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Komatsu D155AX-6 Crawler Bulldozer Shop Manual – PDF DOWNLOAD
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Komatsu D155AX-6 Crawler Bulldozer Shop Manual
SERIAL NUMBERS : 80001 and up
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Description
Komatsu D155AX-6 Crawler Bulldozer Shop Manual
FILE DETAILS:
Komatsu D155AX-6 Crawler Bulldozer Shop Manual
Brands: Komatsu
Equipment Type: Crawler Bulldozer
Manuals Type: Shop Manual
Machine Model: D155AX-6
Serial Number: 80001 and up
Book Code: SEN00596-14
Language: English
Pages: 1569
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu D155AX-6 Crawler Bulldozer Shop Manual
HOW TO READ THE SHOP MANUAL:
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. FOREWORD:
This section explains the safety and basic information.
01. GENERAL:
This section explains the specifications of the machine.
10. STRUCTURE AND FUNCTION, MAINTENANCE STANDARD:
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. TESTING AND ADJUSTING:
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 measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in
the Chassis volume and Engine volume. In this case, see the Chassis volume.
30. DISASSEMBLY AND ASSEMBLY:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. OTHERS (chassis volume)/Repair and replacement of parts (engine volume):
• Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
• Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
Komatsu D155AX-6 Crawler Bulldozer Shop Manual
COVER .............................................................................................. 1 00 Index and foreword............................................................................... 0 Index........................................................................................... 3 Composition of shop manual.................................................................. 4 Table of contents........................................................................... 6 Foreword and general information................................................................ 19 Safety notice............................................................................... 20 How to read the shop manual................................................................. 25 Explanation of terms for maintenance standard............................................... 27 Handling of electric equipment and hydraulic component...................................... 29 Handling of connectors newly used for engines............................................... 38 How to read electric wire code.............................................................. 41 Precautions when carrying out operation..................................................... 44 Method of disassembling and connecting push-pull type coupler............................... 47 Standard tightening torque table............................................................ 50 Conversion table............................................................................ 54 01 Specification.................................................................................... 0 Specification and technical data................................................................ 61 Specification dimension drawings............................................................ 62 Specifications.............................................................................. 63 Weight table................................................................................ 69 Table of fuel, coolant and lubricants....................................................... 72 10 Structure, function and maintenance standard..................................................... 0 Engine and cooling system....................................................................... 75 Engine and cooling system................................................................... 76 Radiator, oil cooler.................................................................... 76 Engine mount............................................................................ 79 Cooling fan pump........................................................................ 80 Cooling fan motor....................................................................... 87 Power train, Part 1............................................................................. 94 Power train skeleton........................................................................ 95 Overall drawing of power train unit......................................................... 97 Power train hydraulic piping drawing........................................................ 99 Damper, universal joint..................................................................... 101 Torque converter, PTO....................................................................... 103 Torque converter control valve.............................................................. 112 Lockup clutch ECMV, stator clutch ECMV...................................................... 113 Transmission control........................................................................ 119 Transmission................................................................................ 121 Transmission ECMV........................................................................... 137 Main relief valve and torque converter relief valve......................................... 143 Lubrication relief valve.................................................................... 145 Scavenging pump............................................................................. 146 Power train and steering lubrication pump................................................... 147 Power train, Part 2............................................................................. 150 HSS system.................................................................................. 151 HSS motor................................................................................... 153 Hydraulic, HSS pump......................................................................... 163 Hydraulic oil cooler bypass valve........................................................... 186 Steering, brake control..................................................................... 187 Steering unit............................................................................... 189 Brake control valve......................................................................... 211 Brake ECMV.................................................................................. 213 Parking brake solenoid valve................................................................ 217 Sudden stop prevention valve................................................................ 219 Final drive................................................................................. 221 Sprocket.................................................................................... 227 Undercarriage and frame......................................................................... 230 Track frame................................................................................. 231 Recoil spring............................................................................... 233 Idler....................................................................................... 235 Track roller................................................................................ 237 Carrier roller.............................................................................. 239 Track shoe.................................................................................. 241 Main frame.................................................................................. 247 Suspension.................................................................................. 249 Hydraulic system................................................................................ 252 Work equipment hydraulic piping diagram..................................................... 253 Work equipment control piping diagram....................................................... 256 Work equipment control...................................................................... 259 Hydraulic tank and filter................................................................... 261 Accumulator................................................................................. 265 PCCS lever.................................................................................. 266 Work equipment lock valve................................................................... 270 Control valve............................................................................... 271 Work equipment cylinder..................................................................... 307 Piston valve................................................................................ 309 Quick drop valve............................................................................ 311 Self pressure reducing valve................................................................ 316 Work equipment.................................................................................. 324 Cylinder stay............................................................................... 325 Blade....................................................................................... 327 Cutting edge, end bit....................................................................... 329 Ripper...................................................................................... 331 Cab and its attachments......................................................................... 336 Cab mount + ROPS pin........................................................................ 337 ROPS cab.................................................................................... 338 Air conditioner............................................................................. 339 Electrical system............................................................................... 342 Engine control.............................................................................. 343 Engine control system....................................................................... 344 Deceleration potentiometer.................................................................. 345 Monitor system.............................................................................. 347 Sensors..................................................................................... 366 Palm command control system................................................................. 369 KOMTRAX system.............................................................................. 372 20 Standard value table............................................................................. 0 Standard service value table.................................................................... 376 Standard value table for engine............................................................. 377 Standard value table for machine............................................................ 378 30 Testing and adjusting............................................................................ 0 Testing and adjusting, Part 1................................................................... 388 Tools for testing, adjusting, and troubleshooting........................................... 390 Measuring engine speed...................................................................... 394 Measuring intake air pressure (boost pressure).............................................. 396 Measuring exhaust temperature............................................................... 397 Measuring exhaust gas color................................................................. 399 Adjusting valve clearance................................................................... 400 Measuring compression pressure.............................................................. 401 Measuring blow-by pressure.................................................................. 403 Measuring engine oil pressure............................................................... 404 Testing EGR valve and bypass valve drive oil pressure....................................... 405 Handling fuel system parts.................................................................. 406 Releasing residual pressure from fuel system................................................ 406 Measuring fuel pressure..................................................................... 407 Measuring fuel return rate and fuel leakage................................................. 408 Bleeding air from fuel circuit.............................................................. 412 Measuring fuel circuit for leakage.......................................................... 414 Testing and adjusting alternator belt tension............................................... 415 Testing and adjusting air conditioner compressor belt tension............................... 416 Measuring fan speed......................................................................... 417 Measuring fan circuit oil pressure.......................................................... 418 Bleeding air from fan pump.................................................................. 419 Adjusting fuel control dial and decelerator pedal........................................... 420 Testing and adjusting, Part 2................................................................... 424 Testing and adjusting, Part 2............................................................... 426 Measuring power train oil pressure...................................................... 426 Adjusting transmission output shaft speed sensor........................................ 434 Simple test procedure for brake performance............................................. 435 Adjusting brake pedal................................................................... 436 Adjusting parking brake lever........................................................... 438 Emergency escape method when power train has trouble.................................... 440 Adjusting idler clearance............................................................... 443 Testing and adjusting track shoe tension................................................ 444 Measuring and adjusting work equipment and HSS oil pressure............................. 445 Measuring control circuit basic pressure................................................ 449 Measuring work equipment lock solenoid valve output pressure............................ 450 Emergency operation method when work equipment has trouble.............................. 451 Measuring ripper pin puller solenoid valve output pressure.............................. 453 Testing parts which cause hydraulic drift of blade and ripper........................... 454 Measuring internal leakage of work equipment cylinder................................... 455 Releasing residual pressure from work equipment cylinder................................ 456 Bleeding air from work equipment cylinder............................................... 456 Adjusting work equipment lock lever..................................................... 457 Adjusting blade......................................................................... 458 Adjusting operator's cab................................................................ 460 Testing and adjusting, Part 3................................................................... 466 Special functions of machine monitor (EMMS)................................................. 467 Testing and adjusting, Part 4................................................................... 546 Testing and adjusting, Part 4............................................................... 547 Handling of power supply circuit of engine controller................................... 547 Preparation work for troubleshooting of electrical system............................... 548 Pm Clinic............................................................................... 550 40 Troubleshooting.................................................................................. 0 Failure code table and fuse locations........................................................... 562 Failure codes table......................................................................... 563 Fuse locations.............................................................................. 570 Information in troubleshooting table........................................................ 574 General information on troubleshooting.......................................................... 578 Points to remember when troubleshooting..................................................... 579 Sequence of events in troubleshooting....................................................... 580 Check before troubleshooting................................................................ 581 Classification and procedures for troubleshooting........................................... 582 Connection table for connector pin numbers.................................................. 585 T- branch box and T- branch adapter table................................................... 621 Troubleshooting by failure and error codes, Part 1.............................................. 626 Failure code [1500L0] Transmission clutch: Abnormal......................................... 628 Failure code [15SAL1] Forward clutch: Fill high............................................. 629 Failure code [15SALH] Forward clutch: Fill low.............................................. 630 Failure code [15SBL1] Reverse clutch: Fill high............................................. 631 Failure code [15SBLH] Reverse clutch: Fill low.............................................. 632 Failure code [15SEL1] Speed 1st clutch: Fill high........................................... 633 Failure code [15SELH] Speed 1st clutch: Fill low............................................ 634 Failure code [15SFL1] Speed 2nd clutch: Fill high........................................... 635 Failure code [15SFLH] Speed 2nd clutch: Fill low............................................ 636 Failure code [15SGL1] Speed 3rd clutch: Fill high........................................... 637 Failure code [15SGLH] Speed 3rd clutch: Fill low............................................ 638 Failure code [15SJL1] L/U: Fill high........................................................ 639 Failure code [15SJLH] L/U: Fill low......................................................... 641 Failure code [2301L1] Right brake: Fill high................................................ 643 Failure code [2301LH] Right brake: Fill low................................................. 644 Failure code [2302L1] Left brake: Fill high................................................. 645 Failure code [2302LH] Left brake: Fill low.................................................. 646 Failure code [7RFAKA] ECM HOLD RELAY: Disconnection......................................... 647 Failure code [AA10NX] Air Cleaner Clogging.................................................. 649 Failure code [AB00MA] Battery Charge Abnormal............................................... 651 Failure code [B@BAZG] Eng Oil Press Low..................................................... 653 Failure code [B@BCNS] Eng Water Overheat.................................................... 653 Failure code [B@BCZK] Eng Water Level Low................................................... 654 Failure code [B@CENS] T/C Oil Overheat...................................................... 654 Failure code [B@HANS] Hyd Oil Overheat...................................................... 655 Troubleshooting by failure and error codes, Part 2.............................................. 658 Failure code [CA111] EMC Critical Internal Failure.......................................... 661 Failure code [CA115] Eng Ne and Bkup Speed Sens Error....................................... 663 Failure code [CA122] Chg Air Press Sensor High Error........................................ 665 Failure code [CA123] Chg Air Press Sensor Low Error......................................... 667 Failure code [CA131] Throttle Sensor High Error............................................. 669 Failure code [CA132] Throttle Sensor Low Error.............................................. 671 Failure code [CA135] Eng Oil Press Sensor High Error........................................ 673 Failure code [CA141] Eng Oil Press Sensor Low Error......................................... 675 Failure code [CA144] Coolant Temp Sens High Error........................................... 677 Failure code [CA145] Coolant Temp Sens Low Error............................................ 679 Failure code [CA153] Chg Air Temp Sensor High Error......................................... 681 Failure code [CA154] Chg Air Temp Sensor Low Error.......................................... 683 Failure code [CA187] Sens Supply 2 Volt Low Error........................................... 683 Failure code [CA221] Ambient Press Sens High Error.......................................... 685 Failure code [CA222] Ambient Press Sens Low Error........................................... 687 Failure code [CA227] Sens Supply 2 Volt High Error.......................................... 689 Failure code [CA234] Eng Overspeed.......................................................... 691 Failure code [CA238] Ne Speed Sens Supply Volt Error........................................ 693 Failure code [CA263] Fuel Temp Sensor High Error............................................ 695 Failure code [CA265] Fuel Temp Sensor Low Error............................................. 697 Failure code [CA271] PCV1 Short Error....................................................... 698 Failure code [CA272] PCV1 Open Error........................................................ 699 Failure code [CA273] PCV2 Short Error....................................................... 700 Failure code [CA274] PCV2 Open Error........................................................ 701 Failure code [CA322] Inj #1 (L#1) Open/Short Error.......................................... 703 Failure code [CA323] Inj #5 (L#5) Open/Short Error.......................................... 705 Failure code [CA324] Inj #3 (L#3) Open/Short Error.......................................... 707 Failure code [CA325] Inj #6 (L#6) Open/Short Error.......................................... 709 Failure code [CA331] Inj #2 (L#2) Open/Short Error.......................................... 711 Failure code [CA332] Inj #4 (L#4) Open/Short Error.......................................... 713 Failure code [CA342] Calibration Code Incompatibility....................................... 715 Failure code [CA351] Injectors Drive Circuit Error.......................................... 717 Failure code [CA352] Sens Supply 1 Volt Low Error........................................... 719 Failure code [CA386] Sens Supply 1 Volt High Error.......................................... 721 Failure code [CA441] Battery Voltage Low Error.............................................. 723 Failure code [CA442] Battery Voltage High Error............................................. 723 Failure code [CA449] Rail Press Very High Error............................................. 724 Failure code [CA451] Rail Press Sensor High Error........................................... 725 Failure code [CA452] Rail Press Sensor Low Error............................................ 727 Failure code [CA553] Rail Press High Error.................................................. 727 Failure code [CA554] Rail Press Sensor In Range Error....................................... 728 Failure code [CA559] Rail Press Low Error................................................... 729 Failure code [CA689] Eng Ne Speed Sensor Error.............................................. 733 Troubleshooting by failure and error codes, Part 3.............................................. 736 Failure code [CA731] Eng Bkup Speed Sens Phase Error........................................ 738 Failure code [CA757] All Continuous Data Lost Error......................................... 738 Failure code [CA778] Eng Bkup Speed Sensor Error............................................ 739 Failure code [CA1228] EGR Valve Servo Error 1............................................... 741 Failure code [CA1625] EGR Valve Servo Error 2............................................... 742 Failure code [CA1626] BP Valve Sol Current High Error....................................... 743 Failure code [CA1627] BP Valve Sol Current Low Error........................................ 745 Failure code [CA1628] Bypass Valve Servo Error 1............................................ 746 Failure code [CA1619] Bypass Valve Servo Error 2............................................ 747 Failure code [CA1631] BP Valve Pos Sens High Error.......................................... 749 Failure code [CA1632] BP Valve Pos Sens Low Error........................................... 751 Failure code [CA1633] KOMNET Datalink Timeout Error......................................... 753 Failure code [CA1642] EGR Inlet Press Sens Low Error........................................ 755 Failure code [CA1653] EGR Inlet Press Sens High Error....................................... 757 Failure code [CA2185] Throt Sens Sup Volt High Error........................................ 759 Failure code [CA2186] Throt Sens Sup Volt Low Error......................................... 761 Failure code [CA2249] Rail Press Very Low Error............................................. 761 Failure code [CA2271] EGR Valve Pos Sens High Error......................................... 763 Failure code [CA2272] EGR Valve Pos Sens Low Error.......................................... 765 Failure code [CA2351] EGR Valve Sol Current High Error...................................... 767 Failure code [CA2352] EGR Valve Sol Current Low Error....................................... 769 Failure code [CA2555] Grid Htr Relay Volt Low Error......................................... 770 Failure code [CA2556] Grid Htr Relay Volt High Error........................................ 771 Failure code [D110KA] Battery relay: Disconnection.......................................... 773 Failure code [D110KB] Battery Relay: Drive Short Circuit.................................... 775 Failure code [D130KA] Neutral relay: Disconnection.......................................... 777 Failure code [D130KB] Neutral relay: Short circuit.......................................... 779 Failure code [D161KA] Back-up alarm relay: Disconnection.................................... 781 Failure code [D161KB] Back-up alarm relay: Short circuit.................................... 783 Failure code [D190KA] ACC signal relay: Disconnection....................................... 785 Failure code [D190KB] ACC signal relay: Short circuit....................................... 787 Failure code [D5ZKKX] Throttle Dial: Out of normal range.................................... 789 Failure code [DAFRKR] CAN Disconnection (Monitor)........................................... 791 Failure code [DB2RKR] CAN Disconnection (Engine controller)................................. 793 Failure code [DB90KK] WE controller: Source voltage reduction............................... 795 Failure code [DB90KR] PT controller: Can communication lost................................. 797 Troubleshooting by failure and error codes, Part 4.............................................. 800 Troubleshooting by failure and error codes, Part 4.......................................... 802 Failure code [DB90KT] WE controller: Abnormality in controller.......................... 802 Failure code [DB95KK] WE controller: Source voltage reduction........................... 803 Failure code [DB97KK] WE controller: Source voltage reduction........................... 805 Failure code [DB99KQ] WE controller: Type select signal................................. 807 Failure code [DB9RKR] WE controller: Can communication lost............................. 808 Failure code [DBE0KK] PT controller: Source voltage reduction........................... 810 Failure code [DBE0KT] PT controller: Abnormality in controller.......................... 812 Failure code [DBE6KK] PT controller: Source voltage reduction........................... 813 Failure code [DBE7KK] PT controller: Source voltage reduction........................... 815 Failure code [DBE9KQ] PT controller: Type select signal................................. 817 Failure code [DD12KA] Shift up Sw: Disconnection........................................ 818 Failure code [DD12KB] Shift up Sw: Short circuit........................................ 820 Failure code [DD13KA] Shift down Sw: Disconnection...................................... 822 Failure code [DD13KB] Shift down Sw: Short circuit...................................... 824 Failure code [DD14KA] Parking lever Sw: Disconnection................................... 826 Failure code [DD14KB] Parking lever Sw: Short circuit................................... 828 Failure code [DDDDKA] Back up brake Sw: Disconnection................................... 830 Failure code [DDDDKB] Back up brake Sw: Short circuit................................... 832 Failure code [DDDDKX] Back up brake Sw: Signal mismatch................................. 834 Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection................................. 835 Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit................................. 837 Failure code [DDN9KA] WEQ Knob Sw (up): Disconnection................................... 839 Failure code [DDN9KB] WEQ Knob Sw (up): Short circuit................................... 841 Failure code [DDNLKA] Weq lock Sw: Disconnection........................................ 843 Failure code [DDNLKB] Weq lock Sw: Short circuit........................................ 845 Failure code [DDTSL1] S/C: Fill high.................................................... 847 Failure code [DDTSLH] S/C: Fill low..................................................... 849 Troubleshooting by failure and error codes, Part 5.............................................. 852 Failure code [DFA4KX] BL lever 1: Out of normal range....................................... 854 Failure code [DFA4KZ] BL lever: Disconnection or short circuit.............................. 854 Failure code [DFA4L8] BL lever: Signal mismatch............................................. 855 Failure code [DFA5KA] BL lever 1: Disconnection............................................. 857 Failure code [DFA5KB] BL lever 1: Short circuit............................................. 859 Failure code [DFA6KA] BL lever 2: Disconnection............................................. 861 Failure code [DFA6KB] BL lever 2: Short circuit............................................. 863 Failure code [DFA7KX] BT lever 1: Out of normal range....................................... 865 Failure code [DFA7KZ] BT lever: Disconnection or short circuit.............................. 865 Failure code [DFA7L8] BT lever: Signal mismatch............................................. 866 Failure code [DFA8KA] BT lever 1: Disconnection............................................. 867 Failure code [DFA8KB] BT lever 1: Short circuit............................................. 869 Failure code [DFA9KA] BT lever 2: Disconnection............................................. 871 Failure code [DFA9KB] BT lever 2: Short circuit............................................. 873 Failure code [DFAAKX] RL lever 1: Out of normal range....................................... 875 Failure code [DFAAKZ] RL lever: Disconnection or short circuit.............................. 875 Failure code [DFAAL8] RL lever: Signal mismatch............................................. 876 Failure code [DFABKA] RL lever 1: Disconnection............................................. 877 Failure code [DFABKB] RL lever 1: Short circuit............................................. 879 Failure code [DFACKA] RL lever 2: Disconnection............................................. 881 Failure code [DFACKB] RL lever 2: Short circuit............................................. 883 Failure code [DFADKX] RL lever 1: Out of normal range....................................... 885 Failure code [DFADKZ] RL lever: Disconnection or short circuit.............................. 885 Failure code [DFADL8] RL lever: Signal mismatch............................................. 886 Failure code [DFAEKA] RL lever 1: Disconnection............................................. 887 Failure code [DFAEKB] RL lever 1: Short circuit............................................. 889 Failure code [DFAFKA] RL lever 2: Disconnection............................................. 891 Failure code [DFAFKB] RL lever 2: Short circuit............................................. 893 Failure code [DGT1KA] T/C oil temp sensor: Abnormal......................................... 895 Failure code [DGT1KX] T/C oil temp sensor: Abnormal......................................... 897 Failure code [DH21KA] Weq pressure sensor: Disconnection.................................... 899 Failure code [DH21KB] Weq pressure sensor: Short circuit.................................... 901 Failure code [DHT5KA] T/C in-pressure sensor: Disconnection................................. 903 Failure code [DHT5KB] T/C in-pressure sensor: Short circuit................................. 905 Failure code [DHT7KA] T/C out-pressure sensor: Disconnection................................ 907 Failure code [DHT7KB] T/C out-pressure sensor: Short circuit................................ 909 Failure code [DK10KX] Fuel control Dial: Out of normal range................................ 911 Troubleshooting by failure and error codes, Part 6.............................................. 914 Failure code [DK30KA] ST lever 1: Disconnection............................................. 917 Failure code [DK30KB] ST lever 1: Short circuit............................................. 919 Failure code [DK30KX] ST lever 1: Out of normal range....................................... 921 Failure code [DK30KZ] RL lever: Disconnection or short circuit.............................. 921 Failure code [DK30L8] ST lever: Signal mismatch............................................. 922 Failure code [DK31KA] ST lever 2: Disconnection............................................. 923 Failure code [DK31KB] ST lever 2: Short circuit............................................. 925 Failure code [DK40KA] Brake potentiometer: Disconnection.................................... 927 Failure code [DK40KB] Brake potentiometer: Short circuit.................................... 929 Failure code [DK55KX] FR lever: Out of normal range......................................... 931 Failure code [DK55KZ] FR lever: Disconnection or short circuit.............................. 931 Failure code [DK55L8] FR lever: Signal mismatch............................................. 932 Failure code [DK56KA] FR lever 1: Disconnection............................................. 933 Failure code [DK56KB] FR lever 1: Short circuit............................................. 935 Failure code [DK57KA] FR lever 2: Disconnection............................................. 937 Failure code [DK57KB] FR lever 2: Short circuit............................................. 939 Failure code [DKH1KA] Pitch angle sensor: Disconnection..................................... 941 Failure code [DKH1KB] Pitch angle sensor: Short circuit..................................... 943 Failure code [DLT3KA] T/M out-speed sensor: Disconnection................................... 945 Failure code [DLT3KB] T/M out-speed sensor: Abnormal........................................ 946 Failure code [DW7BKA] Fan rev EPC: Disconnection............................................ 947 Failure code [DW7BKB] Fan rev EPC: Short circuit............................................ 948 Failure code [DWN1KA] Hss EPC1: Disconnection............................................... 949 Failure code [DWN1KB] Hss EPC1: Short circuit............................................... 950 Failure code [DWN1KY] Hss EPC1: Short circuit............................................... 951 Failure code [DWN2KA] Hss EPC2: Disconnection............................................... 952 Failure code [DWN2KB] Hss EPC2: Short circuit............................................... 953 Failure code [DWN2KY] Hss EPC2: Short circuit............................................... 954 Failure code [DWN3KA] Ssp solenoid: Disconnection........................................... 955 Failure code [DWN3KB] Ssp solenoid: Short circuit........................................... 957 Failure code [DWN3KY] Ssp solenoid: Short circuit........................................... 959 Failure code [DWN5KA] Fan pump solenoid: Disconnection...................................... 961 Failure code [DWN5KB] Fan pump solenoid: Short circuit...................................... 962 Failure code [DXA0KA] TVC Sol.: Disconnection............................................... 963 Failure code [DXA0KB] TVC Sol.: Short circuit............................................... 964 Failure code [DXA0KY] TVC Sol.: Short circuit............................................... 965 Failure code [DXH1KA] Lock-up ECMV: Disconnection........................................... 967 Failure code [DXH1KB] Lock-up ECMV: Short circuit........................................... 969 Failure code [DXH1KY] Lock-up ECMV: Short circuit........................................... 971 Failure code [DXH4KA] 1st clutch ECMV: Disconnection........................................ 973 Troubleshooting by failure and error codes, Part 7.............................................. 976 Troubleshooting by failure and error codes, Part 7.......................................... 978 Failure code [DXH4KB] 1st clutch ECMV: Short circuit.................................... 978 Failure code [DXH4KY] 1st clutch ECMV: Short circuit.................................... 979 Failure code [DXH5KA] 2nd clutch ECMV: Disconnection.................................... 980 Failure code [DXH5KB] 2nd clutch ECMV: Short circuit.................................... 981 Failure code [DXH5KY] 2nd clutch ECMV: Short circuit.................................... 982 Failure code [DXH6KA] 3rd clutch ECMV: Disconnection.................................... 983 Failure code [DXH6KB] 3rd clutch ECMV: Short circuit.................................... 984 Failure code [DXH6KY] 3rd clutch ECMV: Short circuit.................................... 985 Failure code [DXH7KA] R clutch ECMV: Disconnection...................................... 986 Failure code [DXH7KB] R clutch ECMV: Short circuit...................................... 987 Failure code [DXH7KY] R clutch ECMV: Short circuit...................................... 988 Failure code [DXH8KA] F clutch ECMV: Disconnection...................................... 989 Failure code [DXH8KB] F clutch ECMV: Short circuit...................................... 990 Failure code [DXH8KY] F clutch ECMV: Short circuit...................................... 991 Failure code [DXHBKA] Right brake ECMV: Disconnection................................... 992 Failure code [DXHBKB] Right brake ECMV: Short circuit................................... 994 Failure code [DXHBKY] Right brake ECMV: Short circuit................................... 996 Failure code [DXHCKA] Left brake ECMV: Disconnection.................................... 998 Failure code [DXHCKB] Left brake ECMV: Short circuit....................................1000 Failure code [DXHCKY] Left brake ECMV: Short circuit....................................1002 Failure code [DXHRKA] Blade up EPC: Disconnection.......................................1004 Failure code [DXHRKB] Blade up EPC: Short circuit.......................................1005 Failure code [DXHRKY] Blade up EPC: Short circuit.......................................1006 Failure code [DXHSKA] Blade down EPC: Disconnection.....................................1007 Failure code [DXHSKB] Blade down EPC: Short circuit.....................................1008 Failure code [DXHSKY] Blade down EPC: Short circuit.....................................1009 Failure code [DXHTKA] Blade left 1 EPC: Disconnection...................................1010 Failure code [DXHTKB] Blade left 1 EPC: Short circuit...................................1011 Failure code [DXHTKY] Blade left 1 EPC: Short circuit...................................1012 Failure code [DXHUKA] Blade right 1 EPC: Disconnection..................................1013 Failure code [DXHUKB] Blade right 1 EPC: Short circuit..................................1014 Failure code [DXHUKY] Blade right 1 EPC: Short circuit..................................1015 Failure code [DXHWKA] Ripper up EPC: Disconnection......................................1016 Failure code [DXHWKB] Ripper up EPC: Short circuit......................................1017 Failure code [DXHWKY] Ripper up EPC: Short circuit......................................1018 Failure code [DXHXKA] Ripper down EPC: Disconnection....................................1019 Failure code [DXHXKB] Ripper down EPC: Short circuit....................................1020 Failure code [DXHXKY] Ripper down EPC: Short circuit....................................1021 Failure code [DXHYKA] Ripper Tilt In EPC: Disconnection.................................1022 Failure code [DXHYKB] Ripper Tilt In EPC: Short circuit.................................1023 Failure code [DXHYKY] Ripper Tilt In EPC: Short circuit.................................1024 Failure code [DXHZKA] Ripper Tilt Back EPC: Disconnection...............................1025 Failure code [DXHZKB] Ripper Tilt Back EPC: Short circuit...............................1026 Failure code [DXHZKY] Ripper Tilt Back EPC: Short circuit...............................1027 Failure code [DXJ4KA] Weq lock Sol.: Disconnection......................................1028 Failure code [DXJ4KB] Weq lock Sol.: Short circuit......................................1029 Troubleshooting by failure and error codes, Part 8..............................................1031 Troubleshooting by failure and error codes, Part 8..........................................1032 Failure code [DXJ8KA] Blade left 2 EPC: Disconnection...................................1032 Failure code [DXJ8KB] Blade left 2 EPC: Short circuit...................................1033 Failure code [DXJ8KY] Blade left 2 EPC: Short circuit...................................1034 Failure code [DXJ9KA] Blade right 2 EPC: Disconnection..................................1035 Failure code [DXJ9KB] Blade right 2 EPC: Short circuit..................................1036 Failure code [DXJ9KY] Blade right 2 EPC: Short circuit..................................1037 Failure code [DXJAKA] Q-drop EPC: Disconnection.........................................1038 Failure code [DXJAKB] Q-drop EPC: Short circuit.........................................1040 Failure code [DXJAKY] Q-drop EPC: Short circuit.........................................1042 Failure code [DXJBKA] S/C ECMV: Disconnection...........................................1044 Failure code [DXJBKB] S/C ECMV: Short circuit...........................................1046 Failure code [DXJBKY] S/C ECMV: Short circuit...........................................1048 Troubleshooting of electrical system (E-mode)...................................................1051 Information in troubleshooting table........................................................1053 E-1 When starting switch turned ON, machine monitor displays nothing........................1054 E-2 When starting switch turned ON (before starting engine), basic check item lights up.....1056 E-3 Engine does not start (Engine does not turn)............................................1058 E-4 Preheater does not operate..............................................................1060 E-5 Precaution item lights up while engine is running.......................................1064 E-6 Emergency stop item lights up while engine is running...................................1066 E-7 Engine coolant temperature gauge does not indicate normally.............................1068 E-8 Fuel level gauge does not indicate normally.............................................1069 E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally..............1071 E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally...................1072 E-11 Contents of display by machine monitor are different from applicable machine...........1075 E-12 Machine monitor does not display some items............................................1075 E-13 Function switch does not work..........................................................1075 E-14 Operation mode does not change.........................................................1076 E-15 Gearshift mode does not change.........................................................1076 E-16 Customize function does not operate normally...........................................1077 E-17 Customize memory function does not normally............................................1077 E-18 Float mode does not change.............................................................1078 E-19 Alarm buzzer cannot be stopped.........................................................1078 E-20 Air conditioner does not operate normally (including air conditioner fault history)....1079 E-21 When starting switch is turned OFF, service meter is not displayed.....................1092 E-22 Machine monitor cannot be set in service mode..........................................1092 E-23 Ripper pin puller cylinder does not operate............................................1094 E-24 Backup alarm does not sound or does not stop...........................................1096 E-25 Headlamp, rear lamp, and ripper point lamp do not light up.............................1098 E-26 Windshield wiper and window washer do not operate......................................1102 E-27 KOMTRAX system does not operate normally...............................................1118 Troubleshooting of hydraulic and mechanical system (H-mode).....................................1121 Troubleshooting of hydraulic and mechanical system (H-mode).................................1123 Information in troubleshooting table....................................................1123 H-1 Power is low (Drawbar pull is low)..................................................1124 H-2 Machine does not travel (at 2nd or 3rd gear speed)..................................1125 H-3 Machine does not start at any gear speed............................................1126 H-4 Machine can travel only forward or in reverse.......................................1127 H-5 When gear speed or travel direction is changed, time lag is large...................1128 H-6 Machine cannot be steered (Machine does not turn right or left).....................1129 H-7 Steering speed or steering force is low.............................................1129 H-8 Brake does not work.................................................................1130 H-9 Power train oil is overheated.......................................................1131 H-10 Abnormal sound comes out from around HSS pump or HSS motor.........................1132 H-11 Speed of all work equipment is low.................................................1133 H-12 No work equipment moves............................................................1134 H-13 Blade lift speed or power is low...................................................1135 H-14 Blade tilt speed or power is low...................................................1136 H-15 Ripper lift speed or power is low..................................................1137 H-16 Ripper tilt speed or power is low..................................................1138 H-17 Hydraulic drift of blade lift is large.............................................1138 H-18 Hydraulic drift of blade tilt is large.............................................1139 H-19 Hydraulic drift of ripper lift is large............................................1139 H-20 Ripper pin puller cylinder does not operate........................................1140 H-21 Blade does not pitch...............................................................1140 H-22 Abnormal sound comes out from around work equipment pump...........................1141 Troubleshooting of engine (S-mode)..............................................................1143 Method of using troubleshooting chart.......................................................1145 S-1 Starting performance of engine is poor.................................................1148 S-2 Engine does not start..................................................................1150 S-3 Engine does not pick up smoothly.......................................................1154 S-4 Engine stops during operation..........................................................1155 S-5 Engine does not rotate smoothly........................................................1156 S-6 Engine lack output (or lacks power)....................................................1157 S-7 Exhaust gas is black (incomplete combustion)...........................................1158 S-8 Oil consumption is excessive (or exhaust gas is blue)..................................1160 S-9 Oil becomes dirty quickly..............................................................1161 S-10 Fuel consumption is excessive.........................................................1162 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................1163 S-12 Oil pressure drops....................................................................1164 S-13 Oil level rises (Entry of coolant or fuel)............................................1166 S-14 Coolant temperature becomes too high (Overheating)....................................1168 S-15 Abnormal noise is made................................................................1169 S-16 Vibration is excessive................................................................1170 50 Disassembly and assembly......................................................................... 0 General information on disassembly and assembly.................................................1173 How to read this manual.....................................................................1174 Coating materials list......................................................................1176 Special tool list...........................................................................1179 Sketches of special tools...................................................................1187 Engine and cooling system.......................................................................1201 Removal and installation of fuel supply pump assembly.......................................1202 Removal and installation of fuel injector assembly..........................................1206 Removal and installation of cylinder head assembly..........................................1211 Removal and installation of radiator assembly...............................................1222 Removal and installation of aftercooler assembly............................................1225 Removal and installation of engine assembly.................................................1228 Removal and installation of engine hood assembly............................................1233 Removal and installation of engine front seal...............................................1235 Removal and installation of engine rear seal................................................1239 Removal and installation of fuel tank assembly..............................................1244 Removal and installation of fan drive assembly..............................................1245 Removal and installation of fan motor assembly..............................................1246 Power train, Part 1.............................................................................1249 Removal and installation of damper assembly.................................................1250 Disassembly and assembly of damper assembly.................................................1253 Removal and installation of power train unit assembly.......................................1259 Disconnection and connection of power train unit assembly...................................1263 Power train, Part 2.............................................................................1269 Disassembly and assembly of PTO assembly....................................................1270 Disassembly and assembly of torque converter assembly.......................................1277 Disassembly and assembly of transmission assembly...........................................1287 Disassembly and assembly of HSS case assembly...............................................1304 Removal and installation of HSS motor assembly..............................................1321 Power train, Part 3.............................................................................1323 Removal and installation of final drive assembly............................................1324 Disassembly and assembly of final drive assembly............................................1326 Undercarriage and frame.........................................................................1341 Removal and installation of track frame assembly............................................1343 Removal and installation of idler assembly..................................................1346 Disassembly and assembly of idler assembly..................................................1347 Removal and installation of recoil spring assembly..........................................1351 Disassembly and assembly of recoil spring assembly..........................................1352 Removal and installation of track roller....................................................1357 Disassembly and assembly of track roller assembly...........................................1359 Removal and installation of No. 1 bogie assembly............................................1362 Removal and installation of No. 2, No, 3 and No. 4 bogie assemblies.........................1368 Disassembly and assembly of bogie assembly..................................................1374 Removal and installation of carrier roller assembly.........................................1377 Disassembly and assembly of carrier roller assembly.........................................1378 Removal and installation of pivot shaft assembly............................................1382 Spreading and installation of track shoe assembly...........................................1384 General disassembly and assembly of track shoe..............................................1387 Disassembly and assembly of 1 link in field.................................................1401 Disassembly and assembly of master link.....................................................1405 Removal and installation of equalizer bar assembly..........................................1408 Disassembly and assembly of equalizer bar assembly..........................................1410 Removal and installation of segment teeth...................................................1412 Hydraulic system................................................................................1415 Removal and installation of hydraulic tank assembly.........................................1416 Removal and installation of hydraulic pump assembly.........................................1418 Disassembly and assembly of hydraulic cylinder assembly.....................................1421 Work equipment..................................................................................1431 Removal and installation of blade assembly..................................................1432 Disassembly and assembly of multi-shank ripper..............................................1434 Cab and its attachments.........................................................................1439 Removal and installation of operator's cab assembly.........................................1440 Removal and installation of operator's cab glass (Stuck glass)..............................1442 Removal and installation of floor frame assembly............................................1451 Removal and installation of air conditioner unit assembly...................................1454 Electrical system...............................................................................1457 Removal and installation of engine controller assembly......................................1458 Removal and installation of power train controller assembly.................................1459 Removal and installation of work equipment controller assembly..............................1459 80 Air conditioner.................................................................................. 0 Structure, function, testing, adjusting, and troubleshooting....................................1461 Structure and function......................................................................1463 Air conditioner component...............................................................1463 Configuration and function of refrigerating cycle.......................................1464 Outline of refrigerating cycle..........................................................1465 Air conditioner unit....................................................................1467 Functions of major components in the air conditioner unit...............................1469 Control plate...........................................................................1471 Compressor..............................................................................1473 Condenser...............................................................................1474 Receiver drier..........................................................................1475 Testing, adjusting and troubleshooting......................................................1477 Caution about refrigerant...............................................................1477 Troubleshooting procedure...............................................................1478 Block diagram...........................................................................1479 Circuit diagram and arrangement of connector pins.......................................1480 Detail of air conditioner unit..........................................................1482 Part and connector locations............................................................1484 Testing air leakage (duct)..............................................................1491 Testing with self-diagnosis function....................................................1493 Testing temperature control.............................................................1496 Testing vent (mode) changeover..........................................................1499 Testing Recirc/Fresh changeover.........................................................1502 Testing inner sensor....................................................................1504 Testing evaporator temperature sensor...................................................1505 Testing sunlight sensor.................................................................1508 Testing (dual) pressure switch for refrigerant..........................................1509 Testing relays and diodes...............................................................1511 Troubleshooting chart 1.................................................................1513 Troubleshooting chart 2.................................................................1514 Troubleshooting for electrical system (E mode)..............................................1517 E-1 Power supply system (Air conditioner does not operate)..............................1518 E-2 Compressor system (Air is not cooled)...............................................1522 E-3 Blower motor system (No air comes out or air flow is abnormal)......................1525 E-4 Temperature cannot be controlled....................................................1530 E-5 Vent (mode) cannot be changed over..................................................1532 E-6 Recirc/Fresh air cannot be changed over.............................................1534 Troubleshooting with gauge pressure.........................................................1536 Connection of service tool..................................................................1538 Precautions for connecting air conditioner piping...........................................1539 Handling of compressor oil..................................................................1540 1. Control of compressor oil............................................................1540 2. Adding of compressor oil.............................................................1540 3. Compressor replacement...............................................................1541 4. Applying compressor oil for O-ring...................................................1541 90 Diagrams and drawings............................................................................ 0 Hydraulic diagrams and drawings.................................................................1543 Power train hydraulic circuit diagram.......................................................1545 Hydraulic circuit diagram (1/2) Serial No.: 80001 - 80806...................................1546 Hydraulic circuit diagram (2/2) Serial No.: 80001 - 80806...................................1547 Hydraulic circuit diagram (1/2) Serial No.: 80807 and up....................................1548 Hydraulic circuit diagram (2/2) Serial No.: 80807 and up....................................1549 Electrical diagrams and drawings................................................................1552 Electrical circuit diagram (1/12)...........................................................1554 Electrical circuit diagram (2/12)...........................................................1555 Electrical circuit diagram (3/12)...........................................................1556 Electrical circuit diagram (4/12)...........................................................1557 Electrical circuit diagram (5/12)...........................................................1558 Electrical circuit diagram (6/12)...........................................................1559 Electrical circuit diagram (7/12)...........................................................1560 Electrical circuit diagram (8/12)...........................................................1561 Electrical circuit diagram (9/12)...........................................................1562 Electrical circuit diagram (10/12)..........................................................1563 Electrical circuit diagram (11/12)..........................................................1564 Electrical circuit diagram (12/12)..........................................................1565 Electrical circuit diagram for inside cab...................................................1566 Connectors table and arrangement drawing....................................................1567
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