Komatsu BULLDOZER D155AX-7 SHOP Manual SEN05653-05 PDF

Description

Komatsu BULLDOZER D155AX-7 SHOP Manual SEN05653-05  – PDF DOWNLOAD

FILE DETAILS:

Komatsu BULLDOZER D155AX-7 SHOP Manual SEN05653-05  – PDF DOWNLOAD

Language : English
Pages :2796
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu BULLDOZER D155AX-7 SHOP Manual SEN05653-05  – PDF DOWNLOAD

SERIAL NUMBERS 90001 and up

General precautions

Inappropriate handling causes an extreme danger. Read and understand what is described in the operation and maintenance manual before operating the machine. Read and understand what is described in this manual before starting the work.

• Before performing any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the operation and maintenance manual. • Locate a place in the repair workshop to keep the tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
• When performing any work, always wear the safety shoes and helmet. Do not wear loose work cloths, or clothes with buttons missing.
• 1. Always wear the protective eyeglasses when hitting parts with a hammer.
• 2. Always wear the protective eyeglasses when grinding parts with a grinder, etc.
• When performing any work with 2 or more workers, always agree on the working procedure before starting. While working, always keep conversations of the work between your fellow workers and your self on any step of the work. During the work, hang the warning tag of “UNDER WORKING” in the operator’s compartment.
• Only qualified workers must perform the work and operation which require license or qualification.
• Keep the tools in good condition. And learn the correct way to use the tools, and use the proper ones among them. Before starting the work, thoroughly check the tools, lift truck, service vehicle, etc.
• If welding repairs is required, always have a trained and experienced welder with good knowledge of welding perform the work. When performing welding work, always wear welding gloves, apron, shielding goggles, cap, etc. • Before starting work, warm up your body thoroughly to start work under good condition.
• Avoid continuing work for long hours and take rests with proper intervals to keep your body in good condition. Take a rest in a specified safe place.

TABLE OF CONTENTS:

Komatsu BULLDOZER D155AX-7 SHOP Manual SEN05653-05  – PDF DOWNLOAD

SERIAL NUMBERS 90001 and up

Cover 1
00 Index and foreword 3
Index 4
Foreword, safety and general information 19
Important safety notice 19
How to read the shop manual 26
Explanation of terms for maintenance standard 28
Handling equipment of fuel system devices 30
Handling of intake system parts 31
Handling of hydraulic equipment 32
Method of disconnecting and connecting of push-pull type coupler 34
Handling of electrical equipment 37
How to read electric wire code 45
Precautions when performing operation 48
Practical use of KOMTRAX 53
Standard tightening torque table 54
List of abbreviation 60
Conversion table 65
01 Specification 71
Table of contents 72
Specifications 73
Specification drawing 73
Specification 75
Weight table 83
Table of fuel, coolant, and lubricants 85
10 Structure and function 87
Table of contents 88
Engine and cooling system 90
Engine related parts 90
KVGT 92
EGR system piping drawing 98
EGR system circuit diagram 100
EGR valve 101
EGR cooler 103
KCCV layout drawing 105
KCCV ventilator 107
KDPF 109
Damper 113
Cooling system 115
Cooling fan pump 118
Cooling fan motor 128
Power train 136
Power train system 136
HSS system 139
Overall drawing of power train unit 141
Power train mount 143
Layout of power train hydraulic piping 145
Transmission, steering, and brake control 147
Universal joint 149
Torque converter and PTO 150
Torque converter control valve 158
Lockup clutch ECMV 159
Stator clutch ECMV 164
Transmission 168
Transmission ECMV 182
Main relief valve and torque converter relief valve 191
Transmission lubrication relief valve 193
Bevel gear shaft, HSS, and brake 194
Brake control valve 212
Brake ECMV 215
Brake solenoid valve 219
Sudden stop prevention valve 221
Final drive 223
Undercarriage and frame 226
Main frame 226
Suspension 228
Track frame and idler cushion 230
Hydraulic system 232
Hydraulic component layout 232
Work equipment control 235
Hydraulic tank 238
CLSS 242
Scavenging pump 246
Steering lubrication pump and power train pump 247
Work equipment and HSS pump 249
HSS motor 273
Control valve 281
Quick drop valve 319
Work equipment lock solenoid valve 325
Hydraulic oil cooler bypass valve 326
Accumulator 327
Self-pressure reducing valve 329
Work equipment 336
Cylinder stay 336
Blade 337
Ripper 338
Piston valve 340
Cab and its attachments 341
ROPS cab 341
Function 342
Cab mount 343
Electrical system 344
Engine control 344
Engine control system 345
Palm command control system 346
System operating lamp function 350
Battery disconnect switch function 352
Machine monitor system 354
KOMTRAX system 376
System component parts 378
Sensor 396
20 Standard value tables 411
Table of contents 412
Standard service value table 413
Standard value table for engine 413
Standard value table for machine 415
Standard value table for electrical system 426
30 Testing and adjusting 437
Table of contents 438
Related information on testing and adjusting 440
Tools for testing and adjusting 440
Sketch of tools for testing and adjusting 443
Engine and cooling system 445
Testing engine speed 445
Testing boost pressure 447
Testing exhaust gas temperature 448
Testing exhaust gas color 451
Adjusting valve clearance 453
Measuring compression pressure 455
Testing blowby pressure 458
Testing engine oil pressure 459
Testing EGR valve and KVGT driving oil pressure 460
Measuring fuel pressure 462
Testing fuel return rate and leakage 463
Bleeding air from fuel system 466
Testing fuel circuit for leakage 468
Handling cylinder cutout mode operation 469
Handling no-injection cranking operation 470
Replacing belt for alternator and air conditioner compressor, adjusting belt tension 471
Adjusting fuel control dial and decelerator pedal 472
Procedures for cleaning fuel doser 474
Writing compensation values at replacement of injector and engine controller 477
Power train 481
Testing power train oil pressure 481
Adjusting transmission output shaft speed sensor (replacement procedure) 487
Simple test procedure for brake performance 488
Adjusting brake pedal 489
Adjusting parking brake lever 491
Retrieval of disabled machine by using brake release device 493
Undercarriage and frame 496
Adjusting idler clearance 496
Testing and adjusting track tension 498
Hydraulic system 499
Releasing remaining pressure in work equipment cylinder 499
Testing and adjusting work equipment and HSS oil pressures 500
Bleeding air from work equipment and HSS pump 504
Testing source pressure of control circuit 505
Testing work equipment lock solenoid valve output pressure 506
Isolating the parts causing hydraulic drift in blade and ripper 507
Checking fan speed 508
Testing fan circuit oil pressure 509
Bleeding air from fan pump 511
Testing internal oil leakage of work equipment cylinder 512
Bleeding air from work equipment cylinders 513
Emergency operating method when work equipment has trouble 514
Testing ripper pin puller solenoid valve output pressure 516
Work equipment 517
Adjusting work equipment lock lever 517
Adjusting blade 519
Cab and its attachments 521
Adjusting operator’s cab 521
Electrical system 524
Special functions of machine monitor 524
Angle adjustment of rear view camera 603
Handling voltage circuit of engine controller 604
Handling battery disconnect switch 605
Testing diodes 606
Pm clinic 607
Pm Clinic service 607
Check sheet 612
40 Troubleshooting 619
Table of contents 620
Related information on troubleshooting 630
Troubleshooting points 630
Sequence of events in troubleshooting 632
Checks before troubleshooting 634
Inspection procedure before troubleshooting 636
Preparation for troubleshooting of electrical system 654
Classification and procedures for troubleshooting 660
Symptom and troubleshooting numbers 662
Information in troubleshooting table 665
Connector/electrical wiring connection table 667
Layout of connectors 740
Connector contact identification 747
T-branch box and T-branch adapter table 786
Fuse location table 791
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement 795
Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) 798
Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) 799
Failure codes table 800
Troubleshooting by failure code (Display of code) 814
Failure code [1500L0] 814
Failure code [15SAL1] 815
Failure code [15SALH] 817
Failure code [15SBL1] 819
Failure code [15SBLH] 821
Failure code [15SEL1] 823
Failure code [15SELH] 825
Failure code [15SFL1] 827
Failure code [15SFLH] 829
Failure code [15SGL1] 831
Failure code [15SGLH] 833
Failure code [15SJL1] 835
Failure code [15SJLH] 837
Failure code [1800MW] 839
Failure code [2300NR] 841
Failure code [2301L1] 842
Failure code [2301LH] 844
Failure code [2302L1] 846
Failure code [2302LH] 848
Failure code [879AKA] 850
Failure code [879AKB] 851
Failure code [879BKA] 852
Failure code [879BKB] 853
Failure code [879CKA] 854
Failure code [879CKB] 855
Failure code [879DKZ] 856
Failure code [879EMC] 857
Failure code [879FMC] 858
Failure code [879GKX] 859
Failure code [989L00] 860
Failure code [989M00] 861
Failure code [989N00] 862
Failure code [A1U0N3] 863
Failure code [A1U0N4] 865
Failure code [AA10NX] 867
Failure code [AB00KE] 869
Failure code [B@BAZG] 871
Failure code [B@BCNS] 872
Failure code [B@BCZK] 873
Failure code [B@CENS] 875
Failure code [B@HANS] 876
Failure code [CA115] 877
Failure code [CA122] 878
Failure code [CA123] 881
Failure code [CA131] 884
Failure code [CA132] 887
Failure code [CA135] 890
Failure code [CA141] 893
Failure code [CA144] 896
Failure code [CA145] 898
Failure code [CA153] 901
Failure code [CA154] 903
Failure code [CA187] 906
Failure code [CA221] 909
Failure code [CA222] 912
Failure code [CA227] 915
Failure code [CA234] 916
Failure code [CA238] 918
Failure code [CA239] 920
Failure code [CA271] 922
Failure code [CA272] 924
Failure code [CA273] 926
Failure code [CA274] 928
Failure code [CA322] 930
Failure code [CA323] 933
Failure code [CA324] 936
Failure code [CA325] 939
Failure code [CA331] 942
Failure code [CA332] 945
Failure code [CA343] 948
Failure code [CA351] 949
Failure code [CA352] 950
Failure code [CA356] 952
Failure code [CA357] 955
Failure code [CA386] 958
Failure code [CA441] 959
Failure code [CA442] 963
Failure code [CA449] 964
Failure code [CA451] 965
Failure code [CA452] 968
Failure code [CA515] 971
Failure code [CA516] 973
Failure code [CA553] 975
Failure code [CA555] 977
Failure code [CA556] 978
Failure code [CA559] 980
Failure code [CA595] 986
Failure code [CA687] 987
Failure code [CA689] 990
Failure code [CA691] 994
Failure code [CA692] 997
Failure code [CA697]1000
Failure code [CA698]1001
Failure code [CA731]1002
Failure code [CA778]1003
Failure code [CA1117]1007
Failure code [CA1664]1008
Failure code [CA1691]1012
Failure code [CA1695]1016
Failure code [CA1696]1018
Failure code [CA1843]1020
Failure code [CA1844]1023
Failure code [CA1879]1026
Failure code [CA1881]1029
Failure code [CA1883]1032
Failure code [CA1921]1037
Failure code [CA1922]1040
Failure code [CA1923]1046
Failure code [CA1924]1049
Failure code [CA1925]1052
Failure code [CA1927]1055
Failure code [CA1928]1058
Failure code [CA1942]1061
Failure code [CA1963]1063
Failure code [CA1977]1069
Failure code [CA1993]1072
Failure code [CA2185]1075
Failure code [CA2186]1077
Failure code [CA2249]1079
Failure code [CA2265]1080
Failure code [CA2266]1082
Failure code [CA2271]1085
Failure code [CA2272]1088
Failure code [CA2349]1091
Failure code [CA2353]1094
Failure code [CA2357]1097
Failure code [CA2381]1100
Failure code [CA2382]1103
Failure code [CA2383]1106
Failure code [CA2386]1109
Failure code [CA2387]1112
Failure code [CA2555]1115
Failure code [CA2556]1118
Failure code [CA2637]1121
Failure code [CA2639]1124
Failure code [CA2732]1127
Failure code [CA2733]1130
Failure code [CA2741]1132
Failure code [CA2765]1134
Failure code [CA2878]1135
Failure code [CA2881]1139
Failure code [CA3133]1146
Failure code [CA3134]1149
Failure code [CA3135]1152
Failure code [CA3167]1156
Failure code [CA3251]1161
Failure code [CA3253]1166
Failure code [CA3254]1170
Failure code [CA3255]1175
Failure code [CA3256]1180
Failure code [CA3311]1185
Failure code [CA3312]1190
Failure code [CA3313]1195
Failure code [CA3314]1199
Failure code [CA3315]1204
Failure code [CA3316]1211
Failure code [CA3317]1215
Failure code [CA3318]1220
Failure code [CA3319]1227
Failure code [CA3321]1232
Failure code [CA3322]1236
Failure code [CA3419]1243
Failure code [CA3421]1245
Failure code [D130KA]1247
Failure code [D130KB]1250
Failure code [D190KA]1253
Failure code [D190KB]1256
Failure code [D19JKZ]1259
Failure code [D811MC]1263
Failure code [D862KA]1264
Failure code [D8ALKA]1265
Failure code [D8ALKB]1268
Failure code [D8AQKR]1271
Failure code [DAF0MB]1273
Failure code [DAF0MC]1274
Failure code [DAF8KB]1275
Failure code [DAF9KQ]1277
Failure code [DAFGMC]1278
Failure code [DAFLKA]1279
Failure code [DAFLKB]1282
Failure code [DAFQKR]1285
Failure code [DAZ9KQ]1286
Failure code [DAZQKR]1287
Failure code [DB2QKR]1289
Failure code [DB2RKR]1296
Failure code [DB90KT]1303
Failure code [DB90MC]1304
Failure code [DB91KK]1305
Failure code [DB92KK]1308
Failure code [DB95KK]1311
Failure code [DB97KK]1314
Failure code [DB99KQ]1316
Failure code [DB9LKA]1317
Failure code [DB9LKB]1320
Failure code [DB9QKR]1323
Failure code [DB9RKR]1325
Failure code [DBE0KT]1328
Failure code [DBE1KK]1329
Failure code [DBE2KK]1332
Failure code [DBE5KK]1335
Failure code [DBE6KK]1338
Failure code [DBE9KQ]1341
Failure code [DBELKA]1343
Failure code [DBELKB]1346
Failure code [DBEQKR]1349
Failure code [DBERKR]1351
Failure code [DD12KA]1354
Failure code [DD12KB]1356
Failure code [DD13KA]1358
Failure code [DD13KB]1360
Failure code [DD14KA]1362
Failure code [DD14KB]1364
Failure code [DDDDKA]1367
Failure code [DDDDKB]1369
Failure code [DDDDKX]1372
Failure code [DDKAKA]1373
Failure code [DDKAKB]1376
Failure code [DDKBKA]1378
Failure code [DDKBKB]1381
Failure code [DDKCL4]1383
Failure code [DDKEL4]1386
Failure code [DDN7L4]1389
Failure code [DDN8L4]1392
Failure code [DDNLKA]1395
Failure code [DDNLKB]1397
Failure code [DDTSL1]1399
Failure code [DDTSLH]1401
Failure code [DFA4KX]1403
Failure code [DFA4KZ]1404
Failure code [DFA4L8]1405
Failure code [DFA5KA]1406
Failure code [DFA5KB]1409
Failure code [DFA6KA]1412
Failure code [DFA6KB]1415
Failure code [DFA7KX]1418
Failure code [DFA7KZ]1419
Failure code [DFA7L8]1420
Failure code [DFA8KA]1421
Failure code [DFA8KB]1424
Failure code [DFA9KA]1427
Failure code [DFA9KB]1430
Failure code [DFAAKX]1433
Failure code [DFAAKZ]1434
Failure code [DFAAL8]1435
Failure code [DFABKA]1436
Failure code [DFABKB]1439
Failure code [DFACKA]1442
Failure code [DFACKB]1445
Failure code [DGS1KA]1448
Failure code [DGS1KX]1451
Failure code [DGT1KA]1453
Failure code [DGT1KX]1456
Failure code [DH21KA]1458
Failure code [DH21KB]1461
Failure code [DHA4KA]1464
Failure code [DHT5KA]1466
Failure code [DHT5KB]1469
Failure code [DHT7KA]1472
Failure code [DHT7KB]1475
Failure code [DK10KA]1478
Failure code [DK10KB]1481
Failure code [DK30KA]1483
Failure code [DK30KB]1486
Failure code [DK30KX]1489
Failure code [DK30KZ]1490
Failure code [DK30L8]1491
Failure code [DK31KA]1492
Failure code [DK31KB]1495
Failure code [DK40KA]1498
Failure code [DK40KB]1501
Failure code [DK55KX]1504
Failure code [DK55KZ]1505
Failure code [DK55L8]1506
Failure code [DK56KA]1507
Failure code [DK56KB]1510
Failure code [DK57KA]1513
Failure code [DK57KB]1516
Failure code [DKH1KA]1519
Failure code [DKH1KB]1522
Failure code [DLM3KA]1524
Failure code [DLM3MB]1526
Failure code [DLT3KA]1527
Failure code [DLT3KB]1529
Failure code [DR21KX]1531
Failure code [DR31KX]1532
Failure code [DV20KB]1533
Failure code [DW7BKA]1535
Failure code [DW7BKB]1537
Failure code [DWN1KA]1539
Failure code [DWN1KB]1541
Failure code [DWN1KY]1543
Failure code [DWN2KA]1545
Failure code [DWN2KB]1547
Failure code [DWN2KY]1549
Failure code [DWN3KA]1551
Failure code [DWN3KB]1553
Failure code [DWN3KY]1555
Failure code [DWN5KA]1557
Failure code [DWN5KB]1559
Failure code [DWN5KY]1561
Failure code [DXA2KA]1564
Failure code [DXA2KB]1566
Failure code [DXA2KY]1568
Failure code [DXH1KA]1570
Failure code [DXH1KB]1572
Failure code [DXH1KY]1574
Failure code [DXH4KA]1576
Failure code [DXH4KB]1578
Failure code [DXH4KY]1580
Failure code [DXH5KA]1583
Failure code [DXH5KB]1585
Failure code [DXH5KY]1587
Failure code [DXH6KA]1589
Failure code [DXH6KB]1591
Failure code [DXH6KY]1593
Failure code [DXH7KA]1595
Failure code [DXH7KB]1597
Failure code [DXH7KY]1599
Failure code [DXH8KA]1601
Failure code [DXH8KB]1603
Failure code [DXH8KY]1605
Failure code [DXHBKA]1607
Failure code [DXHBKB]1609
Failure code [DXHBKY]1611
Failure code [DXHCKA]1613
Failure code [DXHCKB]1615
Failure code [DXHCKY]1617
Failure code [DXHRKA]1619
Failure code [DXHRKB]1621
Failure code [DXHRKY]1623
Failure code [DXHSKA]1625
Failure code [DXHSKB]1627
Failure code [DXHSKY]1629
Failure code [DXHTKA]1631
Failure code [DXHTKB]1633
Failure code [DXHTKY]1635
Failure code [DXHUKA]1637
Failure code [DXHUKB]1639
Failure code [DXHUKY]1641
Failure code [DXHWKA]1643
Failure code [DXHWKB]1645
Failure code [DXHWKY]1647
Failure code [DXHXKA]1649
Failure code [DXHXKB]1651
Failure code [DXHXKY]1653
Failure code [DXHYKA]1655
Failure code [DXHYKB]1657
Failure code [DXHYKY]1659
Failure code [DXHZKA]1661
Failure code [DXHZKB]1663
Failure code [DXHZKY]1665
Failure code [DXJ4KA]1667
Failure code [DXJ4KB]1669
Failure code [DXJ8KA]1671
Failure code [DXJ8KB]1673
Failure code [DXJ8KY]1675
Failure code [DXJ9KA]1677
Failure code [DXJ9KB]1679
Failure code [DXJ9KY]1681
Failure code [DXJAKA]1683
Failure code [DXJAKB]1685
Failure code [DXJAKY]1687
Failure code [DXJBKA]1689
Failure code [DXJBKB]1691
Failure code [DXJBKY]1693
Troubleshooting of electrical system (E-mode)1695
E-1 Engine does not start (Engine does not crank)1695
E-2 Manual preheating system does not work1705
E-3 Automatic preheating system does not work1709
E-4 While preheating is working, preheating monitor does not light up1712
E-5 When starting switch is turned to ON position, machine monitor displays nothing1714
E-6 When starting switch is turned to ON position (with engine stopped), radiator coolant level monitor lights up in yellow1720
E-7 Air cleaner clogging monitor lights up in yellow while engine is running1722
E-8 Charge level monitor lights up in red while engine is running1723
E-9 Engine coolant temperature monitor lights up in red while engine is running1725
E-10 Engine oil pressure monitor lights up in red while engine is running1726
E-11 Power train oil temperature monitor lights up in red while engine is running1727
E-12 Hydraulic oil temperature monitor lights up in red while engine is running1728
E-13 Engine coolant temperature gauge does not indicate correct temparature1729
E-14 Fuel level gauge does not indicate correct level1731
E-15 Power train oil temperature gauge does not indicate correct temperature1734
E-16 Hydraulic oil temperature gauge does not indicate correct temperature1736
E-17 Operation mode does not change1738
E-18 Gear shift mode does not change1739
E-19 Operating customize switch does not display customize screen1740
E-20 Modifying setting on customize screen does not change setting of machine1741
E-21 Some areas of machine monitor screen are not displayed1742
E-22 Alarm buzzer does not sound or does not stop sounding1743
E-23 While starting switch is in OFF position, service meter is not displayed1744
E-24 Service mode cannot be selected1745
E-25 Horn does not sound1746
E-26 Horn does not stop sounding1749
E-27 Backup alarm does not sound1751
E-28 Backup alarm does not stop sounding1753
E-29 Headlamp does not light up1754
E-30 Rear lamp and ripper point lamp do not light up1760
E-31 No wiper operates continuously or intermittently1766
E-32 Front wiper does not operate (failed continuous and intermittent operations)1771
E-33 Rear wiper does not operate (failed continuous and intermittent operations)1776
E-34 Left door wiper does not operate (failed continuous and intermittent operations)1781
E-35 Right door wiper does not operate (failed continuous and intermittent operations)1786
E-36 Front washer does not operate1791
E-37 Rear washer does not operate1794
E-38 Left door washer does not operate1797
E-39 Right door washer does not operate1800
E-40 Ripper pin puller does not work1803
E-41 Fan does not rotate in reverse1806
E-42 Fuel feed pump does not operate or stop automatically1807
E-43 Gear cannot be shifted1810
E-44 KOMTRAX system does not operate properly1811
Troubleshooting of hydraulic and mechanical system (H-mode)1814
Information described in troubleshooting table (H-mode)1814
System chart of hydraulic and mechanical systems1815
Failure mode and cause table1819
H-1 Machine lacks power (insufficient drawbar pull)1825
H-2 Machine does not travel (at 2nd or 3rd gear speed)1830
H-3 Machine does not start at all gear speeds1833
H-4 Machine travels only in one direction, either forward or in reverse1838
H-5 Large time lag is in gear shifting or directional change1840
H-6 Machine cannot be steered (machine does not turn to left or right)1844
H-7 Steering speed or power is insufficient1847
H-8 Brake does not work1850
H-9 Torque converter lockup clutch does not engage1852
H-10 Power train oil overheats1854
H-11 Unusual noise is heard from around HSS pump or HSS motor1858
H-12 All work equipment operates slowly1860
H-13 All work equipment do not operate1864
H-14 Blade lift speed or power is low1868
H-15 Blade tilt speed or power is low1872
H-16 Ripper lift speed or power is low1876
H-17 Ripper tilt speed or power is low1880
H-18 Hydraulic drift of lifted blade is large1884
H-19 Hydraulic drift of tilted blade is large1885
H-20 Hydraulic drift of lifted ripper is large1886
H-21 Ripper pin puller cylinder does not operate1887
H-22 Blade pitch cylinder does not operate1888
H-23 Unusual noise is heard from around work equipment pump1890
H-24 Fan speed is abnormal (too high or low, or stationary)1892
H-25 Unusual noise is heard from around fan1894
Troubleshooting of engine (S-mode)1895
Information mentioned in troubleshooting table (S mode)1895
S-1 When starting switch is turned to START position, engine does not crank1896
S-2 Engine cranks but no exhaust smoke comes out1898
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start)1901
S-4 Engine startability is poor1905
S-5 Engine does not pick up smoothly1909
S-6 Engine stops during operation1913
S-7 Engine runs rough or is unstable1918
S-8 Engine lacks power1920
S-9 Exhaust smoke from engine outlet (in front of KDPF) is black (KDPF gets clogged in a short time)1926
S-10 Engine oil consumption is excessive1930
S-11 Engine oil becomes contaminated early1934
S-12 Fuel consumption is excessive1937
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)1939
S-14 Engine oil pressure drops1941
S-15 Fuel is contaminated in engine oil1946
S-16 Coolant is contaminated in engine oil (Oil becomes cloudy white)1947
S-17 Coolant temperature rises too high (overheating)1949
S-18 Unusual noise is heard1952
S-19 Vibration is excessive1955
S-20 Air cannot be bled from fuel circuit1958
S-21 Active regeneration is executed frequently1960
S-22 Active regeneration takes time1962
S-23 White smoke is exhausted during active regeneration1964
50 Disassembly and assembly1967
Table of contents1968
Related information on disassembly and assembly1970
How to read this manual1970
Coating materials list1972
Special tools list1976
Sketches of special tools1984
Engine and cooling system1998
Removal and installation of fuel supply pump assembly1998
Removal and installation of fuel injector assembly2005
Removal and installation of cylinder head assembly2023
Removal and installation of air cleaner assembly2051
Removal and installation of KDPF assembly2056
Disassembly and assembly of KDPF assembly2063
Removal and installation of KCCV assembly2076
Removal and installation of engine assembly2081
Removal and installation of engine front seal2094
Removal and installation of engine rear seal2100
Removal and installation of radiator assembly2105
Removal and installation of aftercooler assembly2114
Removal and installation of hydraulic oil cooler assembly2120
Removal and installation of cooling fan drive assembly2125
Removal and installation of cooling in fan motor assembly2130
Removal and installation of engine hood assembly2133
Removal and installation of fuel tank assembly2140
Power train2145
Removal and installation of damper assembly2145
Disassembly and assembly of damper assembly2150
Removal and installation of power train unit assembly2156
Disconnection and connection of power train unit assembly2169
Disassembly and assembly of PTO assembly2175
Disassembly and assembly of torque converter assembly2184
Disassembly and assembly of transmission assembly2195
Disassembly and assembly of HSS assembly2215
Removal and installation of HSS motor assembly2235
Removal and installation of final drive assembly2238
Disassembly and assembly of final drive2245
Undercarriage and frame2261
Removal and installation of track frame assembly2261
Removal and installation of idler assembly2269
Disassembly and assembly of idler assembly2274
Removal and installation of recoil spring assembly2280
Disassembly and assembly of recoil spring assembly2283
Removal and installation of track roller assembly2289
Disassembly and assembly of track roller assembly2293
Removal and installation of 1st bogie assembly 2297
Removal and installation of 2nd, 3rd, and 4th bogie assemblies2307
Disassembly and assembly of bogie assembly2316
Removal and installation of carrier roller assembly 2320
Disassembly and assembly of carrier roller assembly2323
Removal and installation of pivot shaft assembly 2329
Separation and connection of track shoe assembly2332
Overall disassembly and assembly of track shoe assembly2337
Field disassembly and assembly of one link2350
Disassembly and assembly of master link2356
Removal and installation of equalizer bar assembly 2361
Disassembly and assembly of equalizer bar bushing2366
Removal and installation of segment teeth2368
Hydraulic system2371
Removal and installation of hydraulic tank assembly2371
Removal and installation of control valve assembly2376
Removal and installation of work equipment pump and HSS pump assembly2381
Removal and installation of power train pump and steering lubrication pump2384
Removal and installation of cooling fan pump assembly2387
Removal and installation of scavenging pump assembly2393
Disassembly and assembly of hydraulic cylinder assembly2396
Work equipment2407
Removal and installation of blade assembly2407
Disassembly and assembly of blade assembly2412
Disassembly and assembly of multi-shank ripper assembly2418
Disassembly and assembly of giant ripper assembly2423
Cab and its attachments2430
Removal and installation of operator’s cab assembly2430
Removal and installation of operator’s cab glass (adhered window glass)2443
Removal and installation of operator’s seat assembly2450
Removal and installation of seat belt assembly2453
Removal and installation of air conditioner unit assembly2456
Removal and installation of air conditioner compressor assembly2468
Removal and installation of air conditioner condenser assembly2472
Electrical system2476
Removal and installation of machine monitor assembly2476
Removal and installation of engine controller assembly 2479
Removal and installation of power train controller 2482
Removal and installation of work equipment controller assembly 2485
Removal and installation of mass air flow and temperature sensor 2488
Removal and installation of KOMTRAX terminal 2491
60 Maintenance standard 2497
Table of contents 2498
Engine and cooling system 2499
Engine mount 2499
Damper 2500
Cooling system 2502
Cooling fan pump 2505
Cooling fan motor 2509
Power train 2511
Power train mount 2511
Universal joint 2513
Torque converter and PTO 2514
Torque converter control valve 2520
Lockup clutch ECMV 2521
Stator cluch ECMV 2522
Transmission 2523
Transmission ECMV 2528
Main relief valve and torque converter relief valve 2529
Transmission lubrication relief valve 2530
Bevel gear shaft, HSS, and brake 2531
Brake control valve 2537
Brake ECMV 2539
Brake solenoid valve 2540
Sudden stop prevention valve 2541
Final drive 2542
Sprocket 2545
Full-scale drawing of sprocket tooth profile 2546
Undercarriage and frame 2547
Main frame 2547
Suspension 2549
Track frame and idler cushion 2551
Idler 2553
Track roller 2555
Carrier roller 2557
Track shoe 2558
Hydraulic system 2562
Hydraulic tank 2562
Scavenging pump 2563
Steering lubrication pump and power train pump 2564
Work equipment and HSS pump 2566
PC-EPC valve 2568
HSS motor 2569
Control valve 2572
Quick drop valve 2585
Self-pressure reducing valve 2587
Work equipment 2589
Cylinder stay 2589
Blade 2590
Cutting edge and end bit 2592
Ripper 2593
Blade lift cylinder 2601
Blade tilt cylinder 2602
Ripper lift cylinder 2603
Ripper tilt cylinder 2604
Cab and its attachments 2605
Cab mount 2605
80 Appendix 2607
Table of contents 2608
Air conditioner components2609
Precautions for refrigerant2609
Air conditioner component2610
Configuration and function of refrigeration cycle2612
Outline of refrigeration cycle2613
Air conditioner unit2615
Air conditioner controller2622
Compressor2623
Condenser2624
Receiver drier2625
Sunlight sensor2626
Outer temperature sensor (outside air temperature sensor) 2627
Procedure for testing and troubleshooting 2628
Circuit diagram and arrangement of connector pins2630
System diagram2632
Parts and connectors layout2635
Testing air leakage (duct) 2643
Testing with self-diagnosis function2646
Testing vent (mode) changeover2649
Testing FRESH/RECIRC air changeover2650
Testing sunlight sensor2651
Testing (dual) pressure switch for refrigerant2652
Testing relays2654
Troubleshooting chart 1 2655
Troubleshooting chart 22656
Information in troubleshooting table2658
Failure code list related to air conditioner2660
Failure code [879AKA]2661
Failure code [879AKB] 2662
Failure code [879BKA]2663
Failure code [879BKB]2665
Failure code [879CKA]2668
Failure code [879CKB]2669
Failure code [879DKZ] 2670
Failure code [879EMC]2672
Failure code [879FMC]2673
Failure code [879GKX]2674
A-1 Troubleshooting for power supply system (Air conditioner does not operate)2676
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled)2679
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal)2684
A-4 Troubleshooting for FRESH/RECIRC air changeover2687
Troubleshooting with gauge pressure2690
Connection of service tool2693
Precautions for disconnecting and connecting refrigerant piping2695
Handling of compressor oil2697
90 Drawings2699
Table of contents2700
Hydraulic circuit diagram2701
Symbols in hydraulic circuit diagram2701
Power train hydraulic circuit diagram2705
Hydraulic circuit diagram2707
Electric circuit diagram2711
Symbols in electric circuit diagram2711
Electrical circuit diagram2715
Air conditioner electrical circuit diagram2741
Wiring harness diagram2743

IMAGES PREVIEW OF THE MANUAL:

S.M 26/12/24