Komatsu D155AX-6 Bulldozer (80001 and up) Shop Manual – SEN00596-09

This complete service repair workshop manual PDF download for the Komatsu D155AX-6 Bulldozer (SN: 80001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.

APPLICABLE MODELS :

Machine Model : D155AX-6
Serial Numbers : 80001 and up

TABLE OF CONTENTS :

– GENERAL
– STRUCTURE AND FUNCTION
– MAINTENANCE STANDARD
– TESTING AND ADJUSTING
– DISASSEMBLY AND ASSEMBLY
– OTHERS

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEN00596-09
Total Pages : 1567

This service repair workshop manual PDF download has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

–

TABLE OF CONTENTS :

00 Index and foreword
Index
Composition of shop manual
Table of contents
Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table

01 Specification
Specification and technical data
Specification dimension drawings
Specifications
Weight table
Table of fuel, coolant and lubricants

10 Structure, function and maintenance standard
Engine and cooling system
Engine and cooling system
Radiator, oil cooler
Engine mount
Cooling fan pump
Cooling fan motor
Power train, Part 1
Power train skeleton
Overall drawing of power train unit
Power train hydraulic piping drawing
Damper, universal joint
Torque converter, PTO
Torque converter control valve
Lockup clutch ECMV, stator clutch ECMV
Transmission control
Transmission
Transmission ECMV
Main relief valve and torque converter relief valve
Lubrication relief valve
Scavenging pump
Power train and steering lubrication pump
Power train, Part 2
HSS system
HSS motor
Hydraulic, HSS pump
Hydraulic oil cooler bypass valve
Steering, brake control
Steering unit
Brake control valve
Brake ECMV
Parking brake solenoid valve
Sudden stop prevention valve
Final drive
Sprocket
Undercarriage and frame
Track frame
Recoil spring
Idler
Track roller
Carrier roller
Track shoe
Main frame
Suspension
Hydraulic system
Work equipment hydraulic piping diagram
Work equipment control piping diagram
Work equipment control
Hydraulic tank and filter
Accumulator
PCCS lever
Work equipment lock valve
Control valve
Work equipment cylinder
Piston valve
Quick drop valve
Self pressure reducing valve
Work equipment
Cylinder stay
Blade
Cutting edge, end bit
Ripper
Cab and its attachments
Cab mount + ROPS pin
ROPS cab
Air conditioner
Electrical system
Engine control
Engine control system
Deceleration potentiometer
Monitor system
Sensors
Palm command control system
KOMTRAX system

20 Standard value table
Standard service value table
Standard value table for engine
Standard value table for machine

30 Testing and adjusting
Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting
Measuring engine speed
Measuring intake air pressure (boost pressure)
Measuring exhaust temperature
Measuring exhaust gas color
Adjusting valve clearance
Measuring compression pressure
Measuring blow-by pressure
Measuring engine oil pressure
Testing EGR valve and bypass valve drive oil pressure
Handling fuel system parts
Releasing residual pressure from fuel system
Measuring fuel pressure
Measuring fuel return rate and fuel leakage
Bleeding air from fuel circuit
Measuring fuel circuit for leakage
Testing and adjusting alternator belt tension
Testing and adjusting air conditioner compressor belt tension
Measuring fan speed
Measuring fan circuit oil pressure
Bleeding air from fan pump
Adjusting fuel control dial and decelerator pedal
Testing and adjusting, Part 2
Testing and adjusting, Part 2
Measuring power train oil pressure
Adjusting transmission output shaft speed sensor
Simple test procedure for brake performance
Adjusting brake pedal
Adjusting parking brake lever
Emergency escape method when power train has trouble
Adjusting idler clearance
Testing and adjusting track shoe tension
Measuring and adjusting work equipment and HSS oil pressure
Measuring control circuit basic pressure
Measuring work equipment lock solenoid valve output pressure
Emergency operation method when work equipment has trouble
Measuring ripper pin puller solenoid valve output pressure
Testing parts which cause hydraulic drift of blade and ripper
Measuring internal leakage of work equipment cylinder
Releasing residual pressure from work equipment cylinder
Bleeding air from work equipment cylinder
Adjusting work equipment lock lever
Adjusting blade
Adjusting operator’s cab
Testing and adjusting, Part 3
Special functions of machine monitor (EMMS)
Testing and adjusting, Part 4
Testing and adjusting, Part 4
Handling of power supply circuit of engine controller
Preparation work for troubleshooting of electrical system
Pm Clinic

40 Troubleshooting
Failure code table and fuse locations
Failure codes table
Fuse locations
Information in troubleshooting table
General information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Check before troubleshooting
Classification and procedures for troubleshooting
Connection table for connector pin numbers
T- branch box and T- branch adapter table
Troubleshooting by failure and error codes, Part 1
Failure code [1500L0] Transmission clutch: Abnormal
Failure code [15SAL1] Forward clutch: Fill high
Failure code [15SALH] Forward clutch: Fill low
Failure code [15SBL1] Reverse clutch: Fill high
Failure code [15SBLH] Reverse clutch: Fill low
Failure code [15SEL1] Speed 1st clutch: Fill high
Failure code [15SELH] Speed 1st clutch: Fill low
Failure code [15SFL1] Speed 2nd clutch: Fill high
Failure code [15SFLH] Speed 2nd clutch: Fill low
Failure code [15SGL1] Speed 3rd clutch: Fill high
Failure code [15SGLH] Speed 3rd clutch: Fill low
Failure code [15SJL1] L/U: Fill high
Failure code [15SJLH] L/U: Fill low
Failure code [2301L1] Right brake: Fill high
Failure code [2301LH] Right brake: Fill low
Failure code [2302L1] Left brake: Fill high
Failure code [2302LH] Left brake: Fill low
Failure code [7RFAKA] ECM HOLD RELAY: Disconnection
Failure code [AA10NX] Air Cleaner Clogging
Failure code [AB00MA] Battery Charge Abnormal
Failure code [B@BAZG] Eng Oil Press Low
Failure code [B@BCNS] Eng Water Overheat
Failure code [B@BCZK] Eng Water Level Low
Failure code [B@CENS] T/C Oil Overheat
Failure code [B@HANS] Hyd Oil Overheat
Troubleshooting by failure and error codes, Part 2
Failure code [CA111] EMC Critical Internal Failure
Failure code [CA115] Eng Ne and Bkup Speed Sens Error
Failure code [CA122] Chg Air Press Sensor High Error
Failure code [CA123] Chg Air Press Sensor Low Error
Failure code [CA131] Throttle Sensor High Error
Failure code [CA132] Throttle Sensor Low Error
Failure code [CA135] Eng Oil Press Sensor High Error
Failure code [CA141] Eng Oil Press Sensor Low Error
Failure code [CA144] Coolant Temp Sens High Error
Failure code [CA145] Coolant Temp Sens Low Error
Failure code [CA153] Chg Air Temp Sensor High Error
Failure code [CA154] Chg Air Temp Sensor Low Error
Failure code [CA187] Sens Supply 2 Volt Low Error
Failure code [CA221] Ambient Press Sens High Error
Failure code [CA222] Ambient Press Sens Low Error
Failure code [CA227] Sens Supply 2 Volt High Error
Failure code [CA234] Eng Overspeed
Failure code [CA238] Ne Speed Sens Supply Volt Error
Failure code [CA263] Fuel Temp Sensor High Error
Failure code [CA265] Fuel Temp Sensor Low Error
Failure code [CA271] PCV1 Short Error
Failure code [CA272] PCV1 Open Error
Failure code [CA273] PCV2 Short Error
Failure code [CA274] PCV2 Open Error
Failure code [CA322] Inj #1 (L#1) Open/Short Error
Failure code [CA323] Inj #5 (L#5) Open/Short Error
Failure code [CA324] Inj #3 (L#3) Open/Short Error
Failure code [CA325] Inj #6 (L#6) Open/Short Error
Failure code [CA331] Inj #2 (L#2) Open/Short Error
Failure code [CA332] Inj #4 (L#4) Open/Short Error
Failure code [CA342] Calibration Code Incompatibility
Failure code [CA351] Injectors Drive Circuit Error
Failure code [CA352] Sens Supply 1 Volt Low Error
Failure code [CA386] Sens Supply 1 Volt High Error
Failure code [CA441] Battery Voltage Low Error
Failure code [CA442] Battery Voltage High Error
Failure code [CA449] Rail Press Very High Error
Failure code [CA451] Rail Press Sensor High Error
Failure code [CA452] Rail Press Sensor Low Error
Failure code [CA553] Rail Press High Error
Failure code [CA554] Rail Press Sensor In Range Error
Failure code [CA559] Rail Press Low Error
Failure code [CA689] Eng Ne Speed Sensor Error
Troubleshooting by failure and error codes, Part 3
Failure code [CA731] Eng Bkup Speed Sens Phase Error
Failure code [CA757] All Continuous Data Lost Error
Failure code [CA778] Eng Bkup Speed Sensor Error
Failure code [CA1228] EGR Valve Servo Error 1
Failure code [CA1625] EGR Valve Servo Error 2
Failure code [CA1626] BP Valve Sol Current High Error
Failure code [CA1627] BP Valve Sol Current Low Error
Failure code [CA1628] Bypass Valve Servo Error 1
Failure code [CA1619] Bypass Valve Servo Error 2
Failure code [CA1631] BP Valve Pos Sens High Error
Failure code [CA1632] BP Valve Pos Sens Low Error
Failure code [CA1633] KOMNET Datalink Timeout Error
Failure code [CA1642] EGR Inlet Press Sens Low Error
Failure code [CA1653] EGR Inlet Press Sens High Error
Failure code [CA2185] Throt Sens Sup Volt High Error
Failure code [CA2186] Throt Sens Sup Volt Low Error
Failure code [CA2249] Rail Press Very Low Error
Failure code [CA2271] EGR Valve Pos Sens High Error
Failure code [CA2272] EGR Valve Pos Sens Low Error
Failure code [CA2351] EGR Valve Sol Current High Error
Failure code [CA2352] EGR Valve Sol Current Low Error
Failure code [CA2555] Grid Htr Relay Volt Low Error
Failure code [CA2556] Grid Htr Relay Volt High Error
Failure code [D110KA] Battery relay: Disconnection
Failure code [D110KB] Battery Relay: Drive Short Circuit
Failure code [D130KA] Neutral relay: Disconnection
Failure code [D130KB] Neutral relay: Short circuit
Failure code [D161KA] Back-up alarm relay: Disconnection
Failure code [D161KB] Back-up alarm relay: Short circuit
Failure code [D190KA] ACC signal relay: Disconnection
Failure code [D190KB] ACC signal relay: Short circuit
Failure code [D5ZKKX] Throttle Dial: Out of normal range
Failure code [DAFRKR] CAN Disconnection (Monitor)
Failure code [DB2RKR] CAN Disconnection (Engine controller)
Failure code [DB90KK] WE controller: Source voltage reduction
Failure code [DB90KR] PT controller: Can communication lost
Troubleshooting by failure and error codes, Part 4
Troubleshooting by failure and error codes, Part 4
Failure code [DB90KT] WE controller: Abnormality in controller
Failure code [DB95KK] WE controller: Source voltage reduction
Failure code [DB97KK] WE controller: Source voltage reduction
Failure code [DB99KQ] WE controller: Type select signal
Failure code [DB9RKR] WE controller: Can communication lost
Failure code [DBE0KK] PT controller: Source voltage reduction
Failure code [DBE0KT] PT controller: Abnormality in controller
Failure code [DBE6KK] PT controller: Source voltage reduction
Failure code [DBE7KK] PT controller: Source voltage reduction
Failure code [DBE9KQ] PT controller: Type select signal
Failure code [DD12KA] Shift up Sw: Disconnection
Failure code [DD12KB] Shift up Sw: Short circuit
Failure code [DD13KA] Shift down Sw: Disconnection
Failure code [DD13KB] Shift down Sw: Short circuit
Failure code [DD14KA] Parking lever Sw: Disconnection
Failure code [DD14KB] Parking lever Sw: Short circuit
Failure code [DDDDKA] Back up brake Sw: Disconnection
Failure code [DDDDKB] Back up brake Sw: Short circuit
Failure code [DDDDKX] Back up brake Sw: Signal mismatch
Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection
Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit
Failure code [DDN9KA] WEQ Knob Sw (up): Disconnection
Failure code [DDN9KB] WEQ Knob Sw (up): Short circuit
Failure code [DDNLKA] Weq lock Sw: Disconnection
Failure code [DDNLKB] Weq lock Sw: Short circuit
Failure code [DDTSL1] S/C: Fill high
Failure code [DDTSLH] S/C: Fill low
Troubleshooting by failure and error codes, Part 5
Failure code [DFA4KX] BL lever 1: Out of normal range
Failure code [DFA4KZ] BL lever: Disconnection or short circuit
Failure code [DFA4L8] BL lever: Signal mismatch
Failure code [DFA5KA] BL lever 1: Disconnection
Failure code [DFA5KB] BL lever 1: Short circuit
Failure code [DFA6KA] BL lever 2: Disconnection
Failure code [DFA6KB] BL lever 2: Short circuit
Failure code [DFA7KX] BT lever 1: Out of normal range
Failure code [DFA7KZ] BT lever: Disconnection or short circuit
Failure code [DFA7L8] BT lever: Signal mismatch
Failure code [DFA8KA] BT lever 1: Disconnection
Failure code [DFA8KB] BT lever 1: Short circuit
Failure code [DFA9KA] BT lever 2: Disconnection
Failure code [DFA9KB] BT lever 2: Short circuit
Failure code [DFAAKX] RL lever 1: Out of normal range
Failure code [DFAAKZ] RL lever: Disconnection or short circuit
Failure code [DFAAL8] RL lever: Signal mismatch
Failure code [DFABKA] RL lever 1: Disconnection
Failure code [DFABKB] RL lever 1: Short circuit
Failure code [DFACKA] RL lever 2: Disconnection
Failure code [DFACKB] RL lever 2: Short circuit
Failure code [DFADKX] RL lever 1: Out of normal range
Failure code [DFADKZ] RL lever: Disconnection or short circuit
Failure code [DFADL8] RL lever: Signal mismatch
Failure code [DFAEKA] RL lever 1: Disconnection
Failure code [DFAEKB] RL lever 1: Short circuit
Failure code [DFAFKA] RL lever 2: Disconnection
Failure code [DFAFKB] RL lever 2: Short circuit
Failure code [DGT1KA] T/C oil temp sensor: Abnormal
Failure code [DGT1KX] T/C oil temp sensor: Abnormal
Failure code [DH21KA] Weq pressure sensor: Disconnection
Failure code [DH21KB] Weq pressure sensor: Short circuit
Failure code [DHT5KA] T/C in-pressure sensor: Disconnection
Failure code [DHT5KB] T/C in-pressure sensor: Short circuit
Failure code [DHT7KA] T/C out-pressure sensor: Disconnection
Failure code [DHT7KB] T/C out-pressure sensor: Short circuit
Failure code [DK10KX] Fuel control Dial: Out of normal range
Troubleshooting by failure and error codes, Part 6
Failure code [DK30KA] ST lever 1: Disconnection
Failure code [DK30KB] ST lever 1: Short circuit
Failure code [DK30KX] ST lever 1: Out of normal range
Failure code [DK30KZ] RL lever: Disconnection or short circuit
Failure code [DK30L8] ST lever: Signal mismatch
Failure code [DK31KA] ST lever 2: Disconnection
Failure code [DK31KB] ST lever 2: Short circuit
Failure code [DK40KA] Brake potentiometer: Disconnection
Failure code [DK40KB] Brake potentiometer: Short circuit
Failure code [DK55KX] FR lever: Out of normal range
Failure code [DK55KZ] FR lever: Disconnection or short circuit
Failure code [DK55L8] FR lever: Signal mismatch
Failure code [DK56KA] FR lever 1: Disconnection
Failure code [DK56KB] FR lever 1: Short circuit
Failure code [DK57KA] FR lever 2: Disconnection
Failure code [DK57KB] FR lever 2: Short circuit
Failure code [DKH1KA] Pitch angle sensor: Disconnection
Failure code [DKH1KB] Pitch angle sensor: Short circuit
Failure code [DLT3KA] T/M out-speed sensor: Disconnection
Failure code [DLT3KB] T/M out-speed sensor: Abnormal
Failure code [DW7BKA] Fan rev EPC: Disconnection
Failure code [DW7BKB] Fan rev EPC: Short circuit
Failure code [DWN1KA] Hss EPC1: Disconnection
Failure code [DWN1KB] Hss EPC1: Short circuit
Failure code [DWN1KY] Hss EPC1: Short circuit
Failure code [DWN2KA] Hss EPC2: Disconnection
Failure code [DWN2KB] Hss EPC2: Short circuit
Failure code [DWN2KY] Hss EPC2: Short circuit
Failure code [DWN3KA] Ssp solenoid: Disconnection
Failure code [DWN3KB] Ssp solenoid: Short circuit
Failure code [DWN3KY] Ssp solenoid: Short circuit
Failure code [DWN5KA] Fan pump solenoid: Disconnection
Failure code [DWN5KB] Fan pump solenoid: Short circuit
Failure code [DXA0KA] TVC Sol.: Disconnection
Failure code [DXA0KB] TVC Sol.: Short circuit
Failure code [DXA0KY] TVC Sol.: Short circuit
Failure code [DXH1KA] Lock-up ECMV: Disconnection
Failure code [DXH1KB] Lock-up ECMV: Short circuit
Failure code [DXH1KY] Lock-up ECMV: Short circuit
Failure code [DXH4KA] 1st clutch ECMV: Disconnection
Troubleshooting by failure and error codes, Part 7
Troubleshooting by failure and error codes, Part 7
Failure code [DXH4KB] 1st clutch ECMV: Short circuit
Failure code [DXH4KY] 1st clutch ECMV: Short circuit
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit
Failure code [DXH7KA] R clutch ECMV: Disconnection
Failure code [DXH7KB] R clutch ECMV: Short circuit
Failure code [DXH7KY] R clutch ECMV: Short circuit
Failure code [DXH8KA] F clutch ECMV: Disconnection
Failure code [DXH8KB] F clutch ECMV: Short circuit
Failure code [DXH8KY] F clutch ECMV: Short circuit
Failure code [DXHBKA] Right brake ECMV: Disconnection
Failure code [DXHBKB] Right brake ECMV: Short circuit
Failure code [DXHBKY] Right brake ECMV: Short circuit
Failure code [DXHCKA] Left brake ECMV: Disconnection
Failure code [DXHCKB] Left brake ECMV: Short circuit
Failure code [DXHCKY] Left brake ECMV: Short circuit
Failure code [DXHRKA] Blade up EPC: Disconnection
Failure code [DXHRKB] Blade up EPC: Short circuit
Failure code [DXHRKY] Blade up EPC: Short circuit
Failure code [DXHSKA] Blade down EPC: Disconnection
Failure code [DXHSKB] Blade down EPC: Short circuit
Failure code [DXHSKY] Blade down EPC: Short circuit
Failure code [DXHTKA] Blade left 1 EPC: Disconnection
Failure code [DXHTKB] Blade left 1 EPC: Short circuit
Failure code [DXHTKY] Blade left 1 EPC: Short circuit
Failure code [DXHUKA] Blade right 1 EPC: Disconnection
Failure code [DXHUKB] Blade right 1 EPC: Short circuit
Failure code [DXHUKY] Blade right 1 EPC: Short circuit
Failure code [DXHWKA] Ripper up EPC: Disconnection
Failure code [DXHWKB] Ripper up EPC: Short circuit
Failure code [DXHWKY] Ripper up EPC: Short circuit
Failure code [DXHXKA] Ripper down EPC: Disconnection
Failure code [DXHXKB] Ripper down EPC: Short circuit
Failure code [DXHXKY] Ripper down EPC: Short circuit
Failure code [DXHYKA] Ripper Tilt In EPC: Disconnection
Failure code [DXHYKB] Ripper Tilt In EPC: Short circuit
Failure code [DXHYKY] Ripper Tilt In EPC: Short circuit
Failure code [DXHZKA] Ripper Tilt Back EPC: Disconnection
Failure code [DXHZKB] Ripper Tilt Back EPC: Short circuit
Failure code [DXHZKY] Ripper Tilt Back EPC: Short circuit
Failure code [DXJ4KA] Weq lock Sol.: Disconnection
Failure code [DXJ4KB] Weq lock Sol.: Short circuit
Troubleshooting by failure and error codes, Part 8
Troubleshooting by failure and error codes, Part 8
Failure code [DXJ8KA] Blade left 2 EPC: Disconnection
Failure code [DXJ8KB] Blade left 2 EPC: Short circuit
Failure code [DXJ8KY] Blade left 2 EPC: Short circuit
Failure code [DXJ9KA] Blade right 2 EPC: Disconnection
Failure code [DXJ9KB] Blade right 2 EPC: Short circuit
Failure code [DXJ9KY] Blade right 2 EPC: Short circuit
Failure code [DXJAKA] Q-drop EPC: Disconnection
Failure code [DXJAKB] Q-drop EPC: Short circuit
Failure code [DXJAKY] Q-drop EPC: Short circuit
Failure code [DXJBKA] S/C ECMV: Disconnection
Failure code [DXJBKB] S/C ECMV: Short circuit
Failure code [DXJBKY] S/C ECMV: Short circuit
Troubleshooting of electrical system (E-mode)
Information in troubleshooting table
E-1 When starting switch turned ON, machine monitor displays nothing
E-2 When starting switch turned ON (before starting engine), basic check item lights up
E-3 Engine does not start (Engine does not turn)
E-4 Preheater does not operate
E-5 Precaution item lights up while engine is running
E-6 Emergency stop item lights up while engine is running
E-7 Engine coolant temperature gauge does not indicate normally
E-8 Fuel level gauge does not indicate normally
E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally
E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally
E-11 Contents of display by machine monitor are different from applicable machine
E-12 Machine monitor does not display some items
E-13 Function switch does not work
E-14 Operation mode does not change
E-15 Gearshift mode does not change
E-16 Customize function does not operate normally
E-17 Customize memory function does not normally
E-18 Float mode does not change
E-19 Alarm buzzer cannot be stopped
E-20 Air conditioner does not operate normally (including air conditioner fault history)
E-21 When starting switch is turned OFF, service meter is not displayed
E-22 Machine monitor cannot be set in service mode
E-23 Ripper pin puller cylinder does not operate
E-24 Backup alarm does not sound or does not stop
E-25 Headlamp, rear lamp, and ripper point lamp do not light up
E-26 Windshield wiper and window washer do not operate
E-27 KOMTRAX system does not operate normally
Troubleshooting of hydraulic and mechanical system (H-mode)
Troubleshooting of hydraulic and mechanical system (H-mode)
Information in troubleshooting table
H-1 Power is low (Drawbar pull is low)
H-2 Machine does not travel (at 2nd or 3rd gear speed)
H-3 Machine does not start at any gear speed
H-4 Machine can travel only forward or in reverse
H-5 When gear speed or travel direction is changed, time lag is large
H-6 Machine cannot be steered (Machine does not turn right or left)
H-7 Steering speed or steering force is low
H-8 Brake does not work
H-9 Power train oil is overheated
H-10 Abnormal sound comes out from around HSS pump or HSS motor
H-11 Speed of all work equipment is low
H-12 No work equipment moves
H-13 Blade lift speed or power is low
H-14 Blade tilt speed or power is low
H-15 Ripper lift speed or power is low
H-16 Ripper tilt speed or power is low
H-17 Hydraulic drift of blade lift is large
H-18 Hydraulic drift of blade tilt is large
H-19 Hydraulic drift of ripper lift is large
H-20 Ripper pin puller cylinder does not operate
H-21 Blade does not pitch
H-22 Abnormal sound comes out from around work equipment pump
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart
S-1 Starting performance of engine is poor
S-2 Engine does not start
S-3 Engine does not pick up smoothly
S-4 Engine stops during operation
S-5 Engine does not rotate smoothly
S-6 Engine lack output (or lacks power)
S-7 Exhaust gas is black (incomplete combustion)
S-8 Oil consumption is excessive (or exhaust gas is blue)
S-9 Oil becomes dirty quickly
S-10 Fuel consumption is excessive
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)
S-12 Oil pressure drops
S-13 Oil level rises (Entry of coolant or fuel)
S-14 Coolant temperature becomes too high (Overheating)
S-15 Abnormal noise is made
S-16 Vibration is excessive

50 Disassembly and assembly
General information on disassembly and assembly
How to read this manual
Coating materials list
Special tool list
Sketches of special tools
Engine and cooling system
Removal and installation of fuel supply pump assembly
Removal and installation of fuel injector assembly
Removal and installation of cylinder head assembly
Removal and installation of radiator assembly
Removal and installation of aftercooler assembly
Removal and installation of engine assembly
Removal and installation of engine hood assembly
Removal and installation of engine front seal
Removal and installation of engine rear seal
Removal and installation of fuel tank assembly
Removal and installation of fan drive assembly
Removal and installation of fan motor assembly
Power train, Part 1
Removal and installation of damper assembly
Disassembly and assembly of damper assembly
Removal and installation of power train unit assembly
Disconnection and connection of power train unit assembly
Power train, Part 2
Disassembly and assembly of PTO assembly
Disassembly and assembly of torque converter assembly
Disassembly and assembly of transmission assembly
Disassembly and assembly of HSS case assembly
Removal and installation of HSS motor assembly
Power train, Part 3
Removal and installation of final drive assembly
Disassembly and assembly of final drive assembly
Undercarriage and frame
Removal and installation of track frame assembly
Removal and installation of idler assembly
Disassembly and assembly of idler assembly
Removal and installation of recoil spring assembly
Disassembly and assembly of recoil spring assembly
Removal and installation of track roller
Disassembly and assembly of track roller assembly
Removal and installation of No. 1 bogie assembly
Removal and installation of No. 2, No, 3 and No. 4 bogie assemblies
Disassembly and assembly of bogie assembly
Removal and installation of carrier roller assembly
Disassembly and assembly of carrier roller assembly
Removal and installation of pivot shaft assembly
Spreading and installation of track shoe assembly
General disassembly and assembly of track shoe
Disassembly and assembly of 1 link in field
Disassembly and assembly of master link
Removal and installation of equalizer bar assembly
Disassembly and assembly of equalizer bar assembly
Removal and installation of segment teeth
Hydraulic system
Removal and installation of hydraulic tank assembly
Removal and installation of hydraulic pump assembly
Disassembly and assembly of hydraulic cylinder assembly
Work equipment
Removal and installation of blade assembly
Disassembly and assembly of multi-shank ripper
Cab and its attachments
Removal and installation of operator’s cab assembly
Removal and installation of operator’s cab glass (Stuck glass)
Removal and installation of floor frame assembly
Removal and installation of air conditioner unit assembly
Electrical system
Removal and installation of engine controller assembly
Removal and installation of power train controller assembly
Removal and installation of work equipment controller assembly

80 Air conditioner
Structure, function, testing, adjusting, and troubleshooting
Structure and function
Air conditioner component
Configuration and function of refrigerating cycle
Outline of refrigerating cycle
Air conditioner unit
Functions of major components in the air conditioner unit
Control plate
Compressor
Condenser
Receiver drier
Testing, adjusting and troubleshooting
Caution about refrigerant
Troubleshooting procedure
Block diagram
Circuit diagram and arrangement of connector pins
Detail of air conditioner unit
Part and connector locations
Testing air leakage (duct)
Testing with self-diagnosis function
Testing temperature control
Testing vent (mode) changeover
Testing Recirc/Fresh changeover
Testing inner sensor
Testing evaporator temperature sensor
Testing sunlight sensor
Testing (dual) pressure switch for refrigerant
Testing relays and diodes
Troubleshooting chart 1
Troubleshooting chart 2
Troubleshooting for electrical system (E mode)
E-1 Power supply system (Air conditioner does not operate)
E-2 Compressor system (Air is not cooled)
E-3 Blower motor system (No air comes out or air flow is abnormal)
E-4 Temperature cannot be controlled
E-5 Vent (mode) cannot be changed over
E-6 Recirc/Fresh air cannot be changed over
Troubleshooting with gauge pressure
Connection of service tool
Precautions for connecting air conditioner piping
Handling of compressor oil
1. Control of compressor oil
2. Adding of compressor oil
3. Compressor replacement
4. Applying compressor oil for O-ring

90 Diagrams and drawings
Hydraulic diagrams and drawings
Power train hydraulic circuit diagram
Hydraulic circuit diagram (1/2) Serial No.: 80001 – 80806
Hydraulic circuit diagram (2/2) Serial No.: 80001 – 80806
Hydraulic circuit diagram (1/2) Serial No.: 80807 and up
Hydraulic circuit diagram (2/2) Serial No.: 80807 and up
Electrical diagrams and drawings
Electrical circuit diagram (1/12)
Electrical circuit diagram (2/12)
Electrical circuit diagram (3/12)
Electrical circuit diagram (4/12)
Electrical circuit diagram (5/12)
Electrical circuit diagram (6/12)
Electrical circuit diagram (7/12)
Electrical circuit diagram (8/12)
Electrical circuit diagram (9/12)
Electrical circuit diagram (10/12)
Electrical circuit diagram (11/12)
Electrical circuit diagram (12/12)
Electrical circuit diagram for inside cab
Connectors table and arrangement drawing

–