Komatsu D155AX-8 Bulldozer Shop Manual SEN06497-17 PDF

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Komatsu D155AX-8 Bulldozer Shop Manual SEN06497-17 –  PDF DOWNLOAD

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Komatsu D155AX-8 Bulldozer Shop Manual SEN06497-17 –  PDF DOWNLOAD

Language : English
Pages : 3456
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu D155AX-8 Bulldozer Shop Manual SEN06497-17 –  PDF DOWNLOAD

• SERIAL NUMBERS 100001 and up

COVER 1
00 INDEX AND FOREWORD . 3
INDEX . 4
ABBREVIATION LIST . 24
FOREWORD, SAFETY, BASIC INFORMATION . 30
HOW TO READ THE SHOP MANUAL . 30
SAFETY NOTICE FOR OPERATION . 32
PRECAUTIONS TO PREVENT FIRE . 40
ACTIONS IF FIRE OCCURS 42
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 43
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS . 44
PRECAUTIONS FOR DEF . 45
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 45
PRECAUTIONS FOR ADDING 45
PRECAUTIONS FOR STORING . 45
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE . 45
THE OTHER PRECAUTIONS . 45
STORE AdBlue/DEF 46
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 47
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS . 50
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT . 57
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 59
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 60
PRACTICAL USE OF KOMTRAX 61
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER . 62
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER . 62
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER . 63
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER . 64
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 66
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR . 70
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR . 71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL . 73
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH . 74
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 76
HOW TO READ ELECTRICAL WIRE CODE 77
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD . 81
STANDARD TIGHTENING TORQUE TABLE 84
CONVERSION TABLE 91
01 SPECIFICATIONS . 97
CONTENTS 98
ABBREVIATION LIST . 99
SPECIFICATIONS 105
SPECIFICATION DRAWING . 105
SPECIFICATION DRAWING: D155AX-8 . 105
SPECIFICATION DRAWING: D155PX-8 . 106
SPECIFICATIONS 108
SPECIFICATIONS: D155AX-8 108
SPECIFICATIONS: D155PX-8 115
WEIGHT TABLE 120
WEIGHT TABLE: D155AX-8 120
WEIGHT TABLE: D155PX-8 122
TABLE OF FUEL, COOLANT, AND LUBRICANTS 125
10 STRUCTURE AND FUNCTION . 127
CONTENTS 128
ABBREVIATION LIST . 131
UREA SCR SYSTEM . 137
LAYOUT DRAWING OF UREA SCR SYSTEM . 137
UREA SCR SYSTEM DIAGRAM . 139
FUNCTION OF UREA SCR SYSTEM . 140
FUNCTION OF AdBlue/DEF SYSTEM . 140
INDUCEMENT STRATEGY . 143
COMPONENT PARTS OF UREA SCR SYSTEM 157
AdBlue/DEF MIXING TUBE 157
SCR ASSEMBLY 157
AdBlue/DEF TANK . 160
AdBlue/DEF PUMP . 162
AdBlue/DEF INJECTOR . 163
AdBlue/DEF HOSE . 164
AdBlue/DEF TANK HEATING VALVE . 165
BOOT-UP SYSTEM 166
SYSTEM OPERATING LAMP SYSTEM 166
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 166
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 166
BATTERY DISCONNECT SWITCH . 168
LAYOUT DRAWING OF BATTERY DISCONNECT SWITCH . 168
FUNCTION OF BATTERY DISCONNECT SWITCH . 168
ENGINE SYSTEM . 170
LAYOUT DRAWING OF ENGINE SYSTEM . 170
ENGINE CONTROL SYSTEM . 172
LAYOUT OF ENGINE CONTROL SYSTEM . 172
ENGINE CONTROL SYSTEM DIAGRAM . 173
FUNCTION OF ENGINE CONTROL SYSTEM . 174
AUTOMATIC IDLE STOP SYSTEM 175
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 175
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 175
COMPONENT PARTS OF ENGINE SYSTEM 178
DAMPER 178
VGT . 179
EGR SYSTEM 183
EGR VALVE . 185
EGR COOLER 187
KCCV SYSTEM . 189
KCCV VENTILATOR . 191
KDPF 194
COOLING SYSTEM 198
LAYOUT DRAWING OF COOLING SYSTEM 198
SPECIFICATIONS OF COOLING SYSTEM 199
COMPONENT PARTS OF COOLING SYSTEM . 200
COOLING FAN PUMP 200
COOLING FAN MOTOR . 208
HYDRAULIC OIL COOLER BYPASS VALVE . 215
CONTROL SYSTEM 216
LAYOUT DRAWING OF CONTROL SYSTEM 216
MACHINE MONITOR SYSTEM 217
MACHINE MONITOR SYSTEM DIAGRAM 217
FUNCTION OF MACHINE MONITOR SYSTEM 217
KOMTRAX SYSTEM 220
KOMTRAX SYSTEM DIAGRAM 220
FUNCTION OF KOMTRAX SYSTEM 220
COMPONENT PARTS OF CONTROL SYSTEM . 221
MACHINE MONITOR . 221
KOMTRAX TERMINAL 236
POWER TRAIN CONTROLLER 238
WORK EQUIPMENT CONTROLLER . 242
ENGINE CONTROLLER . 246
FUEL FEED PUMP 252
FUEL FEED PUMP SWITCH . 253
HYDRAULIC SYSTEM 254
LAYOUT DRAWING OF HYDRAULIC SYSTEM 254
CLSS 255
STRUCTURE OF CLSS . 255
FUNCTION OF CLSS 256
COMPONENT PARTS OF HYDRAULIC SYSTEM . 258
HYDRAULIC TANK 258
WORK EQUIPMENT AND HSS PUMP . 259
LS VALVE 264
PC VALVE 269
PC-EPC VALVE 275
CONTROL VALVE . 279
POWER TRAIN SYSTEM 321
LAYOUT OF POWER TRAIN SYSTEM 321
OPERATION OF POWER TRAIN SYSTEM . 324
LAYOUT OF POWER TRAIN SYSTEM (D155PX-8) . 326
OPERATION OF POWER TRAIN SYSTEM (D155PX-8) 329
TRANSMISSION, STEERING, AND BRAKE CONTROL . 330
LAYOUT OF TRANSMISSION, STEERING, AND BRAKE CONTROL SYSTEM PARTS 330
FUNCTION OF TRANSMISSION, STEERING, AND BRAKE CONTROL . 331
PALM COMMAND CONTROL SYSTEM . 333
PALM COMMAND CONTROL SYSTEM DIAGRAM . 333
HSS SYSTEM 337
HSS SYSTEM DIAGRAM 337
FUNCTION OF HSS SYSTEM 338
CENTRALIZED PRESSURE PICKUP PORT 340
LAYOUT OF CENTRALIZED PRESSURE PICKUP PORT 340
FUNCTION OF CENTRALIZED PRESSURE PICKUP PORT 341
COMPONENT PARTS OF POWER TRAIN SYSTEM . 342
UNIVERSAL JOINT . 342
POWER TRAIN MOUNT . 343
TORQUE CONVERTER AND PTO 344
TORQUE CONVERTER CONTROL VALVE 351
LOCKUP CLUTCH ECMV 352
STATOR CLUTCH ECMV 355
TRANSMISSION 359
TRANSMISSION ECMV . 369
MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE . 376
TRANSMISSION LUBRICATION RELIEF VALVE . 378
BEVEL GEAR SHAFT, HSS, AND BRAKE 378
FINAL DRIVE . 405
SCAVENGING PUMP . 411
STEERING LUBRICATION PUMP AND POWER TRAIN PUMP 412
HSS MOTOR . 413
ELECTRIC STEERING CONTROL LEVER . 420
WORK EQUIPMENT SYSTEM . 425
WORK EQUIPMENT CONTROL 425
LAYOUT OF WORK EQUIPMENT CONTROL 425
WORK EQUIPMENT CONTROL FUNCTION . 426
LAYOUT DRAWING OF FRONT WORK EQUIPMENT 427
LAYOUT OF VARIABLE GIANT RIPPER . 428
LAYOUT OF VARIABLE MULTI-SHANK RIPPER . 429
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 430
SELF-PRESSURE REDUCING VALVE 430
WORK EQUIPMENT LOCK SOLENOID VALVE 436
PILOT CIRCUIT ACCUMULATOR . 438
QUICK DROP VALVE 439
PISTON VALVE 444
ELECTRIC BLADE CONTROL LEVER 444
RIPPER ELECTRIC LEVER . 446
UNDERCARRIAGE AND FRAME . 447
MAIN FRAME 447
STRUCTURE OF MAIN FRAME . 447
SUSPENSION 448
STRUCTURE OF SUSPENSION . 448
FUNCTION OF SUSPENSION 450
TRACK FRAME AND IDLER CUSHION . 451
STRUCTURE OF TRACK FRAME AND IDLER CUSHION 451
SPECIFICATIONS OF TRACK FRAME AND IDLER CUSHION . 452
FUNCTION OF TRACK FRAME AND IDLER CUSHION . 452
WORK EQUIPMENT 453
STRUCTURE OF FRONT WORK EQUIPMENT . 453
STRUCTURE OF CYLINDER STAY 455
STRUCTURE OF VARIABLE GIANT RIPPER 456
STRUCTURE OF VARIABLE MULTI-SHANK RIPPER 457
CAB AND ITS ATTACHMENTS . 458
ROPS CAB 458
STRUCTURE OF ROPS CAB . 458
FUNCTION OF ROPS CAB 458
CAB MOUNT . 459
STRUCTURE OF CAB MOUNT 459
20 STANDARD VALUE TABLE . 461
CONTENTS 462
ABBREVIATION LIST . 463
STANDARD VALUE TABLE FOR ENGINE . 469
STANDARD VALUE TABLE FOR ENGINE: D155AX-8 . 469
STANDARD VALUE TABLE FOR ENGINE: D155PX-8 . 474
STANDARD VALUE TABLE FOR MACHINE 479
STANDARD VALUE TABLE FOR MACHINE: D155AX-8 479
STANDARD VALUE TABLE FOR MACHINE: D155PX-8 497
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 513
STANDARD VALUE TABLE FOR ELECTRICAL . 515
STANDARD VALUE TABLE FOR ELECTRICITY 515
30 TESTING AND ADJUSTING 525
CONTENTS 526
ABBREVIATION LIST . 529
RELATED INFORMATION ON TESTING AND ADJUSTING 535
TOOLS FOR TESTING AND ADJUSTING . 535
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 543
ENGINE AND COOLING SYSTEM . 546
TEST ENGINE SPEED . 546
METHOD FOR TESTING ENGINE SPEED . 546
TEST BOOST PRESSURE . 551
METHOD FOR TESTING BOOST PRESSURE . 551
TEST EXHAUST GAS TEMPERATURE 553
METHOD FOR TESTING EXHAUST GAS TEMPERATURE 553
TEST EXHAUST GAS COLOR 556
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 556
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER . 557
TEST MASS AIR FLOW AND TEMPERATURE SENSOR . 558
TEST MASS AIR FLOW AND TEMPERATURE SENSOR . 558
TEST AND ADJUST VALVE CLEARANCE . 560
METHOD FOR TESTING VALVE CLEARANCE 560
METHOD FOR ADJUSTING VALVE CLEARANCE 561
TEST COMPRESSION PRESSURE . 563
METHOD FOR TESTING COMPRESSION PRESSURE . 563
TEST BLOWBY PRESSURE 566
METHOD FOR TESTING BLOWBY PRESSURE 566
TEST ENGINE OIL PRESSURE 568
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR . 568
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL 568
TEST EGR VALVE AND VGT OIL PRESSURE . 570
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE . 570
TEST FUEL PRESSURE 572
METHOD FOR TESTING FUEL PRESSURE 572
TEST FUEL RETURN RATE AND LEAKAGE . 574
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE . 575
BLEED AIR FROM FUEL SYSTEM 579
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 579
TEST FUEL CIRCUIT FOR LEAKAGE . 581
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 581
HANDLE CYLINDER CUT-OUT MODE OPERATION 583
HANDLE NO-INJECTION CRANKING OPERATION 584
CLEAN FUEL DOSER 585
METHOD FOR CLEANING FUEL DOSER 585
METHOD FOR CLEANING FUEL DOSER 587
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 589
METHOD FOR WRITING INJECTOR COMPENSATION VALUE 589
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 595
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 595
TEST SCR RELATED FUNCTIONS 596
TEST AdBlue/DEF PUMP RAISED PRESSURE 600
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 603
TEST AdBlue/DEF LINE HEATER RELAY 1 . 608
TEST AdBlue/DEF LINE HEATER RELAY 2 . 611
TEST AdBlue/DEF PUMP HEATER RELAY . 614
TEST AdBlue/DEF TANK HEATER VALVE . 617
TEST DENITRATION EFFICIENCY OF SCR 620
CLEAN AdBlue/DEF TANK . 623
METHOD FOR CLEANING AdBlue/DEF TANK . 624
CLEAN AdBlue/DEF PUMP . 629
METHOD FOR CLEAN AdBlue/DEF PUMP 629
ADJUST DECELERATOR PEDAL 636
METHOD FOR ADJUSTING DECELERATOR PEDAL 636
POWER TRAIN . 639
TEST POWER TRAIN OIL PRESSURE . 639
METHOD FOR TESTING POWER TRAIN OIL PRESSURE . 640
ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR . 650
METHOD FOR ADJUSTING TRANSMISSION OUTPUT SHAFT SPEED SENSOR . 650
TEST BRAKE PERFORMANCE SIMPLY . 651
METHOD FOR TESTING BRAKE PERFORMANCE SIMPLY . 651
TEST AND ADJUST BRAKE PEDAL . 652
METHOD FOR TESTING BRAKE PEDAL 652
METHOD FOR ADJUSTING BRAKE PEDAL 653
ADJUST PARKING BRAKE LEVER 656
METHOD FOR ADJUSTING PARKING BRAKE LEVER 656
MOVE MACHINE BY RELEASING PARKING BRAKE WHEN MACHINE DOES NOT TRAVEL 658
METHOD FOR MOVING MACHINE WITH HYDRAULIC TYPE PARKING BRAKE RELEASE SYSTEM 658
METHOD FOR MOVING MACHINE WITH ELECTRIC TYPE PARKING BRAKE RELEASE SYSTEM . 659
UNDERCARRIAGE AND FRAME . 662
ADJUST IDLER CLEARANCE 662
METHOD FOR ADJUSTING IDLER CLEARANCE 662
METHOD FOR ADJUSTING IDLER CLEARANCE (D155PX-8) . 664
TEST AND ADJUST TRACK TENSION . 666
METHOD FOR TESTING TRACK TENSION 666
METHOD FOR TESTING TRACK TENSION (D155PX-8) . 667
METHOD FOR ADJUSTING TRACK TENSION 667
METHOD FOR ADJUSTING TRACK TENSION (D155PX-8) . 667
HYDRAULIC SYSTEM 669
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 669
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 669
TEST AND ADJUST WORK EQUIPMENT AND HSS OIL PRESSURES 670
TEST OIL PRESSURE OF WORK EQUIPMENT AND HSS . 670
METHOD FOR ADJUSTING WORK EQUIPMENT AND HSS OIL PRESSURES . 673
TEST OIL PRESSURE OF CONTROL CIRCUIT 675
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 675
TEST WORK EQUIPMENT LOCK SOLENOID VALVE OUTPUT PRESSURE . 677
METHOD FOR TESTING WORK EQUIPMENT LOCK SOLENOID VALVE OUTPUT PRESSURE . 677
TEST RIPPER PIN PULLER SOLENOID VALVE OUTPUT PRESSURE . 679
METHOD FOR TESTING RIPPER PIN PULLER SOLENOID VALVE OUTPUT PRESSURE . 679
BLEED AIR FROM WORK EQUIPMENT AND HSS PUMP 681
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT AND HSS PUMP 681
TEST COOLING FAN SPEED 682
METHOD FOR TESTING COOLING FAN SPEED 682
TEST COOLING FAN CIRCUIT OIL PRESSURE . 683
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE . 683
BLEED AIR FROM COOLING FAN PUMP . 685
METHOD FOR BLEEDING AIR FROM COOLING FAN PUMP . 685
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 686
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE LIFT CYLINDER . 686
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE TILT CYLINDER . 686
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF RIPPER LIFT CYLINDER 687
>TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER . 688
TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER 688
BLEED AIR FROM WORK EQUIPMENT CYLINDERS . 690
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT CYLINDERS . 690
OPERATION WHEN WORK EQUIPMENT IS NOT EFFECTIVE 691
METHOD FOR OPERATING WHEN WORK EQUIPMENT IS NOT EFFECTIVE . 691
WORK EQUIPMENT 693
ADJUST WORK EQUIPMENT LOCK LEVER 693
METHOD FOR ADJUSTING WORK EQUIPMENT LOCK LEVER 693
TEST AND ADJUST PLAY OF BLADE ELECTRIC LEVER 695
TEST PLAY OF BLADE ELECTRIC LEVER . 697
ADJUST PLAY OF BLADE ELECTRIC LEVER . 697
REPLACE UNIVERSAL JOINT . 698
CAB AND ITS ATTACHMENTS . 705
TEST AND ADJUST OPERATOR’S CAB 705
METHOD FOR TESTING OPERATOR’S CAB . 705
METHOD FOR ADJUSTING OPERATOR’S CAB . 708
ELECTRICAL SYSTEM . 710
SET AND OPERATE MACHINE MONITOR . 710
OPERATOR MODE . 714
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN . 714
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 714
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) . 715
CHECKING FUNCTION OF SERVICE METER 715
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD . 715
SERVICE MODE 718
METHOD FOR OPERATING SERVICE MODE . 718
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 720
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 725
ABNORMALITY RECORD MENU . 737
METHOD FOR CONFIRMING MAINTENANCE RECORD 741
METHOD FOR OPERATING MAINTENANCE MODE SETTING . 742
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING . 746
DEFAULT MENU 747
DIAGNOSTIC TESTS MENU . 755
ADJUSTMENT MENU . 764
METHOD FOR PERFORMING NO-INJECTION CRANKING . 830
KOMTRAX SETTINGS MENU . 832
METHOD FOR DISPLAYING SERVICE MESSAGE . 834
METHOD FOR STARTING UP KOMTRAX TERMINAL . 836
ADJUST REARVIEW CAMERA ANGLE 841
ADJUST REARVIEW CAMERA ANGLE 841
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 842
HANDLE BATTERY DISCONNECT SWITCH 843
TEST DIODES . 844
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 844
METHOD FOR TESTING DIODE USING ANALOG TESTER 844
Pm CLINIC . 845
Pm CLINIC SERVICE . 845
Pm CLINIC CHECK SHEET . 847
Pm CLINIC CHECK SHEET . 862
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE . 874
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE (D155PX-8) 876
40 TROUBLESHOOTING 879
CONTENTS 880
ABBREVIATION LIST . 892
RELATED INFORMATION ON TROUBLESHOOTING 898
GENERAL TROUBLESHOOTING POINTS 898
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 899
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 914
CHECKS BEFORE TROUBLESHOOTING . 916
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 918
WALK-AROUND CHECK . 918
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 920
FUEL – CHECK LEVEL AND TYPE . 920
FUEL – CHECK FOR FOREIGN MATERIAL . 920
CHECK AdBule/DEF LEVEL AND TYPE . 921
FUEL PREFILTER – CHECK 921
MAIN FILTER – CHECK . 923
OIL PAN – CHECK ENGINE OIL LEVEL AND TYPE . 924
CHECK COOLANT LEVEL (RESERVOIR TANK) 925
CHECK CLOGGING OF AIR CLEANER . 926
OUTER ELEMENT – CLEAN . 927
REPLACE ELEMENT . 929
CHECK HYDRAULIC OIL LEVEL . 929
CHECK HYDRAULIC OIL STRAINER 931
CHECK HYDRAULIC FILTER 932
CHECK OIL LEVEL IN POWER TRAIN CASE . 932
CHECK POWER TRAIN STRAINER 934
CHECK POWER TRAIN FILTER 935
CHECK OIL LEVEL IN DAMPER CASE 935
CHECK OIL LEVEL IN FINAL DRIVE CASE . 936
METHOD FOR CHECKING ELECTRIC EQUIPMENT 938
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 945
SYMPTOM AND TROUBLESHOOTING NUMBERS . 948
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 951
CONNECTORS LIST AND LAYOUT 953
CONNECTOR CONTACT IDENTIFICATION 969
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE .1009
FUSE LOCATION TABLE .1015
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) .1018
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) .1022
FAILURE CODES TABLE .1024
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) .1046
FAILURE CODE [1500L0] .1046
FAILURE CODE [15SAL1] .1047
FAILURE CODE [15SALH] .1049
FAILURE CODE [15SBL1] .1051
FAILURE CODE [15SBLH] .1053
FAILURE CODE [15SEL1] .1055
FAILURE CODE [15SELH] .1057
FAILURE CODE [15SFL1] .1059
FAILURE CODE [15SFLH] .1061
FAILURE CODE [15SGL1] .1063
FAILURE CODE [15SGLH] .1065
FAILURE CODE [15SJL1] .1067
FAILURE CODE [15SJLH] .1069
FAILURE CODE [1800MW] .1071
FAILURE CODE [2300NR] .1072
FAILURE CODE [2301L1] .1073
FAILURE CODE [2301LH] .1075
FAILURE CODE [2302L1] .1077
FAILURE CODE [2302LH] .1079
FAILURE CODE [879AKA] .1081
FAILURE CODE [879AKB] .1082
FAILURE CODE [879BKA] .1083
FAILURE CODE [879BKB] .1085
FAILURE CODE [879CKA] .1087
FAILURE CODE [879CKB] .1088
FAILURE CODE [879DKZ] .1089
FAILURE CODE [879EMC] .1091
FAILURE CODE [879FMC] .1092
FAILURE CODE [879GKX] .1093
FAILURE CODE [989L00] .1095
FAILURE CODE [989M00] .1096
FAILURE CODE [989N00] .1097
FAILURE CODE [A1U0N3] .1098
FAILURE CODE [A1U0N4] .1100
FAILURE CODE [AA10NX] .1102
FAILURE CODE [AB00KE] .1104
FAILURE CODE [AQ10N3] .1106
FAILURE CODE [AS00N3] .1108
FAILURE CODE [AS00R2] .1110
FAILURE CODE [AS00R3] .1111
FAILURE CODE [AS00R4] .1112
FAILURE CODE [AS00R5] .1113
FAILURE CODE [AS00R6] .1114
FAILURE CODE [AS00ZK] .1115
FAILURE CODE [AS10KM] .1116
FAILURE CODE [AS10NR] .1117
FAILURE CODE [AS10NT] .1118
FAILURE CODE [B@BAZG] .1119
FAILURE CODE [B@BCNS] .1120
FAILURE CODE [B@BCZK] .1121
FAILURE CODE [B@CENS] .1123
FAILURE CODE [B@HANS] .1124
FAILURE CODE [CA115] 1125
FAILURE CODE [CA122] 1126
FAILURE CODE [CA123] 1128
FAILURE CODE [CA131] 1130
FAILURE CODE [CA132] 1132
FAILURE CODE [CA135] 1134
FAILURE CODE [CA141] 1136
FAILURE CODE [CA144] 1138
FAILURE CODE [CA145] 1140
FAILURE CODE [CA153] 1142
FAILURE CODE [CA154] 1145
FAILURE CODE [CA187] 1148
FAILURE CODE [CA221] 1150
FAILURE CODE [CA222] 1152
FAILURE CODE [CA227] 1154
FAILURE CODE [CA234] 1155
FAILURE CODE [CA238] 1156
FAILURE CODE [CA239] 1158
FAILURE CODE [CA249] 1160
FAILURE CODE [CA256] 1162
FAILURE CODE [CA271] 1164
FAILURE CODE [CA272] 1166
FAILURE CODE [CA273] 1167
FAILURE CODE [CA274] 1169
FAILURE CODE [CA322] 1170
FAILURE CODE [CA323] 1172
FAILURE CODE [CA324] 1174
FAILURE CODE [CA325] 1176
FAILURE CODE [CA331] 1178
FAILURE CODE [CA332] 1180
FAILURE CODE [CA343] 1182
FAILURE CODE [CA351] 1183
FAILURE CODE [CA352] 1184
FAILURE CODE [CA356] 1187
FAILURE CODE [CA357] 1189
FAILURE CODE [CA386] 1192
FAILURE CODE [CA441] 1193
FAILURE CODE [CA442] 1196
FAILURE CODE [CA449] 1197
FAILURE CODE [CA451] 1198
FAILURE CODE [CA452] 1200
FAILURE CODE [CA515] 1202
FAILURE CODE [CA516] 1204
FAILURE CODE [CA553] 1206
FAILURE CODE [CA555] 1207
FAILURE CODE [CA556] 1208
FAILURE CODE [CA559] 1209
FAILURE CODE [CA595] 1214
FAILURE CODE [CA687] 1215
FAILURE CODE [CA689] 1217
FAILURE CODE [CA691] 1219
FAILURE CODE [CA692] 1221
FAILURE CODE [CA697] 1223
FAILURE CODE [CA698] 1224
FAILURE CODE [CA731] 1225
FAILURE CODE [CA778] 1226
FAILURE CODE [CA1117] .1229
FAILURE CODE [CA1664] .1230
FAILURE CODE [CA1669] .1233
FAILURE CODE [CA1673] .1234
FAILURE CODE [CA1677] .1235
FAILURE CODE [CA1678] .1236
FAILURE CODE [CA1682] .1237
FAILURE CODE [CA1683] .1240
FAILURE CODE [CA1684] .1242
FAILURE CODE [CA1686] .1244
FAILURE CODE [CA1691] .1245
FAILURE CODE [CA1694] .1248
FAILURE CODE [CA1695] .1250
FAILURE CODE [CA1696] .1251
FAILURE CODE [CA1712] .1253
FAILURE CODE [CA1713] .1256
FAILURE CODE [CA1714] .1258
FAILURE CODE [CA1715] .1259
FAILURE CODE [CA1776] .1260
FAILURE CODE [CA1777] .1263
FAILURE CODE [CA1843] .1266
FAILURE CODE [CA1844] .1268
FAILURE CODE [CA1879] .1271
FAILURE CODE [CA1881] .1274
FAILURE CODE [CA1883] .1276
FAILURE CODE [CA1885] .1280
FAILURE CODE [CA1887] .1282
FAILURE CODE [CA1921] .1284
FAILURE CODE [CA1922] .1287
FAILURE CODE [CA1923] .1292
FAILURE CODE [CA1924] .1294
FAILURE CODE [CA1925] .1296
FAILURE CODE [CA1927] .1298
FAILURE CODE [CA1928] .1300
FAILURE CODE [CA1942] .1302
FAILURE CODE [CA1963] .1303
FAILURE CODE [CA1977] .1306
FAILURE CODE [CA1993] .1309
FAILURE CODE [CA2185] .1312
FAILURE CODE [CA2186] .1314
FAILURE CODE [CA2249] .1316
FAILURE CODE [CA2265] .1317
FAILURE CODE [CA2266] .1319
FAILURE CODE [CA2271] .1322
FAILURE CODE [CA2272] .1324
FAILURE CODE [CA2349] .1326
FAILURE CODE [CA2353] .1328
FAILURE CODE [CA2357] .1330
FAILURE CODE [CA2381] .1331
FAILURE CODE [CA2382] .1333
FAILURE CODE [CA2383] .1335
FAILURE CODE [CA2386] .1337
FAILURE CODE [CA2387] .1339
TROUBLESHOOTING FLOWCHART .1343
FAILURE CODE [CA2555] .1344
FAILURE CODE [CA2556] .1347
FAILURE CODE [CA2637] .1349
FAILURE CODE [CA2639] .1351
FAILURE CODE [CA2732] .1354
FAILURE CODE [CA2733] .1356
FAILURE CODE [CA2741] .1358
FAILURE CODE [CA2765] .1359
FAILURE CODE [CA2771] .1360
FAILURE CODE [CA2777] .1366
FAILURE CODE [CA2878] .1369
FAILURE CODE [CA2881] .1372
FAILURE CODE [CA2976] .1375
FAILURE CODE [CA3133] .1377
FAILURE CODE [CA3134] .1379
FAILURE CODE [CA3135] .1381
FAILURE CODE [CA3142] .1385
FAILURE CODE [CA3143] .1386
FAILURE CODE [CA3144] .1387
FAILURE CODE [CA3146] .1389
FAILURE CODE [CA3147] .1390
FAILURE CODE [CA3148] .1391
FAILURE CODE [CA3151] .1393
FAILURE CODE [CA3165] .1399
FAILURE CODE [CA3167] .1401
FAILURE CODE [CA3229] .1404
FAILURE CODE [CA3231] .1406
FAILURE CODE [CA3232] .1408
FAILURE CODE [CA3235] .1412
FAILURE CODE [CA3239] .1414
FAILURE CODE [CA3241] .1417
FAILURE CODE [CA3242] .1420
FAILURE CODE [CA3251] .1423
FAILURE CODE [CA3253] .1426
FAILURE CODE [CA3254] .1430
FAILURE CODE [CA3255] .1433
FAILURE CODE [CA3256] .1437
FAILURE CODE [CA3311] .1439
FAILURE CODE [CA3312] .1441
FAILURE CODE [CA3313] .1444
FAILURE CODE [CA3314] .1445
FAILURE CODE [CA3315] .1446
FAILURE CODE [CA3316] .1449
FAILURE CODE [CA3317] .1450
FAILURE CODE [CA3318] .1451
FAILURE CODE [CA3319] .1454
FAILURE CODE [CA3321] .1455
FAILURE CODE [CA3322] .1457
FAILURE CODE [CA3419] .1460
FAILURE CODE [CA3421] .1462
FAILURE CODE [CA3497] .1464
FAILURE CODE [CA3498] .1465
FAILURE CODE [CA3543] .1466
FAILURE CODE [CA3545] .1473
FAILURE CODE [CA3547] .1475
FAILURE CODE [CA3558] .1476
FAILURE CODE [CA3559] .1478
FAILURE CODE [CA3562] .1480
FAILURE CODE [CA3563] .1482
FAILURE CODE [CA3567] .1485
FAILURE CODE [CA3568] .1488
FAILURE CODE [CA3571] .1492
FAILURE CODE [CA3572] .1494
FAILURE CODE [CA3574] .1496
FAILURE CODE [CA3575] .1498
FAILURE CODE [CA3577] .1500
FAILURE CODE [CA3578] .1502
FAILURE CODE [CA3582] .1504
FAILURE CODE [CA3583] .1511
FAILURE CODE [CA3596] .1513
FAILURE CODE [CA3649] .1515
FAILURE CODE [CA3681] .1517
FAILURE CODE [CA3682] .1522
FAILURE CODE [CA3713] .1528
FAILURE CODE [CA3717] .1531
FAILURE CODE [CA3718] .1532
FAILURE CODE [CA3725] .1533
FAILURE CODE [CA3748] .1536
FAILURE CODE [CA3751] .1539
FAILURE CODE [CA3755] .1541
FAILURE CODE [CA3866] .1543
FAILURE CODE [CA3867] .1547
FAILURE CODE [CA3868] .1550
FAILURE CODE [CA3899] .1554
FAILURE CODE [CA3911] .1556
FAILURE CODE [CA3912] .1560
FAILURE CODE [CA3932] .1562
FAILURE CODE [CA3933] .1564
FAILURE CODE [CA3934] .1566
FAILURE CODE [CA3935] .1569
FAILURE CODE [CA3936] .1571
FAILURE CODE [CA4151] .1573
FAILURE CODE [CA4152] .1577
FAILURE CODE [CA4155] .1581
FAILURE CODE [CA4156] .1583
FAILURE CODE [CA4157] .1586
FAILURE CODE [CA4158] .1588
FAILURE CODE [CA4159] .1589
FAILURE CODE [CA4161] .1590
FAILURE CODE [CA4162] .1593
FAILURE CODE [CA4163] .1596
FAILURE CODE [CA4164] .1598
FAILURE CODE [CA4165] .1600
FAILURE CODE [CA4166] .1602
FAILURE CODE [CA4168] .1604
FAILURE CODE [CA4169] .1607
FAILURE CODE [CA4171] .1609
FAILURE CODE [CA4249] .1612
FAILURE CODE [CA4251] .1614
FAILURE CODE [CA4259] .1616
FAILURE CODE [CA4261] .1619
FAILURE CODE [CA4277] .1622
FAILURE CODE [CA4281] .1626
FAILURE CODE [CA4459] .1630
FAILURE CODE [CA4461] .1633
FAILURE CODE [CA4658] .1636
FAILURE CODE [CA4731] .1640
FAILURE CODE [CA4732] .1641
FAILURE CODE [CA4739] .1642
FAILURE CODE [CA4768] .1643
FAILURE CODE [CA4769] .1645
FAILURE CODE [CA4842] .1648
FAILURE CODE [CA4952] .1652
FAILURE CODE [CA5115] .1654
FAILURE CODE [CA5383] .1657
FAILURE CODE [D130KA] .1659
FAILURE CODE [D130KB] .1662
FAILURE CODE [D190KA] .1664
FAILURE CODE [D190KB] .1666
FAILURE CODE [D19JKZ] .1668
FAILURE CODE [D811MC] .1671
FAILURE CODE [D862KA] .1672
FAILURE CODE [D8ALKA] .1673
FAILURE CODE [D8ALKB] .1675
FAILURE CODE [D8AQKR] .1678
FAILURE CODE [DAF0MB] .1679
FAILURE CODE [DAF0MC] .1680
FAILURE CODE [DAF8KB] .1681
FAILURE CODE [DAF9KQ] .1682
FAILURE CODE [DAFGMC] .1683
FAILURE CODE [DAFLKA] .1684
FAILURE CODE [DAFLKB] .1686
FAILURE CODE [DAFQKR] .1689
FAILURE CODE [DAZ9KQ] .1690
FAILURE CODE [DAZQKR] .1691
FAILURE CODE [DB2QKR] .1692
FAILURE CODE [DB2RKR] .1698
FAILURE CODE [DB90KT] .1704
FAILURE CODE [DB90MC] .1705
FAILURE CODE [DB91KK] .1706
FAILURE CODE [DB92KK] .1709
FAILURE CODE [DB95KK] .1711
FAILURE CODE [DB97KK] .1714
FAILURE CODE [DB99KQ] .1716
FAILURE CODE [DB9LKA] .1718
FAILURE CODE [DB9LKB] .1720
FAILURE CODE [DB9QKR] .1722
FAILURE CODE [DB9RKR] .1723
FAILURE CODE [DBE0KT] .1725
FAILURE CODE [DBE0MC] .1726
FAILURE CODE [DBE1KK] .1727
FAILURE CODE [DBE2KK] .1730
FAILURE CODE [DBE5KK] .1733
FAILURE CODE [DBE6KK] .1735
FAILURE CODE [DBE9KQ] .1737
FAILURE CODE [DBELKA] .1738
FAILURE CODE [DBELKB] .1740
FAILURE CODE [DBEQKR] .1742
FAILURE CODE [DBERKR] .1743
FAILURE CODE [DD12KA] .1745
FAILURE CODE [DD12KB] .1747
FAILURE CODE [DD13KA] .1749
FAILURE CODE [DD13KB] .1751
FAILURE CODE [DD14KA] .1753
FAILURE CODE [DD14KB] .1756
FAILURE CODE [DDDDKA] .1758
FAILURE CODE [DDDDKB] .1761
FAILURE CODE [DDDDKX] .1764
FAILURE CODE [DDKAKA] .1765
FAILURE CODE [DDKAKB] .1767
FAILURE CODE [DDKBKA] .1769
FAILURE CODE [DDKBKB] .1771
FAILURE CODE [DDKCL4] .1773
FAILURE CODE [DDKEL4] .1776
FAILURE CODE [DDN7L4] .1779
FAILURE CODE [DDN8L4] .1782
FAILURE CODE [DDNLKA] .1785
FAILURE CODE [DDNLKB] .1787
FAILURE CODE [DDTSL1] .1789
FAILURE CODE [DDTSLH] .1791
FAILURE CODE [DFA4KX] .1793
FAILURE CODE [DFA4KZ] .1794
FAILURE CODE [DFA4L8] .1795
FAILURE CODE [DFA5KA] .1796
FAILURE CODE [DFA5KY] .1799
FAILURE CODE [DFA6KA] .1801
FAILURE CODE [DFA6KY] .1804
FAILURE CODE [DFA7KX] .1806
FAILURE CODE [DFA7KZ] .1807
FAILURE CODE [DFA7L8] .1808
FAILURE CODE [DFA8KA] .1809
FAILURE CODE [DFA8KY] .1812
FAILURE CODE [DFA9KA] .1814
FAILURE CODE [DFA9KY] .1817
FAILURE CODE [DFAAKX] .1819
FAILURE CODE [DFAAKZ] .1820
FAILURE CODE [DFAAL8] .1821
FAILURE CODE [DFABKA] .1822
FAILURE CODE [DFABKY] .1825
FAILURE CODE [DFACKA] .1827
FAILURE CODE [DFACKY] .1830
FAILURE CODE [DGS1KA] .1832
FAILURE CODE [DGS1KX] .1834
FAILURE CODE [DGT1KA] .1836
FAILURE CODE [DGT1KX] .1839
FAILURE CODE [DH21KA] .1841
FAILURE CODE [DH21KY] .1844
FAILURE CODE [DHA4KA] .1846
FAILURE CODE [DHAAMA] .1848
FAILURE CODE [DHACMA] .1850
FAILURE CODE [DHT5KA] .1852
FAILURE CODE [DHT5KY] .1855
FAILURE CODE [DHT7KA] .1857
FAILURE CODE [DHT7KY] .1860
FAILURE CODE [DK10KA] .1862
FAILURE CODE [DK10KB] .1865
FAILURE CODE [DK30KA] .1867
FAILURE CODE [DK30KX] .1870
FAILURE CODE [DK30KY] .1871
FAILURE CODE [DK30KZ] .1873
FAILURE CODE [DK30L8] .1874
FAILURE CODE [DK31KA] .1875
FAILURE CODE [DK31KY] .1878
FAILURE CODE [DK40KA] .1880
FAILURE CODE [DK40KY] .1883
FAILURE CODE [DK55KX] .1885
FAILURE CODE [DK55KZ] .1886
FAILURE CODE [DK55L8] .1887
FAILURE CODE [DK56KA] .1888
FAILURE CODE [DK56KY] .1891
FAILURE CODE [DK57KA] .1893
FAILURE CODE [DK57KY] .1896
FAILURE CODE [DKH1KA] .1898
FAILURE CODE [DKH1KY] .1901
FAILURE CODE [DLM3KA] .1903
FAILURE CODE [DLM3KB] .1905
FAILURE CODE [DLM3MB] .1906
FAILURE CODE [DLT3KA] .1907
FAILURE CODE [DLT3KB] .1909
FAILURE CODE [DR21KX] .1911
FAILURE CODE [DR31KX] .1912
FAILURE CODE [DV20KB] .1913
FAILURE CODE [DW7BKA] .1915
FAILURE CODE [DW7BKB] .1917
FAILURE CODE [DWN1KA] .1919
FAILURE CODE [DWN1KB] .1921
FAILURE CODE [DWN1KY] .1923
FAILURE CODE [DWN2KA] .1924
FAILURE CODE [DWN2KB] .1926
FAILURE CODE [DWN2KY] .1927
FAILURE CODE [DWN3KA] .1928
FAILURE CODE [DWN3KB] .1930
FAILURE CODE [DWN3KY] .1932
FAILURE CODE [DWN5KA] .1934
FAILURE CODE [DWN5KB] .1936
FAILURE CODE [DWN5KY] .1938
FAILURE CODE [DXA2KA] .1940
FAILURE CODE [DXA2KB] .1942
FAILURE CODE [DXA2KY] .1944
FAILURE CODE [DXH1KA] .1946
FAILURE CODE [DXH1KB] .1948
FAILURE CODE [DXH1KY] .1950
FAILURE CODE [DXH4KA] .1952
FAILURE CODE [DXH4KB] .1954
FAILURE CODE [DXH4KY] .1956
FAILURE CODE [DXH5KA] .1958
FAILURE CODE [DXH5KB] .1960
FAILURE CODE [DXH5KY] .1962
FAILURE CODE [DXH6KA] .1964
FAILURE CODE [DXH6KB] .1966
FAILURE CODE [DXH6KY] .1967
FAILURE CODE [DXH7KA] .1969
FAILURE CODE [DXH7KB] .1971
FAILURE CODE [DXH7KY] .1973
FAILURE CODE [DXH8KA] .1975
FAILURE CODE [DXH8KB] .1977
FAILURE CODE [DXH8KY] .1979
FAILURE CODE [DXHBKA] .1981
FAILURE CODE [DXHBKB] .1983
FAILURE CODE [DXHBKY] .1985
FAILURE CODE [DXHCKA] .1987
FAILURE CODE [DXHCKB] .1989
FAILURE CODE [DXHCKY] .1991
FAILURE CODE [DXHRKA] .1993
FAILURE CODE [DXHRKB] .1995
FAILURE CODE [DXHRKY] .1996
FAILURE CODE [DXHSKA] .1998
FAILURE CODE [DXHSKB] .2000
FAILURE CODE [DXHSKY] .2001
FAILURE CODE [DXHTKA] .2003
FAILURE CODE [DXHTKB] .2005
FAILURE CODE [DXHTKY] .2007
FAILURE CODE [DXHUKA] .2009
FAILURE CODE [DXHUKB] .2011
FAILURE CODE [DXHUKY] .2013
FAILURE CODE [DXHWKA] .2015
FAILURE CODE [DXHWKB] .2017
FAILURE CODE [DXHWKY] .2018
FAILURE CODE [DXHXKA] .2020
FAILURE CODE [DXHXKB] .2022
FAILURE CODE [DXHXKY] .2023
FAILURE CODE [DXHYKA] .2025
FAILURE CODE [DXHYKB] .2027
FAILURE CODE [DXHYKY] .2028
FAILURE CODE [DXHZKA] .2030
FAILURE CODE [DXHZKB] .2032
FAILURE CODE [DXHZKY] .2033
FAILURE CODE [DXJ4KA] .2035
FAILURE CODE [DXJ4KB] .2037
FAILURE CODE [DXJ8KA] .2038
FAILURE CODE [DXJ8KB] .2040
FAILURE CODE [DXJ8KY] .2042
FAILURE CODE [DXJ9KA] .2044
FAILURE CODE [DXJ9KB] .2046
FAILURE CODE [DXJ9KY] .2048
FAILURE CODE [DXJAKA] .2050
FAILURE CODE [DXJAKB] .2052
FAILURE CODE [DXJAKY] .2054
FAILURE CODE [DXJBKA] .2056
FAILURE CODE [DXJBKB] .2058
FAILURE CODE [DXJBKY] .2060
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .2062
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .2062
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 2069
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .2072
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .2074
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .2076
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 2080
E-7 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING 2082
E-8 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .2083
E-9 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .2085
E-10 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .2086
E-11 POWER TRAIN OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .2087
E-12 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .2088
E-13 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE .2089
E-14 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL .2090
E-15 POWER TRAIN OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE 2092
E-16 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE 2093
E-17 OPERATION MODE DOES NOT CHANGE .2094
E-18 GEAR SHIFT MODE DOES NOT CHANGE 2095
E-19 OPERATING CUSTOMIZE SWITCH DOES NOT DISPLAY CUSTOMIZE SCREEN .2096
E-20 MODIFYING SETTING ON CUSTOMIZE SCREEN DOES NOT CHANGE SETTING OF MACHINE .2097
E-21 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .2098
E-22 ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP SOUNDING 2099
E-23 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .2100
E-24 SERVICE MODE CANNOT BE SELECTED 2101
E-25 HORN DOES NOT SOUND 2102
E-26 HORN DOES NOT STOP SOUNDING 2104
E-27 BACKUP ALARM DOES NOT SOUND 2105
E-28 BACKUP ALARM DOES NOT STOP SOUNDING 2106
E-29 HEADLAMP DOES NOT LIGHT UP .2107
E-30 REAR LAMP AND RIPPER POINT LAMP DO NOT LIGHT UP 2111
E-31 ALL WIPERS DO NOT OPERATE 2115
E-32 FRONT WIPER DOES NOT OPERATE .2120
E-33 REAR WIPER DOES NOT OPERATE 2124
E-34 LEFT DOOR WIPER DOES NOT OPERATE .2128
E-35 RIGHT DOOR WIPER DOES NOT OPERATE 2132
E-36 FUEL FEED PUMP DOES NOT OPERATE OR STOP AUTOMATICALLY 2136
E-37 FAN DOES NOT ROTATE IN REVERSE .2137
E-38 GEAR CANNOT BE SHIFTED .2138
E-39 FRONT WASHER DOES NOT OPERATE 2139
E-40 REAR WASHER DOES NOT OPERATE .2142
E-41 LEFT DOOR WASHER DOES NOT OPERATE 2145
E-42 RIGHT DOOR WASHER DOES NOT OPERATE .2148
E-43 RIPPER PIN PULLER DOES NOT WORK 2151
E-44 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .2153
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .2154
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) .2154
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 2155
FAILURE MODE AND CAUSE TABLE 2159
H-1 MACHINE LACKS POWER (INSUFFICIENT DRAWBAR PULL) .2167
H-2 MACHINE DOES NOT TRAVEL (AT 2ND OR 3RD GEAR SPEED) 2170
H-3 MACHINE DOES NOT MOVE OFF AT ALL GEAR SPEEDS 2172
H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION, EITHER FORWARD OR IN REVERSE .2175
H-5 LARGE TIME LAG IS IN GEAR SHIFTING OR DIRECTIONAL CHANGE 2177
H-6 BRAKE DOES NOT WORK .2179
H-7 POWER TRAIN OIL OVERHEATS .2180
H-8 UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT AND HSS PUMP OR HSS MOTOR .2182
H-9 TORQUE CONVERTER LOCKUP CLUTCH DOES NOT ENGAGE 2183
H-10 MACHINE CANNOT BE STEERED (MACHINE DOES NOT TURN LEFT OR RIGHT) 2184
H-11 STEERING SPEED OR POWER IS INSUFFICIENT 2186
H-12 ALL WORK EQUIPMENTS OPERATE SLOWLY .2188
H-13 ALL WORK EQUIPMENTS DO NOT OPERATE .2190
H-14 BLADE LIFT SPEED OR POWER IS LOW .2192
H-15 BLADE TILT SPEED OR POWER IS LOW .2194
H-16 RIPPER LIFT SPEED OR POWER IS LOW 2196
H-17 RIPPER TILT SPEED OR POWER IS LOW 2198
H-18 HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE .2200
H-19 HYDRAULIC DRIFT OF TILTED BLADE IS LARGE .2201
H-20 HYDRAULIC DRIFT OF LIFTED RIPPER IS LARGE 2202
H-21 RIPPER PIN PULLER CYLINDER DOES NOT OPERATE 2203
H-22 BLADE PITCH CYLINDER DOES NOT OPERATE 2204
H-23 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) .2205
H-24 UNUSUAL NOISE IS HEARD FROM AROUND FAN .2206
TROUBLESHOOTING OF ENGINE (S-MODE) 2207
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .2207
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2208
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2209
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 2210
S-4 ENGINE STARTABILITY IS POOR .2211
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 2213
S-6 ENGINE STOPS DURING OPERATION .2215
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 2217
S-8 ENGINE LACKS POWER 2218
S-9 KDPF GETS CLOGGED IN A SHORT TIME .2220
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 2222
S-11 OIL BECOMES CONTAMINATED QUICKLY .2223
S-12 FUEL CONSUMPTION IS EXCESSIVE 2224
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2225
S-14 OIL PRESSURE DROPS .2226
S-15 FUEL MIXES INTO ENGINE OIL .2228
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 2229
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .2230
S-18 UNUSUAL NOISE IS HEARD .2231
S-19 VIBRATION IS EXCESSIVE .2232
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT .2233
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .2234
S-22 ACTIVE REGENERATION TAKES TIME .2236
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2238
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 2239
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .2241
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2242
50 DISASSEMBLY AND ASSEMBLY .2243
CONTENTS 2244
ABBREVIATION LIST .2251
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .2257
HOW TO READ THIS MANUAL .2257
COATING MATERIALS LIST 2259
SPECIAL TOOLS LIST 2264
SKETCHES OF SPECIAL TOOLS .2292
ENGINE AND COOLING SYSTEM .2320
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .2320
REMOVE SUPPLY PUMP ASSEMBLY .2320
INSTALL SUPPLY PUMP ASSEMBLY 2327
REMOVE AND INSTALL INJECTOR ASSEMBLY 2336
REMOVE INJECTOR ASSEMBLY 2336
INSTALL INJECTOR ASSEMBLY .2344
REMOVE AND INSTALL FUEL DOSER ASSEMBLY 2355
REMOVE FUEL DOSER ASSEMBLY 2355
INSTALL FUEL DOSER ASSEMBLY .2356
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .2357
REMOVE CYLINDER HEAD ASSEMBLY .2358
INSTALL CYLINDER HEAD ASSEMBLY 2369
REMOVE AND INSTALL EGR VALVE ASSEMBLY .2387
REMOVE EGR VALVE ASSEMBLY .2387
INSTALL EGR VALVE ASSEMBLY 2388
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2390
REMOVE EGR COOLER ASSEMBLY 2390
INSTALL EGR COOLER ASSEMBLY .2393
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 2397
REMOVE STARTING MOTOR ASSEMBLY 2397
INSTALL STARTING MOTOR ASSEMBLY .2398
REMOVE AND INSTALL ALTERNATOR BELT 2401
REMOVE ALTERNATOR BELT 2401
INSTALL ALTERNATOR BELT .2402
REMOVE AND INSTALL RADIATOR ASSEMBLY 2404
REMOVE RADIATOR ASSEMBLY 2404
INSTALL RADIATOR ASSEMBLY .2409
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2417
REMOVE HYDRAULIC OIL COOLER ASSEMBLY 2417
INSTALL HYDRAULIC OIL COOLER ASSEMBLY .2419
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2421
REMOVE AFTERCOOLER ASSEMBLY .2421
INSTALL AFTERCOOLER ASSEMBLY 2423
REMOVE AND INSTALL COOLING FAN DRIVE ASSEMBLY .2426
REMOVE COOLING FAN DRIVE ASSEMBLY .2426
INSTALL COOLING FAN DRIVE ASSEMBLY 2428
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY .2431
REMOVE COOLING FAN MOTOR ASSEMBLY .2431
INSTALL COOLING FAN MOTOR ASSEMBLY 2432
REMOVE AND INSTALL ENGINE ASSEMBLY 2434
REMOVE ENGINE ASSEMBLY 2435
INSTALL ENGINE ASSEMBLY .2445
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2454
REMOVE ENGINE FRONT OIL SEAL 2454
INSTALL ENGINE FRONT OIL SEAL .2456
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2459
REMOVE ENGINE REAR OIL SEAL .2459
INSTALL ENGINE REAR OIL SEAL 2460
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2464
REMOVE ENGINE HOOD ASSEMBLY .2464
INSTALL ENGINE HOOD ASSEMBLY 2467
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2471
REMOVE FUEL TANK ASSEMBLY .2471
INSTALL FUEL TANK ASSEMBLY 2474
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2478
REMOVE AdBlue/DEF TANK ASSEMBLY .2478
INSTALL AdBlue/DEF TANK ASSEMBLY 2484
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2489
REMOVE AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2489
INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2495
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR .2501
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2501
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2501
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .2508
REMOVE AdBlue/DEF TANK STRAINER .2508
INSTALL AdBlue/DEF TANK STRAINER 2508
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER .2509
REMOVE AdBlue/DEF TANK FILLER PORT FILTER .2509
INSTALL THE AdBlue/DEF TANK FILLER PORT FILTER 2510
REMOVE AND INSTALL KDPF ASSEMBLY 2513
REMOVE KDPF ASSEMBLY 2513
INSTALL KDPF ASSEMBLY .2518
DISASSEMBLE AND ASSEMBLE KDPF ASSEMBLY 2523
DISASSEMBLE KDPF ASSEMBLY .2523
ASSEMBLE KDPF ASSEMBLY 2527
REMOVE AND INSTALL SCR ASSEMBLY .2532
REMOVE SCR ASSEMBLY .2532
INSTALL SCR ASSEMBLY 2536
REMOVE AND INSTALL KDPF AND SCR ASSEMBLY 2540
REMOVE KDPF AND SCR ASSEMBLY 2540
INSTALL KDPF AND SCR ASSEMBLY .2546
REMOVE AND INSTALL KCCV ASSEMBLY 2553
REMOVE KCCV ASSEMBLY 2553
INSTALL KCCV ASSEMBLY .2555
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2559
REMOVE AdBlue/DEF MIXING TUBE .2559
INSTALL AdBlue/DEF MIXING TUBE 2564
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2571
REMOVE AdBlue/DEF INJECTOR 2571
INSTALL AdBlue/DEF INJECTOR .2574
REMOVE AND INSTALL AdBlue/DEF PUMP 2578
REMOVE AdBlue/DEF PUMP 2578
INSTALL AdBlue/DEF PUMP .2582
REMOVE AND INSTALL AdBlue/DEF HOSE 2587
REMOVE AdBlue/DEF HOSE 2587
METHOD FOR INSTALLING AdBlue/DEF HOSE .2595
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2604
REMOVE AIR CLEANER ASSEMBLY .2604
INSTALL AIR CLEANER ASSEMBLY 2605
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2607
REMOVE AIR CONDITIONER COMPRESSOR ASSEMBLY 2607
INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY .2608
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2610
REMOVE AIR CONDITIONER CONDENSER ASSEMBLY .2610
INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 2612
POWER TRAIN .2614
REMOVE AND INSTALL DAMPER ASSEMBLY 2614
REMOVE DAMPER ASSEMBLY 2614
INSTALL DAMPER ASSEMBLY .2616
DISASSEMBLE AND ASSEMBLE DAMPER ASSEMBLY 2619
DISASSEMBLE DAMPER ASSEMBLY .2619
ASSEMBLE DAMPER ASSEMBLY 2621
REMOVE AND INSTALL POWER TRAIN UNIT ASSEMBLY 2624
REMOVE POWER TRAIN UNIT ASSEMBLY 2624
INSTALL POWER TRAIN UNIT ASSEMBLY .2631
DISCONNECT AND CONNECT POWER TRAIN UNIT ASSEMBLY 2638
DISCONNECT POWER TRAIN UNIT ASSEMBLY 2638
CONNECT POWER TRAIN UNIT ASSEMBLY .2646
DISASSEMBLE AND ASSEMBLE PTO ASSEMBLY .2654
DISASSEMBLE PTO ASSEMBLY 2654
ASSEMBLE PTO ASSEMBLY .2658
DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER ASSEMBLY 2663
DISASSEMBLE TORQUE CONVERTER ASSEMBLY .2663
ASSEMBLE TORQUE CONVERTER ASSEMBLY 2669
DISASSEMBLE AND ASSEMBLE TRANSMISSION ASSEMBLY 2676
DISASSEMBLE TRANSMISSION ASSEMBLY .2676
ASSEMBLE TRANSMISSION ASSEMBLY 2686
DISASSEMBLE AND ASSEMBLE HSS ASSEMBLY .2698
DISASSEMBLE HSS ASSEMBLY 2699
ASSEMBLE HSS ASSEMBLY .2707
REMOVE AND INSTALL HSS MOTOR ASSEMBLY .2721
REMOVE HSS MOTOR ASSEMBLY .2721
INSTALL HSS MOTOR ASSEMBLY 2722
REMOVE AND INSTALL FINAL DRIVE ASSEMBLY .2724
REMOVE FINAL DRIVE ASSEMBLY .2724
INSTALL FINAL DRIVE ASSEMBLY 2726
REMOVE AND INSTALL FINAL DRIVE ASSEMBLY (D155PX-8) 2729
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY (D155PX-8) 2729
METHOD FOR INSTALLING FINAL DRIVE ASSEMBLY (D155PX-8) .2732
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY .2736
DISASSEMBLE FINAL DRIVE ASSEMBLY 2737
ASSEMBLE FINAL DRIVE ASSEMBLY .2743
UNDERCARRIAGE AND FRAME .2754
REMOVE AND INSTALL TRACK FRAME ASSEMBLY (APPLICABLE MACHINE: 100001 TO 100616) 2754
REMOVE TRACK FRAME ASSEMBLY .2755
INSTALL TRACK FRAME ASSEMBLY 2759
REMOVE AND INSTALL TRACK FRAME ASSEMBLY (APPLICABLE MACHINE: 100617 AND UP) .2764
REMOVE TRACK FRAME ASSEMBLY (APPLICABLE MACHINE: 100617 AND UP) .2764
INSTALL TRACK FRAME ASSEMBLY (APPLICABLE MACHINE: 100617 AND UP) 2769
REMOVE AND INSTALL TRACK FRAME ASSEMBLY (D155PX-8) 2773
METHOD FOR REMOVING TRACK FRAME ASSEMBLY (D155PX-8) .2774
METHOD FOR INSTALLING TRACK FRAME ASSEMBLY (D155PX-8) .2778
REMOVE AND INSTALL TRACK FRAME ASSEMBLY (D155PX-8) (APPLICABLE MACHINE: 100617 AND UP) 2784
REMOVE TRACK FRAME ASSEMBLY (D155PX-8) (APPLICABLE MACHINE: 100617 AND UP) 2784
INSTALL TRACK FRAME ASSEMBLY (D155PX-8) (APPLICABLE MACHINE: 100617 AND UP) .2790
REMOVE AND INSTALL IDLER ASSEMBLY .2794
REMOVE IDLER ASSEMBLY .2794
INSTALL IDLER ASSEMBLY 2796
REMOVE AND INSTALL IDLER ASSEMBLY (D155PX-8) 2798
METHOD FOR REMOVING IDLER ASSEMBLY (D155PX-8) .2798
METHOD FOR INSTALLING IDLER ASSEMBLY (D155PX-8) .2799
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2801
DISASSEMBLE IDLER ASSEMBLY 2801
ASSEMBLE IDLER ASSEMBLY .2803
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY (D155PX-8) 2807
METHOD FOR DISASSEMBLING IDLER ASSEMBLY(D155PX-8) .2807
METHOD FOR ASSEMBLING IDLER ASSEMBLY(D155PX-8) 2809
REMOVE AND INSTALL RECOIL SPRING ASSEMBLY .2812
REMOVE RECOIL SPRING ASSEMBLY .2812
INSTALL RECOIL SPRING ASSEMBLY 2812
REMOVE AND INSTALL RECOIL SPRING ASSEMBLY (D155PX-8) 2813
METHOD FOR REMOVING RECOIL SPRING ASSEMBLY (D155PX-8) .2813
METHOD FOR INSTALLING RECOIL SPRING ASSEMBLY (D155PX-8) .2814
DISASSEMBLE AND ASSEMBLE RECOIL SPRING ASSEMBLY .2816
DISASSEMBLE RECOIL SPRING ASSEMBLY 2816
ASSEMBLE RECOIL SPRING ASSEMBLY .2820
DISASSEMBLE AND ASSEMBLE RECOIL SPRING (D155PX-8) .2823
METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING (D155PX-8) 2824
METHOD FOR ASSEMNLING RECOIL SPRING ASSEMBLY (D155PX-8) .2828
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY 2833
REMOVE TRACK ROLLER ASSEMBLY 2833
INSTALL TRACK ROLLER ASSEMBLY .2835
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY (D155PX-8) .2838
METHOD FOR REMOVING TRACK ROLLER ASSEMBLY (D155PX-8) 2838
METHOD FOR INSTALLING TRACK ROLLER ASSEMBLY (D155PX-8) 2839
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2841
DISASSEMBLE TRACK ROLLER ASSEMBLY .2841
ASSEMBLE TRACK ROLLER ASSEMBLY 2843
REMOVE AND INSTALL NO.1 BOGIE ASSEMBLY 2846
REMOVE NO.1 BOGIE ASSEMBLY 2847
INSTALL NO. 1 BOGIE ASSEMBLY 2850
REMOVAL AND INSTALLATION OF NO.2, 3, 4 BOGIE ASSEMBLY .2855
REMOVE NO.2, 3, 4 BOGIE ASSEMBLY 2856
INSTALL NO.2, 3, 4 BOGIE ASSEMBLIES .2859
DISASSEMBLE AND ASSEMBLE BOGIE ASSEMBLY .2864
DISASSEMBLE BOGIE ASSEMBLY 2864
ASSEMBLE BOGIE ASSEMBLY .2865
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY 2868
REMOVE CARRIER ROLLER ASSEMBLY 2868
INSTALL CARRIER ROLLER ASSEMBLY .2869
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY (D155PX-8) .2871
METHOD FOR REMOVING CARRIER ROLLER ASSEMBLY (D155PX-8) 2871
METHOD FOR INSTALLING CARRIER ROLLER ASSEMBLY (D155PX-8) 2872
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY 2874
DISASSEMBLE CARRIER ROLLER ASSEMBLY .2875
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY .2877
REMOVE AND INSTALL PIVOT SHAFT ASSEMBLY .2880
REMOVE PIVOT SHAFT ASSEMBLY .2880
INSTALL PIVOT SHAFT ASSEMBLY 2882
REMOVE AND INSTALL PIVOT SHAFT ASSEMBLY(D155PX-8) .2884
METHOD FOR REMOVING PIVOT SHAFT ASSEMBLY(D155PX-8) 2884
METHOD FOR INSTALLING PIVOT SHAFT ASSEMBLY(D155PX-8) 2885
SEPARATION AND CONNECTION OF TRACK ASSEMBLY(D155PX-8) .2887
METHOD FOR CHECKING BEFORE SEPARATION OF THE TRACK ASSEMBLY(D155PX-8) .2887
METHOD FOR SEPARATING OF TRACK ASSEMBLY (NORMAL)(D155PX-8) 2887
METHOD FOR SEPARATING TRACK ASSEMBLY (WHEN TRACK FRAME HAS INTERNAL DEFECT)(D155PX-8) .2888
METHOD FOR INSTALLING TRACK ASSEMBLY(D155PX-8) 2890
SEPARATION AND CONNECTION OF TRACK ASSEMBLY .2892
CHECK METHOD BEFORE SEPARATION OF TRACK SHOE ASSEMBLY .2892
SEPARATE TRACK ASSEMBLY (STANDARD) 2893
SEPARATE TRACK SHOE ASSEMBLY (ABNORMALITY IN TRACK FRAME) .2893
INSTALL TRACK ASSEMBLY 2895
SEPARATION AND CONNECTION OF PLUS TYPE TRACK ASSEMBLY .2897
SEPARATE PLUS TYPE TRACK ASSEMBLY GENERALLY .2897
INSTALL PLUS TYPE TRACK ASSEMBLY 2897
DISASSEMBLE AND ASSEMBLE TRACK ASSEMBLY GENERALLY .2899
DISASSEMBLE WHOLE TRACK SHOE ASSEMBLY .2900
ASSEMBLE WHOLE TRACK SHOE ASSEMBLY 2902
DISASSEMBLE AND ASSEMBLE PLUS TYPE TRACK ASSEMBLY GENERALLY .2914
DISASSEMBLE PLUS TYPE TRACK ASSEMBLY GENERALLY 2915
ASSEMBLE PLUS TYPE TRACK ASSEMBLY GENERALLY .2916
DISASSEMBLE AND ASSEMBLE ONE TRACK LINK ASSEMBLY IN FIELD .2924
DISASSEMBLE ONE TRACK LINK ASSEMBLY IN FIELD 2925
ASSEMBLE ONE TRACK LINK ASSEMBLY IN FIELD .2926
DISASSEMBLE AND ASSEMBLE MASTER LINK 2928
DISASSEMBLE MASTER LINK .2928
ASSEMBLE MASTER LINK 2929
REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY(D155PX-8) .2932
METHOD FOR REMOVING EQUALIZER BAR ASSEMBLY(D155PX-8) 2932
METHOD FOR INSTALLING EQUALIZER BAR ASSEMBLY(D155PX-8) 2935
REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY .2938
REMOVE EQUALIZER BAR ASSEMBLY .2939
INSTALL EQUALIZER BAR ASSEMBLY 2941
DISASSEMBLE AND ASSEMBLE EQUALIZER BAR BUSHINGS(D155PX-8) .2943
METHOD FOR DISASSEMBLING EQUALIZER BAR BUSHINGS(D155PX-8) .2943
METHOD FOR ASSEMBLING EQUALIZER BAR BUSHINGS(D155PX-8) 2944
DISASSEMBLE AND ASSEMBLE EQUALIZER BAR BUSHING 2945
DISASSEMBLE EQUALIZER BAR BUSHING .2945
ASSEMBLE EQUALIZER BAR BUSHING 2946
REMOVE AND INSTALL SPROCKET .2947
REMOVE SPROCKET .2947
INSTALL SPROCKET 2947
REMOVAL AND INSTALLATION OF UNDERGUARD ASSEMBLY .2949
REMOVE UNDERGUARD ASSEMBLY 2949
INSTALL UNDERGUARD ASSEMBLY .2956
HYDRAULIC SYSTEM 2964
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2964
REMOVE HYDRAULIC TANK ASSEMBLY 2964
INSTALL HYDRAULIC TANK ASSEMBLY .2966
REMOVE AND INSTALL WORK EQUIPMENT PUMP AND HSS PUMP ASSEMBLY 2968
REMOVE WORK EQUIPMENT PUMP AND HSS PUMP ASSEMBLY 2969
INSTALL WORK EQUIPMENT PUMP AND HSS PUMP ASSEMBLY .2971
REMOVE AND INSTALL POWER TRAIN PUMP AND STEERING LUBRICATION PUMP ASSEMBLY 2973
REMOVE POWER TRAIN PUMP AND STEERING LUBRICATION PUMP ASSEMBLY 2974
INSTALL POWER TRAIN PUMP AND STEERING LUBRICATION PUMP ASSEMBLY .2976
REMOVE AND INSTALL COOLING FAN PUMP ASSEMBLY 2979
REMOVE COOLING FAN PUMP ASSEMBLY 2979
INSTALL COOLING FAN PUMP ASSEMBLY .2982
REMOVE AND INSTALL SCAVENGING PUMP ASSEMBLY .2985
REMOVE SCAVENGING PUMP ASSEMBLY .2985
INSTALL SCAVENGING PUMP ASSEMBLY 2986
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2988
REMOVE CONTROL VALVE ASSEMBLY .2989
INSTALL CONTROL VALVE ASSEMBLY 2991
WORK EQUIPMENT 2994
REMOVE AND INSTALL BLADE ASSEMBLY .2994
REMOVE BLADE ASSEMBLY .2994
INSTALL BLADE ASSEMBLY 2996
REMOVE AND INSTALL BLADE LIFT CYLINDER ASSEMBLY .2999
REMOVE BLADE LIFT CYLINDER ASSEMBLY .3000
INSTALL BLADE LIFT CYLINDER ASSEMBLY 3003
DISASSEMBLE AND ASSEMBLE BLADE ASSEMBLY .3007
DISASSEMBLE BLADE ASSEMBLY 3007
ASSEMBLE BLADE ASSEMBLY .3011
METHOD OF BLADE ANGLING .3017
DISASSEMBLE AND ASSEMBLE MULTI-SHANK RIPPER ASSEMBLY 3020
DISASSEMBLE MULTI-SHANK RIPPER ASSEMBLY .3020
ASSEMBLE MULTI-SHANK RIPPER ASSEMBLY 3024
DISASSEMBLE AND ASSEMBLE GIANT RIPPER ASSEMBLY 3029
DISASSEMBLE GIANT RIPPER ASSEMBLY .3029
ASSEMBLE GIANT RIPPER ASSEMBLY 3033
METHOD FOR DISASSEMBLING AND ASSEMBLING BLADE LIFT CYLINDER ASSEMBLY 3038
METHOD FOR DISASSEMBLING BLADE LIFT CYLINDER ASSEMBLY .3038
METHOD FOR ASSEMBLING BLADE LIFT CYLINDER ASSEMBLY 3041
DISASSEMBLE AND ASSEMBLE BLADE TILT CYLINDER ASSEMBLY .3045
DISASSEMBLE BLADE TILT CYLINDER ASSEMBLY 3045
ASSEMBLE BLADE TILT CYLINDER ASSEMBLY .3047
DISASSEMBLE AND ASSEMBLE RIPPER CYLINDER ASSEMBLY .3051
DISASSEMBLE RIPPER CYLINDER ASSEMBLY 3051
ASSEMBLE RIPPER CYLINDER ASSEMBLY .3053
CAB RELATED PARTS .3058
REMOVE AND INSTALL OPERATOR CAB ASSEMBLY 3058
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY .3059
INSTALL OPERATOR CAB ASSEMBLY .3066
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) .3075
REMOVE OPERATOR CAB GLASS (ADHERED GLASS) .3076
INSTALL OPERATOR CAB GLASS (ADHERED GLASS) 3076
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 3081
REMOVE AIR CONDITIONER UNIT ASSEMBLY 3081
INSTALL AIR CONDITIONER UNIT ASSEMBLY .3087
REMOVE AND INSTALL OPERATOR’S SEAT 3095
REMOVE OPERATOR’S SEAT 3095
INSTALL OPERATOR’S SEAT .3096
REMOVE AND INSTALL SEATBELT .3098
REMOVE SEATBELT .3098
INSTALL SEATBELT 3098
ELECTRICAL SYSTEM .3100
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .3100
REMOVE ENGINE CONTROLLER ASSEMBLY .3100
INSTALL ENGINE CONTROLLER ASSEMBLY 3103
REMOVE AND INSTALL POWER TRAIN CONTROLLER ASSEMBLY 3108
REMOVE POWER TRAIN CONTROLLER ASSEMBLY 3108
INSTALL POWER TRAIN CONTROLLER ASSEMBLY .3109
REMOVE AND INSTALL WORK EQUIPMENT CONTROLLER ASSEMBLY .3111
REMOVE WORK EQUIPMENT CONTROLLER ASSEMBLY .3111
INSTALL WORK EQUIPMENT CONTROLLER ASSEMBLY 3112
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .3114
REMOVE MACHINE MONITOR ASSEMBLY .3114
INSTALL MACHINE MONITOR ASSEMBLY 3115
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .3117
REMOVE MASS AIR FLOW AND TEMPERATURE SENSOR .3117
INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 3118
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .3120
REMOVE KCCV CRANKCASE PRESSURE SENSOR .3120
INSTALL KCCV CRANKCASE PRESSURE SENSOR 3121
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .3122
REMOVE SCR TEMPERATURE SENSOR .3122
INSTALL SCR TEMPERATURE SENSOR 3124
REMOVE AND INSTALL BATTERY RELAY 3126
REMOVE BATTERY RELAY 3126
INSTALL BATTERY RELAY .3133
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 3139
REMOVE KOMTRAX TERMINAL ASSEMBLY 3139
INSTALL KOMTRAX TERMINAL ASSEMBLY .3141
60 MAINTENANCE STANDARD .3145
CONTENTS 3146
ABBREVIATION LIST .3148
ENGINE AND COOLING SYSTEM .3154
MAINTENANCE STANDARD OF ENGINE MOUNT 3154
MAINTENANCE STANDARD OF DAMPER 3156
MAINTENANCE STANDARD OF COOLING SYSTEM 3158
MAINTENANCE STANDARD OF COOLING FAN PUMP 3160
MAINTENANCE STANDARD OF SERVO VALVE .3162
MAINTENANCE STANDARD OF COOLING FAN MOTOR .3164
POWER TRAIN .3166
MAINTENANCE STANDARD OF UNIVERSAL JOINT .3166
MAINTENANCE STANDARD OF POWER TRAIN MOUNT .3167
MAINTENANCE STANDARD OF POWER TRAIN MOUNT(D155PX-8) .3169
MAINTENANCE STANDARD OF TORQUE CONVERTER AND PTO 3171
MAINTENANCE STANDARD OF TORQUE CONVERTER CONTROL VALVE 3176
MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV 3177
MAINTENANCE STANDARD OF STATOR CLUTCH ECMV 3178
MAINTENANCE STANDARD OF TRANSMISSION 3179
MAINTENANCE STANDARD OF TRANSMISSION ECMV .3184
MAINTENANCE STANDARD OF MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE .3185
MAINTENANCE STANDARD OF TRANSMISSION LUBRICATION RELIEF VALVE .3186
MAINTENANCE STANDARD OF BEVEL GEAR SHAFT, HSS, AND BRAKE 3187
MAINTENANCE STANDARD OF BRAKE CONTROL VALVE .3193
MAINTENANCE STANDARD OF BRAKE ECMV 3195
MAINTENANCE STANDARD OF BRAKE SOLENOID VALVE 3196
MAINTENANCE STANDARD OF SUDDEN STOP PREVENTION VALVE 3197
MAINTENANCE STANDARD OF FINAL DRIVE .3198
MAINTENANCE STANDARD OF FINAL DRIVE(D155PX-8) .3201
MAINTENANCE STANDARD OF SPROCKET FOR CONVENTIONAL TYPE TRACK SHOE .3204
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR CONVENTIONAL TYPE TRACK SHOE 3205
MAINTENANCE STANDARD OF SPROCKET FOR PLUS TYPE TRACK SHOE .3207
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR PLUS TYPE TRACK SHOE 3208
UNDERCARRIAGE AND FRAME .3210
MAINTENANCE STANDARD OF MAIN FRAME 3210
MAINTENANCE STANDARD OF MAIN FRAME(D155PX-8) 3212
MAINTENANCE STANDARD OF SUSPENSION 3214
MAINTENANCE STANDARD OF SUSPENSION(D155PX-8) 3216
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .3219
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION(D155PX-8) .3221
MAINTENANCE STANDARD OF IDLER .3224
MAINTENANCE STANDARD OF IDLER(D155PX-8) .3226
MAINTENANCE STANDARD OF TRACK ROLLER FOR CONVENTIONAL TYPE TRACK SHOES 3228
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES 3230
MAINTENANCE STANDARD OF CARRIER ROLLER FOR CONVENTIONAL TYPE TRACK SHOE .3232
MAINTENANCE STANDARD OF CARRIER ROLLER FOR PLUS TYPE TRACK SHOE .3233
MAINTENANCE STANDARD OF CONVENTIONAL TYPE TRACK SHOE 3234
MAINTENANCE STANDARD OF PLUS TYPE TRACK SHOE 3236
MAINTENANCE STANDARD OF SINGLE SHOE AND HEAVY DUTY SHOE .3238
MAINTENANCE STANDARD OF SINGLE SHOE AND HEAVY DUTY SHOE(D155PX-8) .3239
HYDRAULIC SYSTEM 3240
MAINTENANCE STANDARD OF HYDRAULIC TANK 3240
MAINTENANCE STANDARD OF SCAVENGING PUMP .3241
MAINTENANCE STANDARD OF STEERING LUBRICATION PUMP AND POWER TRAIN PUMP 3242
MAINTENANCE STANDARD OF WORK EQUIPMENT AND HSS PUMP .3244
MAINTENANCE STANDARD OF PC-EPC VALVE 3246
MAINTENANCE STANDARD OF HSS MOTOR .3247
MAINTENANCE STANDARD OF CONTROL VALVE .3250
MAINTENANCE STANDARD OF SELF-PRESSURE REDUCING VALVE 3264
MAINTENANCE STANDARD OF QUICK DROP VALVE 3266
WORK EQUIPMENT 3268
MAINTENANCE STANDARD OF CYLINDER STAY .3268
MAINTENANCE STANDARD OF FRONT WORK EQUIPMENT 3270
MAINTENANCE STANDARD OF CUTTING EDGE AND END BIT 3275
MAINTENANCE STANDARD OF BLADE LIFT CYLINDER .3277
MAINTENANCE STANDARD OF BLADE TILT CYLINDER .3278
MAINTENANCE STANDARD OF VARIABLE MULTI-SHANK RIPPER .3279
MAINTENANCE STANDARD OF VARIABLE GIANT RIPPER .3282
MAINTENANCE STANDARD OF RIPPER LIFT CYLINDER 3285
MAINTENANCE STANDARD OF RIPPER TILT CYLINDER 3286
CAB AND ITS ATTACHMENTS .3287
MAINTENANCE STANDARD OF CAB MOUNT .3287
80 APPENDIX .3289
CONTENTS 3290
ABBREVIATION LIST .3292
AIR CONDITIONER SYSTEM 3298
PRECAUTIONS FOR REFRIGERANT .3298
AIR CONDITIONER COMPONENT .3299
SPECIFICATIONS OF AIR CONDITIONER .3301
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .3302
OUTLINE OF REFRIGERATION CYCLE 3303
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .3305
AIR CONDITIONER UNIT 3305
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .3305
FUNCTION OF AIR CONDITIONER UNIT 3307
COMPONENT PARTS OF AIR CONDITIONER UNIT .3309
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 3310
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .3310
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .3310
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .3310
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3311
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .3311
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .3311
FUNCTION OF TRIPLE PRESSURE SWITCH 3312
AIR CONDITIONER CONTROLLER 3313
STRUCTURE OF AIR CONDITIONER CONTROLLER .3313
COMPRESSOR 3314
STRUCTURE OF COMPRESSOR .3314
SPECIFICATIONS OF COMPRESSOR 3314
FUNCTION OF COMPRESSOR 3314
CONDENSER .3315
STRUCTURE OF CONDENSER 3315
SPECIFICATIONS OF CONDENSER .3315
FUNCTION OF CONDENSER .3315
RECEIVER DRIER 3316
STRUCTURE OF RECEIVER DRIER .3316
SPECIFICATIONS OF RECEIVER DRIER 3316
FUNCTION OF RECEIVER DRIER 3316
SENSORS FOR AIR CONDITIONER SYSTEM 3317
STRUCTURE OF SUNLIGHT SENSOR 3317
FUNCTION OF SUNLIGHT SENSOR .3317
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .3317
FUNCTION OF AMBIENT TEMPERATURE SENSOR 3317
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .3319
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .3321
AIR CONDITIONER SYSTEM DIAGRAM 3323
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 3324
FUNCTION OF AIR CONDITIONER CONTROLLER 3325
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .3326
TESTING AIR LEAKAGE (DUCT) 3334
METHOD FOR TESTING AIR LEAKAGE (DUCT) .3334
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .3337
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 3338
TEST VENT (MODE) CHANGEOVER .3339
METHOD FOR TESTING VENT (MODE) CHANGEOVER .3339
TESTING FRESH/RECIRC AIR CHANGEOVER .3340
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 3340
TEST SUNLIGHT SENSOR 3341
METHOD FOR TESTING SUNLIGHT SENSOR 3341
TEST (TRIPLE) PRESSURE SWITCH FOR REFRIGERANT .3342
METHOD FOR TESTING (TRIPLE) PRESSURE SWITCH FOR REFRIGERANT .3342
TEST RELAYS .3343
METHOD FOR TESTING RELAYS .3343
AIR CONDITIONER TROUBLESHOOTING CHART 1 .3344
AIR CONDITIONER TROUBLESHOOTING CHART 2 .3345
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 3348
FAILURE CODE [879AKA] .3350
FAILURE CODE [879AKB] .3351
FAILURE CODE [879BKA] .3352
FAILURE CODE [879BKB] .3354
FAILURE CODE [879CKA] .3356
FAILURE CODE [879CKB] .3357
FAILURE CODE [879DKZ] .3358
FAILURE CODE [879EMC] .3360
FAILURE CODE [879FMC] .3361
FAILURE CODE [879GKX] .3362
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 3364
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .3366
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 3370
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .3372
TROUBLESHOOTING USING GAUGE PRESSURE 3374
CONNECTION OF SERVICE TOOL 3377
METHOD FOR CONNECTING SERVICE TOOL 3377
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .3379
HANDLE COMPRESSOR OIL .3381
90 CIRCUIT DIAGRAMS .3383
CONTENTS 3384
ABBREVIATION LIST .3385
HYDRAULIC CIRCUIT DIAGRAM .3391
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .3391
HYDRAULIC CIRCUIT DIAGRAM (1/2) .3395
HYDRAULIC CIRCUIT DIAGRAM (2/2) .3397
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM .3399
ELECTRICAL CIRCUIT DIAGRAM 3401
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 3401
ELECTRICAL CIRCUIT DIAGRAM (1/16) .3405
ELECTRICAL CIRCUIT DIAGRAM (2/16) .3407
ELECTRICAL CIRCUIT DIAGRAM (3/16) .3409
ELECTRICAL CIRCUIT DIAGRAM (4/16) .3411
ELECTRICAL CIRCUIT DIAGRAM (5/16) .3413
ELECTRICAL CIRCUIT DIAGRAM (6/16) .3415
ELECTRICAL CIRCUIT DIAGRAM (7/16) .3417
ELECTRICAL CIRCUIT DIAGRAM (8/16) .3419
ELECTRICAL CIRCUIT DIAGRAM (9/16) .3421
ELECTRICAL CIRCUIT DIAGRAM (10/16) 3423
ELECTRICAL CIRCUIT DIAGRAM (11/16) 3425
ELECTRICAL CIRCUIT DIAGRAM (12/16) 3427
ELECTRICAL CIRCUIT DIAGRAM (13/16) 3429
ELECTRICAL CIRCUIT DIAGRAM (14/16) 3431
ELECTRICAL CIRCUIT DIAGRAM (15/16) 3433
ELECTRICAL CIRCUIT DIAGRAM (16/16) 3435
INDEX 3437

DESCRIPTION:

Komatsu D155AX-8 Bulldozer Shop Manual SEN06497-17 –  PDF DOWNLOAD

• SERIAL NUMBERS 100001 and up

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams

G.B 28/12/24