Komatsu D155AX-5 Shop Manual SEBM034808 – PDF DOWNLOAD

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Komatsu D155AX-5 Shop Manual SEBM034808 – PDF DOWNLOAD

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Komatsu D155AX-5 Shop Manual SEBM034808 – PDF DOWNLOAD

Language : English
Pages :1178
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu D155AX-5 Shop Manual SEBM034808 – PDF DOWNLOAD

MACHINE MODEL SERIAL NUMBER
D155AX-5 76001 and up

FOREWORD
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 chapters; these chapters are further
divided into the each main group of components.
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.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance
standards.
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 charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component,
as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.

TABLE OF CONTENTS:

Komatsu D155AX-5 Shop Manual SEBM034808 – PDF DOWNLOAD

MACHINE MODEL SERIAL NUMBER
D155AX-5 76001 and up

COVER 1
CONTENTS 2
SAFETY 3
SAFETY NOTICE 3
FOREWORD 5
GENERAL 5
HOW TO READ THE SHOP MANUAL 6
HOISTING INSTRUCTIONS 7
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER 8
COATING MATERIALS 10
STANDARD TIGHTENING TORQUE 12
ELECTRIC WIRE CODE 15
CONVERSION TABLE 16
UNITS 22
01 GENERAL 23
SPECIFICATION DRAWING 24
SPECIFICATIONS 26
WEIGHT TABLE 32
TABLE OF FUEL, COOLANT AND LUBRICANT 34
10 STRUCTURE AND FUNCTION 35
RADIATOR, OIL COOLER 36
POWER TRAIN SYSTEM 40
OVERALL DRAWING OF POWER TRAIN UNIT 42
POWER TRAIN HYDRAULIC EQUIPMENT LAYOUT 44
DAMPER, UNIVERSAL JOINT 46
TORQUE CONVERTER, PTO 48
TRANSMISSION CONTROL 52
TRANSMISSION 54
TRANMISSION ECMV 64
MAIN RELIEF VALVE 69
LUBRICATION RELIEF VALVE 72
SCAVENGING PUMP STRAINER 73
POWER TRAIN PUMP STRAINER 74
POWER TRAIN OIL FILTER 75
HSS SYSTEM 76
HSS PUMP 90
HSS MOTOR 106
COOLING FAN PUMP 114
COOLING FAN MOTOR 122
HSS CHARGE FILTER BYPASS VALVE 128
HSS OIL COOLER BYPASS VALVE 129
STEERING BRAKE CONTROL 130
BEVEL GEAR SHAFT, HSS, BRAKE 132
BRAKE VALVE 146
FINAL DRIVE 150
TRACK FRAME 153
TRACK ROLLER BOGIE 155
RECOIL SPRING 156
MAIN FRAME 157
SUSPENSION 158
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM 160
PPC CONTROL PIPING DIAGRAM 163
WORK EQUIPMENT CONTROL 164
HYDRAULIC TANK AND FILTER 166
ACCUMULATOR 168
PPC LOCK VALVE 169
PPC VALVE 170
PCCS LEVER 180
PISTON VALVE 183
PIN PULLER SWITCH 184
PIN PULLER SOLENOID VALVE 186
MAIN CONTROL VALVE 188
SELF PRESSURE REDUCING VALVE 214
CYLINDER STAY 221
WORK EQUIPMENT 222
CAB MOUNT 226
CAB 227
AIR CONDITIONER 229
ENGINE CONTROL 230
ENGINE CONTROL SYSTEM 231
CRI ENGINE CONTROL SYSTEM 232
MONITOR SYSTEM 234
MONITOR PANEL 236
SENSORS 239
DECELERATION POTENTIOMETER 243
PALM COMMAND CONTROL SYSTEM 245
20 TESTING AND ADJUSTING 247
STANDARD VALUE TABLES 248
STANDARD VALUE TABLE FOR ENGINE 248
STANDARD VALUE TABLE FOR CHASSIS 249
TESTING AND ADJUSTING 255
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 256
MEASURING ENGINE SPEED 258
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) 261
MEASURING EXHAUST TEMPERATURE 263
MEASURING EXHAUST GAS COLOR 265
ADJUSTING VALVE CLEARANCE 267
MEASURING COMPRESSION PRESSURE 268
MEASURING BLOW-BY PRESSURE 270
MEASURING ENGINE OIL PRESSURE 271
HANDLING OF FUEL SYSTEM DEVICES 272
RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM 272
MEASURING FUEL PRESSURE 273
BLEEDING AIR FROM FUEL CIRCUIT 274
INSPECTION OF FUEL CIRCUIT FOR LEAKAGE 276
TESTING AND ADJUSTING ALTERNATOR BELT TENSION 277
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT 278
ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL 279
MEASURING POWER TRAIN OIL PRESSURE 281
TESTING AND ADJUSTING HSS OIL PRESSURE 286
ADJUSTING TRANSMISSION SPEED SENSOR 291
BLEEDING AIR FROM HSS PUMP 292
SIMPLE METHOD OF TESTING BRAKE PERFORMANCE 292
ADJUSTING BRAKE PEDAL 293
ADJUSTING AT PARKING BRAKE LEVER 295
EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE 296
INSPECTING WEAR OF SPROCKET 298
ADJUSTING CLEARANCE OF IDLER 299
TESTING AND ADJUSTING TRACK SHOE TENSION 300
TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE 301
TESTING AND ADJUSTING CONTROL CIRCUIT MAIN PRESSURE 304
MEASURING PPC VALVE OUTPUT PRESSURE 305
ADJUSTING PLAY OF PPC VALVE 307
MEASURING OUTLET PRESSURE OF RIPPER PIN PULLER SOLENOID VALVE 308
TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF BLADE AND RIPPER 309
MEASURING INTERNAL LEAKAGE OF WORK EQUIPMENT CYLINDER 310
RELEASING RESIDUAL PRESSURE FROM WORK EQUIPMENT CYLINDER 311
BLEEDING AIR FROM WORK EQUIPMENT CYLINDER 311
ADJUSTING WORK EQUIPMENT LOCK LEVER 312
MEASURING FAN MOTOR SPEED 313
MEASURING FAN CIRCUIT OIL PRESSURE 314
BLEEDING AIR FROM FAN PUMP 315
ADJUSTING BLADE (SEMI-U TILTDOZER) 316
TESTING AND ADJUSTING OF OPERATOR’S CAB 318
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) 322
HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER 363
ADJUSTMENT METHOD OF REPLACED CONTROLLER 363
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM 365
Pm CLINIC SERVICE 367
ADJUSTING UNDERCARRIAGE TROUBULNDEESRCHAORROIATGIENTGRORUBELPESOHROOT 374
TROUBLESHOOTING 379
POINTS TO REMEMBER WHEN TROUBLESHOOTING 380
SEQUENCE OF EVENTS IN TROUBLESHOOTING 381
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 382
CHECKS BEFORE TROUBLESHOOTING 390
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING 391
CONNECTOR ALLOCATION DRAWING AND ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM 394
CONNECTOR ARRANGEMENT DRAWING 400
CIRCUIT DRAWING FOR MONITOR PANEL (M CIRCUIT) 406
CIRCUIT DRAWING FOR ENGINE CONTROLLER SYSTEM (E CIRCUIT) 408
CIRCUIT DRAWING FOR STEERING AND TRANSMISSION CONTROLLER SYSTEM (S CIRCUIT) 410
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 412
T-BRANCH BOX AND T-BRANCH TABLE 435
PARTS & SERVICE OPERATION TIPS 437
TROUBLESHOOTING WHEN ERROR CODE IS DISPLAYED (ERROR CODE) 461
ERROR CODES TABLE 462
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST 466
ERROR CODE 1500L0 (TRANSMISSION CLUTCH: DOUBLE ENGAGEMENT) 468
ERROR CODE 15SAL1 (FORWARD CLUTCH ECMV: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS TURNED OFF) 469
ERROR CODE 15SALH (FORWARD CLUTCH ECMV: FILL SIGNAL IS OFF WHEN COMMAND CURRENT IS TURNED ON) 470
ERROR CODE 15SBL1 (REVERSE CLUTCH ECMV: FILL SIGNAL IS ONWHEN COMMAND CURRENT IS TURNED OFF) 471
ERROR CODE 15SBLH (REVERSE CLUTCH ECMV: FILL SIGNAL IS OFF WHEN COMMAND CURRENT IS TURNED ON) 472
ERROR CODE 15SEL1 (1ST CLUTCH ECMV: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS TURNED OFF) 473
ERROR CODE 15SELH (1ST CLUTCH ECMV: FILL SIGNAL IS OFF WHEN COMMAND CURRENT IS TURNED ON) 474
ERROR CODE 15SFL1 (2ND CLUTCH ECMV: FILL SIGNAL IS ONWHEN COMMAND CURRENT IS TURNED OFF) 475
ERROR CODE 15SFLH (2ND CLUTCH ECMV: FILL SIGNAL IS OFF WHEN COMMAND CURRENT IS TURNED ON) 476
ERROR CODE 15SGL1 (3RD CLUTCH ECMV: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS TURNED OFF) 477
ERROR CODE 15SGLH (3RD CLUTCH ECMV: FILL SIGNAL IS OFF WHEN COMMAND CURRENT IS TURNED ON) 478
ERROR CODE A000N1 (ENGINE: OVERRUN) 479
ERROR CODE AB00MA (ALTERNATOR: MALFUNCTION) 480
ERROR CODE AD00L2 (COMMON RAIL: ABNORMAL FUEL PRESSURE) 480
ERROR CODE AD00MA (COMMON RAIL: MALFUNCTION) 481
ERROR CODE AD10L3 (FUEL SUPPLY PUMP: OBJECTIVE PART CANNOT BE CONTROLLED) 482
ERROR CODE AD10MA (FUEL SUPPLY PUMP: MALFUNCTION) 484
ERROR CODE AD10MB (FUEL SUPPLY PUMP: PERFORMANCE REDUCTION) 484
ERROR CODE AD11KA (FUEL SUPPLY PUMP SOLENOID 1: DISCONNECTION IN WIRING) 486
ERROR CODE AD11KB (FUEL SUPPLY PUMP SOLENOID 1: SHORT CIRCUIT) 488
ERROR CODE AD51KA (FUEL SUPPLY PUMP SOLENOID 2: DISCONNECTION IN WIRING) 490
ERROR CODE AD51KB (FUEL SUPPLY PUMP SOLENOID 2: SHORT CIRCUIT) 492
ERROR CODE ADA1KA (NO 1 INJECTOR SOLENOID: DISCONNECTION INWIRING) 494
ERROR CODE ADAZKB (NO 1, 2, AND 3 INJECTOR SOLENOIDS: SHORT CIRCUIT) 496
ERROR CODE ADB1KA (NO 2 INJECTOR SOLENOID: DISCONNECTION INWIRING) 498
ERROR CODE ADC1KA (NO 3 INJECTOR SOLENOID: DISCONNECTION IN WIRING) 499
ERROR CODE ADD1KA (NO 4 INJECTOR SOLENOID: DISCONNECTION INWIRING) 500
ERROR CODE ADDZKB (NO 4, 5, AND 6 INJECTOR SOLENOIDS: SHORT CIRCUIT) 502
ERROR CODE ADE1KA (NO 5 FUEL INJECTOR SOLENOID: DISCONNECTION IN WIRING) 504
ERROR CODE ADF1KA (NO 6 FUEL INJECTOR SOLENOID: DISCONNECTION IN WIRING) 505
ERROR CODE B@BAZG (ENGINE OIL: OIL PRESSURE REDUCTION) 506
ERROR CODE B@BCNS (RADIATOR COOLANT: OVERHEAT) 506
ERROR CODE B@CENS (POWER TRAIN OIL: OVERHEAT) 507
ERROR CODE B@CHZG (HSS CHARGE PRESSURE: OIL PRESSURE REDUCTION) 507
ERROR CODE B@HANS (HYDRAULIC OIL: OVERHEAT) 508
ERROR CODE D110KA (BATTERY RELAY: DISCONNECTION IN WIRING) 510
ERROR CODE D110KB (BATTERY RELAY: SHORT CIRCUIT) 512
ERROR CODE D130KA (NEUTRAL SAFETY RELAY: DISCONNECTION IN WIRING) 514
ERROR CODE D130KB (NEUTRAL SAFETY RELAY: SHORT CIRCUIT) 516
ERROR CODE D161KA (BACK-UP ALARM RELAY: DISCONNECTION IN WIRING) 518
ERROR CODE D161KB (BACK-UP ALARM RELAY: SHORT CIRCUIT) 520
ERROR CODE D182KZ (PREHEATER RELAY COIL: DISCONNECTION IN WIRING OR SHORT CIRCUIT) 522
ERROR CODE D1D0KB (ENGINE CONTROLLER LOAD POWER SUPPLY: SHORT CIRCUIT) 524
ERROR CODE D5ZFKA (TRANSMISSION NEUTRAL SIGNAL: DISCONNECTION IN WIRING) 526
ERROR CODE D5ZFKB (TRANSMISSION NEUTRAL SIGNAL: SHORT CIRCUIT) 527
ERROR CODE DAFRKR (MONITOR PANEL CAN COMMUNICATION: DEFECTIVE COMMUNICATION) 528
ERROR CODE DAQ0KK DB30KK (STEERING AND TRANSMISSION CONTROLLER POWER SOURCE: SOURCE VOLTAGE REDUCTION) 530
ERROR CODE DAQ0KT DB30KT (STEERING AND TRANSMISSION CONTROLLER: ABNORMALITY IN CONTROLLER) 532
ERROR CODE DAQ5KK DB35KK (STEERING AND TRANSMISSION CONTROLLER SENSOR 5V POWER SUPPLY: SOURCE VOLTAGE REDUCTION) 534
ERROR CODE DAQ6KK DB36KK (STEERING AND TRANSMISSION CONTROLLER SENSOR 24V POWER SUPPLY: SOURCE VOLTAGE REDUCTION) 536
ERROR CODE DAQ9KQ DB39KQ (STEERING AND TRANSMISSION CONTROLLER TYPE SELECT: TYPE SELECT SIGNAL INCONSISTENCY) 538
ERROR CODE DAQRKR DB3RKR (STEERING AND TRANSMISSION CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION) 540
ERROR CODE DB20KQ (MALFUNCTION OF ENGINE CONTROLLER MACHINE MODEL COLLECTION: DISAGREEMENT OF MODEL SELECTION SIGNALS) 542
ERROR CODE DB20KT (ENGINE CONTROLLER: ABNORMALITY IN CONTROLLER) 544
ERROR CODE DB22KK (ENGINE CONTROLLER LOAD POWER SUPPLY: SOURCE VOLTAGE REDUCTION) 546
ERROR CODE DB29KQ (ENGINE CONTROLLER TYPE SELECT: TYPE SELECT SIGNAL INCONSISTENCY) 548
ERROR CODE DB2AMA (ENGINE CONTROLLER Q-ADJUSTMENT SWITCH: MALFUNCTION) 549
ERROR CODE DB2RKR (ENGINE CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION) 550
ERROR CODE DB2RMC (STEERING AND TRANSMISSION CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION) 552
ERROR CODE DB30KK DAQ0KK (STEERING AND TRANSMISSION CONTROLLER POWER SOURCE: SOURCE VOLTAGE REDUCTION) 554
ERROR CODE DB30KT DAQ0KT (STEERING AND TRANSMISSION CONTROLLER: ABNORMALITY IN CONTROLLER) 554
ERROR CODE DB35KK DAQ5KK (STEERING AND TRANSMISSION CONTROLLER SENSOR 5V POWER SUPPLY: SOURCE VOLTAGE REDUCTION) 554
ERROR CODE DB36KK DAQ6KK (STEERING AND TRANSMISSION CONTROLLER SENSOR 24V POWER SUPPLY: SOURCE VOLTAGE REDUCTION) 554
ERROR CODE DB39KQ DAQ9KQ (STEERING AND TRANSMISSION CONTROLLER TYPE SELECT: TYPE SELECT SIGNAL INCONSISTENCY) 554
ERROR CODE DB3RKR DAQRKR (STEERING AND TRANSMISSION CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION) 554
ERROR CODE DD11KB (STARTING SWITCH: SHORT CIRCUIT) 556
ERROR CODE DD12KA (SHIFT UP SWITCH: DISCONNECTION IN WIRING) 558
ERROR CODE DD12KB (SHIFT UP SWITCH: SHORT CIRCUIT) 560
ERRORCODE DD13KA (SHIFT DOWN SWITCH: DISCONNECTION INWIRING) 562
ERRORCODE DD13KB (SHIFT DOWN SWITCH: SHORT CIRCUIT) 564
ERROR CODE DD14KA DDQ2KA (TRAVEL LOCK SWITCH: DISCONNECTION IN WIRING) 566
ERROR CODE DD14KB DDQ2KB (TRAVEL LOCK SWITCH: SHORT CIRCUIT) 568
ERROR CODE DDE2L6 (ENGINE OIL PRESSURE SWITCH: OPERATION STATE AND STOP STATE OF ENGINE DO NOT AGREE WITH SIGNALS) 570
ERROR CODE DDN7KA (BLADE KNOB PITCH SWITCH: DISCONNECTION INWIRING) 572
ERROR CODE DDN7KB (BLADE KNOB PITCH SWITCH: SHORT CIRCUIT) 574
ERROR CODE DDQ2KA DD14KA (TRAVEL LOCK SWITCH: DISCONNECTION IN WIRING) 576
ERROR CODE DDQ2KB DD14KB (TRAVEL LOCK SWITCH: SHORT CIRCUIT) 576
ERROR CODE DGE2KX (ENGINE COOLANT TEMPERATURE SENSOR (FOR HIGH TEMPERATURE): INPUT SIGNAL IS OUT OF NORMAL RANGE) 577
ERROR CODE DGE3L6 (ENGINE COOLANT TEMPERATURE SENSOR (FOR LOW TEMPERATURE): OPERATION STATE AND STOP STATE OF ENGINE DO NOT AGREE WITH SIGNALS) 578
ERROR CODE DGE4KX (FUEL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF NORMAL RANGE) 579
ERROR CODE DGS1KX (HYDRAULIC OIL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF NORMAL RANGE) 580
ERROR CODE DH21KB (HYDRAULIC PUMP OIL PRESSURE SENSOR: DISCONNECTION IN WIRING OR SHORT CIRCUIT) 582
ERROR CODE DH22KA (HYDRAULIC PUMP OIL PRESSURE SENSOR: DISCONNECTION IN WIRING) 584
ERROR CODE DH22KB (HYDRAULIC PUMP OIL PRESSURE SENSOR: SHORT CIRCUIT) 586
ERROR CODE DH30KX (BOOST PRESSURE SENSOR: INPUT IS OUT OF NORMAL RANGE) 588
ERROR CODE DH40KX (COMMON RAIL PRESSURE SENSOR: INPUT IS OUT OF NORMAL RANGE) 590
ERROR CODE DHH3KA (HSS PUMP OIL PRESSURE SENSOR A: DISCONNECTION IN WIRING) 592
ERROR CODE DHH3KB (HSS PUMP OIL PRESSURE SENSOR A: SHORT CIRCUIT) 594
ERROR CODE DHH4KA (HSS PUMP OIL PRESSURE SENSOR B: DISCONNECTION IN WIRING) 596
ERROR CODE DHH4KB (HSS PUMP OIL PRESSURE SENSOR B: SHORT CIRCUIT) 598
ERROR CODE DK10KX (FUEL CONTROL DIAL: INPUT IS OUT OF NORMAL RANGE) 600
ERROR CODE DK12KX (DECELERATION PEDAL POTENTIOMETER: INPUT IS OUT OF NORMAL RANGE) 602
ERROR CODE DK30KA (STEERING LEVER POTENTIOMETER 1: DISCONNECTION IN WIRING) 604
ERROR CODE DK30KB (STEERING LEVER POTENTIOMETER 1: SHORT CIRCUIT) 606
ERROR CODE DK30KX (STEERING LEVER POTENTIOMETER: INPUT SIGNAL IS OUT OF NORMAL RANGE) 608
ERROR CODE DK30KZ (STEERING LEVER POTENTIOMETER: DOUBLE FAILURE) 608
ERROR CODE DK30L8 (STEERING LEVER POTENTIOMETER: ANALOG SIGNALS DO NOT AGREE WITH EACH OTHER) 609
ERROR CODE DK31KA (STEERING LEVER POTENTIOMETER 2: DISCONNECTION IN WIRING) 610
ERROR CODE DK31KB (STEERING LEVER POTENTIOMETER 2: SHORT CIRCUIT) 612
ERROR CODE DK40KA (BRAKE PEDAL POTENTIOMETER: DISCONNECTION IN WIRING) 614
ERROR CODE DK40KB (BRAKE PEDAL POTENTIOMETER: SHORT CIRCUIT) 616
ERROR CODE DK55KX (FORWARD-REVERSE LEVER POTENTIOMETER: INPUT SIGNAL IS OUT OF NORMAL RANGE) 618
ERROR CODE DK55KZ (FORWARD-REVERSE LEVER POTENTIOMETER: DOUBLE FAILURE) 618
ERROR CODE DK55L8 (FORWARD-REVERSE LEVER POTENTIOMETER: ANALOG SIGNALS DO NOT AGREE WITH EACH OTHER) 619
ERROR CODE DK56KA (FORWARD-REVERSE LEVER POTENTIOMETER 1: DISCONNECTION IN WIRING) 620
ERROR CODE DK56KB (FORWARD-REVERSE LEVER POTENTIOMETER 1: SHORT CIRCUIT) 622
ERROR CODE DK57KA (FORWARD-REVERSE LEVER POTENTIOMETER 2: DISCONNECTION IN WIRING) 624
ERROR CODE DK57KB (FORWARD-REVERSE LEVER POTENTIOMETER 2: SHORT CIRCUIT) 626
ERROR CODE DKH1KA (BODY PITCH ANGLE SENSOR: DISCONNECTION IN WIRING) 628
ERROR CODE DKH1KB (BODY PITCH ANGLE SENSOR: SHORT CIRCUIT) 630
ERROR CODE DLE3LC (ENGINE NE SPEED SENSOR: MALFUNCTION) 632
ERROR CODE DLF1KA (TRANSMISSION BEVEL SPEED SENSOR: DISCONNECTION IN WIRING) 633
ERROR CODE DLH1LC (ENGINE G SPEED SENSOR: MALFUNCTION) 634
ERROR CODE DV00KB (CAUTION BUZZER: SHORT CIRCUIT) 635
ERROR CODE DW5AKA (BLADE PITCH SELECTOR SOLENOID: DISCONNECTION IN WIRING) 636
ERROR CODE DW5AKB (BLADE PITCH SELECTOR SOLENOID: SHORT CIRCUIT) 637
ERROR CODE DW7BKA (FAN REVERSE SOLENOID: DISCONNECTION IN WIRING) 638
ERROR CODE DW7BKB (FAN REVERSE SOLENOID: SHORT CIRCUIT) 639
ERROR CODE DWN1KA (HSS PUMP SOLENOID B: DISCONNECTION IN WIRING) 640
ERROR CODE DWN1KB (HSS PUMP SOLENOID B: SHORT CIRCUIT) 641
ERROR CODE DWN2KA (HSS PUMP SOLENOID A: DISCONNECTION IN WIRING) 642
ERROR CODE DWN2KB (HSS PUMP SOLENOID A: SHORT CIRCUIT) 643
ERROR CODE DWN5KA (FAN PUMP SOLENOID: DISCONNECTION IN WIRING) 644
ERROR CODE DWN5KB (FAN PUMP SOLENOID: SHORT CIRCUIT) 645
ERROR CODE DXH4KA (1ST CLUTCH ECMV: DISCONNECTION IN WIRING) 646
ERROR CODE DXH4KB (1ST CLUTCH ECMV: SHORT CIRCUIT) 647
ERROR CODE DXH5KA (2ND CLUTCH ECMV: DISCONNECTION IN WIRING) 648
ERROR CODE DXH5KB (2ND CLUTCH ECMV: SHORT CIRCUIT) 649
ERROR CODE DXH6KA (3RD CLUTCH ECMV: DISCONNECTION IN WIRING) 650
ERROR CODE DXH6KB (3RD CLUTCH ECMV: SHORT CIRCUIT) 651
ERROR CODE DXH7KA (REVERSE CLUTCH ECMV: DISCONNECTION IN WIRING) 652
ERROR CODE DXH7KB (REVERSE CLUTCH ECMV: SHORT CIRCUIT) 653
ERROR CODE DXH8KA (FORWARD CLUTCH ECMV: DISCONNECTION IN WIRING) 654
ERROR CODE DXH8KB (FORWARD CLUTCH ECMV: SHORT CIRCUIT) 655
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 657
BEFORE CARRYING OUT TROUBLESHOOTING FOR ELECTRICAL SYSTEM (E-MODE) 658
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST 659
E-1 THE ENGINE DOES NOT START 660
E-2 THE PREHEATER DOES NOT OPERATE (MANUAL PREHEATING FUNCTION) 662
E-3 THE RIPPER PIN PULLER CYLINDER DOES NOT OPERATE (GIANT RIPPER ATTACHMENT MACHINE) 664
E-4 THE MONITOR PANEL DOES NOT COME ON AT ALL WHEN THE STARTING SWITCH IS TURNED ON 666
E-5 WHEN THE STARTING SWITCH IS TURNED ON, THE MONITOR PANEL COMPLETELY REMAINS LIGHTED AND DOES NOT GO OUT 668
E-6 WHILE THE ENGINE IS OPERATING, THE BATTERY CHARGE LEVEL CAUTION FLASHES 670
E-7 WHILE THE ENGINE IS OPERATING, THE EMERGENCY WARNING ITEM FLASHES 672
E-8 WHILE THE PREHEATER IS OPERATING, THE PREHEATING PILOT LAMP DOES NOT COME ON 676
E-9 THE ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY 678
E-10 INDICATION OF THE POWER TRAIN OIL TEMPERATURE GAUGE IS ABNORMAL 679
E-11 THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY 680
E-12 INDICATION OF THE FUEL GAUGE IS ABNORMAL 681
E-13 INDICATIONS OF GEAR SPEED AND ENGINE SPEED ARE ABNORMAL 682
E-14 INDICATION OF THE SHIFT MODE AND SERVICE METER ARE ABNORMAL 682
E-15 THE WARNING LAMP DOES NOT FLASH OR DOES NOT GO OUT 683
E-16 THE ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP 684
E-17 AUTO SHIFT DOWN SWITCH DOES NOT WORK 685
E-18 THE FAN ROTATION SELECT SWITCH DOES NOT WORK 686
E-19 THE BUZZER CANCEL SWITCH DOES NOT WORK 688
E-20 THE INFORMATION SWITCH DOES NOT WORK 690
E-21 CANNOT ENTER INTO SERVICE MODE 692
E-22 THE BACK-UP ALARM DOES NOT SOUND 694
E-23 THE HEAD LAMP, PANEL NIGHT LAMP, REAR LAMP, AND RIPPER POINT LAMP DO NOT LIGHT UP 696
E-24 MALFUNCTION OF WIPERS 698
E-25 WASHING WATER DOES NOT COME OUT 711
E-26 THE AIR CONDITIONER DOES NOT OPERATE 717
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) 723
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST 724
H-1 NO TRAVEL POWER (NO DRAWBAR PULL) 725
H-2 MACHINE DOES NOT MOVE (AT 2ND OR 3RD SPEED) 726
H-3 MACHINE DOES NOT MOVE IN ANY SPEED RANGE 727
H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION FORWARD OR IN REVERSE 728
H-5 WHEN GEAR IS SHIFTED OR TRAVEL DIRECTION IS CHANGED, LARGE TIME LAG IS MADE 729
H-6 MACHINE DOES NOT TURN (NOT TURNED RIGHTWARD OR LEFTWARD) 730
H-7 STEERING SPEED OR POWER IS LOW 730
H-8 BRAKE DOES NOT WORK 731
H-9 OVERHEAT OF POWER TRAIN OIL TEMPERATURE 731
H-10 ABNORMAL SOUND COMES OUT FROM AROUND HSS PUMP OR HSS MOTOR 732
H-11 ALL WORK EQUIPMENT SPEEDS ARE SLOW 733
H-12 WORK EQUIPMENT DOES NOT MOVE 733
H-13 BLADE LIFT SPEED IS SLOW OR LACKS POWER 734
H-14 BLADE TILT SPEED IS SLOW OR LACKS POWER 734
H-15 RIPPER LIFT SPEED IS SLOW OR LACKS POWER 735
H-16 RIPPER TILT SPEED IS SLOW OR LACKS POWER 735
H-17 EXCESSIVE HYDRAULIC DRIFT OF BLADE LIFT 736
H-18 EXCESSIVE HYDRAULIC DRIFT OF BLADE TILT 736
H-19 EXCESSIVE HYDRAULIC DRIFT OF RIPPER LIFT 737
H-20 RIPPER PIN PULLER CYLINDER DOES NOT WORK (GIANT RIPPER ATTACHMENT MACHINE) 737
H-21 BLADE PITCH DOES NOT WORK (PITCH DOZER ATTACHMENT MACHINE) 738
H-22 ABNORMAL SOUND COMES OUT FROM AROUND WORK EQUIPMENT PUMP 738
TROUBLESHOOTING OF ENGINE SYSTEM (S-MODE) 739
METHOD OF USING TROUBLESHOOTING CHARTS 740
S-1 Starting performance is poor (starting always takes time) 744
S-2 Engine does not start 745
a) Engine does not turn 745
b) Engine turns but no exhaust smoke comes out 746
c) Exhaust smoke comes out but engine does not start (Fuel is being injected) 747
S-3 Engine does not pick up smoothly (follow-up is poor) 748
S-4 Engine stops during operations 749
S-5 Engine does not rotate smoothly (hunting) 750
S-6 Engine lacks output (or lacks power) 751
S-7 Exhaust smoke is black (incomplete combustion) 752
S-8 Oil consumption is excessive (or exhaust smoke is blue) 753
S-9 Oil becomes contaminated quickly 754
S-10 Fuel consumption is excessive 755
S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down) 756
S-12 Oil pressure caution lamp lights up (drop in oil pressure) 757
S-13 Oil level rises (coolant, fuel in oil) 758
S-14 Coolant temperature becomes too high (overheating) 759
S-15 Abnormal noise is made 760
S-16 Vibration is excessive 761
30 DISASSEMBLY AND ASSEMBLY 763
METHOD OF USING MANUAL 765
PRECAUTIONS WHEN CARRYING OUT OPERATION 766
SPECIAL TOOL LIST 768
SPECIAL TOOL SKETCH 778
STARTINGMOTOR 787
REMOVAL 787
INSTALLATION 787
ALTERNATOR 788
REMOVAL 788
INSTALLATION 788
ENGINE OIL COOLER CORE 789
REMOVAL 789
INSTALLATION 789
FUEL SUPPLY PUMP 790
REMOVAL 790
INSTALLATION 792
WATER PUMP 794
REMOVAL 794
INSTALLATION 794
TURBOCHARGER 795
REMOVAL 795
INSTALLATION 795
FUEL INJECTOR 796
REMOVAL 796
INSTALLATION 797
NOZZLE TIP 799
REMOVAL 799
INSTALLATION 800
ENGINE FRONT SEAL 802
REMOVAL 802
INSTALLATION 803
ENGINE REAR SEAL 805
REMOVAL 805
INSTALLATION 806
CYLINDER HEAD 810
REMOVAL 810
INSTALLATION 815
THERMOSTAT 819
REMOVAL 819
INSTALLATION 819
AIR CONDITIONER COMPRESSOR 820
REMOVAL 820
INSTALLATION 821
AIR CONDITIONER CONDENSER 822
REMOVAL 822
INSTALLATION 822
FUEL TANK 823
REMOVAL 823
INSTALLATION 823
RADIATOR 824
REMOVAL 824
INSTALLATION 826
RADIATOR, OIL COOLER, GUARD 827
REMOVAL 827
INSTALLATION 829
FAN DRIVE 830
REMOVAL 830
INSTALLATION 830
FAN MOTOR 831
REMOVAL 831
INSTALLATION 831
HYDRAULIC COOLER 832
REMOVAL 832
INSTALLATION 832
ENGINE 833
REMOVAL 833
INSTALLATION 835
DAMPER 836
REMOVAL 836
INSTALLATION 837
DISASSEMBLY 838
ASSEMBLY 841
POWER TRAIN UNIT 845
REMOVAL 845
INSTALLATION 849
SEPARATION 850
POWER TRAIN 854
PTO 855
DISASSEMBLY 855
ASSEMBLY 859
TORQUE CONVERTER 864
DISASSEMBLY 864
ASSEMBLY 867
TORQFLOW TRANSMISSION 870
DISASSEMBLY 870
ASSEMBLY 879
HSS CASE 890
DISASSEMBLY 890
ASSEMBLY 899
HYDRAULIC PUMP 912
REMOVAL 912
INSTALLATION 916
HSS MOTOR 917
REMOVAL 917
INSTALLATION 917
POWER TRAIN MAIN RELIEF VALVE 918
REMOVAL 918
INSTALLATION 918
DISASSEMBLY 919
ASSEMBLY 919
HSS, PPC CHARGE VALVE 920
REMOVAL 920
INSTALLATION 920
HSS AND PPC CHARGE VALVE 921
TRANSMISSION CONTROL VALVE 922
REMOVAL 922
INSTALLATION 923
TRANSMISSION CONTROL VALVE (ECMV ASSEMBLY) 924
DISASSEMBLY 924
ASSEMBLY 924
BRAKE VALVE 926
REMOVAL 926
INSTALLATION 926
DISASSEMBLY 927
ASSEMBLY 927
FINAL DRIVE 929
REMOVAL 929
INSTALLATION 931
DISASSEMBLY 932
ASSEMBLY 937
TRACK FRAME 943
REMOVAL 943
INSTALLATION 945
IDLER 946
REMOVAL 946
INSTALLATION 947
DISASSEMBLY 948
ASSEMBLY 950
RECOIL SPRING 953
REMOVAL 953
INSTALLATION 953
DISASSEMBLY 954
ASSEMBLY 959
TRACK ROLLER 963
REMOVAL 963
INSTALLATION 964
DISASSEMBLY 965
ASSEMBLY 968
BOGIE 971
REMOVAL 971
INSTALLATION 973
DISASSEMBLY 974
ASSEMBLY 977
CARRIER ROLLER 981
REMOVAL 981
INSTALLATION 981
DISASSEMBLY 982
ASSEMBLY 984
TRACK SHOE 987
CHECKING BEFORE REMOVAL 987
REMOVAL (NORMAL) 987
REMOVAL (WHEN THERE IS ABNORMALITY INSIDE TRACK FRAME) 988
INSTALLATION 989
OVERALL DISASSEMBLY 990
OVERALL 995
PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS1009
ONE LINK1010
FIELD DISASSEMBLY1010
FIELD ASSEMBLY1012
MASTER LINK1014
DISASSEMBLY1014
ASSEMBLY1016
PIVOT SHAFT1019
REMOVAL1019
INSTALLATION1019
EQUALIZER BAR1020
REMOVAL1020
INSTALLATION1021
EQUALIZER BAR SIDE BUSHING1022
REMOVAL1022
INSTALLATION1022
SEGMENT TEETH1023
REMOVAL1023
INSTALLATION1023
HYDRAULIC TANK1024
REMOVAL1024
INSTALLATION1024
MAIN CONTROL VALVE1025
REMOVAL1025
INSTALLATION1026
DISASSEMBLY1027
ASSEMBLY1030
HSS OIL COOLER BYPASS VALVE1034
REMOVAL1034
INSTALLATION1034
DISASSEMBLY AND ASSEMBLY1035
BLADE PPC VALVE1036
REMOVAL1036
INSTALLATION1037
RIPPER PPC VALVE1038
REMOVAL1038
INSTALLATION1039
BLADE PPC VALVE1040
DISASSEMBLY1040
ASSEMBLY1041
BLADE LIFT CYLINDER1043
REMOVAL1043
INSTALLATION1043
BLADE TILT CYLINDER1044
REMOVAL1044
INSTALLATION1044
RIPPER LIFT CYLINDER1045
REMOVAL1045
INSTALLATION1045
RIPPER TILT CYLINDER1046
REMOVAL1046
INSTALLATION1046
HYDRAULIC CYLINDER1047
DISASSEMBLY1047
ASSEMBLY1050
BLADE1054
REMOVAL1054
INSTALLATION1055
DISASSEMBLY1056
ASSEMBLY1058
MULTI-SHANK RIPPER1060
DISASSEMBLY1060
ASSEMBLY1062
ROPS GUARD1064
REMOVAL1064
INSTALLATION1064
OPERATOR’S CAB1065
REMOVAL1065
INSTALLATION1066
OPERATOR’S CAB GLASS (STUCK GLASS)1067
REMOVAL1068
INSTALLATION1069
HOOD1077
REMOVAL1077
INSTALLATION1077
FLOOR FRAME1078
REMOVAL1078
INSTALLATION1081
DASHBOARD1083
REMOVAL1083
INSTALLATION1084
MONITOR1085
REMOVAL1085
INSTALLATION1085
HSS CONTROLLER1086
REMOVAL1086
INSTALLATION1086
40 MAINTENANCE STANDARD1087
ENGINE MOUNT1088
POWER TRAIN UNIT MOUNT1089
DAMPER, UNIVERSAL JOINT1090
TORQUE CONVERTER, PTO1091
TRANSMISSION1094
MAIN RELIEF VALVE1096
BEVEL GEAR SHAFT, HSS, BRAKE (1/2)1098
BEVEL GEAR SHAFT, HSS, BRAKE (2/2)1100
BRAKE VALVE1102
SCAVENGING PUMP, HSS, PPC CHARGE PUMP1103
POWER TRAIN PUMP, LUBRICATION PUMP1104
OIL COOLER BYPASS VALVE1105
FINAL DRIVE1106
SPROCKET1108
MAIN FRAME1110
TRACK FRAME1112
RECOIL SPRING1113
TRACK ROLLER BOGIE1114
IDLER1116
TRACK ROLLER1118
CARRIER ROLLER1120
TRACK SHOE1121
SUSPENSION1128
WORK EQUIPMENT PUMP1130
HSS PUMP1131
HSS MOTOR1132
COOLING FAN PUMP1133
COOLING FAN MOTOR1135
PPC VALVE1136
MAIN CONTROL VALVE1138
SELF PRESSURE REDUCING VALVE1143
WORK EQUIPMENT CYLINDER1144
QUICK DROP VALVE1148
CYLINDER STAY1149
WORK EQUIPMENT1150
90 OTHERS1157
HYDRAULIC CIRCUIT DIAGRAM (1/2)1159
HYDRAULIC CIRCUIT DIAGRAM (2/2)1161
ELECTRIC CIRCUIT DIAGRAM (1/6)1163
ELECTRIC CIRCUIT DIAGRAM (2/6)1165
ELECTRIC CIRCUIT DIAGRAM (3/6)1167
ELECTRIC CIRCUIT DIAGRAM (4/6)1169
ELECTRIC CIRCUIT DIAGRAM (5/6)1171
ELECTRIC CIRCUIT DIAGRAM (6/6)1173
ELECTRIC CIRCUIT DIAGRAM INSIDE CAB1175
ELECTRIC CIRCUIT DIAGRAM OF AIR CONDITIONER1177

IMAGES PREVIEW OF THE MANUAL:

S.M 27/12/24