3223
Maintenance Standard for Carrier Roller for PLUS Type Track Shoes 3224
Maintenance Standard for Conventional Type Track Shoes 3225
Maintenance Standard for PLUS Type Track Shoes 3227
Maintenance Standard for Single Shoes and Heavy Duty Shoes 3229
Hydraulic System 3230
Maintenance Standard for Hydraulic Tank 3230
Maintenance Standard for Scavenging Pump 3231
Maintenance Standard for Steering Lubrication Pump and Power Train Pump 3232
Maintenance Standard for Work Equipment and HSS Pump 3234
Maintenance Standard for PC-EPC Valve 3236
Maintenance Standard for HSS Motor 3237
Maintenance Standard for Control Valve 3240
Maintenance Standard for Self-Pressure Reducing Valve 3254
Maintenance Standard for Quick Drop Valve 3256
Work Equipment 3258
Maintenance Standard for Cylinder Stay 3258
Maintenance Standard for Front Work Equipment 3260
Maintenance Standard for Cutting Edge and End Bit 3265
Maintenance Standard for Blade Lift Cylinder 3267
Maintenance Standard for Blade Tilt Cylinder 3268
Maintenance Standard for Variable Multi-Shank Ripper 3269
Maintenance Standard for Variable Giant Ripper 3272
Maintenance Standard for Ripper Lift Cylinder 3275
Maintenance Standard for Ripper Tilt Cylinder 3276
CAB Related Parts 3277
Maintenance Standard for CAB Mount 3277
80 Appendix 3279
Table of Contents 3280
Precautions Before Work 3282
Air Conditioner System 3283
Precautions for Refrigerant 3283
Air Conditioner Component 3284
Specifications of Air Conditioner 3286
Structure and Function of Refrigeration Cycle 3287
Outline of Refrigeration Cycle 3288
Component Parts of Air Conditioner System 3290
Air Conditioner Unit 3290
Configuration Diagram of Air Conditioner Unit 3290
Function of Air Conditioner Unit 3292
Component Parts of Air Conditioner Unit 3294
Function of Evaporator as Air Conditioner Unit Component 3295
Function of Heater Core as Air Conditioner Unit Component 3295
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component 3295
Function of Servo Motor as Air Conditioner Unit Component 3295
Structure of Expansion Valve as Air Conditioner Unit Component 3296
Function of Expansion Valve as Air Conditioner Unit Component 3296
Operate Expansion Valve as Air Conditioner Unit Component 3296
Function of Triple Pressure Switch 3297
Air Conditioner Controller 3298
Structure of Air Conditioner Controller 3298
Compressor 3299
Structure of Compressor 3299
Specifications of Compressor 3299
Function of Compressor 3299
Condenser 3300
Structure of Condenser 3300
Specifications of Condenser 3300
Function of Condenser 3300
Receiver Drier 3301
Structure of Receiver Dryer 3301
Specifications of Receiver Dryer 3301
Function of Receiver Dryer 3301
Air Conditioner Related Sensors 3302
Structure of Sunlight Sensor 3302
Function of Sunlight Sensor 3302
Structure of Outside Temperature Sensor 3302
Function of Outside Air Temperature Sensor 3302
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 3304
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 3306
System Diagram of Air Conditioner 3308
Input and Output Signals of Air Conditioner Controller 3309
Function of Air Conditioner Controller 3310
Locations of Air Conditioner Parts and Layout of Connectors 3311
Examine Air Leakage (Duct) 3319
How to Examine Air Leakage (Duct) 3319
Examine Air Conditioner with Self-Diagnosis Function 3322
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor 3323
Examine Vent (Mode) Changeover 3324
How to Examine Vent (Mode) Changeover 3324
Examine Fresh/Recirc Air Changeover 3325
How to Examine Fresh/Recirc Air Changeover 3325
Examine Sunlight Sensor 3326
How to Examine Sunlight Sensor 3326
Examine Refrigerant (Triple) Pressure Switch 3327
How to Examine Refrigerant (Triple) Pressure Switch 3327
Examine Relay 3328
How to Examine Relay 3328
Air Conditioner Troubleshooting Chart 1 3329
Air Conditioner Troubleshooting Chart 2 3330
Information Shown in Troubleshooting Table 3333
Failure Code [879AKA] 3334
Failure Code [879AKB] 3335
Failure Code [879BKA] 3336
Failure Code [879BKB] 3338
Failure Code [879CKA] 3340
Failure Code [879CKB] 3341
Failure Code [879DKZ] 3342
Failure Code [879EMC] 3344
Failure Code [879FMC] 3345
Failure Code [879GKX] 3346
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 3348
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 3350
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 3354
A-4 Troubleshooting for Fresh/Recirc Air Changeover 3356
Troubleshooting by Gauge Pressure 3358
Connect Service Tool 3361
How to Connect Service Tool 3361
Precautions for Disconnection and Connection of Air Conditioner Piping 3363
Handle Compressor Oil 3365
90 Circuit Diagrams 3367
Table of Contents 3368
Hydraulic Circuit Diagram 3369
Symbols Used in Hydraulic Circuit Diagram 3369
Hydraulic Circuit Diagram (1/2) 3373
Hydraulic Circuit Diagram (2/2) 3375
Power Train Hydraulic Circuit Diagram 3377
Electrical Circuit Diagram 3379
Symbols Used in Electric Circuit Diagram 3379
Electrical Circuit Diagram(1/16) (Machine with KOMTRAX Terminal) 3383
Electrical Circuit Diagram(2/16) (Machine with KOMTRAX Terminal) 3385
Electrical Circuit Diagram(3/16) (Machine with KOMTRAX Terminal) 3387
Electrical Circuit Diagram(4/16) (Machine with KOMTRAX Terminal) 3389
Electrical Circuit Diagram(5/16) (Machine with KOMTRAX Terminal) 3391
Electrical Circuit Diagram(6/16) (Machine with KOMTRAX Terminal) 3393
Electrical Circuit Diagram(7/16) (Machine with KOMTRAX Terminal) 3395
Electrical Circuit Diagram(8/16) (Machine with KOMTRAX Terminal) 3397
Electrical Circuit Diagram(9/16) (Machine with KOMTRAX Terminal) 3399
Electrical Circuit Diagram(10/16) (Machine with KOMTRAX Terminal) 3401
Electrical Circuit Diagram(11/16) (Machine with KOMTRAX Terminal) 3403
Electrical Circuit Diagram(12/16) (Machine with KOMTRAX Terminal) 3405
Electrical Circuit Diagram(13/16) (Machine with KOMTRAX Terminal) 3407
Electrical Circuit Diagram(14/16) (Machine with KOMTRAX Terminal) 3409
Electrical Circuit Diagram(15/16) (Machine with KOMTRAX Terminal) 3411
Electrical Circuit Diagram(16/16) (Machine with KOMTRAX Terminal) 3413
Electrical Circuit Diagram(1/18) (Machine with Gateway Function Controller) 3415
Electrical Circuit Diagram(2/18) (Machine with Gateway Function Controller) 3417
Electrical Circuit Diagram(3/18) (Machine with Gateway Function Controller) 3419
Electrical Circuit Diagram(4/18) (Machine with Gateway Function Controller) 3421
Electrical Circuit Diagram(5/18) (Machine with Gateway Function Controller) 3423
Electrical Circuit Diagram(6/18) (Machine with Gateway Function Controller) 3425
Electrical Circuit Diagram(7/18) (Machine with Gateway Function Controller) 3427
Electrical Circuit Diagram(8/18) (Machine with Gateway Function Controller) 3429
Electrical Circuit Diagram(9/18) (Machine with Gateway Function Controller) 3431
Electrical Circuit Diagram(10/18) (Machine with Gateway Function Controller) 3433
Electrical Circuit Diagram(11/18) (Machine with Gateway Function Controller) 3435
Electrical Circuit Diagram(12/18) (Machine with Gateway Function Controller) 3437
Electrical Circuit Diagram(13/18) (Machine with Gateway Function Controller) 3439
Electrical Circuit Diagram(14/18) (Machine with Gateway Function Controller) 3441
Electrical Circuit Diagram(15/18) (Machine with Gateway Function Controller) 3443
Electrical Circuit Diagram(16/18) (Machine with Gateway Function Controller) 3445
Electrical Circuit Diagram(17/18) (Machine with Gateway Function Controller) 3447
Electrical Circuit Diagram(18/18) (Machine with Gateway Function Controller) 3449
Index 3451

DESCRIPTION:

Komatsu D155AX-8E0 Bulldozer Shop Manual SEN06762-01 – PDF DOWNLOAD 

SERIAL NUMBERS 100358 and up

Foreword, Safety, Basic Information
How to Read the Shop Manual
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
• The caution lamps, pilot lamps, and symbols of the switches on the machine monitor can be different in
accordance with the machine.
• For details of the symbols shown on the machine monitor, see Structure and Operation, “Caution
Lamps Shown on Machine Monitor” and “Pilot Lamps Shown on Machine Monitor”.
• For details of the switches of the machine monitor, see Testing and Adjusting, “Set and Operate Machine
Monitor”.
• For details of the switches, see the “Operation and Maintenance Manual”.
• All “AdBlue/DEF” shown on the machine monitor is referred to as “DEF” in the shop manual. Some machine
monitors installed to the product show “DEF” as “AdBlue/DEF” in the service mode. Thus, be sure to recognize
that “DEF” and “AdBlue/DEF” are the same when you read the shop manual.
Composition of the Shop Manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 Index and Foreword
This section describes the index, foreword, safety, and basic information.
01 Specification
This section describes the specifications of the machine.
10 Structure and Function
This section describes the structure and operation of each component with respect to each system. “Structure
and Function” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 Standard Value Table
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 Testing and Adjusting
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “Standard Value Table”.
40 Troubleshooting
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.

S.V 30/12/24