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Komatsu D155AX-5 Crawler Bulldozer Shop Manual 70001 and up – PDF DOWNLOAD
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Komatsu D155AX-5 Crawler Bulldozer Shop Manual 70001 and up
MACHINE MODEL SERIAL NUMBER
D155AX-5 70001 and up
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Description
Komatsu D155AX-5 Crawler Bulldozer Shop Manual 70001 and up
FILE DETAILS:
Komatsu D155AX-5 Crawler Bulldozer Shop Manual 70001 and up
Brands: Komatsu
Equipment Type: Crawler Bulldozer
Manuals Type: Shop Manual
Machine Model: D155AX-5
Serial Number: 70001 and up
Book Code: SEBM016206
Issued: Printed in Japan 10-2004
Language: English
Pages: 1127
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu D155AX-5 Crawler Bulldozer Shop Manual 70001 and up
1 GENERAL:
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
GENERAL:
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
STRUCTURE AND FUNCTION:
This 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.
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.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs.
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
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu D155AX-5 Crawler Bulldozer Shop Manual 70001 and up
COVER............................................................................................................................................................................ 1 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 ENGINE CONTROL............................................................................................................................................................... 40 RADIATOR,OIL COOLER.......................................................................................................................................................... 42 POWER TRAIN.................................................................................................................................................................. 46 POWER TRAIN SYSTEM........................................................................................................................................................... 47 OVERALL DRAWING OF POWER TRAIN UNIT.......................................................................................................................................... 48 POWER TRAIN HYDRAULIC SYSTEM DRAWING......................................................................................................................................... 50 POWER TRAIN HYDRAULIC PIPING DIAGRAM......................................................................................................................................... 52 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM........................................................................................................................................ 53 DAMPER,UNIVERSAL JOINT....................................................................................................................................................... 54 TORQUE CONVERTER,PTO......................................................................................................................................................... 56 TRANSMISSION CONTROL......................................................................................................................................................... 59 TRANSMISSION................................................................................................................................................................. 60 TRANSMISSION CONTROL VAVLE................................................................................................................................................... 69 MAIN RELIEF VALVE............................................................................................................................................................ 74 LUBRICATION RELIEF VALVE..................................................................................................................................................... 76 SCAVENGING PUMP STRAINER..................................................................................................................................................... 77 POWER TRAIN PUMP STRAINERE................................................................................................................................................... 78 POWER TRAIN OIL FILTER....................................................................................................................................................... 79 HSS SYSTEM................................................................................................................................................................... 80 ACTUATION OF HSS SYSTEM...................................................................................................................................................... 82 HSS PUMP..................................................................................................................................................................... 91 HSS MOTOR.................................................................................................................................................................... 107 PPC,HSS CHARGE FILTER........................................................................................................................................................ 115 PPC,HSS CHARGE VALVE......................................................................................................................................................... 116 HSS OIL COOLER BYPASS VALVE.................................................................................................................................................. 119 STEERING,BRAKE CONTROL....................................................................................................................................................... 120 BEVEL GEAR SHAFT,HSS,BRAKE................................................................................................................................................... 122 BRAKE VALVE.................................................................................................................................................................. 134 FINAL DRIVE.................................................................................................................................................................. 138 TRACK FRAME.................................................................................................................................................................. 141 RECOIL SPRING................................................................................................................................................................ 143 TRACK ROLLER BOGIE........................................................................................................................................................... 144 MAIN FRAME................................................................................................................................................................... 145 SUSPENSION................................................................................................................................................................... 146 WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM...................................................................................................................................... 148 PPC CONTROL PIPING DIAGRAM................................................................................................................................................... 151 WORK EQUIPMENT CONTROL....................................................................................................................................................... 152 WORK EQUIPMENT HYDRAULIC SYSTEM AND HSS SYSTEM DIAGRAM....................................................................................................................... 153 WORK EQUIPMENT HYDRAULIC CIRCUIT AND HSS CIRCUIT DIAGRAM..................................................................................................................... 157 HYDRAULIC TANK AND FILTER.................................................................................................................................................... 159 ACCUMULATOR.................................................................................................................................................................. 161 PPC LOCK VALVE............................................................................................................................................................... 162 PPC VALVE.................................................................................................................................................................... 163 PISTON VALVE................................................................................................................................................................. 173 PIN PULLER SWITCH............................................................................................................................................................ 174 PIN PULLER SOLENOID VALVE.................................................................................................................................................... 175 TILT/PITCH SELECTOR SWITCH................................................................................................................................................... 177 PITCH SOLENOID VALVE......................................................................................................................................................... 178 MAIN CONTROL VALVE........................................................................................................................................................... 180 CYLINDER STAY................................................................................................................................................................ 206 WORK EQUIPMENT............................................................................................................................................................... 207 CAB.......................................................................................................................................................................... 211 AIR CONDITIONER.............................................................................................................................................................. 213 ELECTRIC WIRING DIAGRAM...................................................................................................................................................... 214 ELECTRIC CIRCUIT DIAGRAM..................................................................................................................................................... 222 MONITOR SYSTEM............................................................................................................................................................... 225 SENSORS...................................................................................................................................................................... 235 ENGINE STARTING SYSTEM....................................................................................................................................................... 241 HSS ELECTRONIC CONTROL SYSTEM................................................................................................................................................ 245 20 TESTING AND ADJUSTING......................................................................................................................................................... 259 STANDARD VALUE TABLE FOR ENGINE.............................................................................................................................................. 260 STANDARD VALUE TABLE FOR CHASSIS............................................................................................................................................. 262 STANDARD VALUE TABLE FOR ELECTRICAL PARTS.................................................................................................................................... 267 TESTING AND ADJUSTING........................................................................................................................................................ 282 TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING.......................................................................................................................... 283 MEASURING ENGINE SPEED................................................................................................................................................... 284 MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)........................................................................................................................... 287 MEASURING EXHAUST TEMPERATURE............................................................................................................................................ 289 MEASURING EXHAUST COLOR.................................................................................................................................................. 291 ADJUSTING VALVE CLEARANCE................................................................................................................................................ 292 MEASURING COMPRESSION PRESSURE........................................................................................................................................... 294 MEASURING BLOW-BY PRESSURE............................................................................................................................................... 295 MEASURING ENGINE OIL PRESSURE............................................................................................................................................ 297 TESTING AND ADJUSTING FUEL INJECTION TIMING.............................................................................................................................. 299 HANDLING EQUIPMENT IN FUEL CIRCUIT....................................................................................................................................... 300 RELEASING REMAINING PRESSURE IN FUEL SYSTEM.............................................................................................................................. 300 MEASURING FUEL PRESSURE.................................................................................................................................................. 301 REDUCED CYLINDER MODE OPERATION.......................................................................................................................................... 302 BLEEDING AIR FROM FUEL SYSTEM............................................................................................................................................ 304 CHECK FOR LEAKAGE IN FUEL SYSTEM......................................................................................................................................... 305 TESTING AND ADJUSTING ALTERNATOR BELT TENSION............................................................................................................................ 306 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION............................................................................................................ 307 TESTING AND ADJUSTING FAN BELT TENSION................................................................................................................................... 308 ADJUSTING ENGINE SPEED SENSOR............................................................................................................................................ 309 HANDLING CONTROLLER HIGH VOLTAGE CIRCUIT................................................................................................................................. 310 ADJUSTING FUEL CONTROL LEVER AND DECELERATOR PEDAL....................................................................................................................... 311 MEASURING TORQUE CONVERTER STALL SPEED................................................................................................................................... 314 MEASURING FULL STALL SPEED............................................................................................................................................... 316 MEASURING POWER TRAIN OIL PRESSURE....................................................................................................................................... 318 TESTING AND ADJUSTING HSS MAIN OIL PRESSURE.............................................................................................................................. 321 TESTING AND ADJUSTING HSS CHARGE OIL PRESSURE............................................................................................................................ 323 TESTING AND ADJUSTING HSS SERVO CHARGE PRESSURE AND PPC RELIEF PRESSURE.................................................................................................. 325 BLEEDING AIR FROM HSS PUMP............................................................................................................................................... 327 SIMPLE PROCEDURE FOR TESTING BRAKE PERFORMANCE........................................................................................................................... 328 ADJUSTING JOYSTICK AND PARKING LEVER..................................................................................................................................... 329 TESTING AND ADJUSTING TRAVEL REVERSE SENSING POTENTIOMETER............................................................................................................... 332 ADJUSTING TRAVEL REVERSE LIMIT SWITCH.................................................................................................................................... 333 ADJUSTING STEERING NEUTRAL POSITION...................................................................................................................................... 334 PROCEDURE FOR OPERATING EMERGENCY STEERING SWITCH........................................................................................................................ 341 ADJUSTING INITIAL CURRENT IN HSS STEERING SYSTEM......................................................................................................................... 345 ADJUSTING BRAKE PEDAL.................................................................................................................................................... 347 ADJUSTING CLEARANCE OF IDLER............................................................................................................................................. 349 TESTING WEAR OF SPROCKET................................................................................................................................................. 350 TESTING AND ADJUSTING TRACK SHOE TENSION................................................................................................................................. 351 TESTING AND ADJUSTING HYDRAULIC PRESSURE................................................................................................................................ 352 MEASURING PPC VALVE OUTPUT PRESSURE...................................................................................................................................... 354 ADJUSTING PLAY OF PPC VALVE.............................................................................................................................................. 356 MEASURING SOLENOID VALVE OUTPUT PRESSURE................................................................................................................................. 357 TESTING LOCATION CAUSING HYDRAULIC DRIFT OF BLADE AND RIPPER............................................................................................................. 358 MEASURING LEAKAGE INSIDE HYDRAULIC CYLINDER.............................................................................................................................. 359 RELEASING REMAINING OIL PRESSURE IN HYDRAULIC CYLINDER................................................................................................................... 360 BLEEDING AIR FROM HYDRAULIC CYLINDER..................................................................................................................................... 360 ADJUSTING WORK EQUIPMENT SAFETY LEVER.................................................................................................................................... 361 ADJUSTING SEMI-U TILTDOZER............................................................................................................................................... 362 TROUBLESHOOTING.............................................................................................................................................................. 364 POINTS TO REMEMBER WHEN TROUBLESHOOTING ................................................................................................................................. 365 SEQUENCE OF EVENTS IN TROUBLESHOOTING.................................................................................................................................... 366 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE......................................................................................................................... 367 CHECKS BEFORE TROUBLESHOOTING............................................................................................................................................ 375 TYPE OF CONNECTOR AND POSITION OF INSTALLATION........................................................................................................................... 376 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS............................................................................................................................... 388 FUNCTION OF ELECTRONIC CONTROL SYSTEM.................................................................................................................................... 407 DISPLAY OF HSS CONTROLLER................................................................................................................................................ 411 DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL........................................................................................................................... 415 HOW TO READ JUDGMENT TABLE............................................................................................................................................... 427 JUDGMENT TABLE FOR ENGINE SYSTEM,HYDRAULIC AND MECHANICAL SYSTEM,AND ELECTRICAL SYSTEM................................................................................... 428 METHOD OF USING TROUBLESHOOTING CHARTS................................................................................................................................... 430 TROUBLESHOOTING OF NETWORK SYSTEM (N MODE)[SERIAL NO.75001 AND UP]....................................................................................................... 432 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE........................................................................................... 433 N MODE SYSTEM ELECTRICAL CIRCUIT DIAGRAM............................................................................................................................. 435 SERVICE CODES OF NETWORK SYSTEM...................................................................................................................................... 436 N-1 [E0101] (ABNORMALITY IN NETWORK SYSTEM: ENGINE CONTROLLER SYSTEM) IS DISPLAYED................................................................................... 437 N-2 [E0104] (ABNORMALITY IN NETWORK SYSTEM: MONITOR PANEL SYSTEM) IS DISPLAYED....................................................................................... 438 N-3 [E0105] (ABNORMALITY IN NETWORK SYSTEM: HSS CONTROLLER SYSTEM) IS DISPLAYED...................................................................................... 439 N-4 [E0101],[E0104],AND [E0105] (ABNORMALITY IN NETWORK SYSTEM) ARE DISPLAYED AT SAME TIME........................................................................... 440 N-5 [E0152] (ABNORMALITY IN NETWORK SYSTEM: HSS CONTROLLER SYSTEM) IS DISPLAYED...................................................................................... 441 N-6 [E0165] (ERROR IN NETWORK COMMUNICATION) IS DISPLAYED............................................................................................................ 442 N-7 [E0436] (ABNORMALITY IN NETWORK SYSTEM: ENGINE CONTROLLER) IS DISPLAYED.......................................................................................... 443 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)[SERIAL NO.70001-75000]......................................................................................................... 444 METHOD OF USING TROUBLESHOOTING CHARTS............................................................................................................................... 445 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)........................................................................................................ 449 S-2 ENGINE DOES NOT START............................................................................................................................................ 450 ① ENGINE RUNS BUT EXHAUST GAS DOES NOT COMES OUT (FUEL IS NOT BEING INJECTED).................................................................................... 450 ② EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)....................................................................................... 451 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)............................................................................................................. 452 S-4 ENGINE STOPS DURING OPERATION.................................................................................................................................... 453 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)........................................................................................................................ 454 S-6 ENGINE LACKS POWER............................................................................................................................................... 455 S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)..................................................................................................................... 456 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)............................................................................................................ 457 S-9 OIL BECOMES CONTAMINATED QUICKLY................................................................................................................................. 458 S-10 FUEL CONSUMPTION IS EXCESSIVE................................................................................................................................... 459 S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LAVEL GOES DOWN........................................................................................... 460 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)...................................................................................................... 461 S-13 OIL LEVEL RISES (WATER OR FUEL MIXED WITH OIL).................................................................................................................. 462 S-14 WATER TEMPERATURE BECOMES TOO HIHG (OVERHEATING)................................................................................................................ 463 S-15 ABNORMAL NOISE IS MADE.......................................................................................................................................... 464 S-16 VIBRATION IS EXCESSIVE.......................................................................................................................................... 465 TROUBLESHOOTING OF HSS CONTROLLER AND ELECTRICAL SYSTEM (E MODE)[SERIAL NO.70001-75000].................................................................................. 466 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE........................................................................................... 467 ELECTRICAL CIRCUIT DIAGRAM FOR E MODE................................................................................................................................ 475 E-1. [19] SHORT CIRCUIT IN STEERING OIL PRESSURE SENSOR SYSTEM A IS DISPLAYED........................................................................................ 477 E-2. [20] DISCONNECTION IN STEERING OIL PRESSURE SENSOR SYSTEM A IS DISPLAYED........................................................................................ 478 E-3. [21] SHORT CIRCUIT IN STEERING OIL PRESSURE SENSOR SYSTEM B IS DISPLAYED........................................................................................ 479 E-4. [22] DISCONNECTION IN STEERING OIL PRESSURE SENSOR SYSTEM B IS DISPLAYED........................................................................................ 480 E-5. [23] TROUBLE OF STEERING POTENTIOMETER SYSTEM 1 AND 2 IS DISPLAYED.............................................................................................. 481 E-6. [24] DISCONNECTION IN STEERING POTENTIOMETER SYSTEM 1 IS DISPLAYED.............................................................................................. 482 E-7. [25] SHORT CIRCUIT IN STEERING POTENTIOMETER SYSTEM 1 IS DISPLAYED.............................................................................................. 483 E-8. [26] DISCONNECTION IN STEERING POTENTIOMETER SYSTEM 2 IS DISPLAYED.............................................................................................. 484 E-9. [25] SHORT CIRCUIT IN STEERING POTENTIOMETER SYSTEM 2 IS DISPLAYED.............................................................................................. 485 E-10. [29] TROUBLE OF ENGINE ROTATION SENSOR SYSTEM IS DISPLAYED..................................................................................................... 486 E-11. [51] SHORT CIRCUIT IN TRAVEL REVERSE SENSING POTENTIOMETER SYSTEM IS DISPLAYED................................................................................. 487 E-12. [52] DISCONNECTION IN TRAVEL REVERSE SENSING POTENTIOMETER SYSTEM IS DISPLAYED................................................................................. 488 E-13. [53] DISCONNECTION IN BACKUP ALARM RELAY SYSTEM IS DISPLAYED................................................................................................... 490 E-14. [54] SHORT CIRCUIT IN BACKUP ALARM RELAY SYSTEM IS DISPLAYED................................................................................................... 491 E-15. [57] LOW VOLTAGE OF CONTROLLER IS DISPLAYED.................................................................................................................... 492 E-16. [62] EXCESSIVE DIFFERENCE OF SIGNAL VALUE BETWEEN STEERING POTENTIOMETER SYSTEMS 1 AND 2 IS DISPLAYED [I]...................................................... 493 E-17. [6d] EXCESSIVE DIFFERENCE OF SIGNAL VALUE BETWEEN STEERING POTENTIOMETER SYSTEM 1 AND 2 IS DISPLAYED [II]...................................................... 494 E-18. [6E] TROUBLE OF EITHER STEERING POTENTIOMETER SYSTEM AND EXCESSIVE DEVIATION OF NEUTRAL POINT SIGNAL OF EITHER SYSTEM IS INDICATED............................. 495 E-19. [64] DISCONNECTION IN HSS PUMP SOLENOID VALVE SYSTEM A IS DISPLAYED ........................................................................................... 496 E-20. [65] SHORT CIRCUIT IN HSS PUMP SOLENOID VALVE SYSTEM A IS DISPLAYED............................................................................................ 497 E-21. [66] DISCONNECTION IN HSS PUMP SOLENOID VALVE SYSTEM B IS DISPLAYED............................................................................................ 498 E-22. [67] SHORT CIRCUIT IN HSS PUMP SOLENOID VALVE SYSTEM B IS DISPLAYED............................................................................................ 499 E-23. [70] SHORT CIRCUIT IN WORK EQUIPMENT CIRCUIT OIL PRESSURE SENSOR SYSTEM IS DISPLAYED........................................................................... 500 E-24. [71] DISCONNECTION IN WORK EQUIPMENT CIRCUIT OIL PRESSURE SENSOR SYSTEM IS DISPLAYED .......................................................................... 501 E-25. [8d] SYSTEM NETWORK COMMUNICATION ERROR IS DISPLAYED........................................................................................................... 502 E-26. [99] DISAGREEMENT OF REVERSE SENSING POTENTIOMETER AND BACKUP ALARM SWITCH SIGNALS WITH EACH OTHER IS DISPLAYED................................................ 503 E-27. [E0] TROUBLE OF OFFSET CURRENT MEMORY IS DISPLAYED............................................................................................................. 505 E-28. BACKUP ALARM DOES NOT SOUND.................................................................................................................................... 506 E-29. BLADE PITCH DOES NOT WORK NORMALLY (WHEN EQUIPPED WITH PITCH DOZER)............................................................................................ 507 E-30. [RIPPER PIN PULLER DOES NOT WORK NORMALLY (WHEN EQUIPPED WITH GIANT RIPPER).................................................................................... 509 E-31. ENGINE DOES NOT START (ENGINE DOES NOT ROTATE)................................................................................................................. 511 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE).............................................................................................................. 514 TABLE OF FAILURE MODES AND CAUSES.................................................................................................................................... 515 H-1. MACHINE DOES NOT MOVE OR MOVES SLOWLY AT ANY GEAR SPEED IN EACH DIRECTION....................................................................................... 517 H-2. MACHINE DOES NOT MOVE OR TRAVEL POWER IS LOW IN ONE DIRECTION................................................................................................... 519 H-3. MACHINE DOES NOT MOVE OR MOVES SLOWLY AT SPECIFIC GEAR SPEED.................................................................................................... 519 H-4. LONG TIME LAG IS MADE IN CHANGING TRAVEL DIRECTION OR GEAR SPEED................................................................................................ 520 H-5. TRAVEL POWER (DRAWBAR PULL) IS LOW.............................................................................................................................. 521 H-6. MACHINE CANNOT BE STEERED (TO ONE DIRECTION).................................................................................................................... 522 H-7. STEERING SPEED OR POWER IS LOW.................................................................................................................................. 522 H-8. ABNORMAL SOUND COMES OUT OF HSS PUMP OR HSS MOTOR............................................................................................................... 523 H-9. BRAKE DOES NOT WORK............................................................................................................................................. 525 H-10. POWER TRAIN OIL OVERHEATS...................................................................................................................................... 526 H-11. WORK EQUIPMENT DOES NOT WORK AT ALL............................................................................................................................ 527 H-12. WORK EQUIPMENT SPEED OR POWER IS LOW........................................................................................................................... 528 H-13. BLADE LIFTING SPEED OR POWER IS LOW............................................................................................................................ 529 H-14. BLADE TILTING SPEED OR POWER IS LOW............................................................................................................................ 529 H-15. RIPPER LIFTING SPEED OR POWER IS LOW........................................................................................................................... 530 H-16. RIPPER TILTING SPEED OR POWER IS LOW........................................................................................................................... 530 H-17. HYDRAULIC DRIFT IS LARGE IN BLADE LIFTING DIRECTION............................................................................................................ 531 H-18. HYDRAULIC DRIFT IS LARGE IN BLADE TILTING DIRECTION............................................................................................................ 531 H-19. HYDRAULIC DRIFT IS LARGE IN RIPPER LIFTING DIRECTION........................................................................................................... 532 H-20. BLADE PITCH DOES NOT WORK NORMALLY (WHEN EQUIPPED WITH PITCH DOZER)............................................................................................ 532 H-21. RIPPER PIN PULLER DOES NOT WORK NORMALLY (WHEN EQUIPPED WITH GIANT RIPPER)..................................................................................... 533 H-22. ABNORMAL SOUND COMES OUT OF WORK EQUIPMENT PUMP................................................................................................................ 533 TROUBLESHOOTING OF MONITOR SYSTEM (M MODE)[SERIAL NO.70001-75000]........................................................................................................ 534 ELECTRICAL CIRCUIT DIAGRAM FOR M MODE................................................................................................................................ 535 M-1. MONITOR LAMPS DO NOT LIGHT UP FOR 3 SECONDS WHEN STARTING SWITCH IS TURNED ON................................................................................... 536 M-2. WHEN STARTING SWITCH IS TURNED ON,MONITOR LAMPS ALL LIGHT UP BUT DO NOT GO OUT.................................................................................. 536 M-3. ABNORMALITY IN PREHEATING MONITOR LAMP.......................................................................................................................... 537 M-4. ABNORMALITY IN BATTERY CHARGE LAMP.............................................................................................................................. 539 M-5. ABNORMALITY IN ENGINE OIL PRESSURE CAUTION LAMP................................................................................................................. 541 M-6. ENGINE WATER TEMPERATURE CAUTION LAMP FLASHES................................................................................................................... 543 M-7. TRANSMISSION OIL TEMPERATURE CAUTION LAMP FLASHES............................................................................................................... 543 M-8. HSS OIL TEMPERATURE CAUTION LAMP FLASHES........................................................................................................................ 544 M-9. HSS CHARGE OIL PRESSURE CAUTION LAMP FLASHES.................................................................................................................... 545 M-10. ELECTRONIC SYSTEM CAUTION LAMP ON MONITOR PANEL DOES NOT WORK IN ACCORDANCE WITH LEO DISPLAY ON HSS CONTROLLER................................................. 546 M-11. MONITOR CAUTION LAMP ON MONITOR PANEL DOES NOT WORK IN ACCORDANCE WITH EACH CAUTION LAMP....................................................................... 546 M-12. ALARM BUZZER DOES NOT SOUND OR SOUNDS CONTINUOUSLY............................................................................................................. 547 M-13. ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE.................................................................................................................. 549 M-14. ABNORMALITY IN TRANSMISSION OIL TEMPERATURE GAUGE.............................................................................................................. 551 M-15. ABNORMALITY IN FUEL LEVEL GAUGE................................................................................................................................ 553 M-16. SERVICE METER DOES NOT WORK AFTER ENGINE IS STARTED............................................................................................................ 555 M-17. MONITOR PANEL NIGHT LIGHTING DOES NOT LIGHT UP WHEN HEAD LAMP SWITCH IS TURNED ON.............................................................................. 556 M-18. HEAD LAMPS OR REAR LAMPS DO NOT LIGHT UP....................................................................................................................... 557 M-19. AUTOMATIC PREHEATING IS NOT CARRIED OUT WHEN PREHEATING SWITCH IS TURNED TO AUTO............................................................................... 559 M-20. WINDOW WIPERS AND WINDOW WASHERS DO NOT WORK................................................................................................................... 561 M-21. AIR CONDITIONER DOES NOT WORK.................................................................................................................................. 564 TROUBLESHOOTING OF MONITOR SYSTEM (M MODE)[SERIAL NO.75001 AND UP]....................................................................................................... 569 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE........................................................................................... 570 M MODE SYSTEM ELECTRICAL CIRCUIT DIAGRAM............................................................................................................................. 572 M-1. [E0120] (ABNORMALITY IN MONITOR PANEL CAUTION LAMP SYSTEM) IS DISPLAYED......................................................................................... 574 M-2. [E0121] (ABNORMALITY IN MONITOR PANEL CAUTION BUZZER SYSTEM) IS DISPLAYED....................................................................................... 575 M-3. [E0211] (ABNORMALITY IN OIL TEMPERATURE OF POWER LINE: TORQUE CONVERTER) IS DISPLAYED........................................................................... 576 M-4. [E0329] (ABNORMALITY IN HSS OIL TEMPERATURE) IS DISLAYED........................................................................................................ 576 M-5. [E0430] (ABNORMALITY IN ENGINE OIL PRESSURE) IS DISPLAYED....................................................................................................... 577 M-6. [E0432] (ABNORMALITY IN ENGINE WATER TEMPERATURE) IS DISPLAYED.................................................................................................. 577 M-7. WHEN STARTING SWITCH IS TURNED ON,ALL SEGMENTS OF MONITOR PANEL DO NOT LIGHT UP................................................................................. 578 M-8. WHEN STARTING SWITCH IS TURNED ON,ALL SEGMENTS OF MONITOR PANEL LIGHT UP BUT DO NOT GO OUT ..................................................................... 580 M-9. WHEN STARTING SWITCH IS TURNED ON (WITH ENGINE STOPPED),CAUTION ITEMS (EXCLUDING BATTERY CHARGE LAVEL AND ENGINE OIL PRESSURE) FLASH............................ 581 M-10. WHEN ENGINE IS STARTED,CAUTION ITEMS FLASH (DAILY CHECK ITEMS AND ENGINE RELATED ITEMS ARE NORMAL)............................................................. 583 M-11. HSS CHARGING OIL PRESSURE CAUTION LAMP FLASHES................................................................................................................. 586 M-12. PREHEATER LAMP DOES NOT LIGHT UP OR STAYS LIGHTED UP........................................................................................................... 587 M-13. ABNORMALITY IN CAUTION BUZZER.................................................................................................................................. 588 M-14. ABNORMALITY IN CAUTION LAMP.................................................................................................................................... 590 M-15. ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE.................................................................................................................. 592 M-16. ABNORMALITY IN POWER TRAIN (TORQUE CONVERTER) OIL PRESSURE GAUGE............................................................................................... 593 M-17. ABNORMALITY IN FUEL LEVEL GAUGE................................................................................................................................ 595 M-18. GEAR SPEED DISPLAY SEGMENTS INDICATE [--], AND ENGINE SPEED IS NOT DISPLAYED................................................................................... 597 M-19. SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING......................................................................................................... 597 M-20. ABNORMALITY IN SERVICE MODE DISPLAY............................................................................................................................ 598 M-21. MONITOR PANEL LIGHTING DOES NOT LIGHT UP (THOUGH HEADLAMPS AND WORKING LAMPS LIGHT UP)......................................................................... 600 M-22. WHEN HEAD LAMP SWITCH IS TURNED ON, MONITOR PANEL LIGHTING DOES NOT LIGHT UP .................................................................................. 602 M-23. HEAD LAMPS OR REAR LAMPS DO NOT LIGHT UP....................................................................................................................... 603 M-24. ELECTRIC INTAKE AIR HEATER DOES NOT WORK....................................................................................................................... 605 M-25. WINDSHIELD WIPER OR WASHER DOES NOT WORK....................................................................................................................... 607 M-26. AIR CONDITIONER DOES NOT WORK.................................................................................................................................. 610 TROUBLESHOOTING OF ENGINE CONTROLLER (G MODE)[SERIAL NO.75001 AND UP].................................................................................................... 615 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE........................................................................................... 616 JUDGMENT TABLE FOR ENGINE CONTROLLER AND ENGINE...................................................................................................................... 624 G MODE SYSTEM ELECTRICAL CIRCUIT DIGRAM.............................................................................................................................. 626 G-1. [E0401] (ABNORMALITY IN ENGINE CONTROLLER POWER SUPPLY) IS DISPLAYED............................................................................................ 628 G-2. [E0402] (ABNORMALITY IN ENGINE CONTROLLER) IS DISPLAYED......................................................................................................... 629 G-3. [E0405] (ABNORMALITY IN FUEL CONTROL DIAL SYSTEM) IS DISPLAYED.................................................................................................. 630 G-4. [E0406] (ABNORMALITY IN DECELERATOR POTENTIOMETER SYSTEM) IS DISPLAYED.......................................................................................... 631 G-5. [E0409] (ABNORMALITY IN NE SPEED SENSOR SYSTEM) IS DISPLAYED.................................................................................................... 632 G-6. [E0410] (ABNORMALITY IN G SPEED SENSOR SYSTEM) IS DISPLAYED..................................................................................................... 633 G-7. [E0458] (SHORT CIRCUIT IN FUEL INJECTOR NO.1, NO.2, NO.3 SYSTEM) IS DISPLAYED................................................................................... 634 G-8. [E0459] (SHORT CIRCUIT IN FUEL INJECTOR NO.4, NO.5, NO.6 SYSTEM) IS DISPLAYED................................................................................... 637 G-9. [E0460] (ABNORMALITY IN CONTROLLER CHASSIS GROUND CIRCUIT) IS DISPLAYED......................................................................................... 640 G-10. [E0461] (DISCONNECTION IN FUEL INJECTOR NO.1 SYSTEM) IS DISPLAYED.............................................................................................. 641 G-11. [E0462] (DISCONNECTION IN FUEL INJECTOR NO.2 SYSTEM) IS DISPLAYED.............................................................................................. 642 G-12. [E0463] (DISCONNECTION IN FUEL INJECTOR NO.3 SYSTEM) IS DISPLAYED.............................................................................................. 643 G-13. [E0464] (DISCONNECTION IN FUEL INJECTOR NO.4 SYSTEM) IS DISPLAYED.............................................................................................. 644 G-14. [E0465] (DISCONNECTION IN FUEL INJECTOR NO.5 SYSTEM) IS DISPLAYED.............................................................................................. 645 G-15. [E0466] (DISCONNECTION IN FUEL INJECTOR NO.6 SYSTEM) IS DISPLAYED.............................................................................................. 646 G-16. [E0468] (OVERCURRENT IN FUEL SUPPLY PUMP PCV1 SYSTEM) IS DISPLAYED............................................................................................. 647 G-17. [E0469] (DISCONNECTION IN FUEL SUPPLY PUMP PCV1 SYSTEM) IS DISPLAYED........................................................................................... 648 G-18. [E0470] (OVERCURRENT IN FUEL SUPPLY PUMP PCV2 SYSTEM) IS DISPLAYED............................................................................................. 649 G-19. [E0471] (DISCONNECTION IN FUEL SUPPLY PUMP PCV2 SYSTEM) IS DISPLAYED........................................................................................... 650 G-20. [E0472] (ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM) IS DISPLAYED............................................................................................. 651 G-21. [E0474] (ABNORMALITY IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM) IS DISPLAYED.................................................................................. 652 G-22. [E0476] (ABNORMALITY IN HIGH ENGINE WATER TEMPERATURE SENSOR SYSTEM) IS DISPLAYED.............................................................................. 653 G-23. [E0478] (ABNORMALITY IN LOW ENGINE WATER TEMPERATURE SENSOR SYSTEM) IS DISPLAYED............................................................................... 654 G-24. [E0480] (ABNORMALITY IN COMMON RAIL FUEL PRESSURE SYSTEM) IS DISPLAYED......................................................................................... 655 G-25. [E0481] (ABNORMALITY IN HIGH COMMON RAIL FUEL PRESSURE 1 SYSTEM) IS DISPLAYED [EO482] (ABNORMALITY IN HIGH COMMON RAIL FUEL PRESSURE 2 SYSTEM) IS DISPLAYED.... 656 G-26. [E0483] (N0-PRESSURE FEED BY FUEL SUPPLY PUMP 1) IS DISPLAYED [E0484] (N0-PRESSURE FEED BY FUEL SUPPLY PUMP 2) IS DISPLAYED.................................... 657 G-27. [E0487] (ABNORMALITY IN ENGINE OIL PRESSURE SWITCH SYSTEM1) IS DISPLAYED....................................................................................... 659 G-28. [E0488] (ABNORMALITY IN POWER SUPPLY SYSTEM 1) IS DISPLAYED.................................................................................................... 661 G-29. [E0489] (ABNORMALITY IN POWER SUPPLY SYSTEM 2) IS DISPLAYED.................................................................................................... 663 G-30. [E0490] (ABNORMALITY IN Q REGULATOR SWITCH SIGNAL) IS DISPLAYED................................................................................................ 664 G-31. [E0491] (SHORT CIRCUIT IN STARTING SWITCH C SYSTEM) IS DISPLAYED............................................................................................... 665 TROUBLESHOOTING OF HSS CONTROLLER AND ELECTRICAL SYSTEM (E MODE)[SERIAL NO.75001-75999].................................................................................. 666 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE........................................................................................... 667 ELECTRICAL CIRCUIT DIAGRAM FOR E MODE................................................................................................................................ 675 E-1. [E0113] (DROP OF HSS CONTROLLER POWER SUPPLY VOLTAGE) IS DISPLAYED.............................................................................................. 677 E-2. [E0143] (ABNORMALITY IN HSS CONTROLLER 5V POWER SUPPLY VOLTAGE) IS DISPLAYED.................................................................................... 678 E-3. [E0145] (ABNORMALITY IN HSS CONTROLLER SENSOR POWER SUPPLY VOLTAGE) IS DISPLAYED................................................................................ 679 E-4. [E0161] (ABNORMALITY IN HSS CONTROLLER MEMORY DATA OF OFFSET CURRENT) IS DISPLAYED.............................................................................. 680 E-5. [E0221] (ABNORMALITY IN GEAR SPEED SWITCH SYSTEM) IS DISPLAYED.................................................................................................. 681 E-6. [E0233] (SHORT CIRCUIT IN TRAVEL REVERSE SENSING POTENTIOMETER SYSTEM) IS DISPLAYED............................................................................. 682 E-7. [E0233] (DISCONNECTION IN TRAVEL REVERSE SENSING POTENTIOMETER SYSTEM) IS DISPLAYED............................................................................. 683 E-8. [E0237] (ABNORMALITY IN TRANSMISSION NEUTRAL SIGNAL) IS DISPLAYED............................................................................................... 685 E-9. [E0272] (UNEQUALITY BETWEEN TRAVEL REVERSE SENSING POTENTIOMETER SIGNAL AND BACKUP ALARM SWITCH SIGNAL) IS DISPLAYED............................................ 686 E-10. [E0360] (DISCONNECTION IN WORK EQUIPMENT OIL PRESSURE SENSOR SYSTEM) IS DISPLAYED.............................................................................. 688 E-11. [E0361] (SHORT CIRCUIT IN WORK EQUIPMENT OIL PRESSURE SENSOR SYSTEM) IS DISPLAYED.............................................................................. 689 E-12. [E0610] (DISCONNECTION IN BACKUP ALARM RELAY SYSTEM) IS DISPLAYED.............................................................................................. 690 E-13. [E0611] (SHORT CIRCUIT IN BACKUP ALARM RELAY SYSTEM) IS DISPLAYED.............................................................................................. 691 E-14. [E0730] (ABNORMALITY IN BOTH STEERING POTENTIOMETER SYSTEMS 1 AND 2) IS DISPLAYED.............................................................................. 692 E-15. [E0731] (LARGE DIFFERENCE BETWEEN STEERING POTENTIOMETER SYSTEMS 1 AND 2: CASE I) IS DISPLAYED................................................................. 693 E-16. (ABNORMALITY IN STEERING POTENTIOMETER SYSTEM ON ONE SIDE AND LARGE DEVIATION OF NEUTRAL POSITION ON ONE SIDE) IS DISPLAYED.................................... 694 E-17. [E0733] (DISCONNECTION IN STEERING POTENTIOMETER SYSTEM 1) IS DISPLAYED........................................................................................ 695 E-18. [E0733] (SHORT CIRCUIT IN STEERING POTENTIOMETER SYSTEM 1) IS DISPLAYED........................................................................................ 696 E-19. [E0734] (DISCONNECTION IN STEERING POTENTIOMETER SYSTEM 2) IS DISPLAYED........................................................................................ 697 E-20. [E0734] (SHORT CIRCUIT IN STEERING POTENTIOMETER SYSTEM 2) IS DISPLAYED........................................................................................ 698 E-21. [E0735] (LARGE DIFFERENCE BETWEEN STEERING POTENTIOMETER SYSTEMS 1 AND 2: CASE II) IS DISPLAYED................................................................ 699 E-22. [E0768] (DISCONNECTION IN STEERING OIL PRESSURE SENSOR A SYSTEM) IS DISPLAYED.................................................................................. 700 E-23. [E0769] (SHORT CIRCUIT IN STEERING OIL PRESSURE SENSOR A SYSTEM) IS DISPLAYED.................................................................................. 701 E-24. [E0770] (DISCONNECTION IN STEERING OIL PRESSURE SENSOR B SYSTEM) IS DISPLAYED.................................................................................. 702 E-25. [E0771] (SHORT CIRCUIT IN STEERING OIL PRESSURE SENSOR B SYSTEM) IS DISPLAYED.................................................................................. 703 E-26. [E0774] (DISCONNECTION IN HSS PUMP SOLENOID A SYSTEM) IS DISPLAYED............................................................................................. 704 E-27. [E0775] (SHORT CIRCUIT IN HSS PUMP SOLENOID A SYSTEM) IS DISPLAYED............................................................................................. 705 E-28. [E0772] (DISCONNECTION IN HSS PUMP SOLENOID B SYSTEM) IS DISPLAYED............................................................................................. 706 E-29. [E0773] (SHORT CIRCUIT IN HSS PUMP SOLENOID B SYSTEM) IS DISPLAYED............................................................................................. 707 E-30. [E0930] (ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED............................................................................................... 708 E-31. BACKUP ALARM DOES NOT SOUND.................................................................................................................................... 709 E-32. BLADE PITCH MALFUNCTIONS (MACHINE EQUIPPED WITH PITCH DOZER)................................................................................................... 710 E-33. RIPPER PIN PULLER MALFUNCTIONS (MACHINE EQUIPPED WITH GIANT RIPPER)............................................................................................ 712 E-34. ENGINE DOES NOT START (ENGINE DOES NOT ROTATE)................................................................................................................. 714 30 DISASSEMBLY AND ASSEMBLY...................................................................................................................................................... 717 METHOD OF USING MANUAL....................................................................................................................................................... 719 PRECAUTIONS WHEN CARRYING OUT OPERATION...................................................................................................................................... 721 SPECIAL TOOL LIST............................................................................................................................................................ 723 SPECIAL TOOL SKETCH.......................................................................................................................................................... 733 STARTING MOTOR............................................................................................................................................................... 741 REMOVAL AND INSTALLATION................................................................................................................................................. 741 ALTERNATOR................................................................................................................................................................... 742 REMOVAL AND INSTALLATION................................................................................................................................................. 742 ENGINE OIL COOLER CORE....................................................................................................................................................... 743 REMOVAL AND INSTALLATION................................................................................................................................................. 743 FUEL INJECTION PUMP.......................................................................................................................................................... 744 REMOVAL.................................................................................................................................................................. 744 INSTALLATION............................................................................................................................................................. 745 WATER PUMP................................................................................................................................................................... 746 REMOVAL AND INSTALLATION................................................................................................................................................. 746 TURBOCHARGER................................................................................................................................................................. 747 REMOVAL AND INSTALLATION................................................................................................................................................. 747 NOZZLE HOLDER................................................................................................................................................................ 749 REMOVAL AND INSTALLATION................................................................................................................................................. 749 FUEL INJECTOR................................................................................................................................................................ 750 REMOVAL.................................................................................................................................................................. 750 INSTALLATION............................................................................................................................................................. 751 ENGINE FRONT SEAL............................................................................................................................................................ 753 REMOVAL.................................................................................................................................................................. 753 INSTALLATION............................................................................................................................................................. 754 ENGINE REAR SEAL............................................................................................................................................................. 756 REMOVAL.................................................................................................................................................................. 756 INSTALLATION............................................................................................................................................................. 757 CYLINDER HEAD................................................................................................................................................................ 761 REMOVAL.................................................................................................................................................................. 761 INSTALLATION............................................................................................................................................................. 766 THERMOSTAT................................................................................................................................................................... 768 REMOVAL AND INSTALLATION................................................................................................................................................. 768 AIR CONDITIONER COMPRESSOR................................................................................................................................................... 769 REMOVAL.................................................................................................................................................................. 769 INSTALLATION............................................................................................................................................................. 770 AIR CONDITIONER CONDESER..................................................................................................................................................... 771 REMOVAL AND INSTALLATION................................................................................................................................................. 771 FUEL TANK.................................................................................................................................................................... 772 REMOVAL AND INSTALLATION................................................................................................................................................. 772 RADIATOR..................................................................................................................................................................... 773 REMOVAL.................................................................................................................................................................. 773 INSTALLATION............................................................................................................................................................. 775 RADIATOR,OIL COOLER,GUARD.................................................................................................................................................... 776 REMOVAL.................................................................................................................................................................. 776 INSTALLATION............................................................................................................................................................. 778 FAN DRIVE.................................................................................................................................................................... 779 REMOVAL.................................................................................................................................................................. 779 INSTALLATION............................................................................................................................................................. 780 HYDRAULIC COOLER............................................................................................................................................................. 781 REMOVAL AND INSTALLATION................................................................................................................................................. 781 ENGINE....................................................................................................................................................................... 782 REMOVAL.................................................................................................................................................................. 782 INSTALLATION............................................................................................................................................................. 786 DAMPER....................................................................................................................................................................... 787 REMOVAL.................................................................................................................................................................. 787 INSTALLATION............................................................................................................................................................. 788 DISASSEMBLY.............................................................................................................................................................. 789 ASSEMBLY................................................................................................................................................................. 792 POWER TRAIN UNIT............................................................................................................................................................. 796 REMOVAL.................................................................................................................................................................. 796 INSTALLATION............................................................................................................................................................. 800 SEPARATION............................................................................................................................................................... 801 CONNECTION............................................................................................................................................................... 805 PTO.......................................................................................................................................................................... 806 DISASSEMBLY.............................................................................................................................................................. 806 ASSEMBLY................................................................................................................................................................. 810 TORQUE CONVERTER............................................................................................................................................................. 815 DISASSEMBLY.............................................................................................................................................................. 815 ASSEMBLY................................................................................................................................................................. 818 TORQFLOW TRANSMISSION........................................................................................................................................................ 821 DISASSEMBLY.............................................................................................................................................................. 821 ASSEMBLY................................................................................................................................................................. 830 HSS CASE..................................................................................................................................................................... 841 DISASSEMBLY.............................................................................................................................................................. 841 ASSEMBLY................................................................................................................................................................. 850 HYDRAULIC PUMP............................................................................................................................................................... 863 REMOVAL.................................................................................................................................................................. 863 INSTALLATION............................................................................................................................................................. 867 HSS PUMP..................................................................................................................................................................... 868 DISASSEMBLY.............................................................................................................................................................. 868 ASSEMBLY................................................................................................................................................................. 875 HSS MOTOR.................................................................................................................................................................... 885 REMOVAL AND INSTALLATION................................................................................................................................................. 885 POWER TRAIN MAIN RELIEF VALVE................................................................................................................................................ 886 REMOVAL AND INSTALLATION................................................................................................................................................. 886 DISASSEMBLY AND ASSEMBLY................................................................................................................................................. 887 HSS,PPC CHARGE VALVE......................................................................................................................................................... 888 REMOVAL AND INSTALLATION................................................................................................................................................. 888 HSS,PPC CHARGING VALVE....................................................................................................................................................... 889 DISASSEMBLY.............................................................................................................................................................. 889 ASSEMBLY................................................................................................................................................................. 890 TRANSMISSION CONTROL VALVE................................................................................................................................................... 891 REMOVAL.................................................................................................................................................................. 891 INSTALLATION............................................................................................................................................................. 892 DISASSEMBLY AND ASSEMBLY................................................................................................................................................. 893 BRAKE VALVE.................................................................................................................................................................. 895 REMOVAL AND INSTALLATION................................................................................................................................................. 895 DISASSEMBLY AND ASSEMBLY................................................................................................................................................. 896 FINAL DRIVE.................................................................................................................................................................. 898 REMOVAL.................................................................................................................................................................. 898 INSTALLATION............................................................................................................................................................. 900 DISASSEMBLY.............................................................................................................................................................. 901 ASSEMBLY................................................................................................................................................................. 906 TRACK FRAME.................................................................................................................................................................. 912 REMOVAL.................................................................................................................................................................. 912 INSTALLATION............................................................................................................................................................. 914 IDLER........................................................................................................................................................................ 915 REMOVAL.................................................................................................................................................................. 915 INSTALLATION............................................................................................................................................................. 916 DISASSEMBLY.............................................................................................................................................................. 917 ASSEMBLY................................................................................................................................................................. 919 RECOIL SPRING................................................................................................................................................................ 922 REMOVAL AND INSTALLATION................................................................................................................................................. 922 DISASSEMBLY.............................................................................................................................................................. 923 ASSEMBLY................................................................................................................................................................. 928 TRACK ROLLER................................................................................................................................................................. 932 REMOVAL.................................................................................................................................................................. 932 INSTALLATION............................................................................................................................................................. 933 DISASSEMBLY.............................................................................................................................................................. 934 ASSEMBLY................................................................................................................................................................. 937 BOGLE........................................................................................................................................................................ 940 REMOVAL.................................................................................................................................................................. 940 INSTALLATION............................................................................................................................................................. 942 DISASSEMBLY.............................................................................................................................................................. 943 ASSEMBLY................................................................................................................................................................. 946 CARRIER ROLLER............................................................................................................................................................... 950 REMOVAL AND INSTALLATION................................................................................................................................................. 950 DISASSEMBLY.............................................................................................................................................................. 951 ASSEMBLY................................................................................................................................................................. 953 TRACK SHOE................................................................................................................................................................... 956 CHECKING BEFORE REMOVAL.................................................................................................................................................. 956 REMOVAL (NORMAL)......................................................................................................................................................... 956 REMOVAL (WHEN THERE IS ABNORMALITY INSIDE TRACK FRAME)................................................................................................................... 957 INSTALLATION............................................................................................................................................................. 958 OVERALL DISASSEMBLY...................................................................................................................................................... 959 OVERALL ASSEMBLY......................................................................................................................................................... 964 PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS............................................................................................................................. 978 ONE LINK..................................................................................................................................................................... 979 FIELD DISASSEMBLY........................................................................................................................................................ 979 FIELD ASSEMBLY........................................................................................................................................................... 981 MASTER LINK.................................................................................................................................................................. 983 DISASSEMBLY.............................................................................................................................................................. 983 ASSEMBLY................................................................................................................................................................. 985 PIVOT SHAFT.................................................................................................................................................................. 988 REMOVAL AND INSTALLATION................................................................................................................................................. 988 EQUALIZER BAR................................................................................................................................................................ 989 REMOVAL.................................................................................................................................................................. 989 INSTALLATION............................................................................................................................................................. 990 EQUALIZER BAR SIDE BUSHING................................................................................................................................................... 991 REMOVAL AND INSTALLATION................................................................................................................................................. 991 SEGMENT TEETH................................................................................................................................................................ 992 REMOVAL AND INSTALLATION................................................................................................................................................. 992 HYDRAULIC TANK .............................................................................................................................................................. 993 REMOVAL AND INSTALLATION................................................................................................................................................. 993 MAIN CONTROL VALVE .......................................................................................................................................................... 994 REMOVAL.................................................................................................................................................................. 994 INSTALLATION............................................................................................................................................................. 995 DISASSEMBLY.............................................................................................................................................................. 996 ASSEMBLY................................................................................................................................................................. 999 HSS OIL COOLER BYPASS VALVE..................................................................................................................................................1003 REMOVAL AND INSTALLATION.................................................................................................................................................1003 DISASSEMBLY, ASSEMBLY OF HMT OIL COOLER BYPASS VALVE.........................................................................................................................1004 BLADE PPC VALVE..............................................................................................................................................................1005 REMOVAL..................................................................................................................................................................1005 INSTALLATION.............................................................................................................................................................1006 RIPPER PPC VALVE.............................................................................................................................................................1007 REMOVAL..................................................................................................................................................................1007 INSTALLATION.............................................................................................................................................................1008 BLADE PPC VALVE .............................................................................................................................................................1009 DISASSEMBLY..............................................................................................................................................................1009 INSTALLATION.............................................................................................................................................................1010 BLADE LIFT CYLINDER .........................................................................................................................................................1012 REMOVAL AND INSTALLATION.................................................................................................................................................1012 BLADE TILT CYLINDER..........................................................................................................................................................1013 REMOVAL AND INSTALLATION.................................................................................................................................................1013 RIPPER LIFT CYLINDER.........................................................................................................................................................1014 REMOVAL AND INSTALLATION.................................................................................................................................................1014 RIPPER TILT CYLINDER.........................................................................................................................................................1015 REMOVAL AND INSTALLATION.................................................................................................................................................1015 HYDRAULIC CYLINDER...........................................................................................................................................................1016 DISASSEMBLY..............................................................................................................................................................1016 ASSEMBLY.................................................................................................................................................................1019 BLADE........................................................................................................................................................................1023 REMOVAL..................................................................................................................................................................1023 INSTALLATION.............................................................................................................................................................1024 DISASSEMBLY..............................................................................................................................................................1025 ASSEMBLY.................................................................................................................................................................1027 MULTI-SHANK RIPPER...........................................................................................................................................................1029 DISASSEMBLY..............................................................................................................................................................1029 ASSEMBLY.................................................................................................................................................................1031 ROPS GUARD...................................................................................................................................................................1033 REMOVAL AND INSTALLATION.................................................................................................................................................1033 OPERATOR CAB ................................................................................................................................................................1034 REMOVAL AND INSTALLATION.................................................................................................................................................1034 HOOD ........................................................................................................................................................................1035 REMOVAL AND INSTALLATION.................................................................................................................................................1035 FLOOR FRAME..................................................................................................................................................................1036 REMOVAL..................................................................................................................................................................1036 INSTALLATION.............................................................................................................................................................1041 DASHBOARD....................................................................................................................................................................1042 REMOVAL..................................................................................................................................................................1042 INSTALLATION.............................................................................................................................................................1043 MONITOR......................................................................................................................................................................1044 REMOVAL AND INSTALLATION.................................................................................................................................................1044 HSS CONTROLLER...............................................................................................................................................................1045 REMOVAL AND INSTALLATION.................................................................................................................................................1045 40 MAINTENANCE STANDARD..........................................................................................................................................................1047 ENGINE MOUNT.................................................................................................................................................................1048 POWER TRAIN UNIT MOUNT.......................................................................................................................................................1049 DAMPER, UNIVERSAL JOINT......................................................................................................................................................1050 TORQUE CONVERTER,PTO.........................................................................................................................................................1051 TRANSMISSION.................................................................................................................................................................1054 TRANSMISSION CONTROL VALVE...................................................................................................................................................1057 MAIN RELIEF VALVE............................................................................................................................................................1058 BEVEL GEAR SHAFT,HSS BRAKE...................................................................................................................................................1059 BRAKE VALVE..................................................................................................................................................................1063 SCAVENGING PUMP, PPC, HSS CHARGE PUMP........................................................................................................................................1064 POWER TRAIN PUMP, LUBRICATION PUMP...........................................................................................................................................1065 PPC,HSS CHARGE VALVE.........................................................................................................................................................1066 OIL COOLER BYPASS VALVE......................................................................................................................................................1068 FINAL DRIVE..................................................................................................................................................................1069 SPROCKET.....................................................................................................................................................................1071 MAIN FRAME...................................................................................................................................................................1073 TRACK FRAME..................................................................................................................................................................1075 RECOIL SPRING................................................................................................................................................................1076 TRACK ROLLER BOGIE...........................................................................................................................................................1077 IDLER........................................................................................................................................................................1079 TRACK ROLLER.................................................................................................................................................................1081 CARRIER ROLLER...............................................................................................................................................................1083 TRACK SHOE...................................................................................................................................................................1084 SUSPENSION...................................................................................................................................................................1091 WORK EQUIPMENT PUMP..........................................................................................................................................................1093 HSS PUMP.....................................................................................................................................................................1094 HSS MOTOR....................................................................................................................................................................1095 PPC VALVE....................................................................................................................................................................1096 STEERING LEVER...............................................................................................................................................................1099 MAIN CONTROL VALVE...........................................................................................................................................................1100 WORK EQUIPMENT CYLINDER......................................................................................................................................................1105 QUICK DROP VALVE.............................................................................................................................................................1109 CYLINDER STAY................................................................................................................................................................1110 WORK EQUIPMENT...............................................................................................................................................................1111 90 OTHERS........................................................................................................................................................................1118 WORK EQUIPMENT HYDRAULIC CIRCUIT AND HSS CIRCUIT DIAGRAM.....................................................................................................................1119 MACHINE EQUIPPED WITH PITCH DOZER............................................................................................................................................1120 ELECTRIC CIRCUIT DIAGRAM (1/3) (SERIAL NO.70001-75000).......................................................................................................................1121 ELECTRIC CIRCUIT DIAGRAM (2/3) (SERIAL NO.70001-75000).......................................................................................................................1122 ELECTRIC CIRCUIT DIAGRAM (3/3) (SERIAL NO.70001-75000).......................................................................................................................1123 ELECTRIC CIRCUIT DIAGRAM (1/3) (SERIAL NO.75001 AND UP)......................................................................................................................1124 ELECTRIC CIRCUIT DIAGRAM (2/3) (SERIAL NO.75001 AND UP)......................................................................................................................1125 ELECTRIC CIRCUIT DIAGRAM (3/3) (SERIAL NO.75001 AND UP)......................................................................................................................1126 ELECTRIC CIRCUIT DIAGRAM INSIDE CAB (SERIAL NO.75001 AND UP).................................................................................................................1127
KOMATSU D155AX-5 CRAWLER BULLDOZER SHOP MANUAL 70001 AND UP – PDF DOWNLOAD:
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Salvador Kristopher –
too early to tell if the product is useful