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KOMATSU D155AX-3 SUPER DOZER SERVICE REPAIR MANUAL – PDF Download
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- KOMATSU D155AX-3 SUPER DOZER SERVICE REPAIR MANUAL
- SERIAL NUMBERS: D155AX-3 – 60001 & up
- PUBLICATION NUMBER:SEBM005207
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Description
KOMATSU D155AX-3 SUPER DOZER SERVICE REPAIR MANUAL
KOMATSU D155AX-3 SUPER DOZER SERVICE REPAIR MANUAL – PDF DOWNLOAD:
SCREENSHOTS OF THE MANUAL:
DESCRIPTION:
KOMATSU D155AX-3 SUPER DOZER SERVICE REPAIR MANUAL
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
KOMATSU D155AX-3 SUPER DOZER SERVICE REPAIR MANUAL
MAIN MENU...................................................................................................................... 0 CONTENTS....................................................................................................................... 2 01 GENERAL..................................................................................................................... 27 SPECIFICATION DRAWING .................................................................................................... 28 SPECIFICATIONS ............................................................................................................ 30 WEIGHT TABLE............................................................................................................... 36 TABLE OF FUEL, COOLANT AND LUBRICANTS ..................................................................................... 38 10 STRUCTURE AND FUNCTION...................................................................................................... 39 RADIATOR .................................................................................................................. 40 OIL COOLER ................................................................................................................ 42 ENGINE CONTROL ........................................................................................................... 44 POWER TRAIN................................................................................................................ 46 POWER TRAIN SYSTEM ........................................................................................................ 47 POWER TRAIN UNIT MOUNT .................................................................................................... 48 OVERALL DRAWING OF POWER TRAIN UNIT........................................................................................ 49 POWER TRAIN HYDRAULIC PIPING DIAGRAM....................................................................................... 50 POWER TRAIN HYDRAULIC SYSTEM DRAWING....................................................................................... 52 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM...................................................................................... 53 DAMPER, UNIVERSAL JOINT.................................................................................................... 54 HMT SYSTEM................................................................................................................. 56 HMT CONTROL................................................................................................................ 62 PTO........................................................................................................................ 66 HMT........................................................................................................................ 68 HMT CONTROL VALVE.......................................................................................................... 86 LUBRICATION RELIEF VALVE................................................................................................... 98 HMT PUMP ASSEMBLY.......................................................................................................... 100 HMT MOTOR ASSEMBLY......................................................................................................... 118 OPERATION OF HMT SYSTEM.................................................................................................... 134 PPC, EPC, HMT CHARGE FILTER................................................................................................ 140 PPC, EPC, HMT CHARGE VALVE................................................................................................. 141 HMT OIL COOLER BYPASS VALVE................................................................................................ 144 STEERING, BRAKE CONTROL.................................................................................................... 146 BEVEL GEAR SHAFT, HSS, BRAKE............................................................................................... 149 OPERATION OF HSS........................................................................................................... 154 BRAKE VALVE................................................................................................................ 165 SCAVENGING PUMP STRAINER................................................................................................... 174 POWER TRAIN PUMP STRAINER.................................................................................................. 175 POWER TRAIN OIL FILTER..................................................................................................... 176 FINAL DRIVE................................................................................................................ 177 RADIATOR GUARD............................................................................................................. 180 MAIN FRAME, UNDERGUARD..................................................................................................... 181 TRACK FRAME................................................................................................................ 182 RECOIL SPRING.............................................................................................................. 184 TRACK ROLLER BOGIE......................................................................................................... 185 SUSPENSION................................................................................................................. 186 WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM.................................................................................... 188 PPC CONTROL PIPING DIAGRAM................................................................................................. 191 WORK EQUIPMENT CONTROL..................................................................................................... 192 WORK EQUIPMENT, HMT AND HSS HYDRAULIC SYSTEM DIAGRAM....................................................................... 194 WORK EQUIPMENT, HMT AND HSS HYDRAULIC CIRCUIT DIAGRAM...................................................................... 195 HYDRAULIC TANK AND FILTER.................................................................................................. 198 HYDRAULIC, HSS PUMP........................................................................................................ 200 ACCUMULATOR................................................................................................................ 215 EPC SOLENOID VALVE......................................................................................................... 216 PPC LOCK VALVE............................................................................................................. 219 PPC VALVE.................................................................................................................. 220 MAIN CONTROL VALVE......................................................................................................... 232 OPERATION OF MAIN CONTROL VALVE............................................................................................ 236 HSS MOTOR.................................................................................................................. 258 OPERATION OF STEERING, WORK EQUIPMENT CONTROL CIRCUIT...................................................................... 264 PISTON VALVE............................................................................................................... 274 QUICK DROP VALVE........................................................................................................... 275 CYLINDER STAY.............................................................................................................. 276 WORK EQUIPMENT............................................................................................................. 277 PIN PULLER SWITCH.......................................................................................................... 281 PIN PULLER SOLENOID VALVE.................................................................................................. 282 TILT/PITCH SELECTOR SWITCH................................................................................................. 284 PITCH SOLENOID VALVE....................................................................................................... 285 CAB MOUNT.................................................................................................................. 288 CAB........................................................................................................................ 289 AIR CONDITIONER............................................................................................................ 291 ELECTRICAL WIRING DIAGRAM.................................................................................................. 293 ELECTRICAL CIRCUIT DIAGRAM................................................................................................. 295 MACHINE MONITOR SYSTEM..................................................................................................... 301 SENSORS.................................................................................................................... 307 ENGINE CONTROL SYSTEM...................................................................................................... 311 HMT CONTROL SYSTEM......................................................................................................... 318 20 TESTING AND ADJUSTING....................................................................................................... 339 STANDARD VALUE TABLES...................................................................................................... 340 STANDARD VALUE TABLE FOR ENGINE RELATED PARTS.......................................................................... 340 STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS ........................................................................ 343 STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS ..................................................................... 348 STANDARD VALUE TABLE FOR MACHINE MONITOR .............................................................................. 355 TESTING AND ADJUSTING...................................................................................................... 359 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING ..................................................................... 360 MEASURING ENGINE SPEED ................................................................................................ 361 MEASURING EXHAUST COLOR ............................................................................................... 362 ADJUSTING VALVE CLEARANCE ............................................................................................. 363 MEASURING COMPRESSION PRESSURE ........................................................................................ 364 MEASURING BLOW-BY PRESSURE ............................................................................................ 365 MEASURING ENGINE OIL PRESSURE ......................................................................................... 366 TESTING AND ADJUSTING FUEL INJECTION TIMING ........................................................................... 367 TESTING AND ADJUSTING ALTERNATOR BELT TENSION ....................................................................... 370 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION ......................................................... 370 MEASURING EXHAUST TEMPERATURE ......................................................................................... 371 MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE) ........................................................................ 372 MEASURING ENGINE SPEED AT STEERING RELIEF + BLADE RAISE ............................................................... 373 ADJUSTING FUEL CONTROL LINKAGE ........................................................................................ 374 ADJUSTING DECELERATOR PEDAL .......................................................................................... 377 TESTING AND ADJUSTING THROTTLE POTENTIOMETER........................................................................... 378 ADJUSTING JOYSTICK (STEERING, DIRECTIONAL LEVER), MAX. SPEED SETTER, PARKING BRAKE LEVER LINKAGE ............... 380 ADJUSTING BRAKE PEDAL LINKAGE ......................................................................................... 382 TESTING AND ADJUSTING BRAKE PEDAL POTENTIOMETER ....................................................................... 383 ADJUSTING WORK EQUIPMENT CONTROL LINKAGE ............................................................................. 384 TESTING AND ADJUSTING WORK EQUIPMENT, STEERING CONTROL PRESSURE ..................................................... 388 MEASURING STEERING EPC SOLENOID VALVE OUTPUT PRESSURE.................................................................. 389 MEASURING ON-OFF SOLENOID VALVE OUTPUT PRESSURE ....................................................................... 390 MEASURING WORK EQUIPMENT PPC VALVE OUTPUT PRESSURE .................................................................... 391 ADJUSTING PPC VALVE ................................................................................................... 392 MEASURING POWER TRAIN OIL PRESSURE .................................................................................... 393 MEASURING AND ADJUSTING HMT PUMP MAIN (HIGH PRESSURE) RELIEF PRESSURE ................................................. 395 MEASURING AND ADJUSTING HMT CHARGE PRESSURE .......................................................................... 396 MEASURING AND ADJUSTING CHARGE VALVE RELIEF PRESSURE (HMT SERVO, PPC CIRCUIT CHARGE PRESSURE) ......................... 397 TESTING AND ADJUSTING WORK EQUIPMENT, STEERING PRESSURE................................................................ 398 BLEEDING AIR FROM HYDRAULIC CYLINDERS.................................................................................. 400 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...................................................................... 400 BLEEDING AIR FROM HMT PUMP............................................................................................. 401 CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF BLADE AND RIPPER...................................................... 402 MEASURING LEAKAGE INSIDE CYLINDER...................................................................................... 403 ADJUSTING SEMI-U-TILTDOZER............................................................................................. 404 ADJUSTING CLEARANCE OF IDLER........................................................................................... 406 SIMPLE PROCEDURE FOR TESTING BRAKE PERFORMANCE......................................................................... 407 TROUBLESHOOTING............................................................................................................ 409 POINTS TO REMEMBER WHEN TROUBLESHOOTING ............................................................................... 410 SEQUENCE OF EVENTS IN TROUBLESHOOTING ................................................................................. 411 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE....................................................................... 412 CHECKS BEFORE TROUBLESHOOTING ......................................................................................... 421 TYPE OF CONNECTOR AND POSITION OF INSTALLATION ........................................................................ 422 CONNECTOR ARRANGEMENT DIAGRAM.......................................................................................... 426 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS............................................................................. 430 EXPLANATION OF FUNCTION SYSTEM OF ELECTRICAL CONTROL MECHANISM ................................................... 440 MONITOR PANEL, HMT CONTROLLER DISPLAY METHOD .......................................................................... 444 METHOD OF USING JUDGEMENT TABLE ....................................................................................... 449 METHOD OF USING TROUBLESHOOTING CHARTS ................................................................................ 450 TROUBLESHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM (E MODE).......................................................... 453 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM.......................... 454 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE......................................... 455 JUDGEMENT TABLE FOR ENGINE THROTTLE GOVERNOR, ENGINE RELATED PARTS ............................................... 457 ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE THROTTLE CONTROLLER SYSTEM ................................................ 458 E-1. Abnormality in engine throttle controller power source....................................................... 459 E-2. [8E] S-NET communication error (between governor controller and HMT controller) is displayed.................. 460 E-3. [96] Abnormality in feedback potentiometer system is displayed................................................ 461 E-4. [98] Abnormality in fuel control dial signal system is displayed.............................................. 462 E-5. [A5] Short circuit in battery relay drive system is displayed................................................. 463 E-6. [E7] Disconnection in governor motor drive system is displayed................................................ 464 E-7. [A8] Short circuit in governor motor drive system is displayed................................................ 465 E-8. Engine does not start......................................................................................... 466 E-9. Engine speed is irregular (Idling speed is irregular or there is hunting)..................................... 473 E-10. Lack of output (engine high idling speed is too low)......................................................... 474 E-11. Engine does not stop......................................................................................... 476 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE).............................................................................. 479 METHOD OF USING TROUBLESHOOTING CHARTS............................................................................. 480 S-1 Starting performance is poor (starting always takes time)...................................................... 484 S-2 Engine does not start.......................................................................................... 485 1) Engine does not turn........................................................................................ 485 2) Engine runs but exhaust gas does not come out (fuel is not being injected).................................. 486 3) Exhaust gas comes out but engine does not start (fuel is being injected).................................... 487 S-3 Engine does not pick up smoothly (follow-up is poor)........................................................... 488 S-4 Engine stops during operation.................................................................................. 489 S-5 Engine does not rotate smoothly (hunting)...................................................................... 490 S-6 Engine lacks output (no power)................................................................................. 491 S-7 Exhaust gas is black (incomplete combustion)................................................................... 492 S-8 Oil consumption is excessive (or exhaust gas is blue).......................................................... 493 S-9 Oil becomes contaminated quickly............................................................................... 494 S-10 Fuel consumption is excessive................................................................................. 495 S-11 Oil is in cooling water, or water spurts back, or water level goes down....................................... 496 S-12 Oil pressure caution lamp lights up (drop in oil pressure).................................................... 497 S-13 Oil level rises (water mixed with fuel)....................................................................... 498 S-14 Water temperature becomes too high (overheating).............................................................. 499 S-15 Abnormal noise is made........................................................................................ 500 S-16 Vibration is excessive........................................................................................ 501 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE).......................................................................... 503 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF HMT CONTROLLER SYSTEM...................................... 505 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE......................................... 506 JUDGEMENT TABLE FOR HMT CONTROLLER HYDRAULIC AND MECHANICAL SYSTEMS................................................ 517 ELECTRICAL CIRCUIT DIAGRAM OF HMT CONTROLLER SYSTEM................................................................ 519 E-101 [10] Abnormality in HMT charge pressure is displayed ........................................................ 521 E-102 [11] Abnormality in HMT charge pressure sensor system is displayed........................................... 522 E-103 [12] Abnormality in travel speed selector switch system is displayed ........................................ 523 E-104 [14] Abnormality in throttle potentiometer system is displayed............................................... 524 E-105 [15] Abnormality in throttle potentiometer system is displayed............................................... 525 E-106 [16] Abnormality in FORWARD speed control potentiometer system is displayed.................................. 526 E-107 [17] Abnormality in FORWARD speed control potentiometer system is displayed.................................. 527 E-108 [18] Abnormality in REVERSE speed control potentiometer system is displayed ................................ 528 E-109 [19] Abnormality in REVERSE speed control potentiometer system is displayed ................................ 529 E-110 [1A] Abnormality in brake pedal potentiometer system is displayed............................................ 530 E-111 [1c] Abnormality in power train oil temperature sensor system is displayed................................... 531 E-112 [1d] Abnormality in both directional lever potentiometer signal system is displayed.......................... 532 E-113 [1E] Abnormality in directional lever potentiometer [I] system is displayed.................................. 532 E-114 [1F] Abnormality in directional lever potentiometer [I] system is displayed.................................. 533 E-115 [20] Abnormality in brake pedal potentiometer system is displayed............................................ 534 E-116 [21] Abnormality in directional lever potentiometer [II] system is displayed................................. 535 E-117 [22] Abnormality in directional lever potentiometer [II] system is displayed................................. 536 E-118 [23] Abnormality in both steering lever potentiometer signal systems is displayed............................ 537 E-119 [24] Abnormality in steering lever potentiometer [I] system is displayed..................................... 537 E-120 [25] Abnormality in steering lever potentiometer [I] system is displayed..................................... 538 E-121 [26] Abnormality in steering lever potentiometer [II] system is displayed.................................... 539 E-122 [27] Abnormality in steering lever potentiometer [II] system is displayed .................................. 540 E-123 [28] Abnormality in both engine speed sensor systems displayed............................................... 541 E-124 [29] Abnormality in engine speed sensor [I] system is displayed.............................................. 541 E-125 [2A] Abnormality in engine speed sensor [II] system is displayed............................................. 542 E-126 [2c] Abnormality in HMT motor speed sensor system is displayed............................................... 543 E-127 [2d] Abnormality in HMT motor speed sensor system is displayed............................................... 544 E-128 [30] Disconnection in 1st clutch solenoid system is displayed................................................ 545 E-129 [31] Short circuit in 1st clutch solenoid system is displayed................................................ 546 E-130 [32] Disconnection in 2nd clutch solenoid system is displayed................................................ 547 E-131 [33] Short circuit in 2nd clutch solenoid system is displayed................................................ 548 E-132 [34] Disconnection in 3rd clutch solenoid system is displayed................................................ 549 E-133 [35] Short circuit in 3rd clutch solenoid system is displayed................................................ 550 E-134 [38] Disconnection in brake solenoid system is displayed..................................................... 551 E-135 [39] Short circuit in brake solenoid system is displayed..................................................... 552 E-136 [3A] Disconnection in R clutch solenoid system is displayed.................................................. 553 E-137 [3c] Short circuit in R clutch solenoid system is displayed.................................................. 554 E-138 [3d] Disconnection in F clutch solenoid system is displayed.................................................. 555 E-139 [3E] Short circuit in F clutch solenoid system is displayed.................................................. 556 E-140 [40] Abnormality in operation of F spool switch is displayed................................................. 557 E-141 [41] Abnormality in operation of F spool switch is displayed................................................. 558 E-142 [42] Abnormality in operation of R spool switch is displayed................................................. 559 E-143 [43] Abnormality in operation of R spool switch is displayed................................................. 560 E-144 [44] Abnormality in operation of 1st spool switch is displayed............................................... 561 E-145 [45] Abnormality in operation of 1st spool switch is displayed............................................... 562 E-146 [46] Abnormality in operation of 2nd spool switch is displayed............................................... 563 E-147 [47] Abnormality in operation of 2nd spool switch is displayed............................................... 564 E-148 [48] Abnormality in operation of 3rd spool switch is displayed............................................... 565 E-149 [49] Abnormality in operation of 3rd spool switch is displayed............................................... 566 E-150 [4F] Disconnection in HMT pump servo solenoid system is displayed............................................ 568 E-151 [50] Short circuit in HMT pump servo solenoid system is displayed............................................ 570 E-152 [51] Disconnection in HMT motor servo solenoid [A] system is displayed....................................... 572 E-153 [52] Short circuit in HMT motor servo solenoid [A] system is displayed....................................... 573 E-154 [53] Disconnection in HMT motor servo solenoid [B] system is displayed....................................... 574 E-155 [54] Short circuit in HMT motor servo solenoid [B] system is displayed....................................... 575 E-156 [55] Disconnection in steering EPC solenoid system is displayed.............................................. 576 E-157 [56] Short circuit in steering EPC solenoid system is displayed.............................................. 578 E-158 [57] Drop in controller power source voltage is displayed ................................................... 580 E-159 [59] When parking brake switch [II] is ON (closed), [I] is displayed ....................................... 581 E-160 [5A] When parking brake switch [I] is ON (closed), [II] OFF (open) is displayed.............................. 582 E-161 [5C] Excessive difference between directional lever potentiometer signal values [1] and [II] is displayed.... 583 E-162 [5E] Excessive difference between steering lever potentiometer signal values [I] and [II] is displayed....... 583 E-163 [60] Abnormality in signal for engine speed sensor [I] system is displayed................................... 584 E-164 [61] Abnormality in signal for engine speed sensor [II] system is displayed.................................. 585 E-165 [64] Disconnection in neutral safety relay output system is displayed........................................ 586 E-166 [65] Short circuit in neutral safety relay output system is displayed........................................ 587 E-167 [64] Disconnection in 2, 3, F, R clutch solenoid cut relay output system is displayed........................ 588 E-168 [65] Short circuit in 2, 3, F, R clutch solenoid cut relay output system is displayed........................ 589 E-169 [66] Disconnection in backup alarm relay drive system is displayed........................................... 590 E-170 [67] Short circuit in backup alarm relay drive system is displayed........................................... 591 E-171 [68] Disconnection in 1st clutch solenoid cut relay system is displayed .................................... 592 E-172 [69] Short circuit in 1st clutch solenoid cut relay system is displayed...................................... 593 E-173 [6A] Misalignment in neutral position of directional lever potentiometer [I] system is displayed............. 594 E-174 [6c] Misalignment in neutral position of directional lever potentiometer [II] system is displayed............ 594 E-175 [6d] Misalignment in neutral position of steering lever potentiometer [I] is displayed....................... 595 E-176 [6E] Misalignment in neutral position of steering lever potentiometer [II] system is displayed............... 595 E-177 [6F] 1st fixed, 2nd start both impossible is displayed....................................................... 595 E-178 [70] Abnormality in F spool switch system is displayed....................................................... 596 E-179 [71] Abnormality in F spool switch system is displayed....................................................... 596 E-180 [72] Abnormality in R spool switch system is displayed....................................................... 597 E-181 [73] Abnormality in R spool switch system is displayed....................................................... 597 E-182 [74] Abnormality in 1st spool switch system is displayed..................................................... 598 E-183 [76] Abnormality in 2nd spool switch system is displayed..................................................... 599 E-184 [78] Abnormality in 3rd spool switch system is displayed..................................................... 600 E-185 [79] Abnormality in 3rd spool switch system is displayed..................................................... 600 E-186 [8A] Abnormality in monitor panel alarm system is displayed.................................................. 601 E-187 [8d] S-NET communication error (abnormality between monitor panel and HMT controller) is displayed........... 602 E-188 Backup alarm does not sound.................................................................................. 603 E-189 Pin-puller cylinder does not work (machines with giant ripper only).......................................... 604 E-190 Blade pitch does not work.................................................................................... 605 E-191 Travel speed does not shift (mark does not light up on monitor panel when button is pressed)................. 606 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)............................................................ 607 TABLE OF FAILURE MODES AND CAUSES (HMT, HSS, AND POWER TRAIN SYSTEM)............................................... 608 H-1. Machine does not move......................................................................................... 610 H-2. Machine does not start if engine is not at full throttle...................................................... 612 H-3. Travel speed does not rise when traveling forward............................................................. 614 H-4. Travel speed does not rise when traveling in reverse.......................................................... 616 H-5. Acceleration is poor.......................................................................................... 618 H-6. Machine lacks power (lacks drawbar pull)...................................................................... 619 H-7. Machine does not turn (turns in one direction only (left or right))........................................... 620 H-8. Travel speed is slow (machine does not turn) or turning power weak............................................ 622 H-9. Machine does not stop turning when steering lever is returned to neutral...................................... 624 H-10. Brakes do not work........................................................................................... 625 H-11. Power train oil overheats.................................................................................... 626 H-12. Abnormal noise from around HMT pump.......................................................................... 628 H-13. Abnormal noise from around HMT motor......................................................................... 629 H-101. All work equipment and turning speeds are slow or lack power................................................ 630 H-102. Work equipment does not move and machine does not turn...................................................... 631 H-103. Blade RAISE speed is slow or lacks power.................................................................... 632 H-104. Blade tilt speed is slow or lacks power..................................................................... 632 H-105. Ripper RAISE speed slow or lacks power...................................................................... 633 H-106. Ripper tilt speed slow or lacks power....................................................................... 633 H-107. Excessive hydraulic drift of blade lift..................................................................... 634 H-108. Excessive hydraulic drift of blade tilt..................................................................... 634 H-109. Excessive hydraulic drift of ripper......................................................................... 635 H-110. Pin-puller cylinder does not work........................................................................... 635 H-111. Blade pitch does not work................................................................................... 636 H-112. Abnormal noise from around hydraulic, HSS pump.............................................................. 636 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)..................................................................... 637 ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR RELATED PARTS....................................................... 638 M-1. Monitor panel display does not appear when starting switch is turned ON ..................................... 641 M-2. When starting switch is turned ON, monitor panel lamps all light up but do not go out ..................... 641 M-3. Abnormality in preheating .................................................................................... 642 a) Preheating monitor lamp does not light up................................................................... 642 b) Preheating monitor lamp is lighted up continuously.......................................................... 642 M-4. Caution item lights up or flashes ............................................................................ 644 a) Battery charge lights up or flashes......................................................................... 644 b) When starting switch is turned ON and engine is started, engine oil pressure lights up or flashes........... 645 c) Coolant temperature flashes................................................................................. 646 d) Power train oil temperature flashes......................................................................... 647 e) Hydraulic oil temperature flashes........................................................................... 648 M-5. Abnormality in buzzer........................................................................................ 649 a) Caution item flashes but buzzer does not sound.............................................................. 649 b) Monitor display is normal but buzzer sounds................................................................. 649 M-6. Abnormality in warning lamp................................................................................... 650 a) Caution item flashes but lamp does not flash................................................................ 650 b) Monitor display is normal but lamp lights up................................................................ 650 M-7. Abnormality in gauge.......................................................................................... 651 a) Abnormality in engine coolant temperature gauge............................................................. 651 b) Abnormality in power train oil temperature gauge............................................................ 652 c) Abnormality in fuel level gauge............................................................................. 653 M-8. Service meter does not move after engine is started .......................................................... 654 M-9. Monitor panel lighting does not light up (front lamp is normal) .............................................. 655 M-10. Lamp does not light up ...................................................................................... 656 a) Front lamp.................................................................................................. 656 b) Rear lamp (ripper lamp)..................................................................................... 657 M-11. Automatic preheating is not carried out when glow switch is set to AUTO .................................... 658 M-12. Wiper does not work ......................................................................................... 660 M-13. Washer fluid is not sprayed out ............................................................................. 664 M-14. Air conditioner has no effect ............................................................................... 666 a) Air does not blow out....................................................................................... 666 b) There is no cooling effect.................................................................................. 670 M-15. Overrun alarm continues to sound ............................................................................ 674 30 DISASSEMBLY AND ASSEMBLY.................................................................................................... 675 METHOD OF USING MANUAL .................................................................................................... 679 PRECAUTIONS WHEN CARRYING OUT OPERATION ................................................................................... 681 SPECIAL TOOL LIST ......................................................................................................... 683 SPECIAL TOOL SKETCH ....................................................................................................... 694 STARTING MOTOR............................................................................................................ 706 REMOVAL AND INSTALLATION............................................................................................... 706 ALTERNATOR................................................................................................................. 707 REMOVAL AND INSTALLATION .............................................................................................. 707 ENGINE OIL COOLER CORE..................................................................................................... 708 REMOVAL AND INSTALLATION............................................................................................... 708 FUEL INJECTION PUMP ....................................................................................................... 709 REMOVAL................................................................................................................ 709 INSTALLATION .......................................................................................................... 710 WATER PUMP................................................................................................................. 711 REMOVAL AND INSTALLATION............................................................................................... 711 TURBOCHARGER............................................................................................................... 712 REMOVAL AND INSTALLATION............................................................................................... 712 NOZZLE HOLDER.............................................................................................................. 713 REMOVAL AND INSTALLATION............................................................................................... 713 ENGINE FRONT SEAL ......................................................................................................... 714 REMOVAL AND INSTALLATION............................................................................................... 714 ENGINE REAR SEAL .......................................................................................................... 715 REMOVAL................................................................................................................ 715 INSTALLATION .......................................................................................................... 716 CYLINDER HEAD.............................................................................................................. 718 REMOVAL................................................................................................................ 718 INSTALLATION .......................................................................................................... 722 THERMOSTAT................................................................................................................. 732 REMOVAL AND INSTALLATION .............................................................................................. 732 AIR CONDITIONER COMPRESSOR................................................................................................. 733 REMOVAL................................................................................................................ 733 INSTALLATION .......................................................................................................... 734 AIR CONDITIONER CONDENSER.................................................................................................. 735 REMOVAL................................................................................................................ 735 INSTALLATION........................................................................................................... 736 FUEL TANK.................................................................................................................. 737 REMOVAL................................................................................................................ 737 INSTALLATION........................................................................................................... 738 RADIATOR................................................................................................................... 739 REMOVAL................................................................................................................ 739 INSTALLATION .......................................................................................................... 741 RADIATOR, OIL COOLER, GUARD ............................................................................................... 742 REMOVAL................................................................................................................ 742 INSTALLATION........................................................................................................... 744 FAN DRIVE.................................................................................................................. 745 REMOVAL................................................................................................................ 745 INSTALLATION .......................................................................................................... 747 HYDRAULIC COOLER........................................................................................................... 748 REMOVAL AND INSTALLATION............................................................................................... 748 ENGINE .................................................................................................................... 749 REMOVAL................................................................................................................ 749 INSTALLATION........................................................................................................... 751 DAMPER..................................................................................................................... 752 REMOVAL................................................................................................................ 752 INSTALLATION........................................................................................................... 753 DISASSEMBLY ........................................................................................................... 754 ASSEMBLY .............................................................................................................. 757 POWER TRAIN UNIT .......................................................................................................... 761 REMOVAL................................................................................................................ 761 INSTALLATION .......................................................................................................... 766 SEPARATION ............................................................................................................ 767 CONNECTION ............................................................................................................ 772 PTO ....................................................................................................................... 776 DISASSEMBLY............................................................................................................ 776 ASSEMBLY .............................................................................................................. 780 HMT........................................................................................................................ 785 DISASSEMBLY............................................................................................................ 785 ASSEMBLY............................................................................................................... 799 HSS CASE................................................................................................................... 816 DISASSEMBLY............................................................................................................ 816 ASSEMBLY............................................................................................................... 825 POWER TRAIN, LUBRICATION PUMP.............................................................................................. 838 REMOVAL................................................................................................................ 838 INSTALLATION........................................................................................................... 839 SCAVENGING, CHARGE PUMP.................................................................................................... 840 REMOVAL AND INSTALLATION............................................................................................... 840 HMT PUMP................................................................................................................... 841 REMOVAL................................................................................................................ 841 INSTALLATION........................................................................................................... 842 DISASSEMBLY............................................................................................................ 843 ASSEMBLY............................................................................................................... 849 HMT MOTOR.................................................................................................................. 859 REMOVAL................................................................................................................ 859 INSTALLATION........................................................................................................... 861 DISASSEMBLY............................................................................................................ 862 ASSEMBLY............................................................................................................... 871 PPC, EPC, HMT CHARGE VALVE................................................................................................. 884 REMOVAL AND INSTALLATION............................................................................................... 884 DISASSEMBLY............................................................................................................ 885 ASSEMBLY............................................................................................................... 886 HMT CONTROL VALVE.......................................................................................................... 887 REMOVAL................................................................................................................ 887 INSTALLATION........................................................................................................... 889 DISASSEMBLY AND ASSEMBLY............................................................................................... 890 HSS MOTOR.................................................................................................................. 893 REMOVAL AND INSTALLATION............................................................................................... 893 DISASSEMBLY............................................................................................................ 894 ASSEMBLY............................................................................................................... 898 STEERING EPC VALVE......................................................................................................... 906 REMOVAL AND INSTALLATION............................................................................................... 906 BRAKE VALVE................................................................................................................ 907 REMOVAL AND INSTALLATION............................................................................................... 907 DISASSEMBLY............................................................................................................ 908 ASSEMBLY............................................................................................................... 908 FINAL DRIVE................................................................................................................ 910 REMOVAL................................................................................................................ 910 INSTALLATION........................................................................................................... 912 DISASSEMBLY............................................................................................................ 913 ASSEMBLY............................................................................................................... 918 TRACK FRAME................................................................................................................ 924 REMOVAL................................................................................................................ 924 INSTALLATION........................................................................................................... 926 IDLER...................................................................................................................... 927 REMOVAL................................................................................................................ 927 INSTALLATION........................................................................................................... 928 DISASSEMBLY............................................................................................................ 929 ASSEMBLY............................................................................................................... 931 RECOIL SPRING.............................................................................................................. 934 REMOVAL AND INSTALLATION............................................................................................... 934 DISASSEMBLY............................................................................................................ 935 ASSEMBLY............................................................................................................... 940 TRACK ROLLER............................................................................................................... 945 REMOVAL................................................................................................................ 945 INSTALLATION........................................................................................................... 946 DISASSEMBLY............................................................................................................ 947 ASSEMBLY............................................................................................................... 950 BOGIE...................................................................................................................... 953 REMOVAL................................................................................................................ 953 INSTALLATION........................................................................................................... 955 DISASSEMBLY............................................................................................................ 956 ASSEMBLY............................................................................................................... 959 CARRIER ROLLER............................................................................................................. 963 REMOVAL AND INSTALLATION............................................................................................... 963 DISASSEMBLY............................................................................................................ 964 ASSEMBLY............................................................................................................... 966 TRACK SHOE................................................................................................................. 969 CHECKING BEFORE REMOVAL................................................................................................ 969 REMOVAL (NORMAL)....................................................................................................... 969 REMOVAL (WHEN THERE IS ABNORMALITY INSIDE TRACK FRAME)................................................................. 970 INSTALLATION........................................................................................................... 971 OVERALL DISASSEMBLY.................................................................................................... 972 OVERALL ASSEMBLY....................................................................................................... 977 PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS........................................................................... 991 ONE LINK................................................................................................................... 992 DISASSEMBLY............................................................................................................ 992 ASSEMBLY............................................................................................................... 994 MASTER LINK................................................................................................................ 996 DISASSEMBLY............................................................................................................ 996 ASSEMBLY............................................................................................................... 998 PIVOT SHAFT................................................................................................................1001 REMOVAL AND INSTALLATION...............................................................................................1001 EQUALIZER BAR..............................................................................................................1002 REMOVAL................................................................................................................1002 INSTALLATION...........................................................................................................1003 EQUALIZER BAR SIDE BUSHING.................................................................................................1004 REMOVAL AND INSTALLATION...............................................................................................1004 SEGMENT TEETH..............................................................................................................1005 REMOVAL AND INSTALLATION...............................................................................................1005 HYDRAULIC TANK.............................................................................................................1006 REMOVAL AND INSTALLATION...............................................................................................1006 HYDRAULIC, HSS PUMP .......................................................................................................1007 REMOVAL AND INSTALLATION...............................................................................................1007 DISASSEMBLY............................................................................................................1008 ASSEMBLY...............................................................................................................1014 MAIN CONTROL VALVE.........................................................................................................1026 REMOVAL................................................................................................................1026 INSTALLATION...........................................................................................................1028 DISASSEMBLY............................................................................................................1029 ASSEMBLY...............................................................................................................1033 HMT OIL COOLER BYPASS VALVE................................................................................................1038 REMOVAL AND INSTALLATION...............................................................................................1038 DISASSEMBLY AND ASSEMBLY...............................................................................................1039 BLADE PPC VALVE............................................................................................................1040 REMOVAL................................................................................................................1040 INSTALLATION...........................................................................................................1041 RIPPER PPC VALVE...........................................................................................................1044 REMOVAL................................................................................................................1044 INSTALLATION...........................................................................................................1045 PPC VALVE..................................................................................................................1048 DISASSEMBLY............................................................................................................1048 ASSEMBLY...............................................................................................................1049 BLADE PPC VALVE............................................................................................................1050 DISASSEMBLY............................................................................................................1050 ASSEMBLY...............................................................................................................1051 BLADE LIFT CYLINDER........................................................................................................1054 REMOVAL AND INSTALLATION...............................................................................................1054 BLADE TILT CYLINDER........................................................................................................1055 REMOVAL AND INSTALLATION...............................................................................................1055 RIPPER LIFT CYLINDER.......................................................................................................1056 REMOVAL AND INSTALLATION...............................................................................................1056 RIPPER TlLT CYLINDER.......................................................................................................1057 REMOVAL AND INSTALLATION...............................................................................................1057 HYDRAULIC CYLINDER.........................................................................................................1058 DISASSEMBLY............................................................................................................1058 ASSEMBLY...............................................................................................................1061 BLADE......................................................................................................................1065 REMOVAL................................................................................................................1065 INSTALLATION...........................................................................................................1066 DISASSEMBLY............................................................................................................1067 ASSEMBLY...............................................................................................................1069 MULTISHANK RIPPER..........................................................................................................1071 DISASSEMBLY............................................................................................................1071 ASSEMBLY...............................................................................................................1073 ROPS GUARD.................................................................................................................1075 REMOVAL AND INSTALLATION...............................................................................................1075 OPERATOR CAB...............................................................................................................1076 REMOVAL AND INSTALLATION...............................................................................................1076 HOOD.......................................................................................................................1077 REMOVAL AND INSTALLATION...............................................................................................1077 FLOOR FRAME................................................................................................................1078 REMOVAL................................................................................................................1078 INSTALLATION...........................................................................................................1083 DASHBOARD..................................................................................................................1085 REMOVAL................................................................................................................1085 INSTALLATION...........................................................................................................1086 MONITOR....................................................................................................................1087 REMOVAL AND INSTALLATION...............................................................................................1087 GOVERNOR MOTOR.............................................................................................................1088 REMOVAL AND INSTALLATION...............................................................................................1088 JOYSTICK...................................................................................................................1089 REMOVAL AND INSTALLATION...............................................................................................1089 ENGINE THROTTLE CONTROLLER.................................................................................................1090 REMOVAL AND INSTALLATION...............................................................................................1090 HMT CONTROLLER.............................................................................................................1091 REMOVAL AND INSTALLATION...............................................................................................1091 40 MAINTENANCE STANDARD........................................................................................................1093 ENGINE MOUNT .............................................................................................................1094 POWER TRAIN UNIT MOUNT ...................................................................................................1095 DAMPER, UNIVERSAL JOINT ...................................................................................................1096 PTO .......................................................................................................................1098 HMT........................................................................................................................1101 HMT CONTROL VALVE..........................................................................................................1105 BEVEL GEAR SHAFT, HSS, BRAKE ..............................................................................................1110 BRAKE VALVE................................................................................................................1112 SCAVENGING, PPC CHARGE PUMP ...............................................................................................1113 POWER TRAIN, LUBRICATION PUMP .............................................................................................1114 PPC, EPC, HMT CHARGE VALVE ................................................................................................1116 OIL COOLER BYPASS VALVE ...................................................................................................1118 FINAL DRIVE ...............................................................................................................1120 MAIN FRAME ................................................................................................................1122 TRACK FRAME ...............................................................................................................1124 RECOIL SPRING .............................................................................................................1125 TRACK ROLLER BOGIE ........................................................................................................1126 IDLER .....................................................................................................................1128 TRACK ROLLER ..............................................................................................................1130 CARRIER ROLLER ............................................................................................................1132 TRACK SHOE (DRY TYPE)......................................................................................................1134 TRACK SHOE(SEALED AND LUBRICATED TYPE).....................................................................................1138 SUSPENSION ................................................................................................................1142 HYDRAULIC, HSS PUMP .......................................................................................................1144 EPC SOLENOID VALVE ........................................................................................................1145 PPC VALVE .................................................................................................................1146 MAIN CONTROL VALVE ........................................................................................................1151 HSS MOTOR .................................................................................................................1162 WORK EQUIPMENT CYLINDER . ................................................................................................1164 QUICK DROP VALVE ..........................................................................................................1168 CYLINDER STAY .............................................................................................................1169 WORK EQUIPMENT ............................................................................................................1170
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