Komatsu D155AXi-8 Bulldozer Shop Manual SEN06521-16 PDF

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Komatsu D155AXi-8 Bulldozer Shop Manual SEN06521-16 – PDF DOWNLOAD

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Komatsu D155AXi-8 Bulldozer Shop Manual SEN06521-16 – PDF DOWNLOAD 

Language : English
Pages : 3658
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu D155AXi-8 Bulldozer Shop Manual SEN06521-16 – PDF DOWNLOAD 

SERIAL NUMBERS 100040 and up

SEN06521-16 1
00 Index and Foreword 3
Index 4
Abbreviation List 25
Foreword, Safety, Basic Information 28
How to Read the Shop Manual 28
Safety Notice for Operation 30
Precautions to Prevent Fire 38
Procedures If Fire Occurs 40
Precautions for Disposing of Waste Materials 41
Procedures for Exhaust Gas Regulations 42
Precautions for DEF 43
General Character and Precautions for Handling 43
Precautions for Adding 43
Precautions for Storage 43
Precautions for Fire Hazard and Leakage 43
Other Precautions 43
Store DEF 44
Precautions When You Handle Hydraulic Equipment 45
Precautions When You Disconnect and Connect Pipings 48
Precautions When You Handle Electrical Equipment 55
Precautions When You Handle Fuel System Equipment 57
Precautions When You Handle Intake System Equipment 58
Practical Use of KOMTRAX 59
Disconnect and Connect Push-Pull Type Coupler 60
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 60
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 61
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 62
Precautions for Disconnection and Connection of Connectors 64
How to Disconnect and Connect Deutsch Connector 68
How to Disconnect and Connect Slide Lock Type Connector 69
How to Disconnect and Connect Connector with Lock to Pull 71
How to Disconnect and Connect Connector with Lock to Push 72
How to Disconnect and Connect Connector with Housing to Rotate 74
How to Read the Codes for Electric Cable 75
Explanation of Terms for Maintenance Standard 79
Standard Tightening Torque Table 82
Conversion Table 89
01 Specifications 95
Table of Contents 96
Specifications 97
Specification Drawing 97
Specification Drawing: D155AXI-8 97
Specifications 99
Specifications: D155AXI-8 99
Weight Table 106
Weight Table: D155AXI-8 106
Table of Fuel, Coolant, and Lubricants 108
10 Structure and Function 109
Table of Contents 110
Urea SCR System 114
Layout Drawing of Urea SCR System 114
Urea SCR System Diagram 116
Function of Urea SCR System 117
Function of DEF System 117
Inducement Strategy 119
Component Parts of Urea SCR System 133
DEF Mixing Tube 133
SCR Assembly 133
DEF Tank 136
DEF Pump 138
DEF Injector 139
DEF Hose 140
DEF Tank Heating Valve 141
Boot-up System 142
Layout Drawing of Boot-up System (Machine with Gateway Function Controller) 142
System Operating Lamp System 143
System Diagram of System Operating Lamp System (Machine with KOMTRAX Terminal) 143
System Diagram of System Operating Lamp System (Machine with Gateway Function Controller) 143
Function of System Operating Lamp System (Machine with KOMTRAX Terminal) 143
Function of System Operating Lamp System (Machine with Gateway Function Controller) 144
Battery Disconnect Switch 146
Layout Drawing of Battery Disconnect Switch 146
Function of Battery Disconnect Switch 146
Engine System 148
Layout Drawing of Engine System 148
Engine Control System 150
Layout of Engine Control System (Machine with KOMTRAX Terminal) 150
Layout of Engine Control System (Machine with Gateway Function Controller) 151
System Diagram of Engine Control System (Machine with KOMTRAX Terminal) 152
System Diagram of Engine Control System (Machine with Gateway Function Controller) 154
Function of Engine Control System 155
Automatic Idle Stop System 156
Automatic Idle Stop System Diagram (Machine with KOMTRAX Terminal) 156
System Diagram of Automatic Idle Stop System (Machine with Gateway Function Controller) 157
Function of Automatic Idle Stop System 157
Component Parts of Engine System 160
Damper 160
VGT 161
EGR System 165
EGR Valve 167
EGR Cooler 169
KCCV System 171
KCCV Ventilator 173
KDPF 176
Cooling System 180
Layout Drawing of Cooling System 180
Specifications of Cooling System 181
Component Parts of Cooling System 182
Cooling Fan Pump 182
Cooling Fan Motor 190
Hydraulic Oil Cooler Bypass Valve 197
Control System 198
Layout Drawing of Control System (Machine with KOMTRAX Terminal) 198
Layout Drawing of Control System (Machine with Gateway Function Controller) 199
Machine Monitor System 200
System Diagram of Machine Monitor System (Machine with KOMTRAX Terminal) 200
System Diagram of Machine Monitor System (Machine with Gateway Function Controller) 201
Function of Machine Monitor System 201
KOMTRAX System 204
System Diagram of KOMTRAX System (Machine with KOMTRAX Terminal) 204
System Diagram of KOMTRAX System (Machine with Gateway Function Controller) 204
Function of KOMTRAX System 205
Component Parts of Control System 206
Machine Monitor 206
KOMTRAX Terminal 222
Gateway Function Controller 224
Communication Terminal 227
Power Train Controller 229
Work Equipment Controller 233
Engine Controller 237
Fuel Feed Pump 243
Fuel Feed Pump Switch 244
Hydraulic System 245
Layout Drawing of Hydraulic System 245
CLSS 246
Structure of CLSS 246
Function of CLSS 247
Component Parts of Hydraulic System 249
Hydraulic Tank 249
Work Equipment and HSS Pump 250
LS Valve 255
PC Valve 260
PC-EPC Valve 266
Control Valve 270
Power Train System 312
Layout Drawing of Power Train System 312
Operation of Power Train System 315
Transmission, Steering, and Brake Control 317
Layout Drawing of Transmission, Steering, and Brake Control System 317
Function of Transmission, Steering, and Brake Control System 318
Palm Command Control System 320
Palm Command Control System Diagram 320
HSS System 324
HSS System Diagram 324
Function of HSS System 325
Centralized Pressure Pickup Port 327
Layout Drawing of Centralized Pressure Pickup Port 327
Function of Centralized Pressure Pickup Port 328
Component Parts of Power Train System 329
Universal Joint 329
Power Train Mount 330
Torque Converter and PTO 331
Torque Converter Control Valve 338
Lockup Clutch ECMV 339
Stator Clutch ECMV 342
Transmission 346
Transmission ECMV 356
Main Relief Valve and Torque Converter Relief Valve 363
Transmission Lubrication Relief Valve 365
Bevel Gear Shaft, HSS, and Brake 365
Final Drive 392
Scavenging Pump 395
Steering Lubrication Pump and Power Train Pump 396
HSS Motor 397
Electric Steering Electric Lever 404
Work Equipment System 409
Work Equipment Control 409
Layout Drawing of Work Equipment Control 409
Function of Work Equipment Control 410
Layout Drawing of Front Work Equipment 411
Layout Drawing of Variable Giant Ripper 412
Layout Drawing of Variable Multi-Shank Ripper 413
Component Parts of Work Equipment System 414
Self-Pressure Reducing Valve 414
Work Equipment Lock Solenoid Valve 420
Pilot Circuit Accumulator 422
Quick Drop Valve 423
Piston Valve 428
Electric Blade Control Lever 428
Ripper Electric Lever 430
ICT System 431
Layout Drawing of ICT System 431
System Diagram of ICT Control System 433
Blade Control System 435
Function of Blade Control System 435
Leveling Mode System Diagram 437
Function of Leveling Mode 438
Operation of Leveling Mode 438
Dozing Mode System Diagram 439
Function of Dozing Mode 439
Operation of Dozing Mode 439
Smooth Start System 441
Smooth Start System Diagram 441
Function of Smooth Start System 441
Operation of Smooth Start System 441
Slip Control System 443
Slip Control System Diagram 443
Function of Slip Control System 443
Operation of Slip Control System 443
Assist Control System 444
Assist Control System Diagram 444
Function of Assist Control System 444
Operation of Assist Control System 445
Component Parts of ICT System 446
Control Box 446
GNSS Receiver 448
GNSS Antenna 452
IMU Sensor 452
Stroke and Reset Sensor for Blade Lift Cylinder 455
Undercarriage and Frame 458
Main Frame 458
Structure of Main Frame 458
Suspension 459
Structure of Suspension 459
Function of Suspension 461
Track Frame and Idler Cushion 462
Structure of Track Frame and Idler Cushion 462
Specifications of Track Frame and Idler Cushion 463
Function of Track Frame and Idler Cushion 463
Work Equipment 464
Structure of Front Work Equipment 464
Structure of Cylinder Stay 466
Structure of Variable Giant Ripper 467
Structure of Variable Multi-Shank Ripper 468
CAB Related Parts 469
ROPS CAB 469
Structure of ROPS CAB 469
Function of ROPS CAB 469
CAB Mount 470
Structure of CAB Mount 470
20 Standard Value Table 471
Table of Contents 472
Standard Value Table for Engine 473
Standard Value Table for Engine: D155AXI-8 473
Standard Value Table for Machine 478
Standard Value Table for Machine: D155AXI-8 478
Machine Posture and Procedures to Measure Performance 498
Standard Value Table for Electricity 500
Standard Value Table for Electricity 500
30 Testing and Adjusting 511
Table of Contents 512
Precautions Before Work 516
Related Information on Testing and Adjusting 517
Tools for Testing and Adjusting 517
Sketch of Tools for Testing and Adjusting 525
Engine and Cooling System 528
Examine Engine Speed 528
How to Examine Engine Speed 528
Examine Boost Pressure 533
How to Examine Boost Pressure 533
Examine Exhaust Gas Temperature 535
How to Examine Exhaust Gas Temperature 535
Examine Exhaust Gas Color 538
How to Examine Exhaust Gas Color with the Handy Smoke Checker 538
How to Examine Exhaust Gas Color with Smoke Meter 539
Examine Mass Air Flow and Temperature Sensor 540
How to Examine Mass Air Flow and Temperature Sensor 540
Examine and Adjust Valve Clearance 542
How to Examine Valve Clearance 542
How to Adjust Valve Clearance 543
Examine Compression Pressure 545
How to Examine Compression Pressure 545
Examine Blowby Pressure 548
How to Examine Blowby Pressure 548
Examine Engine Oil Pressure 550
How to Examine Engine Oil Pressure on Machine Monitor 550
How to Examine Engine Oil Pressure by Testing Tool 550
Examine EGR Valve and VGT Oil Pressure 552
How to Examine EGR Valve and VGT Oil Pressure 552
Examine Fuel Pressure 554
How to Examine Fuel Pressure 554
Examine Fuel Return Rate and Leakage 556
How to Examine Fuel Return Rate and Leakage 557
Bleed Air from Fuel System 561
How to Bleed Air from Fuel System 561
Examine Fuel Circuit for Leakage 563
How to Examine Fuel System for Leakage 563
Handle Cylinder Cut-out Mode Operation 565
Handle No-Injection Cranking Operation 566
Clean Fuel Doser 567
How to Clean Fuel Doser 567
Write Injector Compensation Value to Engine Controller 569
How to Write Injector Compensation Value 569
Write Correction for Ash in Soot Accumulation to Engine Controller 575
How to Write Correction for Ash in Soot Accumulation to Engine Controller 575
Examine SCR Related Functions 576
Examine DEF Pump Raised Pressure 580
Examine Injection Volume from DEF Injector 583
Examine DEF Line Heater Relay 1 588
Examine DEF Line Heater Relay 2 591
Examine DEF Pump Heater Relay 594
Examine DEF Tank Heater Valve 597
Examine SCR Denitration Efficiency 600
Clean DEF Tank 603
How to Clean DEF Tank 604
Clean DEF Pump 609
How to Clean DEF Pump 609
Adjust Decelerator Pedal 616
How to Adjust Decelerator Pedal 616
Power Train 619
Examine Power Train Oil Pressure 619
How to Examine Power Train Oil Pressure 620
Adjust Transmission Output Shaft Speed Sensor 630
How to Adjust Transmission Output Shaft Speed Sensor 630
Examine Brake Performance Simply 631
How to Examine Brake Performance Simply 631
Examine and Adjust Brake Pedal 632
How to Examine Brake Pedal 632
How to Adjust Brake Pedal 633
Adjust Parking Brake Lever 636
How to Adjust Parking Brake Lever 636
Move Machine by Parking Brake Release When Machine Does Not Travel 638
How to Move Machine with Hydraulic Type Parking Brake Release System 638
How to Move Machine with Electric Type Parking Brake Release System 639
Undercarriage and Frame 642
Adjust Idler Clearance 642
How to Adjust Idler Clearance 642
Examine and Adjust Track Tension 644
How to Examine Track Tension 644
How to Adjust Track Tension 644
Hydraulic System 645
Release Remained Pressure in Hydraulic Circuit 645
How to Release Remained Pressure in Hydraulic System 645
Examine and Adjust Work Equipment and HSS Oil Pressure 646
How to Examine Work Equipment and HSS Oil Pressure 646
How to Adjust Oil Pressure of Work Equipment and HSS 649
Examine Oil Pressure of Control Circuit 651
How to Examine Oil Pressure in Control Circuit 651
Examine Work Equipment Lock Solenoid Valve Outlet Pressure 653
How to Examine Work Equipment Lock Solenoid Valve Outlet Pressure 653
Examine Ripper Pin Puller Solenoid Valve Outlet Pressure 655
How to Examine Ripper Pin Puller Solenoid Valve Outlet Pressure 655
Examine Cooling Fan Speed 657
How to Examine Cooling Fan Speed 657
Examine Cooling Fan Circuit Oil Pressure 658
How to Examine Cooling Fan Circuit Oil Pressure 658
Bleed Air in Cooling Fan Pump 660
How to Bleed Air in Cooling Fan Pump 660
Examine Parts Which Cause Hydraulic Drift of Work Equipment 661
How to Examine Parts Which Cause Hydraulic Drift of Blade Lift Cylinder 661
How to Examine the Parts Which Cause Hydraulic Drift of Blade Tilt Cylinder 661
How to Examine the Parts Which Cause Hydraulic Drift of Ripper Lift Cylinder 662
Examine Oil Leakage from Work Equipment Cylinder 663
How to Examine Internal Oil Leakage of Work Equipment Cylinder 663
Bleed Air from Work Equipment Cylinders 665
How to Bleed Air from Work Equipment Cylinder 665
Operation When Work Equipment is Disabled 666
How to Operate When Work Equipment is Disabled 666
Work Equipment 668
Adjust Work Equipment Lock Lever 668
How to Adjust Work Equipment Lock Lever 668
Examine and Adjust Play of Blade Electric Lever 670
How to Examine Play of Blade Electric Lever 672
How to Adjust Play of Blade Electric Lever 672
How to Replace Universal Joint 673
CAB Related Parts 680
Examine and Adjust Operator Cab 680
How to Examine Operator Cab 680
How to Adjust Operator Cab 683
Electrical System 685
Set and Operate Machine Monitor 685
Operator Mode 689
Function to Show Technician Identification Status Screen 689
Function to Show Operator Identification Input Screen 689
Examine Function by LCD (Liquid Crystal Display) 690
Examine Function of Service Meter 690
How to Set Usage Limitation and Change Maintenance Password 690
Service Mode 693
How to Operate Service Mode 693
How to See Pre-defined Monitoring Information 695
How to Examine Self-Define Monitor Information 701
Abnormality Record Menu 713
How to See Maintenance Record 717
Maintenance Mode Setting 718
How to Set Phone Number Entry 722
Default Menu 723
Diagnostic Tests Menu 732
Adjustment Menu 741
No-Injection Cranking Operation 834
KOMTRAX Settings Menu 836
How to Show Service Message 838
How to Start Up KOMTRAX Terminal (Machine with KOMTRAX Terminal) 840
Stop Use of KOMTRAX Terminal (Machine with KOMTRAX Terminal) 844
How to Start Up KOMTRAX System (Machine with Gateway Function Controller) 846
Stop Use of KOMTRAX System (Machine with Gateway Function Controller) 851
Adjust Rearview Camera Angle 853
How to Adjust Rearview Camera Angle 853
Handle Voltage Circuit of Engine Controller 854
Handle Battery Disconnect Switch 855
Examine Diodes 856
How to Examine Diodes by Digital Tester 856
How to Examine Diodes by Analog Tester 856
ICT System 857
Set and Operate Control Box 857
Examine and Adjust ICT Related Devices (Dual Tilt) 859
Examine and Adjust ICT Related Devices (Single Tilt) 863
Calibrate Blade Edge Position 867
How to Operate Blade Calibration Menu (Pitch Rod Calibration) (Single Tilt) 868
How to Operate Blade Calibration Menu (Machine Cal Step A) (Dual Tilt) 871
How to Operate Blade Calibration Menu (Machine Cal Step A) (Single Tilt) 875
How to Operate Blade Calibration Menu (Machine Cal Step B) (Dual Tilt) 879
How to Operate Blade Calibration Menu (Machine Cal Step B) (Single Tilt) 893
Calibrate IMU Sensor 907
How to Calibrate IMU Sensor 907
Reset Cylinder Stroke End 911
Reset Lift Cylinder Stroke End 911
Set Standard Angle of Blade Edge (Dual Tilt) 913
How to Input Wear Volume of Blade Edge and Track Shoes 915
Examine and Adjust Blade Elevation 916
Examine Blade Elevation (Dual Tilt) (For Old Control Box) 916
Examine Blade Elevation (Dual Tilt) (For New Control Box) 919
Examine Blade Elevation (Single Tilt) (For Old Control Box) 922
Examine Blade Elevation (Single Tilt) (For New Control Box) 924
Adjust Blade Elevation (For Old Control Box) 927
Adjust Blade Elevation (For New Control Box) 928
Examine Stroke Sensor for Lift Cylinder 930
How to Examine Stroke Sensor for Lift Cylinder 930
Examine and Adjust Reset Sensor for Lift Cylinder 934
How to Examine Reset Sensor for Lift Cylinder 934
How to Adjust Reset Sensor for Lift Cylinder 935
Adjust When Work Equipment Controller is Replaced 936
How to Adjust When Work Equipment Controller is Replaced 936
Adjust When ICT Related Devices are Repaired or Replaced (Dual Tilt) 939
Adjust When ICT Related Devices are Repaired or Replaced (Single Tilt) 943
Pm Clinic 946
Pm Clinic Service 946
Pm Clinic Check Sheet: D155AXI-8 948
Pm Clinic Check Sheet for Undercarriage: D155AXI-8 962
40 Troubleshooting 965
Table of Contents 966
Precautions Before Work 979
Related Information to Troubleshooting 980
General Troubleshooting Points 980
Troubleshooting Points for Urea SCR System 981
Sequence of Events in Troubleshooting 995
Checks Before Troubleshooting 997
Inspection Procedure Before Troubleshooting 999
Walk-Around Check 999
Test in Accordance with Testing Procedure 1001
Examine Fuel Level and Type 1001
Examine for Impure Ingredient in Fuel 1001
Examine DEF Level and Type 1002
Examine Fuel Prefilter 1002
Examine Fuel Main Filter 1004
Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type 1005
Examine Coolant Level (Reservoir Tank) 1006
Examine Air Cleaner Clogging 1007
Clean Outer Element 1008
Replace Element 1010
Examine Hydraulic Oil Level 1010
Examine Hydraulic Oil Strainer 1012
Examine Hydraulic Oil Filter 1012
Examine Oil Level in Power Train Case 1013
Examine Power Train Strainer 1015
Examine Power Train Filter 1016
Examine Oil Level in Damper Case 1016
Examine Oil Level in Final Drive Case 1017
How to Examine Electric Equipment 1019
Procedure for Troubleshooting 1026
Symptom and Troubleshooting Numbers 1029
Information Shown in Troubleshooting Table 1034
Connector List and Layout (Machine with KOMTRAX Terminal) 1036
Connectors List (Machine with Gateway Function Controller) 1055
Connector Layout (Machine with Gateway Function Controller) 1064
Connector Contact Connection Table 1071
T-Branch Box and T-Branch Adapter Table 1111
Fuse Location Table 1117
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 1120
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 1124
Failure Code Table (Machine with KOMTRAX Terminal) 1126
Failure Codes Table (Machine with Gateway Function Controller) 1149
Troubleshooting by Failure Code (Display of Code) 1174
Failure Code [1500L0] 1174
Failure Code [15SAL1] 1175
Failure Code [15SALH] 1177
Failure Code [15SBL1] 1179
Failure Code [15SBLH] 1181
Failure Code [15SEL1] 1183
Failure Code [15SELH] 1185
Failure Code [15SFL1] 1187
Failure Code [15SFLH] 1189
Failure Code [15SGL1] 1191
Failure Code [15SGLH] 1193
Failure Code [15SJL1] 1195
Failure Code [15SJLH] 1197
Failure Code [1800MW] 1199
Failure Code [2300NR] 1200
Failure Code [2301L1] 1201
Failure Code [2301LH] 1203
Failure Code [2302L1] 1205
Failure Code [2302LH] 1207
Failure Code [879AKA] 1209
Failure Code [879AKB] 1210
Failure Code [879BKA] 1211
Failure Code [879BKB] 1213
Failure Code [879CKA] 1215
Failure Code [879CKB] 1216
Failure Code [879DKZ] 1217
Failure Code [879EMC] 1219
Failure Code [879FMC] 1220
Failure Code [879GKX] 1221
Failure Code [989L00] 1223
Failure Code [989M00] 1224
Failure Code [989N00] 1225
Failure Code [A1U0N3] 1226
Failure Code [A1U0N4] 1228
Failure Code [AA10NX] 1230
Failure Code [AB00KE] 1232
Failure Code [AQ10N3] 1234
Failure Code [AS00N3] 1236
Failure Code [AS00R2] 1238
Failure Code [AS00R3] 1239
Failure Code [AS00R4] 1240
Failure Code [AS00R5] 1241
Failure Code [AS00R6] 1242
Failure Code [AS00ZK] 1243
Failure Code [AS10KM] 1244
Failure Code [AS10NR] 1245
Failure Code [AS10NT] 1246
Failure Code [B@BAZG] 1247
Failure Code [B@BCNS] 1248
Failure Code [B@BCQA] 1249
Failure Code [B@BCZK] 1251
Failure Code [B@CENS] 1253
Failure Code [B@HANS] 1254
Failure Code [CA115] 1255
Failure Code [CA122] 1256
Failure Code [CA123] 1258
Failure Code [CA131] 1260
Failure Code [CA132] 1262
Failure Code [CA135] 1264
Failure Code [CA141] 1266
Failure Code [CA144] 1268
Failure Code [CA145] 1270
Failure Code [CA153] 1272
Failure Code [CA154] 1275
Failure Code [CA187] 1278
Failure Code [CA221] 1280
Failure Code [CA222] 1282
Failure Code [CA227] 1284
Failure Code [CA234] 1285
Failure Code [CA238] 1286
Failure Code [CA239] 1288
Failure Code [CA249] 1290
Failure Code [CA256] 1292
Failure Code [CA271] 1294
Failure Code [CA272] 1296
Failure Code [CA273] 1297
Failure Code [CA274] 1299
Failure Code [CA322] 1300
Failure Code [CA323] 1302
Failure Code [CA324] 1304
Failure Code [CA325] 1306
Failure Code [CA331] 1308
Failure Code [CA332] 1310
Failure Code [CA343] 1312
Failure Code [CA351] 1313
Failure Code [CA352] 1314
Failure Code [CA356] 1317
Failure Code [CA357] 1319
Failure Code [CA386] 1322
Failure Code [CA441] 1323
Failure Code [CA442] 1326
Failure Code [CA449] 1327
Failure Code [CA451] 1328
Failure Code [CA452] 1330
Failure Code [CA515] 1332
Failure Code [CA516] 1334
Failure Code [CA553] 1336
Failure Code [CA555] 1337
Failure Code [CA556] 1338
Failure Code [CA559] 1339
Failure Code [CA595] 1344
Failure Code [CA687] 1345
Failure Code [CA689] 1347
Failure Code [CA691] 1349
Failure Code [CA692] 1351
Failure Code [CA697] 1353
Failure Code [CA698] 1354
Failure Code [CA731] 1355
Failure Code [CA778] 1356
Failure Code [CA1117] 1359
Failure Code [CA1664] 1360
Failure Code [CA1669] 1363
Failure Code [CA1673] 1364
Failure Code [CA1677] 1365
Failure Code [CA1678] 1366
Failure Code [CA1682] 1367
Failure Code [CA1683] 1369
Failure Code [CA1684] 1371
Failure Code [CA1686] 1373
Failure Code [CA1691] 1374
Failure Code [CA1694] 1377
Failure Code [CA1695] 1379
Failure Code [CA1696] 1380
Failure Code [CA1712] 1382
Failure Code [CA1713] 1385
Failure Code [CA1714] 1387
Failure Code [CA1715] 1388
Failure Code [CA1776] 1389
Failure Code [CA1777] 1392
Failure Code [CA1843] 1395
Failure Code [CA1844] 1397
Failure Code [CA1879] 1400
Failure Code [CA1881] 1403
Failure Code [CA1883] 1405
Failure Code [CA1885] 1409
Failure Code [CA1887] 1411
Failure Code [CA1921] 1413
Failure Code [CA1922] 1416
Failure Code [CA1923] 1421
Failure Code [CA1924] 1423
Failure Code [CA1925] 1425
Failure Code [CA1927] 1427
Failure Code [CA1928] 1429
Failure Code [CA1942] 1431
Failure Code [CA1963] 1432
Failure Code [CA1977] 1435
Failure Code [CA1993] 1438
Failure Code [CA2185] 1441
Failure Code [CA2186] 1443
Failure Code [CA2249] 1445
Failure Code [CA2265] 1446
Failure Code [CA2266] 1448
Failure Code [CA2271] 1451
Failure Code [CA2272] 1453
Failure Code [CA2349] 1455
Failure Code [CA2353] 1457
Failure Code [CA2357] 1459
Failure Code [CA2381] 1460
Failure Code [CA2382] 1462
Failure Code [CA2383] 1464
Failure Code [CA2386] 1466
Failure Code [CA2387] 1468
Troubleshooting Flowchart 1472
Failure Code [CA2555] 1473
Failure Code [CA2556] 1476
Failure Code [CA2637] 1478
Failure Code [CA2639] 1480
Failure Code [CA2732] 1483
Failure Code [CA2733] 1485
Failure Code [CA2741] 1487
Failure Code [CA2765] 1488
Failure Code [CA2771] 1489
Failure Code [CA2777] 1495
Failure Code [CA2878] 1498
Failure Code [CA2881] 1501
Failure Code [CA2976] 1504
Failure Code [CA3133] 1506
Failure Code [CA3134] 1508
Failure Code [CA3135] 1510
Failure Code [CA3142] 1514
Failure Code [CA3143] 1515
Failure Code [CA3144] 1516
Failure Code [CA3146] 1518
Failure Code [CA3147] 1519
Failure Code [CA3148] 1520
Failure Code [CA3151] 1522
Failure Code [CA3165] 1528
Failure Code [CA3167] 1530
Failure Code [CA3229] 1533
Failure Code [CA3231] 1535
Failure Code [CA3232] 1537
Failure Code [CA3235] 1541
Failure Code [CA3239] 1543
Failure Code [CA3241] 1546
Failure Code [CA3242] 1549
Failure Code [CA3251] 1552
Failure Code [CA3253] 1555
Failure Code [CA3254] 1559
Failure Code [CA3255] 1562
Failure Code [CA3256] 1566
Failure Code [CA3311] 1568
Failure Code [CA3312] 1570
Failure Code [CA3313] 1573
Failure Code [CA3314] 1574
Failure Code [CA3315] 1575
Failure Code [CA3316] 1578
Failure Code [CA3317] 1579
Failure Code [CA3318] 1580
Failure Code [CA3319] 1583
Failure Code [CA3321] 1584
Failure Code [CA3322] 1586
Failure Code [CA3419] 1589
Failure Code [CA3421] 1591
Failure Code [CA3497] 1593
Failure Code [CA3498] 1594
Failure Code [CA3543] 1595
Failure Code [CA3545] 1602
Failure Code [CA3547] 1604
Failure Code [CA3558] 1605
Failure Code [CA3559] 1607
Failure Code [CA3562] 1609
Failure Code [CA3563] 1611
Failure Code [CA3567] 1614
Failure Code [CA3568] 1617
Failure Code [CA3571] 1621
Failure Code [CA3572] 1623
Failure Code [CA3574] 1625
Failure Code [CA3575] 1627
Failure Code [CA3577] 1629
Failure Code [CA3578] 1631
Failure Code [CA3582] 1633
Failure Code [CA3583] 1640
Failure Code [CA3596] 1642
Failure Code [CA3649] 1644
Failure Code [CA3681] 1646
Failure Code [CA3682] 1651
Failure Code [CA3713] 1657
Failure Code [CA3717] 1660
Failure Code [CA3718] 1661
Failure Code [CA3725] 1662
Failure Code [CA3748] 1665
Failure Code [CA3751] 1668
Failure Code [CA3755] 1670
Failure Code [CA3866] 1672
Failure Code [CA3867] 1676
Failure Code [CA3868] 1679
Failure Code [CA3899] 1683
Failure Code [CA3911] 1685
Failure Code [CA3912] 1689
Failure Code [CA3932] 1691
Failure Code [CA3933] 1693
Failure Code [CA3934] 1695
Failure Code [CA3935] 1698
Failure Code [CA3936] 1700
Failure Code [CA4151] 1702
Failure Code [CA4152] 1706
Failure Code [CA4155] 1710
Failure Code [CA4156] 1712
Failure Code [CA4157] 1715
Failure Code [CA4158] 1717
Failure Code [CA4159] 1718
Failure Code [CA4161] 1719
Failure Code [CA4162] 1722
Failure Code [CA4163] 1725
Failure Code [CA4164] 1727
Failure Code [CA4165] 1729
Failure Code [CA4166] 1731
Failure Code [CA4168] 1733
Failure Code [CA4169] 1736
Failure Code [CA4171] 1738
Failure Code [CA4249] 1741
Failure Code [CA4251] 1743
Failure Code [CA4259] 1745
Failure Code [CA4261] 1748
Failure Code [CA4277] 1751
Failure Code [CA4281] 1755
Failure Code [CA4459] 1759
Failure Code [CA4461] 1762
Failure Code [CA4658] 1765
Failure Code [CA4731] 1769
Failure Code [CA4732] 1770
Failure Code [CA4739] 1771
Failure Code [CA4768] 1772
Failure Code [CA4769] 1774
Failure Code [CA4842] 1777
Failure Code [CA4952] 1781
Failure Code [CA5115] 1783
Failure Code [CA5383] 1786
Failure Code [D130KA] 1788
Failure Code [D130KB] 1791
Failure Code [D190KA] 1793
Failure Code [D190KB] 1795
Failure Code [D19JKZ] 1797
Failure Code [D811MC] (Machine with KOMTRAX Terminal) 1800
Failure Code [D811MC] (Machine with Gateway Function Controller) 1801
Failure Code [D862KA] (Machine with KOMTRAX Terminal) 1802
Failure Code [D862KA] (Machine with Gateway Function Controller) 1803
Failure Code [D8ALKA] (Machine with KOMTRAX Terminal) 1804
Failure Code [D8ALKA] (Machine with Gateway Function Controller) 1806
Failure Code [D8ALKB] (Machine with KOMTRAX Terminal) 1808
Failure Code [D8ALKB] (Machine with Gateway Function Controller) 1811
Failure Code [D8AQKR] 1814
Failure Code [D8ARKR] (Machine with Gateway Function Controller) 1815
Failure Code [D8G1KT] (Machine with Gateway Function Controller) 1817
Failure Code [D8G6KT] (Machine with Gateway Function Controller) 1818
Failure Code [DAF0MB] 1819
Failure Code [DAF0MC] 1820
Failure Code [DAF8KB] 1821
Failure Code [DAF9KQ] 1822
Failure Code [DAFGMC] 1823
Failure Code [DAFLKA] 1824
Failure Code [DAFLKB] 1826
Failure Code [DAFQKR] 1829
Failure Code [DAZ9KQ] 1830
Failure Code [DAZQKR] 1831
Failure Code [DB2QKR] 1832
Failure Code [DB2RKR] 1839
Failure Code [DB90KT] 1845
Failure Code [DB90MC] 1846
Failure Code [DB91KK] 1847
Failure Code [DB92KK] 1850
Failure Code [DB95KK] 1852
Failure Code [DB97KK] 1855
Failure Code [DB99KQ] 1857
Failure Code [DB9LKA] 1859
Failure Code [DB9LKB] 1861
Failure Code [DB9QKR] 1863
Failure Code [DB9RKR] 1864
Failure Code [DBE0KT] 1866
Failure Code [DBE0MC] 1867
Failure Code [DBE1KK] 1868
Failure Code [DBE2KK] 1871
Failure Code [DBE5KK] 1874
Failure Code [DBE6KK] 1876
Failure Code [DBE9KQ] 1878
Failure Code [DBELKA] 1879
Failure Code [DBELKB] 1881
Failure Code [DBEQKR] 1883
Failure Code [DBERKR] 1884
Failure Code [DBTSKR] 1886
Failure Code [DBUTKA] 1889
Failure Code [DD12KA] 1890
Failure Code [DD12KB] 1892
Failure Code [DD13KA] 1894
Failure Code [DD13KB] 1896
Failure Code [DD14KA] 1898
Failure Code [DD14KB] 1901
Failure Code [DDDDKA] 1903
Failure Code [DDDDKB] 1906
Failure Code [DDDDKX] 1909
Failure Code [DDKAKA] 1910
Failure Code [DDKAKB] 1912
Failure Code [DDKBKA] 1914
Failure Code [DDKBKB] 1916
Failure Code [DDKCL4] 1918
Failure Code [DDKEL4] 1921
Failure Code [DDKQKA] 1924
Failure Code [DDKQKB] 1926
Failure Code [DDKRKA] 1928
Failure Code [DDKRKB] 1930
Failure Code [DDKSKA] 1932
Failure Code [DDKSKB] 1934
Failure Code [DDN7L4] 1937
Failure Code [DDN8L4] 1940
Failure Code [DDNLKA] 1943
Failure Code [DDNLKB] 1945
Failure Code [DDTSL1] 1947
Failure Code [DDTSLH] 1949
Failure Code [DFA4KX] 1951
Failure Code [DFA4KZ] 1952
Failure Code [DFA4L8] 1953
Failure Code [DFA5KA] 1954
Failure Code [DFA5KY] 1957
Failure Code [DFA6KA] 1959
Failure Code [DFA6KY] 1962
Failure Code [DFA7KX] 1964
Failure Code [DFA7KZ] 1965
Failure Code [DFA7L8] 1966
Failure Code [DFA8KA] 1967
Failure Code [DFA8KY] 1970
Failure Code [DFA9KA] 1972
Failure Code [DFA9KY] 1975
Failure Code [DFAAKX] 1977
Failure Code [DFAAKZ] 1978
Failure Code [DFAAL8] 1979
Failure Code [DFABKA] 1980
Failure Code [DFABKY] 1983
Failure Code [DFACKA] 1985
Failure Code [DFACKY] 1988
Failure Code [DGS1KA] 1990
Failure Code [DGS1KX] 1992
Failure Code [DGT1KA] 1994
Failure Code [DGT1KX] 1997
Failure Code [DH21KA] 1999
Failure Code [DH21KY] 2002
Failure Code [DHA4KA] 2004
Failure Code [DHAAMA] 2006
Failure Code [DHACMA] 2008
Failure Code [DHT5KA] 2010
Failure Code [DHT5KY] 2013
Failure Code [DHT7KA] 2015
Failure Code [DHT7KY] 2018
Failure Code [DK10KA] 2020
Failure Code [DK10KB] 2023
Failure Code [DK30KA] 2025
Failure Code [DK30KX] 2028
Failure Code [DK30KY] 2029
Failure Code [DK30KZ] 2031
Failure Code [DK30L8] 2032
Failure Code [DK31KA] 2033
Failure Code [DK31KY] 2036
Failure Code [DK40KA] 2038
Failure Code [DK40KY] 2041
Failure Code [DK55KX] 2043
Failure Code [DK55KZ] 2044
Failure Code [DK55L8] 2045
Failure Code [DK56KA] 2046
Failure Code [DK56KY] 2049
Failure Code [DK57KA] 2051
Failure Code [DK57KY] 2054
Failure Code [DK80KA] 2056
Failure Code [DKH1KA] 2059
Failure Code [DKH1KY] 2062
Failure Code [DKSGL8] 2064
Failure Code [DKSHKA] 2066
Failure Code [DKSHKB] 2068
Failure Code [DKSJKA] 2070
Failure Code [DKSJKB] 2072
Failure Code [DKSKKA] 2074
Failure Code [DKSKKB] 2076
Failure Code [DKSKMB] 2078
Failure Code [DKSLL8] 2080
Failure Code [DKSMKA] 2082
Failure Code [DKSMKB] 2084
Failure Code [DKSNKA] 2086
Failure Code [DKSNKB] 2088
Failure Code [DKSPKA] 2090
Failure Code [DKSPKB] 2092
Failure Code [DKSPMB] 2094
Failure Code [DLM3KA] 2096
Failure Code [DLM3KB] 2098
Failure Code [DLM3MB] 2099
Failure Code [DLT3KA] 2100
Failure Code [DLT3KB] 2102
Failure Code [DR21KX] 2104
Failure Code [DR31KX] 2105
Failure Code [DV20KB] 2106
Failure Code [DW7BKA] 2108
Failure Code [DW7BKB] 2110
Failure Code [DWN1KA] 2112
Failure Code [DWN1KB] 2114
Failure Code [DWN1KY] 2116
Failure Code [DWN2KA] 2117
Failure Code [DWN2KB] 2119
Failure Code [DWN2KY] 2120
Failure Code [DWN3KA] 2121
Failure Code [DWN3KB] 2123
Failure Code [DWN3KY] 2125
Failure Code [DWN5KA] 2127
Failure Code [DWN5KB] 2129
Failure Code [DWN5KY] 2131
Failure Code [DXA2KA] 2133
Failure Code [DXA2KB] 2135
Failure Code [DXA2KY] 2137
Failure Code [DXH1KA] 2139
Failure Code [DXH1KB] 2141
Failure Code [DXH1KY] 2143
Failure Code [DXH4KA] 2145
Failure Code [DXH4KB] 2147
Failure Code [DXH4KY] 2149
Failure Code [DXH5KA] 2151
Failure Code [DXH5KB] 2152
Failure Code [DXH5KY] 2153
Failure Code [DXH6KA] 2154
Failure Code [DXH6KB] 2156
Failure Code [DXH6KY] 2157
Failure Code [DXH7KA] 2159
Failure Code [DXH7KB] 2161
Failure Code [DXH7KY] 2163
Failure Code [DXH8KA] 2165
Failure Code [DXH8KB] 2167
Failure Code [DXH8KY] 2169
Failure Code [DXHBKA] 2171
Failure Code [DXHBKB] 2173
Failure Code [DXHBKY] 2175
Failure Code [DXHCKA] 2177
Failure Code [DXHCKB] 2179
Failure Code [DXHCKY] 2181
Failure Code [DXHRKA] 2183
Failure Code [DXHRKB] 2185
Failure Code [DXHRKY] 2186
Failure Code [DXHSKA] 2188
Failure Code [DXHSKB] 2190
Failure Code [DXHSKY] 2191
Failure Code [DXHTKA] 2193
Failure Code [DXHTKB] 2195
Failure Code [DXHTKY] 2197
Failure Code [DXHUKA] 2199
Failure Code [DXHUKB] 2201
Failure Code [DXHUKY] 2203
Failure Code [DXHWKA] 2205
Failure Code [DXHWKB] 2207
Failure Code [DXHWKY] 2208
Failure Code [DXHXKA] 2210
Failure Code [DXHXKB] 2212
Failure Code [DXHXKY] 2213
Failure Code [DXHYKA] 2215
Failure Code [DXHYKB] 2217
Failure Code [DXHYKY] 2218
Failure Code [DXHZKA] 2220
Failure Code [DXHZKB] 2222
Failure Code [DXHZKY] 2223
Failure Code [DXJ4KA] 2225
Failure Code [DXJ4KB] 2227
Failure Code [DXJ8KA] 2228
Failure Code [DXJ8KB] 2230
Failure Code [DXJ8KY] 2232
Failure Code [DXJ9KA] 2234
Failure Code [DXJ9KB] 2236
Failure Code [DXJ9KY] 2238
Failure Code [DXJAKA] 2240
Failure Code [DXJAKB] 2242
Failure Code [DXJAKY] 2244
Failure Code [DXJBKA] 2246
Failure Code [DXJBKB] 2248
Failure Code [DXJBKY] 2250
Failure Code [F311KA] 2252
Failure Code [F311KB] 2254
Failure Code [F312KA] 2256
Failure Code [F312KB] 2258
Failure Code [F313KA] 2260
Failure Code [F313KB] 2262
Failure Code [F314KA] 2265
Failure Code [F314KB] 2267
Failure Code [F315KB] 2269
Failure Code [F315KY] 2271
Failure Code [F316KB] 2273
Failure Code [F316KY] 2275
Failure Code [F318KB] 2277
Failure Code [F318KY] 2280
Failure Code [F31AKB] 2282
Failure Code [F31AKY] 2284
Failure Code [F31BKB] 2286
Failure Code [F31BKY] 2288
Failure Code [F31CKB] 2290
Failure Code [F31CKY] 2292
Failure Code [F31DKB] 2294
Failure Code [F31DKY] 2296
Failure Code [F31EKB] 2298
Failure Code [F31EKY] 2300
Troubleshooting of Electrical System (E-Mode) 2302
E-1 Engine Does Not Start (Engine Does Not Crank) 2302
E-2 Manual Preheating System Does Not Operate 2309
E-3 Automatic Preheating System Does Not Operate 2312
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On 2314
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 2316
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow 2320
E-7 Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation 2322
E-8 Charge Level Monitor Comes On in Red While Engine is in Operation 2323
E-9 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 2325
E-10 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation 2326
E-11 Power Train Oil Temperature Monitor Comes On in Red While Engine is in Operation 2327
E-12 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 2328
E-13 Engine Coolant Temperature Gauge Does Not Show Correct Temperature 2329
E-14 Fuel Gauge Does Not Show Normally 2330
E-15 Power Train Oil Temperature Gauge Does Not Show Correct Temperature 2332
E-16 Hydraulic Oil Temperature Gauge Does Not Show Correct Temperature 2333
E-17 Operation Mode Does Not Change 2334
E-18 Gear Shift Mode Does Not Change 2335
E-19 Operating Customize Switch Does Not Display Customize Screen 2336
E-20 Modifying Setting on Customize Screen Does Not Change Setting of Machine 2337
E-21 Some Areas of Machine Monitor Screen are Not Shown 2338
E-22 Alarm Buzzer Does Not Sound or Cannot be Stopped 2339
E-23 Service Meter is Not Shown, While Starting Switch is in OFF Position 2340
E-24 Machine Does Not Change to Service Mode 2341
E-25 Horn Does Not Sound 2342
E-26 Horn Does Not Stop 2344
E-27 Backup Alarm Does Not Sound 2345
E-28 Backup Alarm Does Not Stop 2346
E-29 Headlamp Does Not Come On 2347
E-30 Rear Lamp and Ripper Point Lamp Do Not Come On 2351
E-31 No Wiper Operates 2355
E-32 Front Wiper Does Not Operate 2360
E-33 Rear Wiper Does Not Operate 2364
E-34 Left Door Wiper Does Not Operate 2368
E-35 Right Door Wiper Does Not Operate 2372
E-36 Fuel Feed Pump Does Not Operate or Stop Automatically 2376
E-37 Fan Does Not Rotate in Reverse 2377
E-38 Gear Cannot be Shifted 2378
E-39 Front Washer Does Not Operate 2379
E-40 Rear Washer Does Not Operate 2382
E-41 Left Door Washer Does Not Operate 2385
E-42 Right Door Washer Does Not Operate 2388
E-43 Ripper Pin Puller Does Not Work 2391
E-44 KOMTRAX System Does Not Operate Correctly 2393
E-45 Control Box Shuts Down After It Shows Messages [GPS receiver not connected !] and [Slope sensor not connected !] 2394
E-46 Control Box Shows Messages [GPS receiver not connected !] and [Slope sensor not connected !] 2398
E-47 Control Box Shows Message [Waiting for radio link ] 2401
E-48 Control Box Shows Message [IMU sensor not connected] Show Production 2402
E-49 Control Box Shows Message [Waiting for satellites ] 2403
E-50 Control Box Shows Message [Komatsu controller not connected!] Show Production 2404
E-51 Control Box Shows Message [Cylinder Stroke Reading Abnormal] 2406
E-52 Control Box Shows Message [Komatsu CAN Comms Abnormal] 2407
E-53 Control Box Shows Message [Komatsu Machine Trouble] 2408
E-54 Control Box Shows Message [Waiting to initialize ] 2409
E-55 Control Box Shows Message [System Initializing] 2410
E-56 Control Box Shows Message [Initializing ] 2411
E-57 Control Box Shows Message [Configuring GPS] 2412
E-58 Control Box Shows Message [No GPS Localization ] 2413
E-59 Control Box Shows Message [Low precisions ] 2414
E-60 Control Box Shows Message [Heading Initializing] 2415
E-61 Control Box Displays [Out of design area ] 2416
E-62 Control Box Can Not be Turned on 2417
E-63 Control Box Does Not Display Intelligent Machine Control Screen 2418
E-64 Control Box Does Not Display Bulldozer Image 2419
E-65 Control Box Does Not Display Design Surface 2420
E-66 Control Box Touch Panel Does Not Respond 2421
E-67 Control Box Touch Panel is Inaccurate 2422
E-68 Cylinder Stroke Reset Indication Does Not Go Out 2423
E-69 AUTO is Not Shown When AUTO/Manual Switch is Pushed (AUTO Indication Goes Out) 2424
E-70 Blade Automatic Lower Control Does Not Start While AUTO is Shown 2425
E-71 Blade Automatic Raise Control Does Not Start While AUTO is Shown 2426
E-72 Blade Automatic Control Function is Not Activated While AUTO is Shown (Blade Automatic Control Stops) 2427
E-73 When You Examine and Adjust the Blade Elevation, the Value is Different from Actual Machine 2428
E-74 Finished Surface is Inaccurate (The Average Height of Finished Surface is Lower Than Designed Surface or Blade Does Not Touch the Surface) 2429
E-75 Finished Surface is Inaccurate (The Finished Surface is Not Smooth) 2430
E-76 Finished Surface is Inaccurate (When You Finish Slope Horizontally, Steps are Made in Each Direction) 2431
E-77 Machine Can Not Escape from Shoes Slip While Blade Automatic Control is Activated (Shoes Frequently Slips) 2432
E-78 Blade Tilt Angle Does Not Align with Design Surface 2433
E-79 When You Push Cut/Fill Level Switch (Raise), the Design Surface Does Not Rise 2435
E-80 When You Push Cut/Fill Level Switch (Lower), the Design Surface Does Not Lower 2438
E-81 When Starting Switch is Turned to ON Position, Reverse Leveling Mode Switch LED Does Not Come On or Does Not Go Out 2441
E-82 When Reverse Leveling Mode Switch is Pushed, Buzzer Does Not Sound (Does Not Switch to Reverse Leveling Mode) 2443
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 2446
Information Shown in Troubleshooting Table (H-Mode) 2446
System Chart of Hydraulic and Mechanical Systems 2447
Failure Mode and Cause Table 2451
H-1 Machine Power is Not Sufficient (Not Sufficient Drawbar Pull) 2459
H-2 Machine Does Not Travel (at 2nd or 3rd Gear Speed) 2462
H-3 Machine Does Not Move Off at All Gear Speeds 2464
H-4 Machine Travels Only in One Direction, Forward or in Reverse 2467
H-5 Large Time Lag is in Gear Shifting or Directional Change 2468
H-6 Brake Does Not Work 2470
H-7 Power Train Oil Overheats 2471
H-8 Unusual Noise is Heard from Around Work Equipment and HSS Pump or HSS Motor 2473
H-9 Torque Converter Lockup Clutch Does Not Engage 2474
H-10 Machine Cannot be Steered (Machine Does Not Turn LEFT or RIGHT) 2475
H-11 Steering Speed or Power is Not Sufficient 2477
H-12 All Work Equipment Operate Slowly 2479
H-13 All Work Equipment Do Not Operate 2481
H-14 Blade Lift Speed or Power is Low 2483
H-15 Blade Tilt Speed or Power is Low 2485
H-16 Ripper Lift Speed or Power is Low 2487
H-17 Ripper Tilt Speed or Power is Low 2489
H-18 Hydraulic Drift of Blade Lift is Large 2491
H-19 Hydraulic Drift of Tilted Blade is Large 2492
H-20 Hydraulic Drift of Lifted Ripper is Large 2493
H-21 Ripper Pin Puller Cylinder Does Not Operate 2494
H-22 Blade Pitch Cylinder Does Not Operate 2495
H-23 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) 2496
H-24 Unusual Noise is Heard from Around Fan 2497
Troubleshooting of Engine (S-Mode) 2498
Information Shown in Troubleshooting Table (S-Mode) 2498
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position 2499
S-2 Engine Cranks but No Exhaust Smoke Comes Out 2500
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 2501
S-4 Engine Startability is Unsatisfactory 2502
S-5 Engine Does Not Pick Up Smoothly 2504
S-6 Engine Stops During Operation 2506
S-7 Engine Runs Rough or is Not Stable 2508
S-8 Engine Lacks Power 2509
S-9 KDPF Becomes Clogged in a Short Time 2511
S-10 Engine Oil Consumption is Excessive 2513
S-11 Oil Becomes Dirty Quickly 2514
S-12 Fuel Consumption is Excessive 2515
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant 2516
S-14 Oil Pressure Drops 2517
S-15 Fuel Mixes Into Engine Oil 2519
S-16 Water Mixes Into Engine Oil (Milky) 2520
S-17 Coolant Temperature Increases Too High (Overheating) 2521
S-18 Unusual Noise is Heard 2522
S-19 Vibration is Excessive 2523
S-20 Air Cannot be Bled from Fuel Circuit 2524
S-21 Active Regeneration is Done Frequently 2525
S-22 Active Regeneration Continues Long 2527
S-23 White Smoke is Exhausted During Active Regeneration 2528
S-24 DEF Consumption is Excessive 2529
S-25 There is Unusual Smell (Irritating Odor) 2531
S-26 Foreign Materials Enter DEF (DEF Increases) 2532
50 Disassembly and Assembly 2533
Table of Contents 2534
Precautions Before Work 2540
Related Information on Disassembly and Assembly 2541
How to Read This Manual 2541
Coating Materials List 2542
Special Tool List 2547
Sketches of Special Tools 2576
Engine and Cooling System 2603
Remove and Install Supply Pump Assembly 2603
How to Remove Supply Pump Assembly 2603
How to Install Supply Pump Assembly 2605
Remove and Install Injector Assembly 2611
How to Remove Injector Assembly 2611
How to Install Injector Assembly 2617
Remove and Install Fuel Doser Assembly 2626
How to Remove Fuel Doser Assembly 2626
How to Install Fuel Doser Assembly 2627
Remove and Install Cylinder Head Assembly 2628
How to Remove Cylinder Head Assembly 2629
How to Install Cylinder Head Assembly 2639
Remove and Install EGR Valve Assembly 2655
How to Remove EGR Valve Assembly 2655
How to Install EGR Valve Assembly 2656
Remove and Install EGR Cooler Assembly 2658
How to Remove EGR Cooler Assembly 2658
How to Install EGR Cooler Assembly 2660
Remove and Install Starter Assembly 2663
How to Remove Starting Motor Assembly 2663
How to Install Starting Motor Assembly 2664
Remove and Install Alternator Belt 2666
How to Remove Alternator Belt 2666
How to Install Alternator Belt 2667
Remove and Install Radiator Assembly 2669
How to Remove Radiator Assembly 2669
How to Install Radiator Assembly 2672
Remove and Install Hydraulic Oil Cooler Assembly 2678
How to Remove Hydraulic Oil Cooler Assembly 2678
How to Install Hydraulic Oil Cooler Assembly 2679
Remove and Install Aftercooler Assembly 2681
How to Remove Aftercooler Assembly 2681
How to Install Aftercooler Assembly 2682
Remove and Install Cooling Fan Drive Assembly 2685
How to Remove Cooling Fan Drive Assembly 2685
How to Install Cooling Fan Drive Assembly 2687
Remove and Install Cooling Fan Motor Assembly 2689
How to Remove Cooling Fan Motor Assembly 2689
How to Install Cooling Fan Motor Assembly 2690
Remove and Install Engine Assembly 2691
How to Remove Engine Assembly 2691
How to Install Engine Assembly 2698
Remove and Install Engine Front Oil Seal 2705
How to Remove Engine Front Oil Seal 2705
How to Install Engine Front Oil Seal 2707
Remove and Install Engine Rear Oil Seal 2711
How to Remove Engine Rear Oil Seal 2711
How to Install Engine Rear Oil Seal 2713
Remove and Install Engine Hood Assembly 2717
How to Remove Engine Hood Assembly 2717
How to Install Engine Hood Assembly 2720
Remove and Install Fuel Tank Assembly 2723
How to Remove Fuel Tank Assembly 2723
How to Install Fuel Tank Assembly 2726
Remove and Install DEF Tank Assembly 2730
How to Remove DEF Tank Assembly 2730
How to Install DEF Tank Assembly 2736
Remove and Install DEF Tank Sensor Flange Assembly 2741
How to Remove DEF Tank Sensor Flange Assembly 2741
How to Install DEF Tank Sensor Flange Assembly 2747
Remove and Install DEF Tank Sensor 2752
How to Remove DEF Tank Sensor 2752
How to Install DEF Tank Sensor 2752
Remove and Install DEF Tank Strainer 2759
How to Remove DEF Tank Strainer 2759
How to Install DEF Tank Strainer 2759
Remove and Install DEF Tank Filler Port Filter 2760
How to Remove DEF Tank Filler Port Filter 2760
How to Install DEF Tank Filler Port Filter 2761
Remove and Install KDPF Assembly 2764
How to Remove KDPF Assembly 2764
How to Install KDPF Assembly 2768
Disassemble and Assemble KDPF Assembly 2772
How to Disassemble KDPF Assembly 2772
How to Assemble KDPF Assembly 2777
Remove and Install SCR Assembly 2782
How to Remove SCR Assembly 2782
How to Install SCR Assembly 2785
Remove and Install KDPF and SCR Assembly 2790
How to Remove KDPF and SCR Assembly 2790
How to Install KDPF and SCR Assembly 2795
Remove and Install KCCV Assembly 2802
How to Remove KCCV Assembly 2802
How to Install KCCV Assembly 2804
Remove and Install DEF Mixing Tube 2807
How to Remove DEF Mixing Tube 2807
How to Install DEF Mixing Tube 2810
Remove and Install DEF Injector 2815
How to Remove DEF Injector 2815
How to Install DEF Injector 2818
Remove and Install DEF Pump 2821
How to Remove DEF Pump 2821
How to Install DEF Pump 2825
Remove and Install DEF Hose 2829
How to Remove DEF Hose 2829
How to Install DEF Hose 2835
Remove and Install Air Cleaner Assembly 2841
How to Remove Air Cleaner Assembly 2841
How to Install Air Cleaner Assembly 2842
Remove and Install Air Conditioner Compressor Assembly 2844
How to Remove Air Conditioner Compressor Assembly 2844
How to Install Air Conditioner Compressor Assembly 2845
Remove and Install Air Conditioner Condenser Assembly 2846
How to Remove Air Conditioner Condenser Assembly 2846
How to Install Air Conditioner Condenser Assembly 2847
Power Train 2850
Remove and Install Damper Assembly 2850
How to Remove Damper Assembly 2850
How to Install Damper Assembly 2852
Disassemble and Assemble Damper Assembly 2855
How to Disassemble Damper Assembly 2856
How to Assemble Damper Assembly 2857
Remove and Install Power Train Unit Assembly 2860
How to Remove Power Train Unit Assembly 2860
How to Install Power Train Unit Assembly 2865
Disconnect and Connect Power Train Unit Assembly 2870
How to Disconnect Power Train Unit Assembly 2870
How to Connect Power Train Unit Assembly 2876
Disassemble and Assemble PTO Assembly 2882
How to Disassemble PTO Assembly 2882
How to Assemble PTO Assembly 2886
Disassemble and Assemble Torque Converter Assembly 2893
How to Disassemble Torque Converter Assembly 2893
How to Assemble Torque Converter Assembly 2899
Disassemble and Assemble Transmission Assembly 2907
How to Disassemble Transmission Assembly 2908
How to Assemble Transmission Assembly 2918
Disassemble and Assemble HSS Assembly 2931
How to Disassemble HSS Assembly 2933
How to Assemble HSS Assembly 2942
Remove and Install HSS Motor Assembly 2956
How to Remove HSS Motor Assembly 2956
How to Install HSS Motor Assembly 2957
Remove and Install Final Drive Assembly 2959
How to Remove Final Drive Assembly 2959
How to Install Final Drive Assembly 2961
Disassemble and Assemble Final Drive Assembly 2964
How to Disassemble Final Drive Assembly 2966
How to Assemble Final Drive Assembly 2973
Undercarriage and Frame 2984
Remove and Install Track Frame Assembly (Applicable Machine: 100001 to 100616) 2984
How to Remove Track Frame Assembly 2985
How to Install Track Frame Assembly 2989
Remove and Install Track Frame Assembly (Applicable Machine: 100617 and up) 2994
How to Remove Track Frame Assembly (Applicable Machine: 100617 and up) 2994
How to Install Track Frame Assembly (Applicable Machine: 100617 and up) 2999
Remove and Install Idler Assembly 3003
How to Remove Idler Assembly 3003
How to Install Idler Assembly 3004
Disassemble and Assemble Idler Assembly 3006
How to Disassemble Idler Assembly 3006
How to Assemble Idler Assembly 3007
Remove and Install Recoil Spring Assembly 3011
How to Remove Recoil Spring Assembly 3011
How to Install Recoil Spring Assembly 3011
Disassemble and Assemble Recoil Spring Assembly 3012
How to Disassemble Recoil Spring Assembly 3012
How to Assemble Recoil Spring Assembly 3016
Remove and Install Track Roller Assembly 3019
How to Remove Track Roller Assembly 3019
How to Install Track Roller Assembly 3021
Disassemble and Assemble Track Roller Assembly 3023
How to Disassemble Track Roller Assembly 3023
How to Assemble Track Roller Assembly 3024
Remove and Install No 1 Bogie Assembly 3027
How to Remove No 1 Bogie Assembly 3028
How to Install No 1 Bogie Assembly 3031
Remove and Install No 2, 3, 4 Bogie Assemblies 3036
How to Remove No 2, 3, 4 Bogie Assemblies 3037
How to Install No 2, 3, 4 Bogie Assemblies 3039
Disassemble and Assemble Bogie Assembly 3044
How to Disassemble Bogie Assembly 3044
How to Assemble Bogie Assembly 3045
Remove and Install Carrier Roller Assembly 3047
How to Remove Carrier Roller Assembly 3047
How to Install Carrier Roller Assembly 3048
Disassemble and Assemble Carrier Roller Assembly 3049
How to Disassemble Carrier Roller Assembly 3049
How to Assemble Carrier Roller Assembly 3051
Remove and Install Pivot Shaft Assembly 3054
How to Remove Pivot Shaft Assembly 3054
How to Install Pivot Shaft Assembly 3055
Separate and Connect Track Assembly 3056
How to Examine Before Separation of Track Assembly 3056
How to Separate Track Assembly (Standard) 3056
How to Separate Track Assembly (When Track Frame Has Internal Defect) 3057
How to Install Track Assembly 3059
Separate and Connect PLUS Type Track Assembly 3061
Separate PLUS Type Track Assembly Generally 3061
Install PLUS Type Track Assembly 3061
Disassemble and Assemble Track Assembly Generally 3062
How to Disassemble Full Track Shoes Assembly 3062
How to Assemble Full Track Shoes Assembly 3064
Disassemble and Assemble PLUS Type Track Assembly Generally 3077
Disassemble PLUS Type Track Assembly Generally 3077
How to Assemble PLUS Type Track Shoes Assembly Generally 3078
Disassemble and Assemble One Track Link Assembly in Field 3087
How to Disassemble One Track Link Assembly in Field 3088
How to Assemble One Track Link Assembly in Field 3089
Disassemble and Assemble Master Link 3092
How to Disassemble Master Link 3092
How to Assemble Master Link 3093
Remove and Install Equalizer Bar Assembly 3096
How to Remove Equalizer Bar Assembly 3096
How to Install Equalizer Bar Assembly 3098
Disassemble and Assemble Equalizer Bar Bushing 3100
How to Disassemble Equalizer Bar Bushing 3100
How to Assemble Equalizer Bar Bushing 3101
Remove and Install Sprocket 3102
How to Remove Sprocket 3102
How to Install Sprocket 3102
Remove and Install Center Under Guard Assembly 3103
How to Remove Underguard Assembly 3103
How to Install Underguard Assembly 3110
Hydraulic System 3118
Remove and Install Hydraulic Tank Assembly 3118
How to Remove Hydraulic Tank Assembly 3118
How to Install Hydraulic Tank Assembly 3119
Remove and Install Work Equipment Pump and HSS Pump Assembly 3121
How to Remove Work Equipment Pump and HSS Pump Assembly 3121
How to Install Work Equipment Pump and HSS Pump Assembly 3123
Remove and Install Power Train Pump and Steering Lubrication Pump Assembly 3125
How to Remove Power Train Pump and Steering Lubrication Pump Assembly 3125
How to Install Power Train Pump and Steering Lubrication Pump Assembly 3127
Remove and Install Cooling Fan Pump Assembly 3129
How to Remove Cooling Fan Pump Assembly 3129
How to Install Cooling Fan Pump Assembly 3131
Remove and Install Scavenging Pump Assembly 3133
How to Remove Scavenging Pump Assembly 3133
How to Install Scavenging Pump Assembly 3134
Remove and Install Control Valve Assembly 3135
How to Remove Control Valve Assembly 3135
How to Install Control Valve Assembly 3136
Work Equipment 3139
Remove and Install Blade Assembly 3139
How to Remove Blade Assembly 3139
How to Install Blade Assembly 3141
Disassemble and Assemble Blade Assembly 3144
How to Disassemble Blade Assembly 3144
How to Assemble Blade Assembly 3147
Disassemble and Assemble Multi-Shank Ripper Assembly 3150
How to Disassemble Multi-Shank Ripper Assembly 3150
How to Assemble Multi-Shank Ripper Assembly 3152
Disassemble and Assemble Giant Ripper Assembly 3155
How to Disassemble Giant Ripper Assembly 3155
How to Assemble Giant Ripper Assembly 3158
Remove and Install Stroke and Reset Sensing Blade Lift Cylinder Assembly 3161
How to Remove Stroke and Reset Sensing Blade Lift Cylinder Assembly 3162
How to Install Stroke and Reset Sensing Blade Lift Cylinder Assembly 3166
Disassemble and Assemble Stroke and Reset Sensing Blade Lift Cylinder Assembly 3171
How to Disassemble Stroke and Reset Sensing Blade Lift Cylinder Assembly 3172
How to Assemble Stroke and Reset Sensing Blade Lift Cylinder Assembly 3177
Disassemble and Assemble Blade Tilt Cylinder Assembly 3189
How to Disassemble Blade Tilt Cylinder Assembly 3189
How to Assemble Blade Tilt Cylinder Assembly 3191
Disassemble and Assemble Ripper Cylinder Assembly 3194
How to Disassemble Ripper Cylinder Assembly 3194
How to Assemble Ripper Cylinder Assembly 3196
CAB Related Parts 3201
Remove and Install Operator Cab Assembly 3201
How to Remove Operator Cab Assembly 3202
How to Install Operator Cab Assembly 3212
Remove and Install Operator Cab Glass (Adhered Glass) 3221
How to Remove Operator Cab Glass (Adhered Glass) 3223
How to Install Operator Cab Glass (Adhered Glass) 3223
Remove and Install Air Conditioner Unit Assembly 3228
How to Remove Air Conditioner Unit Assembly 3228
How to Install Air Conditioner Unit Assembly 3234
Remove and Install Operator Seat 3241
How to Remove Operator Seat 3241
How to Install Operator Seat 3242
How to Remove and Install Seat Belt 3243
How to Remove Seat Belt 3243
How to Install Seatbelt 3244
Electrical System 3245
Remove and Install Engine Controller Assembly 3245
How to Remove Engine Controller Assembly 3245
How to Install Engine Controller Assembly 3248
Remove and Install Power Train Controller Assembly 3251
How to Remove Power Train Controller Assembly 3251
How to Install Power Train Controller Assembly 3252
Remove and Install Work Equipment Controller Assembly 3253
How to Remove Work Equipment Controller Assembly 3253
How to Install Work Equipment Controller Assembly 3253
Remove and Install Machine Monitor Assembly 3255
How to Remove Machine Monitor Assembly 3255
How to Install Machine Monitor Assembly 3256
Remove and Install Mass Air Flow and Temperature Sensor 3258
How to Remove Mass Air Flow and Temperature Sensor 3258
How to Install Mass Air Flow and Temperature Sensor 3259
Remove and Install KCCV Crankcase Pressure Sensor 3261
How to Remove KCCV Crankcase Pressure Sensor 3261
How to Install KCCV Crankcase Pressure Sensor 3262
Remove and Install SCR Temperature Sensor 3263
How to Remove SCR Temperature Sensor 3263
How to Install SCR Temperature Sensor 3265
Remove and Install Battery Relay 3267
How to Remove Battery Relay 3267
How to Install Battery Relay 3275
Remove and Install KOMTRAX Terminal Assembly 3280
How to Remove KOMTRAX Terminal Assembly 3280
How to Install KOMTRAX Terminal Assembly 3282
Remove and Install Gateway Controller Assembly 3285
How to Remove Gateway Controller Assembly 3285
How to Install Gateway Controller Assembly 3289
Remove and Install Communication Terminal 3294
How to Remove Communication Terminal 3294
How to Install Communication Terminal 3300
Remove and Install Communication Terminal Wiring Harness 3306
How to Remove Communication Terminal Wiring Harness 3307
How to Install Communication Terminal Wiring Harness 3319
Remove and Install Control Box 3332
How to Remove Control Box (For Old Control Box) 3332
How to Remove Control Box (For New Control Box) 3333
How to Install Control Box (For Old Control Box) 3333
How to Install Control Box (For New Control Box) 3334
Remove and Install GNSS Receiver 3336
How to Remove GNSS Receiver 3336
How to Install GNSS Receiver 3337
Remove and Install GNSS Antenna 3338
How to Remove GNSS Antenna 3338
How to Install GNSS Antenna 3339
Remove and Install IMU Sensor 3344
How to Remove IMU Sensor 3344
How to Install IMU Sensor 3346
60 Maintenance Standard 3351
Table of Contents 3352
Engine and Cooling System 3354
Maintenance Standard for Engine Mount 3354
Maintenance Standard for Damper 3356
Maintenance Standard for Cooling System 3358
Maintenance Standard for Cooling Fan Pump 3360
Maintenance Standard for Servo Valve 3362
Maintenance Standard for Cooling Fan Motor 3364
Power Train 3366
Maintenance Standard for Universal Joint 3366
Maintenance Standard for Power Train Mount 3367
Maintenance Standard for Torque Converter and PTO 3369
Maintenance Standard for Torque Converter Control Valve 3374
Maintenance Standard for Lockup Clutch ECMV 3375
Maintenance Standard for Stator Clutch ECMV 3376
Maintenance Standard for Transmission 3377
Maintenance Standard for Transmission ECMV 3382
Maintenance Standard for Main Relief Valve and Torque Converter Relief Valve 3383
Maintenance Standard for Transmission Lubrication Relief Valve 3384
Maintenance Standard for Bevel Gear Shaft, HSS, and Brake 3385
Maintenance Standard for Brake Control Valve 3391
Maintenance Standard for Brake ECMV 3393
Maintenance Standard for Brake Solenoid Valve 3394
Maintenance Standard for Sudden Stop Prevention Valve 3395
Maintenance Standard for Final Drive 3396
Maintenance Standard for Sprocket for Conventional Type Track Shoes 3399
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for Conventional Type Track Shoes 3400
Maintenance Standard for Sprocket for PLUS Type Track Shoes 3402
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for PLUS Type Track Shoes 3403
Undercarriage and Frame 3405
Maintenance Standard for Main Frame 3405
Maintenance Standard for Suspension 3407
Maintenance Standard for Track Frame and Idler Cushion 3409
Maintenance Standard for Idler 3411
Maintenance Standard for Track Roller for Conventional Type Track Shoes 3413
Maintenance Standard for Track Roller for PLUS Type Track Shoes 3415
Maintenance Standard for Carrier Roller for Conventional Type Track Shoes 3417
Maintenance Standard for Carrier Roller for PLUS Type Track Shoes 3418
Maintenance Standard for Conventional Type Track Shoes 3419
Maintenance Standard for PLUS Type Track Shoes 3421
Maintenance Standard for Single Shoes and Heavy Duty Shoes 3423
Hydraulic System 3424
Maintenance Standard for Hydraulic Tank 3424
Maintenance Standard for Scavenging Pump 3425
Maintenance Standard for Steering Lubrication Pump and Power Train Pump 3426
Maintenance Standard for Work Equipment and HSS Pump 3428
Maintenance Standard for PC-EPC Valve 3430
Maintenance Standard for HSS Motor 3431
Maintenance Standard for Control Valve 3434
Maintenance Standard for Self-Pressure Reducing Valve 3448
Maintenance Standard for Quick Drop Valve 3450
Work Equipment 3452
Maintenance Standard for Cylinder Stay 3452
Maintenance Standard for Front Work Equipment 3454
Maintenance Standard for Cutting Edge and End Bit 3456
Maintenance Standard for Stroke and Reset Sensing Blade Lift Cylinder 3457
Maintenance Standard for Blade Tilt Cylinder 3458
Maintenance Standard for Variable Multi-Shank Ripper 3459
Maintenance Standard for Variable Giant Ripper 3462
Maintenance Standard for Ripper Lift Cylinder 3465
Maintenance Standard for Ripper Tilt Cylinder 3466
CAB Related Parts 3467
Maintenance Standard for CAB Mount 3467
80 Appendix 3469
Table of Contents 3470
Precautions Before Work 3472
Air Conditioner System 3473
Precautions for Refrigerant 3473
Air Conditioner Component 3474
Specifications of Air Conditioner 3476
Structure and Function of Refrigeration Cycle 3477
Outline of Refrigeration Cycle 3478
Component Parts of Air Conditioner System 3480
Air Conditioner Unit 3480
Configuration Diagram of Air Conditioner Unit 3480
Function of Air Conditioner Unit 3482
Component Parts of Air Conditioner Unit 3484
Function of Evaporator as Air Conditioner Unit Component 3485
Function of Heater Core as Air Conditioner Unit Component 3485
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component 3485
Function of Servo Motor as Air Conditioner Unit Component 3485
Structure of Expansion Valve as Air Conditioner Unit Component 3486
Function of Expansion Valve as Air Conditioner Unit Component 3486
Operate Expansion Valve as Air Conditioner Unit Component 3486
Function of Triple Pressure Switch 3487
Air Conditioner Controller 3488
Structure of Air Conditioner Controller 3488
Compressor 3489
Structure of Compressor 3489
Specifications of Compressor 3489
Function of Compressor 3489
Condenser 3490
Structure of Condenser 3490
Specifications of Condenser 3490
Function of Condenser 3490
Receiver Drier 3491
Structure of Receiver Dryer 3491
Specifications of Receiver Dryer 3491
Function of Receiver Dryer 3491
Air Conditioner Related Sensors 3492
Structure of Sunlight Sensor 3492
Function of Sunlight Sensor 3492
Structure of Outside Temperature Sensor 3492
Function of Outside Air Temperature Sensor 3492
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 3494
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 3496
System Diagram of Air Conditioner 3498
Input and Output Signals of Air Conditioner Controller 3499
Function of Air Conditioner Controller 3500
Locations of Air Conditioner Parts and Layout of Connectors 3501
Examine Air Leakage (Duct) 3509
How to Examine Air Leakage (Duct) 3509
Examine Air Conditioner with Self-Diagnosis Function 3512
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor 3513
Examine Vent (Mode) Changeover 3514
How to Examine Vent (Mode) Changeover 3514
Examine Fresh/Recirc Air Changeover 3515
How to Examine Fresh/Recirc Air Changeover 3515
Examine Sunlight Sensor 3516
How to Examine Sunlight Sensor 3516
Examine Refrigerant (Triple) Pressure Switch 3517
How to Examine Refrigerant (Triple) Pressure Switch 3517
Examine Relay 3518
How to Examine Relay 3518
Air Conditioner Troubleshooting Chart 1 3519
Air Conditioner Troubleshooting Chart 2 3520
Information Shown in Troubleshooting Table 3523
Failure Code [879AKA] 3524
Failure Code [879AKB] 3525
Failure Code [879BKA] 3526
Failure Code [879BKB] 3528
Failure Code [879CKA] 3530
Failure Code [879CKB] 3531
Failure Code [879DKZ] 3532
Failure Code [879EMC] 3534
Failure Code [879FMC] 3535
Failure Code [879GKX] 3536
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 3538
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 3539
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 3540
A-4 Troubleshooting for Fresh/Recirc Air Changeover 3541
Troubleshooting by Gauge Pressure 3542
Connect Service Tool 3545
How to Connect Service Tool 3545
Precautions for Disconnection and Connection of Air Conditioner Piping 3547
Handle Compressor Oil 3549
90 Circuit Diagrams 3551
Table of Contents 3552
Hydraulic Circuit Diagram 3553
Symbols Used in Hydraulic Circuit Diagram 3553
Hydraulic Circuit Diagram (1/2) 3557
Hydraulic Circuit Diagram (2/2) 3559
Power Train Hydraulic Circuit Diagram 3561
Electrical Circuit Diagram 3563
Symbols Used in Electric Circuit Diagram 3563
Electrical Circuit Diagram(1/16) (Machine with KOMTRAX Terminal) 3567
Electrical Circuit Diagram(2/16) (Machine with KOMTRAX Terminal) 3569
Electrical Circuit Diagram(3/16) (Machine with KOMTRAX Terminal) 3571
Electrical Circuit Diagram(4/16) (Machine with KOMTRAX Terminal) 3573
Electrical Circuit Diagram(5/16) (Machine with KOMTRAX Terminal) 3575
Electrical Circuit Diagram(6/16) (Machine with KOMTRAX Terminal) 3577
Electrical Circuit Diagram(7/16) (Machine with KOMTRAX Terminal) 3579
Electrical Circuit Diagram(8/16) (Machine with KOMTRAX Terminal) 3581
Electrical Circuit Diagram(9/16) (Machine with KOMTRAX Terminal) 3583
Electrical Circuit Diagram(10/16) (Machine with KOMTRAX Terminal) 3585
Electrical Circuit Diagram(11/16) (Machine with KOMTRAX Terminal) 3587
Electrical Circuit Diagram(12/16) (Machine with KOMTRAX Terminal) 3589
Electrical Circuit Diagram(13/16) (Machine with KOMTRAX Terminal) 3591
Electrical Circuit Diagram(14/16) (Machine with KOMTRAX Terminal) 3593
Electrical Circuit Diagram(15/16) (Machine with KOMTRAX Terminal) 3595
Electrical Circuit Diagram(16/16) (Machine with KOMTRAX Terminal) 3597
Electrical Circuit Diagram(1/18) (Machine with Gateway Function Controller) 3599
Electrical Circuit Diagram(2/18) (Machine with Gateway Function Controller) 3601
Electrical Circuit Diagram(3/18) (Machine with Gateway Function Controller) 3603
Electrical Circuit Diagram(4/18) (Machine with Gateway Function Controller) 3605
Electrical Circuit Diagram(5/18) (Machine with Gateway Function Controller) 3607
Electrical Circuit Diagram(6/18) (Machine with Gateway Function Controller) 3609
Electrical Circuit Diagram(7/18) (Machine with Gateway Function Controller) 3611
Electrical Circuit Diagram(8/18) (Machine with Gateway Function Controller) 3613
Electrical Circuit Diagram(9/18) (Machine with Gateway Function Controller) 3615
Electrical Circuit Diagram(10/18) (Machine with Gateway Function Controller) 3617
Electrical Circuit Diagram(11/18) (Machine with Gateway Function Controller) 3619
Electrical Circuit Diagram(12/18) (Machine with Gateway Function Controller) 3621
Electrical Circuit Diagram(13/18) (Machine with Gateway Function Controller) 3623
Electrical Circuit Diagram(14/18) (Machine with Gateway Function Controller) 3625
Electrical Circuit Diagram(15/18) (Machine with Gateway Function Controller) 3627
Electrical Circuit Diagram(16/18) (Machine with Gateway Function Controller) 3629
Electrical Circuit Diagram(17/18) (Machine with Gateway Function Controller) 3631
Electrical Circuit Diagram(18/18) (Machine with Gateway Function Controller) 3633
Index 3635

DESCRIPTION:

Komatsu D155AXi-8 Bulldozer Shop Manual SEN06521-16 – PDF DOWNLOAD 

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.
• The caution lamps, pilot lamps, and symbols of the switches on the machine monitor can be different in
accordance with the machine.
• For details of the symbols shown on the machine monitor, see Structure and Operation, “Caution
Lamps Shown on Machine Monitor” and “Pilot Lamps Shown on Machine Monitor”.
• For details of the switches of the machine monitor, see Testing and Adjusting, “Set and Operate Machine
Monitor”.
• For details of the switches, see the “Operation and Maintenance Manual”.
• All “AdBlue/DEF” shown on the machine monitor is referred to as “DEF” in the shop manual. Some machine
monitors installed to the product show “DEF” as “AdBlue/DEF” in the service mode. Thus, be sure to recognize
that “DEF” and “AdBlue/DEF” are the same when you read the 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 Specification
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.

S.V 29/12/24