Komatsu D155AXi-8 Bulldozer Shop Manual SEN06582-10 PDF

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Komatsu D155AXi-8 Bulldozer Shop Manual SEN06582-10 – PDF DOWNLOAD

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Komatsu D155AXi-8 Bulldozer Shop Manual SEN06582-10 – PDF DOWNLOAD 

Language : English
Pages : 3762
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu D155AXi-8 Bulldozer Shop Manual SEN06582-10 – PDF DOWNLOAD 

SERIAL NUMBERS 100040 and up

Cover 1
00 Index and Foreword 3
Index 4
Abbreviation List 26
Foreword, Safety, Basic Information 29
How to Read the Shop Manual 29
Safety Notice for Operation 31
Precautions to Prevent Fire 39
Procedures If Fire Occurs 41
Precautions When You Discard Waste Materials 42
Procedures for Exhaust Gas Regulations 43
Precautions for DEF 44
General Character and Precautions for Handling 44
Precautions When You Add 44
Precautions for Storage 44
Precautions for Fire Hazard and Leakage 44
Other Precautions 44
Store DEF 45
Precautions When You Handle Hydraulic Equipment 46
Precautions When You Disconnect and Connect Pipings 49
Precautions When You Handle Electrical Equipment 56
Precautions When You Handle Fuel System Equipment 58
Precautions When You Handle Intake System Equipment 59
Practical Use of KOMTRAX 60
Disconnect and Connect Push-Pull Type Coupler 61
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 61
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 62
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 63
Precautions for Disconnection and Connection of Connectors 65
Disconnect and Connect Deutsch Connector 69
How to Disconnect and Connect Slide Lock Type Connector 70
Disconnect and Connect Connector with Lock to Pull 72
Disconnect and Connect Connector with Lock to Push 73
Disconnect and Connect Connector with Housing to Rotate 75
How to Read the Codes for Electric Cable 76
Explanation of Terms for Maintenance Standard 80
Standard Tightening Torque Table 83
Conversion Table 90
01 Specification 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 134
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 of Engine Control System (Machine with KOMTRAX Terminal) 148
Layout of Engine Control System (Machine with Gateway Function Controller) 149
Engine Control System 151
Layout Drawing of Engine Control System 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 157
Automatic Idle Stop System Diagram (Machine with KOMTRAX Terminal) 157
System Diagram of Automatic Idle Stop System (Machine with Gateway Function Controller) 158
Function of Automatic Idle Stop System 158
Component Parts of Engine System 161
Damper 161
VGT 163
EGR System 167
EGR Valve 170
EGR Cooler 172
KCCV System 174
KCCV Ventilator 176
KDPF 179
Cooling System 183
Layout Drawing of Cooling System 183
Specifications of Cooling System 184
Component Parts of Cooling System 185
Cooling Fan Pump 185
Cooling Fan Motor 194
Hydraulic Oil Cooler Bypass Valve 201
Control System 202
Layout Drawing of Control System (Machine with KOMTRAX Terminal) 202
Layout Drawing of Control System (Machine with Gateway Function Controller) 203
Machine Monitor System 204
System Diagram of Machine Monitor System (Machine with KOMTRAX Terminal) 204
System Diagram of Machine Monitor System (Machine with Gateway Function Controller) 205
Function of Machine Monitor System 205
KOMTRAX System 208
System Diagram of KOMTRAX System (Machine with KOMTRAX Terminal) 208
System Diagram of KOMTRAX System (Machine with Gateway Function Controller) 208
Function of KOMTRAX System 209
Component Parts of Control System 210
Machine Monitor 210
KOMTRAX Terminal 227
Gateway Function Controller 229
Communication Terminal 232
Power Train Controller 234
Work Equipment Controller 238
Engine Controller 242
Fuel Feed Pump 249
Fuel Feed Pump Switch 250
Hydraulic System 251
Layout Drawing of Hydraulic System 251
CLSS 252
Structure of CLSS 252
Function of CLSS 253
Component Parts of Hydraulic System 255
Hydraulic Tank 255
Work Equipment and HSS Pump 257
LS Valve 263
PC Valve 268
PC-EPC Valve 274
Control Valve 277
Power Train System 319
Layout Drawing of Power Train System 319
Operation of Power Train System 322
Transmission, Steering, and Brake Control 324
Layout Drawing of Transmission, Steering, and Brake Control System 324
Function of Transmission, Steering, and Brake Control System 325
Palm Command Control System 327
Palm Command Control System Diagram 327
HSS System 331
HSS System Diagram 331
Function of HSS System 332
Centralized Pressure Pickup Port 334
Layout Drawing of Centralized Pressure Pickup Port 334
Function of Centralized Pressure Pickup Port 335
Component Parts of Power Train System 336
Universal Joint 336
Power Train Mount 337
Torque Converter and PTO 339
Torque Converter Control Valve 346
Lockup Clutch ECMV 347
Stator Clutch ECMV 351
Transmission 354
Transmission ECMV 365
Main Relief Valve and Torque Converter Relief Valve 372
Transmission Lubrication Relief Valve 374
Bevel Gear Shaft, HSS, and Brake 375
Final Drive 401
Scavenging Pump 404
Steering Lubrication Pump and Power Train Pump 405
HSS Motor 407
Electric Steering Electric Lever 415
Work Equipment System 419
Work Equipment Control 419
Layout Drawing of Work Equipment Control 419
Function of Work Equipment Control 420
Layout Drawing of Front Work Equipment 421
Layout Drawing of Variable Giant Ripper 422
Layout Drawing of Variable Multi-Shank Ripper 423
Component Parts of Work Equipment System 424
Self-Pressure Reducing Valve 424
Work Equipment Lock Solenoid Valve 431
Pilot Circuit Accumulator 433
Quick Drop Valve 434
Piston Valve 439
Electric Blade Control Lever 440
Ripper Electric Lever 441
ICT System 442
Layout Drawing of ICT System 442
System Diagram of ICT Control System 444
Blade Control System 446
Function of Blade Control System 446
Leveling Mode System Diagram 448
Function of Leveling Mode 449
Operation of Leveling Mode 449
Dozing Mode System Diagram 450
Function of Dozing Mode 450
Operation of Dozing Mode 450
Smooth Start System 452
Smooth Start System Diagram 452
Function of Smooth Start System 452
Operation of Smooth Start System 452
Slip Control System 454
Slip Control System Diagram 454
Function of Slip Control System 454
Operation of Slip Control System 454
Assist Control System 455
Assist Control System Diagram 455
Function of Assist Control System 455
Operation of Assist Control System 456
Component Parts of ICT System 457
Control Box 457
GNSS Receiver 460
GNSS Antenna 464
IMU Sensor 465
Stroke and Reset Sensor for Blade Lift Cylinder 468
Radio Control System 471
Layout Drawing of Radio Control System 471
Specifications of Radio Control System 472
Component Parts of Radio Control System 473
Radio Control Transmitter 473
Radio Control Receiver 475
Radio Control Controller 476
Undercarriage and Frame 480
Main Frame 480
Structure of Main Frame 480
Suspension 481
Structure of Suspension 481
Function of Suspension 483
Track Frame and Idler Cushion 484
Structure of Track Frame and Idler Cushion 484
Specifications of Track Frame and Idler Cushion 485
Function of Track Frame and Idler Cushion 485
Work Equipment 486
Structure of Front Work Equipment 486
Structure of Cylinder Stay 488
Structure of Variable Giant Ripper 489
Structure of Variable Multi-Shank Ripper 490
CAB Related Parts 491
ROPS CAB 491
Structure of ROPS CAB 491
Function of ROPS CAB 491
CAB Mount 492
Structure of CAB Mount 492
20 Standard Value Table 493
Table of Contents 494
Standard Value Table for Engine 495
Standard Value Table for Engine: D155AXI-8 495
Standard Value Table for Machine 500
Standard Value Table for Machine: D155AXI-8 500
Machine Posture and Procedures to Measure Performance 520
Standard Value Table for Electricity 522
Standard Value Table for Electricity 522
30 Testing and Adjusting 533
Table of Contents 534
Precautions Before Work 538
Related Information on Testing and Adjusting 539
Tools for Testing and Adjusting 539
Sketch of Tools for Testing and Adjusting 547
Engine and Cooling System 549
Examine Engine Speed 549
How to Examine Engine Speed 549
Examine Boost Pressure 554
How to Examine Boost Pressure 554
Examine Exhaust Gas Temperature 556
How to Examine Exhaust Gas Temperature 556
Examine Exhaust Gas Color 559
How to Examine Exhaust Gas Color with the Handy Smoke Checker 559
How to Examine Exhaust Gas Color with Smoke Meter 560
Examine Mass Air Flow and Temperature Sensor 561
How to Examine Mass Air Flow and Temperature Sensor 561
Examine and Adjust Valve Clearance 563
Check Valve Clearance 563
Adjust Valve Clearance 564
Examine Compression Pressure 566
How to Examine Compression Pressure 566
Examine Blowby Pressure 569
How to Examine Blowby Pressure 569
Examine Engine Oil Pressure 571
Examine Engine Oil Pressure on Machine Monitor 571
Examine Engine Oil Pressure by Testing Tool 571
Examine EGR Valve and VGT Oil Pressure 573
How to Examine EGR Valve and VGT Oil Pressure 573
Examine Fuel Pressure 575
How to Examine Fuel Pressure 575
Examine Fuel Return Rate and Leakage 577
How to Examine Fuel Return Rate and Leakage 578
Bleed Air from Fuel System 582
How to Bleed Air from Fuel System 582
Examine Fuel Circuit for Leakage 584
How to Examine Fuel System for Leakage 584
Handle Cylinder Cut-out Mode Operation 586
Handle No-Injection Cranking Operation 587
Clean Fuel Doser 588
How to Clean Fuel Doser 588
Write Injector Compensation Value to Engine Controller 590
Write Injector Compensation Value 590
Write Correction for Ash in Soot Accumulation to Engine Controller 596
How to Write Correction for Ash in Soot Accumulation to Engine Controller 596
Examine SCR Related Functions 597
Examine DEF Pump Raised Pressure 601
Examine Injection Volume from DEF Injector 604
Examine DEF Line Heater Relay 1 609
Examine DEF Line Heater Relay 2 612
Examine DEF Pump Heater Relay 615
Examine DEF Tank Heater Valve 618
Examine SCR Denitration Efficiency 621
Clean DEF Tank 624
How to Clean DEF Tank 625
Clean DEF Pump 630
How to Clean DEF Pump 630
Adjust Decelerator Pedal 637
How to Adjust Decelerator Pedal 637
Power Train 640
Examine Power Train Oil Pressure 640
How to Examine Power Train Oil Pressure 641
Adjust Transmission Output Shaft Speed Sensor 651
How to Adjust Transmission Output Shaft Speed Sensor 651
Examine Brake Performance Simply 652
How to Examine Brake Performance Simply 652
Examine and Adjust Brake Pedal 653
How to Examine Brake Pedal 653
How to Adjust Brake Pedal 654
Adjust Parking Brake Lever 657
How to Adjust Parking Brake Lever 657
Move Machine by Parking Brake Release When Machine Does Not Travel 659
Move Machine with Hydraulic Type Parking Brake Release System 659
Move Machine with Electric Type Parking Brake Release System 660
Undercarriage and Frame 663
Adjust Idler Clearance 663
How to Adjust Idler Clearance 663
Examine and Adjust Track Tension 665
How to Examine Track Tension 665
How to Adjust Track Tension 665
Hydraulic System 666
Release Remained Pressure in Hydraulic Circuit 666
How to Release Remained Pressure in Hydraulic System 666
Examine and Adjust Work Equipment and HSS Oil Pressure 667
How to Examine Work Equipment and HSS Oil Pressure 667
Adjust Oil Pressure of Work Equipment and HSS 670
Examine Oil Pressure of Control Circuit 672
Examine Oil Pressure in Control Circuit 672
Examine Work Equipment Lock Solenoid Valve Outlet Pressure 674
How to Examine Work Equipment Lock Solenoid Valve Outlet Pressure 674
Examine Ripper Pin Puller Solenoid Valve Outlet Pressure 676
How to Examine Ripper Pin Puller Solenoid Valve Outlet Pressure 676
Bleed Air from Work Equipment and HSS Pump 678
How to Bleed Air from Work Equipment and HSS Pump 678
Examine Cooling Fan Speed 679
How to Examine Cooling Fan Speed 679
Examine Cooling Fan Circuit Oil Pressure 680
How to Examine Cooling Fan Circuit Oil Pressure 680
Bleed Air in Cooling Fan Pump 682
How to Bleed Air in Cooling Fan Pump 682
Examine Parts Which Cause Hydraulic Drift of Work Equipment 683
How to Examine Parts Which Cause Hydraulic Drift of Blade Lift Cylinder 683
How to Examine the Parts Which Cause Hydraulic Drift of Blade Tilt Cylinder 683
How to Examine the Parts Which Cause Hydraulic Drift of Ripper Lift Cylinder 684
Examine Oil Leakage from Work Equipment Cylinder 685
How to Examine Internal Oil Leakage of Work Equipment Cylinder 685
Bleed Air from Work Equipment Cylinders 687
Bleed Air from Work Equipment Cylinder 687
Operation When Work Equipment is Disabled 688
Operate When Work Equipment is Disabled 688
Work Equipment 690
Adjust Work Equipment Lock Lever 690
How to Adjust Work Equipment Lock Lever 690
CAB Related Parts 692
Examine and Adjust Operator Cab 692
Examine Operator Cab 692
Adjust Operator Cab 695
Electrical System 697
Set and Operate Machine Monitor 697
Operator Mode 701
Function to Show Technician Identification Status Screen 701
Function to Show Operator Identification Input Screen 701
Examine Function by LCD (Liquid Crystal Display) 702
Examine Function of Service Meter 702
Usage Limitation and Change Maintenance Password 702
Service Mode 705
How to Operate Service Mode 705
How to See Pre-defined Monitoring Information 707
How to Examine Self-Define Monitor Information 713
Abnormality Record Menu 726
How to See Maintenance Record 730
Maintenance Mode Setting 731
Set Phone Number Entry 735
Default Menu 736
Diagnostic Tests Menu 745
Adjustment Menu 754
No-Injection Cranking Operation 837
KOMTRAX Settings Menu 839
Show Service Message 841
Start Up KOMTRAX Terminal (Machine with KOMTRAX Terminal) 843
Stop Use of KOMTRAX Terminal (Machine with KOMTRAX Terminal) 847
Start Up KOMTRAX System (Machine with Gateway Function Controller) 849
Stop Use of KOMTRAX System (Machine with Gateway Function Controller) 854
Adjust Rearview Camera Angle 856
How to Adjust Rearview Camera Angle 856
Handle Voltage Circuit of Engine Controller 857
Handle Battery Disconnect Switch 858
Examine Diodes 859
Examine Diodes by Digital Tester 859
How to Examine Diodes by Analog Tester 859
ICT System 860
Set and Operate Control Box 860
Examine and Adjust ICT Related Devices (Dual Tilt) 861
Calibrate Blade Edge Position 866
How to Operate Blade Calibration Menu (Machine Cal Step A) (Dual Tilt) 867
How to Operate Blade Calibration Menu (Machine Cal Step B) (Dual Tilt) 871
Calibrate IMU Sensor 885
How to Calibrate IMU Sensor 885
Reset Cylinder Stroke End 889
Reset Lift Cylinder Stroke End 889
Set Standard Angle of Blade Edge (Dual Tilt) 891
How to Input Wear Volume of Blade Edge and Track Shoes 893
Examine and Adjust Blade Elevation 894
Examine Blade Elevation (Dual Tilt) (For Old Control Box) 894
Examine Blade Elevation (Dual Tilt) (For New Control Box) 897
Adjust Blade Elevation (For Old Control Box) 900
Adjust Blade Elevation (For New Control Box) 900
Examine Stroke Sensor for Lift Cylinder 902
How to Examine Stroke Sensor for Lift Cylinder 902
Examine and Adjust Reset Sensor for Lift Cylinder 906
How to Examine Reset Sensor for Lift Cylinder 906
Adjust Reset Sensor for Lift Cylinder 907
Adjust When Work Equipment Controller is Replaced 908
How to Adjust When Work Equipment Controller is Replaced 908
Adjust When ICT Related Devices are Repaired or Replaced (Dual Tilt) 911
Radio Control 915
ID Setup 915
How to Set Radio Control Transmitter ID 915
How to Set Radio Control Receiver ID 916
Pm Clinic 919
Pm Clinic Service 919
Pm Clinic Check Sheet: D155AXI-8 921
Pm Clinic Check Sheet for Undercarriage: D155AXI-8 935
40 Troubleshooting 939
Table of Contents 940
Precautions Before Work 954
Related Information to Troubleshooting 955
General Troubleshooting Points 955
Troubleshooting Points for Urea SCR System 956
Sequence of Events in Troubleshooting 970
Troubleshooting for Radio Control System 972
Checks Before Troubleshooting (Specifications of Radio Control) 972
Examine Operating State of Radio Control Receiver 973
Examine Operating State of Radio Control Transmitter 974
Checks Before Troubleshooting 975
Inspection Procedure Before Troubleshooting 977
Walk-Around Check 977
Test in Accordance with Testing Procedure 979
Examine Fuel Level and Type 979
Examine for Impure Ingredient in Fuel 979
Examine DEF Level and Type 980
Examine Fuel Prefilter 980
Examine Fuel Main Filter 982
Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type 983
Examine Coolant Level (Reservoir Tank) 984
Examine Air Cleaner Clogging 985
Clean Outer Element 986
Replace Element 988
Examine Hydraulic Oil Level 988
Examine Hydraulic Oil Strainer 990
Examine Hydraulic Oil Filter 990
Examine Oil Level in Power Train Case 991
Examine Power Train Strainer 993
Examine Power Train Filter 994
Examine Oil Level in Damper Case 994
Examine Oil Level in Final Drive Case 995
How to Examine Electric Equipment 997
Procedure for Troubleshooting 1004
Symptom and Troubleshooting Numbers 1007
Information Shown in Troubleshooting Table 1012
Connector List and Layout (Machine with KOMTRAX Terminal) 1014
Connectors List (Machine with Gateway Function Controller) 1033
Connector Layout (Machine with Gateway Function Controller) 1042
Connector Contact Connection Table 1049
T-Branch Box and T-Branch Adapter Table 1089
Fuse Location Table 1095
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 1098
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 1102
Failure Code Table (Machine with KOMTRAX Terminal) 1104
Failure Codes Table (Machine with Gateway Function Controller) 1131
Troubleshooting by Failure Code (Display of Code) 1159
Failure Code [1500L0] 1159
Failure Code [15SAL1] 1160
Failure Code [15SALH] 1162
Failure Code [15SBL1] 1164
Failure Code [15SBLH] 1166
Failure Code [15SEL1] 1168
Failure Code [15SELH] 1170
Failure Code [15SFL1] 1172
Failure Code [15SFLH] 1174
Failure Code [15SGL1] 1176
Failure Code [15SGLH] 1178
Failure Code [15SJL1] 1180
Failure Code [15SJLH] 1182
Failure Code [1800MW] 1184
Failure Code [2300NR] 1185
Failure Code [2301L1] 1186
Failure Code [2301LH] 1188
Failure Code [2302L1] 1190
Failure Code [2302LH] 1192
Failure Code [7RFAKA] 1194
Failure Code [7RFAKB] 1196
Failure Code [7RFAKY] 1198
Failure Code [8512KX] 1200
Failure Code [8513KX] 1201
Failure Code [8514KX] 1202
Failure Code [8515KX] 1203
Failure Code [8516KX] 1204
Failure Code [8517KX] 1205
Failure Code [8518KX] 1206
Failure Code [8519KX] 1207
Failure Code [851AKX] 1208
Failure Code [851BKX] 1209
Failure Code [851CKX] 1210
Failure Code [851DKX] 1211
Failure Code [851EKX] 1212
Failure Code [851FKX] 1213
Failure Code [851GKX] 1214
Failure Code [851HKX] 1215
Failure Code [851JKX] 1216
Failure Code [851KKX] 1217
Failure Code [851LKX] 1218
Failure Code [851MKX] 1219
Failure Code [851NKX] 1220
Failure Code [8580MC] 1221
Failure Code [8581KK] 1222
Failure Code [8582KK] 1225
Failure Code [858LKA] 1227
Failure Code [858LKB] 1229
Failure Code [858QKR] 1231
Failure Code [858RKR] 1232
Failure Code [879AKA] 1233
Failure Code [879AKB] 1234
Failure Code [879BKA] 1235
Failure Code [879BKB] 1237
Failure Code [879CKA] 1239
Failure Code [879CKB] 1240
Failure Code [879DKZ] 1241
Failure Code [879EMC] 1243
Failure Code [879FMC] 1244
Failure Code [879GKX] 1245
Failure Code [989L00] 1247
Failure Code [989M00] 1248
Failure Code [989N00] 1249
Failure Code [A1U0N3] 1250
Failure Code [A1U0N4] 1252
Failure Code [AA10NX] 1254
Failure Code [AB00KE] 1256
Failure Code [AQ10N3] 1258
Failure Code [AS00N3] 1260
Failure Code [AS00R2] 1262
Failure Code [AS00R3] 1263
Failure Code [AS00R4] 1264
Failure Code [AS00R5] 1265
Failure Code [AS00R6] 1266
Failure Code [AS00ZK] 1267
Failure Code [AS10KM] 1268
Failure Code [AS10NR] 1269
Failure Code [AS10NT] 1270
Failure Code [B@BAZG] 1271
Failure Code [B@BCNS] 1272
Failure Code [B@BCQA] 1273
Failure Code [B@BCZK] 1275
Failure Code [B@CENS] 1277
Failure Code [B@HANS] 1278
Failure Code [CA115] 1279
Failure Code [CA122] 1280
Failure Code [CA123] 1282
Failure Code [CA131] 1284
Failure Code [CA132] 1286
Failure Code [CA135] 1288
Failure Code [CA141] 1290
Failure Code [CA144] 1292
Failure Code [CA145] 1294
Failure Code [CA153] 1296
Failure Code [CA154] 1299
Failure Code [CA187] 1302
Failure Code [CA221] 1304
Failure Code [CA222] 1306
Failure Code [CA227] 1308
Failure Code [CA234] 1309
Failure Code [CA238] 1310
Failure Code [CA239] 1312
Failure Code [CA249] 1314
Failure Code [CA256] 1316
Failure Code [CA271] 1318
Failure Code [CA272] 1320
Failure Code [CA273] 1321
Failure Code [CA274] 1323
Failure Code [CA322] 1324
Failure Code [CA323] 1326
Failure Code [CA324] 1328
Failure Code [CA325] 1330
Failure Code [CA331] 1332
Failure Code [CA332] 1334
Failure Code [CA343] 1336
Failure Code [CA351] 1337
Failure Code [CA352] 1338
Failure Code [CA356] 1341
Failure Code [CA357] 1343
Failure Code [CA386] 1346
Failure Code [CA441] 1347
Failure Code [CA442] 1350
Failure Code [CA449] 1351
Failure Code [CA451] 1352
Failure Code [CA452] 1354
Failure Code [CA515] 1356
Failure Code [CA516] 1358
Failure Code [CA553] 1360
Failure Code [CA555] 1361
Failure Code [CA556] 1362
Failure Code [CA559] 1363
Failure Code [CA595] 1368
Failure Code [CA687] 1369
Failure Code [CA689] 1371
Failure Code [CA691] 1373
Failure Code [CA692] 1375
Failure Code [CA697] 1377
Failure Code [CA698] 1378
Failure Code [CA731] 1379
Failure Code [CA778] 1380
Failure Code [CA1117] 1383
Failure Code [CA1664] 1384
Failure Code [CA1669] 1387
Failure Code [CA1673] 1388
Failure Code [CA1677] 1389
Failure Code [CA1678] 1390
Failure Code [CA1682] 1391
Failure Code [CA1683] 1393
Failure Code [CA1684] 1395
Failure Code [CA1686] 1397
Failure Code [CA1691] 1398
Failure Code [CA1694] 1401
Failure Code [CA1695] 1403
Failure Code [CA1696] 1404
Failure Code [CA1712] 1406
Failure Code [CA1713] 1409
Failure Code [CA1714] 1411
Failure Code [CA1715] 1412
Failure Code [CA1776] 1413
Failure Code [CA1777] 1416
Failure Code [CA1843] 1419
Failure Code [CA1844] 1421
Failure Code [CA1879] 1424
Failure Code [CA1881] 1427
Failure Code [CA1883] 1429
Failure Code [CA1885] 1433
Failure Code [CA1887] 1435
Failure Code [CA1921] 1437
Failure Code [CA1922] 1440
Failure Code [CA1923] 1445
Failure Code [CA1924] 1447
Failure Code [CA1925] 1449
Failure Code [CA1927] 1451
Failure Code [CA1928] 1453
Failure Code [CA1942] 1455
Failure Code [CA1963] 1456
Failure Code [CA1977] 1459
Failure Code [CA1993] 1462
Failure Code [CA2185] 1465
Failure Code [CA2186] 1467
Failure Code [CA2249] 1469
Failure Code [CA2265] 1470
Failure Code [CA2266] 1472
Failure Code [CA2271] 1475
Failure Code [CA2272] 1477
Failure Code [CA2349] 1479
Failure Code [CA2353] 1481
Failure Code [CA2357] 1483
Failure Code [CA2381] 1484
Failure Code [CA2382] 1486
Failure Code [CA2383] 1488
Failure Code [CA2386] 1490
Failure Code [CA2387] 1492
Troubleshooting Flowchart 1496
Failure Code [CA2555] 1497
Failure Code [CA2556] 1500
Failure Code [CA2637] 1502
Failure Code [CA2639] 1504
Failure Code [CA2732] 1507
Failure Code [CA2733] 1509
Failure Code [CA2741] 1511
Failure Code [CA2765] 1512
Failure Code [CA2771] 1513
Failure Code [CA2777] 1519
Failure Code [CA2878] 1522
Failure Code [CA2881] 1525
Failure Code [CA2976] 1528
Failure Code [CA3133] 1530
Failure Code [CA3134] 1532
Failure Code [CA3135] 1534
Failure Code [CA3142] 1538
Failure Code [CA3143] 1539
Failure Code [CA3144] 1540
Failure Code [CA3146] 1542
Failure Code [CA3147] 1543
Failure Code [CA3148] 1544
Failure Code [CA3151] 1546
Failure Code [CA3165] 1552
Failure Code [CA3167] 1554
Failure Code [CA3229] 1557
Failure Code [CA3231] 1559
Failure Code [CA3232] 1561
Failure Code [CA3235] 1565
Failure Code [CA3239] 1567
Failure Code [CA3241] 1570
Failure Code [CA3242] 1573
Failure Code [CA3251] 1576
Failure Code [CA3253] 1579
Failure Code [CA3254] 1583
Failure Code [CA3255] 1586
Failure Code [CA3256] 1590
Failure Code [CA3311] 1592
Failure Code [CA3312] 1594
Failure Code [CA3313] 1597
Failure Code [CA3314] 1598
Failure Code [CA3315] 1599
Failure Code [CA3316] 1602
Failure Code [CA3317] 1603
Failure Code [CA3318] 1604
Failure Code [CA3319] 1607
Failure Code [CA3321] 1608
Failure Code [CA3322] 1610
Failure Code [CA3419] 1613
Failure Code [CA3421] 1615
Failure Code [CA3497] 1617
Failure Code [CA3498] 1618
Failure Code [CA3543] 1619
Failure Code [CA3545] 1626
Failure Code [CA3547] 1628
Failure Code [CA3558] 1629
Failure Code [CA3559] 1631
Failure Code [CA3562] 1633
Failure Code [CA3563] 1635
Failure Code [CA3567] 1638
Failure Code [CA3568] 1641
Failure Code [CA3571] 1645
Failure Code [CA3572] 1647
Failure Code [CA3574] 1649
Failure Code [CA3575] 1651
Failure Code [CA3577] 1653
Failure Code [CA3578] 1655
Failure Code [CA3582] 1657
Failure Code [CA3583] 1664
Failure Code [CA3596] 1666
Failure Code [CA3649] 1668
Failure Code [CA3681] 1670
Failure Code [CA3682] 1675
Failure Code [CA3713] 1681
Failure Code [CA3717] 1684
Failure Code [CA3718] 1685
Failure Code [CA3725] 1686
Failure Code [CA3748] 1689
Failure Code [CA3751] 1692
Failure Code [CA3755] 1694
Failure Code [CA3866] 1696
Failure Code [CA3867] 1700
Failure Code [CA3868] 1703
Failure Code [CA3899] 1707
Failure Code [CA3911] 1709
Failure Code [CA3912] 1713
Failure Code [CA3932] 1715
Failure Code [CA3933] 1717
Failure Code [CA3934] 1719
Failure Code [CA3935] 1722
Failure Code [CA3936] 1724
Failure Code [CA4151] 1726
Failure Code [CA4152] 1730
Failure Code [CA4155] 1734
Failure Code [CA4156] 1736
Failure Code [CA4157] 1739
Failure Code [CA4158] 1741
Failure Code [CA4159] 1742
Failure Code [CA4161] 1743
Failure Code [CA4162] 1746
Failure Code [CA4163] 1749
Failure Code [CA4164] 1751
Failure Code [CA4165] 1753
Failure Code [CA4166] 1755
Failure Code [CA4168] 1757
Failure Code [CA4169] 1760
Failure Code [CA4171] 1762
Failure Code [CA4249] 1765
Failure Code [CA4251] 1767
Failure Code [CA4259] 1769
Failure Code [CA4261] 1772
Failure Code [CA4277] 1775
Failure Code [CA4281] 1779
Failure Code [CA4459] 1783
Failure Code [CA4461] 1786
Failure Code [CA4658] 1789
Failure Code [CA4731] 1793
Failure Code [CA4732] 1794
Failure Code [CA4739] 1795
Failure Code [CA4768] 1796
Failure Code [CA4769] 1798
Failure Code [CA4842] 1801
Failure Code [CA4952] 1805
Failure Code [CA5115] 1807
Failure Code [CA5383] 1810
Failure Code [D130KA] 1812
Failure Code [D130KB] 1815
Failure Code [D141KA] 1817
Failure Code [D141KB] 1819
Failure Code [D141KY] 1821
Failure Code [D162KA] 1823
Failure Code [D162KB] 1825
Failure Code [D162KY] 1827
Failure Code [D190KA] 1829
Failure Code [D190KB] 1831
Failure Code [D19CKA] 1833
Failure Code [D19CKB] 1835
Failure Code [D19CKY] 1837
Failure Code [D19DKA] 1839
Failure Code [D19DKB] 1841
Failure Code [D19DKY] 1843
Failure Code [D19EKA] 1845
Failure Code [D19EKB] 1847
Failure Code [D19EKY] 1849
Failure Code [D19FKA] 1851
Failure Code [D19FKB] 1853
Failure Code [D19FKY] 1855
Failure Code [D19GKA] 1857
Failure Code [D19GKB] 1859
Failure Code [D19GKY] 1861
Failure Code [D19JKZ] 1863
Failure Code [D811MC] (Machine with KOMTRAX Terminal) 1866
Failure Code [D811MC] (Machine with Gateway Function Controller) 1867
Failure Code [D862KA] (Machine with KOMTRAX Terminal) 1868
Failure Code [D862KA] (Machine with Gateway Function Controller) 1869
Failure Code [D8ALKA] (Machine with KOMTRAX Terminal) 1870
Failure Code [D8ALKA] (Machine with Gateway Function Controller) 1872
Failure Code [D8ALKB] (Machine with KOMTRAX Terminal) 1874
Failure Code [D8ALKB] (Machine with Gateway Function Controller) 1877
Failure Code [D8AQKR] 1880
Failure Code [D8ARKR] (Machine with Gateway Function Controller) 1881
Failure Code [D8G1KT] (Machine with Gateway Function Controller) 1883
Failure Code [D8G6KT] (Machine with Gateway Function Controller) 1884
Failure Code [DAF0MB] 1885
Failure Code [DAF0MC] 1886
Failure Code [DAF8KB] 1887
Failure Code [DAF9KQ] 1888
Failure Code [DAFGMC] 1889
Failure Code [DAFLKA] 1890
Failure Code [DAFLKB] 1892
Failure Code [DAFQKR] 1895
Failure Code [DAZ9KQ] 1896
Failure Code [DAZQKR] 1897
Failure Code [DB2QKR] 1898
Failure Code [DB2RKR] 1905
Failure Code [DB90KT] 1911
Failure Code [DB90MC] 1912
Failure Code [DB91KK] 1913
Failure Code [DB92KK] 1916
Failure Code [DB95KK] 1918
Failure Code [DB97KK] 1921
Failure Code [DB99KQ] 1923
Failure Code [DB9LKA] 1925
Failure Code [DB9LKB] 1927
Failure Code [DB9QKR] 1929
Failure Code [DB9RKR] 1930
Failure Code [DBE0KT] 1932
Failure Code [DBE0MC] 1933
Failure Code [DBE1KK] 1934
Failure Code [DBE2KK] 1937
Failure Code [DBE5KK] 1940
Failure Code [DBE6KK] 1942
Failure Code [DBE9KQ] 1944
Failure Code [DBELKA] 1945
Failure Code [DBELKB] 1947
Failure Code [DBEQKR] 1949
Failure Code [DBERKR] 1950
Failure Code [DBTSKR] 1952
Failure Code [DBUTKA] 1955
Failure Code [DD12KA] 1956
Failure Code [DD12KB] 1958
Failure Code [DD13KA] 1960
Failure Code [DD13KB] 1962
Failure Code [DD14KA] 1964
Failure Code [DD14KB] 1967
Failure Code [DDDDKA] 1969
Failure Code [DDDDKB] 1972
Failure Code [DDDDKX] 1975
Failure Code [DDKAKA] 1976
Failure Code [DDKAKB] 1978
Failure Code [DDKBKA] 1980
Failure Code [DDKBKB] 1982
Failure Code [DDKCL4] 1984
Failure Code [DDKEL4] 1987
Failure Code [DDKQKA] 1990
Failure Code [DDKQKB] 1992
Failure Code [DDKRKA] 1994
Failure Code [DDKRKB] 1996
Failure Code [DDKSKA] 1998
Failure Code [DDKSKB] 2000
Failure Code [DDN7L4] 2003
Failure Code [DDN8L4] 2006
Failure Code [DDNLKA] 2009
Failure Code [DDNLKB] 2011
Failure Code [DDTSL1] 2013
Failure Code [DDTSLH] 2015
Failure Code [DFA4KX] 2017
Failure Code [DFA4KZ] 2018
Failure Code [DFA4L8] 2019
Failure Code [DFA5KA] 2020
Failure Code [DFA5KY] 2023
Failure Code [DFA6KA] 2025
Failure Code [DFA6KY] 2028
Failure Code [DFA7KX] 2030
Failure Code [DFA7KZ] 2031
Failure Code [DFA7L8] 2032
Failure Code [DFA8KA] 2033
Failure Code [DFA8KY] 2036
Failure Code [DFA9KA] 2038
Failure Code [DFA9KY] 2041
Failure Code [DFAAKX] 2043
Failure Code [DFAAKZ] 2044
Failure Code [DFAAL8] 2045
Failure Code [DFABKA] 2046
Failure Code [DFABKY] 2049
Failure Code [DFACKA] 2051
Failure Code [DFACKY] 2054
Failure Code [DGS1KA] 2056
Failure Code [DGS1KX] 2058
Failure Code [DGT1KA] 2060
Failure Code [DGT1KX] 2063
Failure Code [DH21KA] 2065
Failure Code [DH21KY] 2068
Failure Code [DHA4KA] 2070
Failure Code [DHAAMA] 2072
Failure Code [DHACMA] 2074
Failure Code [DHT5KA] 2076
Failure Code [DHT5KY] 2079
Failure Code [DHT7KA] 2081
Failure Code [DHT7KY] 2084
Failure Code [DK10KA] 2086
Failure Code [DK10KB] 2089
Failure Code [DK30KA] 2091
Failure Code [DK30KX] 2094
Failure Code [DK30KY] 2095
Failure Code [DK30KZ] 2097
Failure Code [DK30L8] 2098
Failure Code [DK31KA] 2099
Failure Code [DK31KY] 2102
Failure Code [DK40KA] 2104
Failure Code [DK40KY] 2107
Failure Code [DK55KX] 2109
Failure Code [DK55KZ] 2110
Failure Code [DK55L8] 2111
Failure Code [DK56KA] 2112
Failure Code [DK56KY] 2115
Failure Code [DK57KA] 2117
Failure Code [DK57KY] 2120
Failure Code [DK80KA] 2122
Failure Code [DKH1KA] 2125
Failure Code [DKH1KY] 2128
Failure Code [DKSGL8] 2130
Failure Code [DKSHKA] 2132
Failure Code [DKSHKB] 2134
Failure Code [DKSJKA] 2136
Failure Code [DKSJKB] 2138
Failure Code [DKSKKA] 2140
Failure Code [DKSKKB] 2142
Failure Code [DKSKMB] 2144
Failure Code [DKSLL8] 2146
Failure Code [DKSMKA] 2148
Failure Code [DKSMKB] 2150
Failure Code [DKSNKA] 2152
Failure Code [DKSNKB] 2154
Failure Code [DKSPKA] 2156
Failure Code [DKSPKB] 2158
Failure Code [DKSPMB] 2160
Failure Code [DLM3KA] 2162
Failure Code [DLM3KB] 2164
Failure Code [DLM3MB] 2165
Failure Code [DLT3KA] 2166
Failure Code [DLT3KB] 2168
Failure Code [DR21KX] 2170
Failure Code [DR31KX] 2171
Failure Code [DV20KB] 2172
Failure Code [DW7BKA] 2174
Failure Code [DW7BKB] 2176
Failure Code [DWN1KA] 2178
Failure Code [DWN1KB] 2180
Failure Code [DWN1KY] 2182
Failure Code [DWN2KA] 2183
Failure Code [DWN2KB] 2185
Failure Code [DWN2KY] 2186
Failure Code [DWN3KA] 2187
Failure Code [DWN3KB] 2189
Failure Code [DWN3KY] 2191
Failure Code [DWN5KA] 2193
Failure Code [DWN5KB] 2195
Failure Code [DWN5KY] 2197
Failure Code [DXA2KA] 2199
Failure Code [DXA2KB] 2201
Failure Code [DXA2KY] 2203
Failure Code [DXH1KA] 2205
Failure Code [DXH1KB] 2207
Failure Code [DXH1KY] 2209
Failure Code [DXH4KA] 2211
Failure Code [DXH4KB] 2213
Failure Code [DXH4KY] 2215
Failure Code [DXH5KA] 2217
Failure Code [DXH5KB] 2218
Failure Code [DXH5KY] 2219
Failure Code [DXH6KA] 2220
Failure Code [DXH6KB] 2222
Failure Code [DXH6KY] 2223
Failure Code [DXH7KA] 2225
Failure Code [DXH7KB] 2227
Failure Code [DXH7KY] 2229
Failure Code [DXH8KA] 2231
Failure Code [DXH8KB] 2233
Failure Code [DXH8KY] 2235
Failure Code [DXHBKA] 2237
Failure Code [DXHBKB] 2239
Failure Code [DXHBKY] 2241
Failure Code [DXHCKA] 2243
Failure Code [DXHCKB] 2245
Failure Code [DXHCKY] 2247
Failure Code [DXHRKA] 2249
Failure Code [DXHRKB] 2251
Failure Code [DXHRKY] 2252
Failure Code [DXHSKA] 2254
Failure Code [DXHSKB] 2256
Failure Code [DXHSKY] 2257
Failure Code [DXHTKA] 2259
Failure Code [DXHTKB] 2261
Failure Code [DXHTKY] 2263
Failure Code [DXHUKA] 2265
Failure Code [DXHUKB] 2267
Failure Code [DXHUKY] 2269
Failure Code [DXHWKA] 2271
Failure Code [DXHWKB] 2273
Failure Code [DXHWKY] 2274
Failure Code [DXHXKA] 2276
Failure Code [DXHXKB] 2278
Failure Code [DXHXKY] 2279
Failure Code [DXHYKA] 2281
Failure Code [DXHYKB] 2283
Failure Code [DXHYKY] 2284
Failure Code [DXHZKA] 2286
Failure Code [DXHZKB] 2288
Failure Code [DXHZKY] 2289
Failure Code [DXJ4KA] 2291
Failure Code [DXJ4KB] 2293
Failure Code [DXJ8KA] 2294
Failure Code [DXJ8KB] 2296
Failure Code [DXJ8KY] 2298
Failure Code [DXJ9KA] 2300
Failure Code [DXJ9KB] 2302
Failure Code [DXJ9KY] 2304
Failure Code [DXJAKA] 2306
Failure Code [DXJAKB] 2308
Failure Code [DXJAKY] 2310
Failure Code [DXJBKA] 2312
Failure Code [DXJBKB] 2314
Failure Code [DXJBKY] 2316
Failure Code [F311KA] 2318
Failure Code [F311KB] 2320
Failure Code [F312KA] 2322
Failure Code [F312KB] 2324
Failure Code [F313KA] 2326
Failure Code [F313KB] 2328
Failure Code [F314KA] 2331
Failure Code [F314KB] 2333
Failure Code [F315KB] 2335
Failure Code [F315KY] 2337
Failure Code [F316KB] 2339
Failure Code [F316KY] 2341
Failure Code [F318KB] 2343
Failure Code [F318KY] 2346
Failure Code [F31AKB] 2348
Failure Code [F31AKY] 2350
Failure Code [F31BKB] 2352
Failure Code [F31BKY] 2354
Failure Code [F31CKB] 2356
Failure Code [F31CKY] 2358
Failure Code [F31DKB] 2360
Failure Code [F31DKY] 2362
Failure Code [F31EKB] 2364
Failure Code [F31EKY] 2366
Troubleshooting of Electrical System (E-Mode) 2368
E-1 Engine Does Not Start (Engine Does Not Crank) 2368
E-2 Engine Does Not Start in Radio Control Mode (Engine Does Not Crank) 2375
E-3 Engine Stops During Operation (Specifications of Radio Control) 2378
E-4 Manual Preheating System Does Not Work 2382
E-5 Automatic Preheating System Does Not Work 2385
E-6 While Preheating is in Operation, Preheating Monitor Does Not Come On 2387
E-7 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 2389
E-8 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow 2393
E-9 Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation 2395
E-10 Charge Level Monitor Comes On in Red While Engine Runs 2396
E-11 Engine Coolant Temperature Monitor Comes on in Red While Engine is in Operation 2398
E-12 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation 2399
E-13 Power Train Oil Temperature Monitor Comes On in Red While Engine Runs 2400
E-14 Hydraulic Oil Temperature Monitor Comes on in Red While Engine Runs 2401
E-15 Engine Coolant Temperature Gauge Does Not Show Correct Temperature 2402
E-16 Fuel Level Gauge Does Not Show Correct Level 2403
E-17 Power Train Oil Temperature Gauge Does Not Show Correct Temperature 2405
E-18 Hydraulic Oil Temperature Gauge Does Not Show Correct Temperature 2406
E-19 Operation Mode Does Not Change 2407
E-20 Gear Shift Mode Does Not Change 2408
E-21 Movement of Machine Does Not Align to Instructions in Radio Control Transmitter Operation 2409
E-22 Radio Control/on-Board Can Not be Changed 2412
E-23 All Radio Control Can Not be Operated 2414
E-24 Operating Customize Switch Does Not Display Customize Screen 2416
E-25 Modifying Setting on Customize Screen Does Not Change Setting of Machine 2417
E-26 Some Areas of Machine Monitor Screen are Not Shown 2418
E-27 Alarm Buzzer Does Not Sound or Cannot be Stopped 2419
E-28 Service Meter is Not Shown, While Starting Switch is in OFF Position 2420
E-29 Service Mode Cannot be Selected 2421
E-30 Horn Does Not Sound 2422
E-31 Horn Does Not Stop 2424
E-32 Horn Does Not Sound or Does Not Stop (Specifications of Radio Control) 2425
E-33 Backup Alarm Does Not Sound 2427
E-34 Backup Alarm Does Not Stop 2428
E-35 Headlamp Does Not Come On 2429
E-36 Rear Lamp and Ripper Point Lamp Do Not Come On 2433
E-37 Working Lamp Does Not Come On or Go Out (Specifications of Radio Control) 2437
E-38 Red Revolving Lamp Does Not Come On or Go Out (Specifications of Radio Control) 2441
E-39 Yellow Revolving Lamp Does Not Come On or Go Out (Specifications of Radio Control) 2444
E-40 Blue Revolving Lamp Does Not Come On or Go Out (Specifications of Radio Control) 2447
E-41 Green Revolving Lamp Does Not Come On or Go Out (Specifications of Radio Control) 2450
E-42 No Wiper Operates 2453
E-43 Front Wiper Does Not Operate 2458
E-44 Rear Wiper Does Not Operate 2462
E-45 Left Door Wiper Does Not Operate 2466
E-46 Right Door Wiper Does Not Operate 2470
E-1 Fuel Feed Pump Does Not Operate or Stop Automatically 2474
E-48 Fan Does Not Rotate in Reverse 2475
E-49 Gear Cannot be Shifted 2476
E-50 Front Washer Does Not Operate 2477
E-51 Rear Washer Does Not Operate 2480
E-52 Left Door Washer Does Not Operate 2483
E-53 Right Door Washer Does Not Operate 2486
E-54 Ripper Pin Puller Does Not Work 2489
E-55 KOMTRAX System Does Not Operate Correctly 2491
E-56 Control Box Shows Message [GPS Receiver Not Connected !] and [Slope Sensor Not Connected !], and Then Shuts Down 2492
E-57 Control Box Shows Messages [GPS receiver not connected !] and [Slope sensor not connected !] 2496
E-58 Control Box Shows Message [Waiting for Radio Link] 2499
E-59 Control Box Shows Message [IMU sensor not connected] Show Production 2500
E-60 Control Box Shows Message [Waiting for satellites ] 2501
E-61 Control Box Shows Message [GPS Receiver Not Connected!] Show Production 2502
E-62 Control Box Shows Message [Cylinder Stroke Reading Abnormal] 2504
E-63 Control Box Shows Message [Komatsu CAN Comms Abnormal] 2505
E-64 Control Box Shows Message [Komatsu Machine Trouble] 2506
E-65 Control Box Shows Message [Waiting to Initialize ] 2507
E-66 Control Box Shows Message [System Initializing] 2508
E-67 Control Box Shows Message [Waiting to Initialize ] 2509
E-68 Control Box Shows Message [Configuring GPS] 2510
E-69 Control Box Shows Message [No GPS Localization] 2511
E-70 Control Box Shows Message [Low Precisions ] 2512
E-71 Control Box Shows Message [Heading Initializing] 2513
E-72 Control Box Shows Message [Out of Design Area] 2514
E-73 Control Box Cannot be Turned on 2515
E-74 Control Box Does Not Show Intelligent Machine Control Screen 2516
E-75 Control Box Does Not Display Bulldozer Image 2517
E-76 Control Box Does Not Show Design Surface 2518
E-77 Control Box Touch Panel Does Not Respond 2519
E-78 Control Box Touch Panel is Inaccurate 2520
E-79 Cylinder Stroke Reset Indication Does Not Go Out 2521
E-80 AUTO is Not Shown When AUTO/Manual Switch is Pushed (AUTO Indication Goes Out) 2522
E-81 Blade Automatic Lower Control Does Not Start While AUTO is Shown 2523
E-82 Blade Automatic Raise Control Does Not Start While AUTO is Shown 2524
E-83 Blade Automatic Control Function is Not Activated While AUTO is Shown (Blade Automatic Control Stops) 2525
E-84 When You Examine and Adjust the Blade Elevation, the Value is Different from Actual Machine 2526
E-85 Finished Surface is Inaccurate (The Average Height of Finished Surface is Lower Than Designed Surface or Blade Does Not Touch the Surface) 2527
E-86 Finished Surface is Inaccurate (the Finished Surface is Not Smooth) 2528
E-87 Finished Surface is Inaccurate (When You Finish Slope Horizontally, Steps are Made in Each Direction) 2529
E-88 Machine Can Not Escape from Shoes Slip While Blade Automatic Control is Activated (Shoes Frequently Slips) 2530
E-89 Blade Tilt Angle is Different from Design Surface 2531
E-90 When You Push Cut/Fill Level Switch (Raise), the Design Surface Does Not Rise 2533
E-91 When You Push Cut/Fill Level Switch (Lower), the Design Surface Does Not Lower 2536
E-92 When Starting Switch is Turned to ON Position, Reverse Leveling Mode Switch LED Does Not Come On or Does Not Go Out 2539
E-93 When Reverse Leveling Mode Switch is Pushed, Buzzer Does Not Sound (Does Not Switch to Reverse Leveling Mode) 2541
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 2544
Information Shown in Troubleshooting Table (H-Mode) 2544
System Chart of Hydraulic and Mechanical Systems 2545
Failure Mode and Cause Table 2549
H-1 Machine Power is Not Sufficient (Not Sufficient Drawbar Pull) 2557
H-2 Machine Does Not Travel (at 2nd or 3rd Gear Speed) 2560
H-3 Machine Does Not Move Off at All Gear Speeds 2562
H-4 Machine Travels Only in One Direction, Forward or in Reverse 2565
H-5 Large Time Lag is in Gear Shifting or Directional Change 2566
H-6 Brake Does Not Work 2568
H-7 Power Train Oil Overheats 2569
H-8 Unusual Noise is Heard from Around Work Equipment and HSS Pump or HSS Motor 2571
H-9 Torque Converter Lockup Clutch Does Not Engage 2572
H-10 Machine Cannot be Steered (Machine Does Not Turn Left or Right) 2573
H-11 Steering Speed or Power is Not Sufficient 2575
H-12 All Work Equipment Operate Slowly 2577
H-13 All Work Equipment Do Not Operate 2579
H-14 Blade Lift Speed or Power is Low 2581
H-15 Blade Tilt Speed or Power is Low 2583
H-16 Ripper Lift Speed or Power is Low 2585
H-17 Ripper Tilt Speed or Power is Low 2587
H-18 Hydraulic Drift of Blade Lift is Large 2589
H-19 Hydraulic Drift of Tilted Blade is Large 2590
H-20 Hydraulic Drift of Lifted Ripper is Large 2591
H-21 Ripper Pin Puller Cylinder Does Not Operate 2592
H-22 Blade Pitch Cylinder Does Not Operate 2593
H-23 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) 2594
H-24 Unusual Noise is Heard from Around Fan 2595
Troubleshooting of Engine (S-Mode) 2596
Information Shown in Troubleshooting Table (S-Mode) 2596
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position 2597
S-2 Engine Cranks but No Exhaust Smoke Comes Out 2598
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 2599
S-4 Engine Startability is Unsatisfactory 2600
S-5 Engine Does Not Pick Up Smoothly 2602
S-6 Engine Stops During Operation 2604
S-7 Engine Runs Rough or is Not Stable 2606
S-8 Engine Lacks Power 2607
S-9 KDPF Becomes Clogged in a Short Time 2609
S-10 Engine Oil Consumption is Excessive 2611
S-11 Oil Becomes Dirty Quickly 2612
S-1 Fuel Consumption is Excessive 2613
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant 2614
S-14 Oil Pressure Drops 2615
S-15 Fuel Mixes Into Engine Oil 2617
S-16 Water Mixes Into Engine Oil (Milky) 2618
S-17 Coolant Temperature Increases Too High (Overheating) 2619
S-18 Unusual Noise is Heard 2620
S-19 Vibration is Excessive 2621
S-2 Air Cannot be Bled from Fuel Circuit 2622
S-21 Active Regeneration is Done Frequently 2623
S-22 Active Regeneration Continues Long 2625
S-23 White Smoke is Exhausted During Active Regeneration 2626
S-24 DEF Consumption is Excessive 2627
S-25 There is Unusual Smell (Irritating Odor) 2629
S-26 Foreign Materials Enter DEF (DEF Increases) 2630
50 Disassembly and Assembly 2631
Table of Contents 2632
Precautions Before Work 2638
Related Information on Disassembly and Assembly 2639
How to Read This Manual 2639
Coating Materials List 2640
Special Tool List 2645
Sketches of Special Tools 2674
Engine and Cooling System 2701
Remove and Install Supply Pump Assembly 2701
Remove Supply Pump Assembly 2701
Install Supply Pump Assembly 2703
Remove and Install Injector Assembly 2709
How to Remove Injector Assembly 2709
How to Install Injector Assembly 2715
Remove and Install Fuel Doser Assembly 2724
Remove Fuel Doser Assembly 2724
Install Fuel Doser Assembly 2725
Remove and Install Cylinder Head Assembly 2726
How to Remove Cylinder Head Assembly 2727
How to Install Cylinder Head Assembly 2737
Remove and Install EGR Valve Assembly 2753
Remove EGR Valve Assembly 2753
Install EGR Valve Assembly 2754
Remove and Install EGR Cooler Assembly 2756
How to Remove EGR Cooler Assembly 2756
How to Install EGR Cooler Assembly 2758
Remove and Install Starter Assembly 2761
Remove Starting Motor Assembly 2761
Install Starting Motor Assembly 2762
Remove and Install Alternator Belt 2764
Remove Alternator Belt 2764
Install Alternator Belt 2765
Remove and Install Radiator Assembly 2767
How to Remove Radiator Assembly 2767
How to Install Radiator Assembly 2770
Remove and Install Hydraulic Oil Cooler Assembly 2776
How to Remove Hydraulic Oil Cooler Assembly 2776
How to Install Hydraulic Oil Cooler Assembly 2777
Remove and Install Aftercooler Assembly 2779
Remove Aftercooler Assembly 2779
Install Aftercooler Assembly 2780
Remove and Install Cooling Fan Drive Assembly 2783
Remove Cooling Fan Drive Assembly 2783
Install Cooling Fan Drive Assembly 2785
Remove and Install Cooling Fan Motor Assembly 2787
Remove Cooling Fan Motor Assembly 2787
Install Cooling Fan Motor Assembly 2788
Remove and Install Engine Assembly 2789
Remove Engine Assembly 2789
Install Engine Assembly 2796
Remove and Install Engine Front Oil Seal 2803
How to Remove Engine Front Oil Seal 2803
How to Install Engine Front Oil Seal 2805
Remove and Install Engine Rear Oil Seal 2809
How to Remove Engine Rear Oil Seal 2809
How to Install Engine Rear Oil Seal 2811
Remove and Install Engine Hood Assembly 2815
How to Remove Engine Hood Assembly 2815
How to Install Engine Hood Assembly 2818
Remove and Install Fuel Tank Assembly 2821
Remove Fuel Tank Assembly 2821
Install Fuel Tank Assembly 2824
Remove and Install DEF Tank Assembly 2828
How to Remove DEF Tank Assembly 2828
How to Install DEF Tank Assembly 2834
Remove and Install DEF Tank Sensor Flange Assembly 2839
How to Remove DEF Tank Sensor Flange Assembly 2839
How to Install DEF Tank Sensor Flange Assembly 2845
Remove and Install DEF Tank Sensor 2850
Remove DEF Tank Sensor 2850
Install DEF Tank Sensor 2850
Remove and Install DEF Tank Strainer 2857
Remove DEF Tank Strainer 2857
Install DEF Tank Strainer 2857
Remove and Install DEF Tank Filler Port Filter 2858
Remove DEF Tank Filler Port Filter 2858
Install DEF Tank Filler Port Filter 2859
Remove and Install KDPF Assembly 2862
How to Remove KDPF Assembly 2862
How to Install KDPF Assembly 2866
Disassemble and Assemble KDPF Assembly 2870
Disassemble KDPF Assembly 2870
Assemble KDPF Assembly 2875
Remove and Install SCR Assembly 2880
How to Remove SCR Assembly 2880
How to Install SCR Assembly 2883
Remove and Install KDPF and SCR Assembly 2888
How to Remove KDPF and SCR Assembly 2888
Install KDPF and SCR Assembly 2893
Remove and Install KCCV Assembly 2900
Remove KCCV Assembly 2900
Install KCCV Assembly 2902
Remove and Install DEF Mixing Tube 2905
Remove DEF Mixing Tube 2905
Install DEF Mixing Tube 2908
Remove and Install DEF Injector 2913
Remove DEF Injector 2913
Install DEF Injector 2916
Remove and Install DEF Pump 2919
Remove DEF Pump 2919
Install DEF Pump 2923
Remove and Install DEF Hose 2927
Remove DEF Hose 2927
Install DEF Hose 2933
Remove and Install Air Cleaner Assembly 2939
Remove Air Cleaner Assembly 2939
Install Air Cleaner Assembly 2940
Remove and Install Air Conditioner Compressor Assembly 2942
Remove Air Conditioner Compressor Assembly 2942
How to Install Air Conditioner Compressor Assembly 2943
Remove and Install Air Conditioner Condenser Assembly 2944
How to Remove Air Conditioner Condenser Assembly 2944
How to Install Air Conditioner Condenser Assembly 2945
Power Train 2948
Remove and Install Damper Assembly 2948
How to Remove Damper Assembly 2948
How to Install Damper Assembly 2950
Disassemble and Assemble Damper Assembly 2953
Disassemble Damper Assembly 2954
Assemble Damper Assembly 2955
Remove and Install Power Train Unit Assembly 2958
Remove Power Train Unit Assembly 2958
How to Install Power Train Unit Assembly 2963
Disconnect and Connect Power Train Unit Assembly 2968
How to Disconnect Power Train Unit Assembly 2968
Connect Power Train Unit Assembly 2974
Disassemble and Assemble PTO Assembly 2980
Disassemble PTO Assembly 2980
Assemble PTO Assembly 2984
Disassemble and Assemble Torque Converter Assembly 2991
Disassemble Torque Converter Assembly 2991
Assemble Torque Converter Assembly 2997
Disassemble and Assemble Transmission Assembly 3005
Disassemble Transmission Assembly 3006
Assemble Transmission Assembly 3016
Disassemble and Assemble HSS Assembly 3029
Disassemble HSS Assembly 3031
Assemble HSS Assembly 3040
Remove and Install HSS Motor Assembly 3054
Remove HSS Motor Assembly 3054
How to Install HSS Motor Assembly 3055
Remove and Install Final Drive Assembly 3057
Remove Final Drive Assembly 3057
Install Final Drive Assembly 3059
Disassemble and Assemble Final Drive Assembly 3062
Disassemble Final Drive Assembly 3064
Assemble Final Drive Assembly 3071
Undercarriage and Frame 3082
Remove and Install Track Frame Assembly (Applicable Machine: 100001 to 100616) 3082
Remove Track Frame Assembly 3083
How to Install Track Frame Assembly 3087
Remove and Install Track Frame Assembly (Applicable Machine: 100617 and up) 3092
How to Remove Track Frame Assembly (Applicable Machine: 100617 and up) 3092
How to Install Track Frame Assembly (Applicable Machine: 100617 and up) 3097
Remove and Install Idler Assembly 3101
Remove Idler Assembly 3101
Install Idler Assembly 3102
Disassemble and Assemble Idler Assembly 3104
Disassemble Idler Assembly 3104
Assemble Idler Assembly 3105
Remove and Install Recoil Spring Assembly 3109
Remove Recoil Spring Assembly 3109
Install Recoil Spring Assembly 3109
Disassemble and Assemble Recoil Spring Assembly 3110
Disassemble Recoil Spring Assembly 3110
Assemble Recoil Spring Assembly 3114
Remove and Install Track Roller Assembly 3117
Remove Track Roller Assembly 3117
Install Track Roller Assembly 3119
Disassemble and Assemble Track Roller Assembly 3121
Disassemble Track Roller Assembly 3121
Assemble Track Roller Assembly 3122
Remove and Install No 1 Bogie Assembly 3125
Remove No 1 Bogie Assembly 3126
Install No 1 Bogie Assembly 3129
Remove and Install No 2, 3, 4 Bogie Assemblies 3134
How to Remove No 2, 3, 4 Bogie Assemblies 3135
Install No 2, 3, 4 Bogie Assemblies 3137
Disassemble and Assemble Bogie Assembly 3142
Disassemble Bogie Assembly 3142
Assemble Bogie Assembly 3143
Remove and Install Carrier Roller Assembly 3145
Remove Carrier Roller Assembly 3145
Install Carrier Roller Assembly 3146
Disassemble and Assemble Carrier Roller Assembly 3147
Disassemble Carrier Roller Assembly 3147
Assemble Carrier Roller Assembly 3149
Remove and Install Pivot Shaft Assembly 3152
How to Remove Pivot Shaft Assembly 3152
How to Install Pivot Shaft Assembly 3153
Separate and Connect Track Assembly 3154
Examine Before Separation of Track Assembly 3154
Separate Track Assembly (Standard) 3154
How to Separate Track Assembly (When Track Frame Has Internal Defect) 3155
Install Track Assembly 3157
Separate and Connect PLUS Type Track Assembly 3159
Separate PLUS Type Track Assembly Generally 3159
Install PLUS Type Track Assembly 3159
Disassemble and Assemble Track Assembly Generally 3160
How to Disassemble Full Track Shoes Assembly 3160
How to Assemble Full Track Shoes Assembly 3162
Disassemble and Assemble PLUS Type Track Assembly Generally 3175
Disassemble PLUS Type Track Assembly Generally 3175
How to Assemble PLUS Type Track Shoes Assembly Generally 3176
Disassemble and Assemble One Track Link Assembly in Field 3185
Disassemble One Track Link Assembly in Field 3186
Assemble One Track Link Assembly in Field 3187
Disassemble and Assemble Master Link 3190
Disassemble Master Link 3190
Assemble Master Link 3191
Remove and Install Equalizer Bar Assembly 3194
Remove Equalizer Bar Assembly 3194
Install Equalizer Bar Assembly 3196
Disassemble and Assemble Equalizer Bar Bushing 3198
Disassemble Equalizer Bar Bushing 3198
Assemble Equalizer Bar Bushing 3199
Remove and Install Sprocket 3200
Remove Sprocket 3200
Install Sprocket 3200
Remove and Install Center Under Guard Assembly 3201
Remove Underguard Assembly 3201
Install Underguard Assembly 3208
Hydraulic System 3216
Remove and Install Hydraulic Tank Assembly 3216
Remove Hydraulic Tank Assembly 3216
How to Install Hydraulic Tank Assembly 3217
Remove and Install Work Equipment Pump and HSS Pump Assembly 3219
Remove Work Equipment Pump and HSS Pump Assembly 3219
Install Work Equipment Pump and HSS Pump Assembly 3221
Remove and Install Power Train Pump and Steering Lubrication Pump Assembly 3223
Remove Power Train Pump and Steering Lubrication Pump Assembly 3223
Install Power Train Pump and Steering Lubrication Pump Assembly 3225
Remove and Install Cooling Fan Pump Assembly 3227
Remove Cooling Fan Pump Assembly 3227
Install Cooling Fan Pump Assembly 3229
Remove and Install Scavenging Pump Assembly 3231
Remove Scavenging Pump Assembly 3231
Install Scavenging Pump Assembly 3232
Remove and Install Control Valve Assembly 3233
How to Remove Control Valve Assembly 3233
How to Install Control Valve Assembly 3234
Work Equipment 3237
Remove and Install Blade Assembly 3237
Remove Blade Assembly 3237
Install Blade Assembly 3239
Disassemble and Assemble Blade Assembly 3242
Disassemble Blade Assembly 3242
Assemble Blade Assembly 3245
Disassemble and Assemble Multi-Shank Ripper Assembly 3248
Disassemble Multi-Shank Ripper Assembly 3248
Assemble Multi-Shank Ripper Assembly 3250
Disassemble and Assemble Giant Ripper Assembly 3253
Disassemble Giant Ripper Assembly 3253
Assemble Giant Ripper Assembly 3256
Remove and Install Stroke and Reset Sensing Blade Lift Cylinder Assembly 3259
Remove Stroke and Reset Sensing Blade Lift Cylinder Assembly 3260
Install Stroke and Reset Sensing Blade Lift Cylinder Assembly 3264
Disassemble and Assemble Stroke and Reset Sensing Blade Lift Cylinder Assembly 3269
Disassemble Stroke and Reset Sensing Blade Lift Cylinder Assembly 3270
Assemble Stroke and Reset Sensing Blade Lift Cylinder Assembly 3275
Disassemble and Assemble Blade Tilt Cylinder Assembly 3288
Disassemble Blade Tilt Cylinder Assembly 3288
Assemble Blade Tilt Cylinder Assembly 3290
Disassemble and Assemble Ripper Cylinder Assembly 3293
Disassemble Ripper Cylinder Assembly 3293
Assemble Ripper Cylinder Assembly 3295
CAB Related Parts 3300
Remove and Install Operator Cab Assembly 3300
How to Remove Operator Cab Assembly 3301
Install Operator CAB Assembly 3311
Remove and Install Operator Cab Glass (Adhered Glass) 3320
Remove Operator CAB Glass (Adhered Glass) 3322
Install Operator CAB Glass (Adhered Glass) 3322
Remove and Install Air Conditioner Unit Assembly 3327
Remove Air Conditioner Unit Assembly 3327
Install Air Conditioner Unit Assembly 3333
Remove and Install Operator Seat 3340
Remove Operator’s Seat 3340
Install Operator’s Seat 3341
How to Remove and Install Seat Belt 3342
How to Remove Seat Belt 3342
How to Install Seatbelt 3343
Electrical System 3344
Remove and Install Engine Controller Assembly 3344
Remove Engine Controller Assembly 3344
Install Engine Controller Assembly 3347
Remove and Install Power Train Controller Assembly 3350
Remove Power Train Controller Assembly 3350
Install Power Train Controller Assembly 3351
Remove and Install Work Equipment Controller Assembly 3352
Remove Work Equipment Controller Assembly 3352
Install Work Equipment Controller Assembly 3352
Remove and Install Radio Control Controller 3354
How to Remove Radio Control Controller 3354
How to Install Radio Control Controller 3354
Remove and Install Machine Monitor Assembly 3356
Remove Machine Monitor Assembly 3356
Install Machine Monitor Assembly 3357
Remove and Install Mass Air Flow and Temperature Sensor 3359
How to Remove Mass Air Flow and Temperature Sensor 3359
How to Install Mass Air Flow and Temperature Sensor 3360
Remove and Install KCCV Crankcase Pressure Sensor 3362
How to Remove KCCV Crankcase Pressure Sensor 3362
How to Install KCCV Crankcase Pressure Sensor 3363
Remove and Install SCR Temperature Sensor 3364
Remove SCR Temperature Sensor 3364
Install SCR Temperature Sensor 3366
Remove and Install Battery Relay 3368
Remove Battery Relay 3368
Install Battery Relay 3376
Remove and Install KOMTRAX Terminal Assembly 3381
Remove KOMTRAX Terminal Assembly 3381
Install KOMTRAX Terminal Assembly 3383
Remove and Install Gateway Controller Assembly 3386
Remove Gateway Controller Assembly 3386
Install Gateway Controller Assembly 3390
Remove and Install Communication Terminal 3395
How to Remove Communication Terminal 3395
How to Install Communication Terminal 3401
Remove and Install Communication Terminal Wiring Harness 3407
How to Remove Communication Terminal Wiring Harness 3408
How to Install Communication Terminal Wiring Harness 3420
Remove and Install Control Box 3433
How to Remove Control Box (For Old Control Box) 3433
How to Remove Control Box (For New Control Box) 3434
How to Install Control Box (For Old Control Box) 3434
How to Install Control Box (For New Control Box) 3435
Remove and Install GNSS Receiver 3437
Remove GNSS Receiver 3437
Install GNSS Receiver 3438
Remove and Install GNSS Antenna 3439
Remove GNSS Antenna 3439
Install GNSS Antenna 3440
Remove and Install IMU Sensor 3445
Remove IMU Sensor 3445
Install IMU Sensor 3447
Remove and Install Radio Control Receiver 3451
How to Remove Radio Control Receiver 3451
How to Install Radio Control Receiver 3451
Remove and Install Revolving Lamp 3453
Remove Revolving Lamp 3453
Install Revolving Lamp 3454
Remove and Install Radio Control Antenna 3455
How to Remove Radio Control Antenna 3455
How to Install Radio Control Antenna 3455
60 Maintenance Standard 3457
Table of Contents 3458
Engine and Cooling System 3460
Maintenance Standard for Engine Mount 3460
Maintenance Standard for Damper 3462
Maintenance Standard for Cooling System 3464
Maintenance Standard for Cooling Fan Pump 3466
Maintenance Standard for Servo Valve 3468
Maintenance Standard for Cooling Fan Motor 3470
Power Train 3472
Maintenance Standard for Universal Joint 3472
Maintenance Standard for Power Train Mount 3473
Maintenance Standard for Torque Converter and PTO 3475
Maintenance Standard for Torque Converter Control Valve 3480
Maintenance Standard for Lockup Clutch ECMV 3481
Maintenance Standard for Stator Clutch ECMV 3482
Maintenance Standard for Transmission 3483
Maintenance Standard for Transmission ECMV 3488
Maintenance Standard for Main Relief Valve and Torque Converter Relief Valve 3489
Maintenance Standard for Transmission Lubrication Relief Valve 3490
Maintenance Standard for Bevel Gear Shaft, HSS, and Brake 3491
Maintenance Standard for Brake Control Valve 3497
Maintenance Standard for Brake ECMV 3499
Maintenance Standard for Brake Solenoid Valve 3500
Maintenance Standard for Sudden Stop Prevention Valve 3501
Maintenance Standard for Final Drive 3502
Maintenance Standard for Sprocket for Conventional Type Track Shoes 3505
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for Conventional Type Track Shoes 3506
Maintenance Standard for Sprocket for PLUS Type Track Shoes 3508
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for PLUS Type Track Shoes 3509
Undercarriage and Frame 3511
Maintenance Standard for Main Frame 3511
Maintenance Standard for Suspension 3513
Maintenance Standard for Track Frame and Idler Cushion 3515
Maintenance Standard for Idler 3517
Maintenance Standard for Track Roller for Conventional Type Track Shoes 3519
Maintenance Standard for Track Roller for PLUS Type Track Shoes 3521
Maintenance Standard for Carrier Roller for Conventional Type Track Shoes 3523
Maintenance Standard for Carrier Roller for PLUS Type Track Shoes 3524
Maintenance Standard for Conventional Type Track Shoes 3525
Maintenance Standard for PLUS Type Track Shoes 3527
Maintenance Standard for Single Shoes and Heavy Duty Shoes 3529
Hydraulic System 3530
Maintenance Standard for Hydraulic Tank 3530
Maintenance Standard for Scavenging Pump 3531
Maintenance Standard for Steering Lubrication Pump and Power Train Pump 3532
Maintenance Standard for Work Equipment and HSS Pump 3534
Maintenance Standard for PC-EPC Valve 3536
Maintenance Standard for HSS Motor 3537
Maintenance Standard for Control Valve 3540
Maintenance Standard for Self-Pressure Reducing Valve 3554
Maintenance Standard for Quick Drop Valve 3556
Work Equipment 3558
Maintenance Standard for Cylinder Stay 3558
Maintenance Standard for Front Work Equipment 3560
Maintenance Standard for Cutting Edge and End Bit 3562
Maintenance Standard for Stroke and Reset Sensing Blade Lift Cylinder 3563
Maintenance Standard for Blade Tilt Cylinder 3564
Maintenance Standard for Variable Multi-Shank Ripper 3565
Maintenance Standard for Variable Giant Ripper 3568
Maintenance Standard for Ripper Lift Cylinder 3571
Maintenance Standard for Ripper Tilt Cylinder 3572
CAB Related Parts 3573
Maintenance Standard for CAB Mount 3573
80 Appendix 3575
Table of Contents 3576
Precautions Before Work 3578
Air Conditioner System 3579
Precautions for Refrigerant 3579
Air Conditioner Component 3580
Specifications of Air Conditioner 3582
Structure and Function of Refrigeration Cycle 3583
Outline of Refrigeration Cycle 3584
Component Parts of Air Conditioner System 3586
Air Conditioner Unit 3586
Configuration Diagram of Air Conditioner Unit 3586
Function of Air Conditioner Unit 3588
Component Parts of Air Conditioner Unit 3590
Function of Evaporator as Air Conditioner Unit Component 3591
Function of Heater Core as Air Conditioner Unit Component 3591
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component 3591
Function of Servo Motor as Air Conditioner Unit Component 3591
Structure of Expansion Valve as Air Conditioner Unit Component 3592
Function of Expansion Valve as Air Conditioner Unit Component 3592
Operate Expansion Valve as Air Conditioner Unit Component 3592
Function of Triple Pressure Switch 3593
Air Conditioner Controller 3594
Structure of Air Conditioner Controller 3594
Compressor 3595
Structure of Compressor 3595
Specifications of Compressor 3595
Function of Compressor 3595
Condenser 3596
Structure of Condenser 3596
Specifications of Condenser 3596
Function of Condenser 3596
Receiver Drier 3597
Structure of Receiver Dryer 3597
Specifications of Receiver Dryer 3597
Function of Receiver Dryer 3597
Air Conditioner Related Sensors 3598
Structure of Sunlight Sensor 3598
Function of Sunlight Sensor 3598
Structure of Outside Temperature Sensor 3598
Function of Outside Air Temperature Sensor 3598
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 3600
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 3602
System Diagram of Air Conditioner 3604
Input and Output Signals of Air Conditioner Controller 3605
Function of Air Conditioner Controller 3606
Locations of Air Conditioner Parts and Layout of Connectors 3607
Examine Air Leakage (Duct) 3615
How to Examine Air Leakage (Duct) 3615
Examine Air Conditioner with Self-Diagnosis Function 3618
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor 3619
Examine Vent (Mode) Changeover 3620
How to Examine Vent (Mode) Changeover 3620
Examine Fresh/Recirc Air Changeover 3621
How to Examine Fresh/Recirc Air Changeover 3621
Examine Sunlight Sensor 3622
How to Examine Sunlight Sensor 3622
Examine Refrigerant (Triple) Pressure Switch 3623
How to Examine Refrigerant (Triple) Pressure Switch 3623
Examine Relay 3624
How to Examine Relay 3624
Air Conditioner Troubleshooting Chart 1 3625
Air Conditioner Troubleshooting Chart 2 3626
Information Shown in Troubleshooting Table 3629
Failure Code [879AKA] 3630
Failure Code [879AKB] 3631
Failure Code [879BKA] 3632
Failure Code [879BKB] 3634
Failure Code [879CKA] 3636
Failure Code [879CKB] 3637
Failure Code [879DKZ] 3638
Failure Code [879EMC] 3640
Failure Code [879FMC] 3641
Failure Code [879GKX] 3642
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 3644
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 3645
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 3646
A-4 Troubleshooting for Fresh/Recirc Air Changeover 3647
Troubleshooting by Gauge Pressure 3648
Connect Service Tool 3651
How to Connect Service Tool 3651
Precautions for Disconnection and Connection of Air Conditioner Piping 3653
Handle Compressor Oil 3655
90 Circuit Diagrams 3657
Table of Contents 3658
Hydraulic Circuit Diagram 3659
Symbols Used in Hydraulic Circuit Diagram 3659
Hydraulic Circuit Diagram (1/2) 3663
Hydraulic Circuit Diagram (2/2) 3665
Power Train Hydraulic Circuit Diagram 3667
Electrical Circuit Diagram 3669
Symbols Used in Electric Circuit Diagram 3669
Electrical Circuit Diagram (1/17) 3673
Electrical Circuit Diagram (2/17) 3675
Electrical Circuit Diagram (3/17) 3677
Electrical Circuit Diagram (4/17) 3679
Electrical Circuit Diagram (5/17) 3681
Electrical Circuit Diagram (6/17) 3683
Electrical Circuit Diagram (7/17) 3685
Electrical Circuit Diagram (8/17) 3687
Electrical Circuit Diagram (9/17) 3689
Electrical Circuit Diagram (10/17) 3691
Electrical Circuit Diagram (11/17) 3693
Electrical Circuit Diagram (12/17) 3695
Electrical Circuit Diagram (13/17) 3697
Electrical Circuit Diagram (14/17) 3699
Electrical Circuit Diagram (15/17) 3701
Electrical Circuit Diagram (16/17) 3703
Electrical Circuit Diagram (17/17) 3705
Electrical Circuit Diagram(1/16) (Machine with Gateway Function Controller) 3707
Electrical Circuit Diagram(2/16) (Machine with Gateway Function Controller) 3709
Electrical Circuit Diagram(3/16) (Machine with Gateway Function Controller) 3711
Electrical Circuit Diagram(4/16) (Machine with Gateway Function Controller) 3713
Electrical Circuit Diagram(5/16) (Machine with Gateway Function Controller) 3715
Electrical Circuit Diagram(6/16) (Machine with Gateway Function Controller) 3717
Electrical Circuit Diagram(7/16) (Machine with Gateway Function Controller) 3719
Electrical Circuit Diagram(8/16) (Machine with Gateway Function Controller) 3721
Electrical Circuit Diagram(9/16) (Machine with Gateway Function Controller) 3723
Electrical Circuit Diagram(10/16) (Machine with Gateway Function Controller) 3725
Electrical Circuit Diagram(11/16) (Machine with Gateway Function Controller) 3727
Electrical Circuit Diagram(12/16) (Machine with Gateway Function Controller) 3729
Electrical Circuit Diagram(13/16) (Machine with Gateway Function Controller) 3731
Electrical Circuit Diagram(14/16) (Machine with Gateway Function Controller) 3733
Electrical Circuit Diagram(15/16) (Machine with Gateway Function Controller) 3735
Electrical Circuit Diagram(16/16) (Machine with Gateway Function Controller) 3737
Index 3739

DESCRIPTION:

Komatsu D155AXi-8 Bulldozer Shop Manual SEN06582-10 – PDF DOWNLOAD 

SERIAL NUMBERS 100040 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.
• 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 30/12/24