Komatsu D155AX-5 Bulldozer (70001 and up) Service Repair Shop Manual - SEBM016205

This complete service repair workshop manual PDF download for the D155AX-5 Komatsu Bulldozer (SN: 70001 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-5
Serial Numbers : 70001 and up
Engine : SA6D140E-2 or SA6D140E-3


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 : SEBM016205
Total Pages : 1154


D155AX-5 mounts the SA6D140E-2 or SA6D140E-3 engine.
For details of the engine, see the 6D140-2 or 140-3 Series Engine Shop Manual.

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.

-

FORWARD
HOW TO READ THE SHOP MANUAL
HOISTING INSTRUCTIONS
METHOD OD DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
COATING MATERIALS
STANDARD TIGHTENING TORQUE
ELECTRIC WIRE CODE
CONVERSION TABLE

01 GENERAL
SPECIFICATION DRAWING
SPECIFICATIONS
WEIGHT TABLE
TABLE OF FUEL, COOLANT AND LUBRICANTS

10 STRUCTURE AND FUNCTION
ENGINE CONTROL
RADIATOR, OIL COOLER
POWER TRAIN
POWER TRAIN SYSTEM
OVERALL DRAWING OF POWER TRAIN UNIT
POWER TRAIN HYDRAULIC SYSTEM DRAWING
POWER TRAIN HYDRAULIC PIPING DIAGRAM
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
DAMPER, UNIVERSAL JOINT
TORQUE CONVERTER, PTO
TRANSMISSION CONTROL
TRANSMISSION
TRANSMISSION CONTROL VALVE
MAIN RELIEF VALVE
LUBRICATION RELIEF VALVE
SCAVENGING PUMP STRAINER
POWER TRAIN PUMP STRAINER
POWER TRAIN OIL FILTER
HSS SYSTEM
HSS PUMP
HSS MOTOR
PPC, HSS CHARGE FILTER
PPC, HSS CHARGE VALVE
HSS OIL COOLER BYPASS VALVE
STEERING, BRAKE CONTROL
BEVEL GEAR SHAFT, HSS BRAKE
BRAKE VALVE
FINAL DRIVE
TRACK FRAME
RECOIL SPRING
TRACK ROLLER BOGIE
MAIN FRAME
SUSPENSION
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM
PPC CONTROL PIPING DIAGRAM
WORK EQUIPMENT CONTROL
WORK EQUIPMENT HYDRAULIC SYSTEM AND HSS SYSTEM DIAGRAM
WORK EQUIPMENT HYDRAULIC CIRCUIT AND HSS CIRCUIT DIAGRAM
HYDRAULIC TANK AND FILTER
ACCUMULATOR
PPC LOCK VALVE
PPC VALVE
PISTON VALVE
PIN PULLER SWITCH
PIN PULLER SOLENOID VALVE
TILT/PITCH SELECTOR SWITCH
PITCH SOLENOID VALVE
MAIN CONTROL VALVE
CYLINDER STAY
WORK EQUIPMENT
CAB
AIR CONDITIONER
ELECTRIC WIRING DIAGRAM
ELECTRIC CIRCUIT DIAGRAM
MONITOR SYSTEM
SENSORS
ENGINE STARTING SYSTEM
HSS ELECTRONIC CONTROL SYSTEM

20 TESTING AND ADJUSTING
STANDARD VALUE TABLES
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
TESTING AND ADJUSTING
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
MEASURING ENGINE SPEED
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST COLOR
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
MEASURING BLOW-BY PRESSURE
MEASURING ENGINE OIL PRESSURE
TESTING AND ADJUSTING FUEL INJECTION TIMING
HANDLING EQUIPMENT IN FUEL CIRCUIT
RELEASING REMAINING PRESSURE IN FUEL SYSTEM
MEASURING FUEL PRESSURE
REDUCED CYLINDER MODE OPERATION
BLEEDING AIR FROM FUEL SYSTEM
CHECK FOR LEAKAGE IN FUEL FUEL SYSTEM
TESTING AND ADJUSTING ALTERNATOR BELT TENSION
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION
TESTING AND ADJUSTING FUN BELT TENSION
ADJUSTING ENGINE SPEED SENSOR
HANDLING CONTROLLER HIGH VOLTAGE CIRCUIT
ADJUSTING FUEL CONTROL LEVER AND DECELERATOR PEDAL
MEASURING TORQUE CONVERTER STALL SPEED
MEASURING FULL STALL SPEED
MEASURING POWER TRAIN OIL PRESSURE
TESTING AND ADJUSTING HSS MAIN OIL PRESSURE
TESTING AND ADJUSTING HSS CHARGE OIL PRESSURE
TESTING AND ADJUSTING HSS SERVO CHARGE PRESSURE AND PPC RELIEF PRESSURE
BLEEDING AIR FROM HSS PUMP
SIMPLE PROCEDURE FOR TESTING BRAKE PERFORMANCE
ADJUSTING JOYSTICK AND PARKING LEVER
TESTING AND ADJUSTING TRAVEL REVERSE SENSING POTENTIOMETER
ADJUSTING TRAVEL REVERSE LIMIT SWITCH
ADJUSTING STEERING NEUTRAL POSITION
PROCEDURE FOR OPERATING EMERGENCY STEERING SWITCH
ADJUSTING INITIAL CURRENT IN HSS STEERING SYSTEM
ADJUSTING BRAKE PEDAL
ADJUSTING CLEARANCE OF IDLER
TESTING WEAR OF SPROCKET
TESTING AND ADJUSTING TRACK SHOE TENSION
TESTING AND ADJUSTING HYDRAULIC PRESSURE
MEASURING PPC VALVE OUTPUT PRESSURE
ADJUTING PLAY OF PPC VALVE
MEASURING SOLENOID VALVE OUTPUT PRESSURE
TESTING LOCATION CAUSING HYDRAULIC DRIFT OF BLADE AND RIPPER
MEASURING LEAKAGE INSIDE HYDRAULIC CYLINDER
RELEASING REMAINING OIL PRESSURE IN HYDRAULIC CYLINDER
BLEEDING AIR FROM HYDRAULIC CYLINDER
ADJUSTING WORK EQUIPMENT SAFETY LEVER
ADJUSTING SEMI-U TILTDOZER
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
CHECKS BEFORE TROUBLESHOOTING
TYPE OF CONNECTOR AND POSITION OF INSTALLATION
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
FUNCTION OF ELECTRONIC CONTROL SYSTEM
DISPLAY OF HSS CONTROLLER
DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL
HOW TO READ JUDGMENT TABLE
JUDGMENT TABLE FOR ENGINE SYSTEM, HYDRAULIC AND MECHANJCAL SYSTEM, AND ELECTRICAL SYSTEM
METHOD OF USING TROUBLESHOOTING CHARTS
TROUBLESHOOTING OF NETWORK SYSTEM (N MODE)
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
N MODE SYSTEM ELECTRICAL CIRCUIT DIAGRAM
SERVICE CODES OF NETWORK SYSTEM
N-1 [E0101] (ABNORMALITY IN NETWORK SYSTEM: ENGINE CONTROLLER SYSTEM) IS DISPLAYED
N-2 [E0104] (ABNORMALITY IN NETWORK SYSTEM: MONITOR PANEL SYSTEM) IS DISPLAYED
N-3 [E0105] (ABNORMALITY IN NETWORK SYSTEM: HSS CONTROLLER SYSTEM) IS DISPLAYED
N-4 [E0101], [E0104], AND [E0105] (ABNORMALITY IN NETWORK SYSTEM) ARE DISPLAYED AT SAME TIME
N-5 [E0152] (ABNORMALITY IN NETWORK SYSTEM: HSS CONTROLLER SYSTEM) IS DISPLAYED
N-6 [E0165] (ERROR IN NETWORK COMMUNICATION) IS DISPLAYED
N-7 [E0436] (ABNORMALITY IN NETWORK SYSTEM: ENGINE CONTROLLER SYSTEM) IS DISPLAYED
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)
METHOD OF USING TROUBLESHOOTING CHARTS
S-1 Starting performance is poor (starting always takes time)
S-2 Engine does not start
(1) Engine runs but exhaust gas does not come out (fuel is not being injected)
(2) Exhaust gas comes out but engine does not start (fuel is being injected)
S-3 Engine does not pick up smoothly (follow-up is poor)
S-4 Engine stops during operation
S-5 Engine does not rotate smoothly (hunting)
S-6 Engine 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 contaminated quickly
S-10 Fuel consumption is excessive
S-11 Oil is in cooling water, or water spurts back, or water level goes down
S-12 Oil pressure caution lamp lights up (drop in oil pressure)
S-13 Oil level rises (water or fuel mixed with oil)
S-14 Water temperature becomes too high (overheating)
S-15 Abnormal noise is made
S-16 Vibration is excessive
TROUBLESHOOTING OF HSS CONTROLLER AND ELECTRICAL SYSTEM (E MODE)
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE
E-1. [19] Short circuit in steering oil pressure sensor system A is displayed
E-2. [20] Disconnection in steering oil pressure sensor system A is displayed
E-3. [21] Short circuit in steering oil pressure sensor system B is displayed
E-4. [22] Disconnection in steering oil pressure sensor system B is displayed
E-5. [23] Trouble of steering potentiometer systems and 2 is displayed
E-6. [24] Disconnection in steering potentiometer system 1 is displayed
E-7. [25] Short circuit in steering potentiometer system 1 is displayed
E-8. [26] Disconnection in steering potentiometer system 2 is displayed
E-9. [25] Short circuit in steering potentiometer system is displayed
E-10. [29] Trouble of engine rotation sensor system is displayed
E-11. [51] Short circuit in travel reverse sensing potentiometer system is displayed
E-12. [52] Disconnection in travel reverse sensing potentiometer system is displayed
E-13. [53] Disconnection in backup alarm relay system is displayed
E-14. [54] Short circuit in backup alarm relay system is displayed
E-15. [57] Low voltage of controller is displayed
E-16. [62] Excessive difference of signal value between steering potentiometer systems 1 and 2 is displayed
E-17. [6d] Excessive difference of signal value between steering potentiometer systems 1 and 2 is displayed
E-18. [6E] Trouble of either steering potentiometer system and excessive deviation of neutral point signal of either system is indicated
E-19. [64] Disconnection in HSS pump solenoid valve system A is displayed
E-20. [65] Short circuit in HSS pump solenoid valve system A is displayed
E-21. [66] Disconnection in HSS pump solenoid valve system B is displayed
E-22. [67] Short circuit in HSS pump solenoid valve system B is displayed
E-23 [70] Short circuit in work equipment circuit oil pressure sensor system is displayed
E-24. [71] Disconnection in work equipment circuit oil pressure sensor system is displayed
E-25. [8d] System network communication error is displayed
E-26. [99] Disagreement of reverse sensing potentiometer and backup alarm switch signals with each other is displayed
E-27. [E0] Trouble of offset current memory is displayed
E-28. Backup alarm does not sound
E-29. Blade pitch does not work normally (When equipped with pitch dozer)
E-30. Ripper pin puller does not work normally (When equipped with giant ripper)
E-31. Engine does not start (Engine does not rotate)
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)
TABLE OF FAILURE MODES AND CAUSES
H-1. Machine does not move or moves slowly at any gear speed in each direction
H-2. Machine does not move or travel power is low in one direction
H-3. Machine does not move or moves slowly at specific gear speed
H-4. Long time lag is made in changing travel direction or gear speed
H-5. Travel power (Drawbar pull) is low
H-6. Machine cannot be steered (to one direction)
H-7. Steering speed or power is low
H-8. Abnormal sound comes out of HSS pump or HSS motor
H-9. Brake does not work
H-10. Power train oil overheats
H-11. Work equipment does not work at all
H-12. Work equipment speed or power is low
H-13. Blade lifting speed or power is low
H-14. Blade tilting speed or power is low
H-15. Ripper lifting speed or power is low
H-16. Ripper tilting speed or power is low
H-17. Hydraulic drift is large in blade lifting direction
H-18. Hydraulic drift is large in blade tilting direction
H-19. Hydraulic drift is large in ripper lifting direction
H-20. Blade pitch does not work normally (When equipped with pitch dozer)
H-21. Ripper pin puller does not work normally (When equipped with giant ripper)
H-22. Abnormal sound comes out of work equipment pump
TROUBLESHOOTING OF MONITOR SYSTEM (M MODE)
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE
M-1. Monitor lamps do not light up for 3 seconds when starting switch is turned ON -
M-2. When starting switch is turned ON, monitor lamps all light up but do not go out
M-3. Abnormality in preheating monitor lamp
M-4. Abnormality in battery charge lamp
M-5. Abnormality in engine oil pressure caution lamp
M-6. Engine water temperature caution lamp flashes
M-7. Transmission oil temperature caution lamp flashes
M-8. HSS oil temperature caution lamp flashes
M-9. HSS charge oil pressure caution lamp flashes
M-10. Electronic system caution lamp on monitor panel does not work in accordance with LED display on HSS controller
M-11. Monitor caution lamp on monitor panel does not work in accordance with each caution lamp
M-12. Alarm buzzer does not sound or sounds continuously
M-13. Abnormality in engine water temperature gauge
M-14. Abnormality in transmission oil temperature gauge
M-15. Abnormality in fuel level gauge
M-16. Service meter does not work after engine is started
M-17. Monitor panel night lighting does not light up when head lamp switch is turned on
M-18. Head lamps or rear lamps do not light up
M-19. Automatic preheating is not carried out when preheating switch is turned to AUTO
M-20. Window wipers and window washers do not work
M-21. Air conditioner does not work
TROUBLESHOOTING OF MONITOR SYSTEM (M MODE) (SERIAL NO. 75001 AND UP)
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
M MODE SYSTEM ELECTRICAL CIRCUIT DIAGRAM
M-1 [E0120] (ABNORMALITY IN MONITOR PANEL CAUTION LAMP SYSTEM) IS DISPLAYED
M-2 [E0121] (ABNORMALITY IN MONITOR PANEL CAUTION BUZZER SYSTEM) IS DISPLAYED
M-3 [E0211] (ABNORMALITY IN OIL TEMPERATURE OF POWER LINE: TORQUE CONVERTER) IS DISPLAYED
M-4 [E0329] (ABNORMALITY IN HSS OIL TEMPERATURE) IS DISPLAYED
M-5 [E0430] (ABORMALITY IN ENGINE OIL PRESSURE) IS DISPLAYED
M-6 [E0432] ABNORMALITY IN ENGINE WATER TEMPERATURE) IS DISPLAYED
M-7 WHEN STARTING SWITCH IS TURNED ON, ALL SEGMENTS OF MONITOR PANEL DO NOT LIGHT UP
M-8 WHEN STARTING SWITCH IS TURNED ON, ALL SEGMENTS OF MONITOR PANEL LIGHT UP BUT DO NOT GO OUT
M-9 WHEN STARTING
M-10 WHEN ENGINE IS STARTED, CAUTION ITEMS FLASH (DAILY CHECK ITEMS AND ENGINE RELATED ITEMS ARE NORMAL)
M-11 HSS CHARGING OIL PRESSURE CAUTION LAMP FLASHES
M-12 PREHEATER LAMP DOES NOT LIGHT UP OR STAYS LIGHTED UP
M-13 ABNORMALITY IN CAUTION BUZZER
M-14 ABNORMALITY IN CAUTION LAMP
M-15 ABNORMALITY IN ENGINE WATER TEMPERANCE GAUGE
M-16 ABNORMALITY IN POWER TRAIN (TORQUE CONVERTER) OIL PRESSURE GAUGE
M-17 ABNORMALITY IN FUEL LEVEL LEVEL GAUGE
M-18 GEAR SPEED DISPLAY SEGMENTS INDICATE [--], AND ENGINE SPEED IS NOT DISPLAYED
M-19 SERVIVE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING
M-20 ABNORMALITY IN SERVICE MODE DISPLAY
M-21 MONITOR PANEL LIGHTING DOES NOT LIGHT UP (THROUGH HEADLAMPS AND WORKING LAMPS LIGHT UP)
M-22 WHEN HEAD LAMPS OR REAR LAMPS DO NOT LIGHT UP
M-23 HEAD LAMPS OR REAR LAMPS DO NOT LIGHT UP
M-24 ELECTRIC INTAKE AIR HEATER DOES NOT WORK
M-25 WINDSHEILD WIPER OR WASHER DOES NOT WORK
M-26 AIR CONDITIONER DOES NOT WORK
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (G MODE)
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
JUDGEMENT TABLE FOR ENGINE CONTROLLER AND ENGINE
G MODE SYSTEM ELECTRICAL CIRCUIT DIAGRAM
G-1 [E0401] (ABNORMALITY IN ENGINE CONTROLLER POWER SUPPLY) IS DIPLAYED
G-2 [E0402] (ABNORMALITY IN ENGINE CONTROLLER) IS DIPLAYED
G-3 [E0405] (ABNORMALITY IN FUEL CONTROL DIAL SYSTEM) IS DISPLAYED
G-4 [E0406] (ABNORMALITY IN DECELERATOR POTENTIOMETER SYSTEM) IS DISPLAYED
G-5 [E0419] (ABNORMALITY IN NE SPEED SENSOR SYSTEM) IS DISPLAYED
G-6 [E0410] (ABNORMALITY IN G SPEED SENSOR SYSTEM) IS DISPLAYED
G-7 [E0458] (SHORT CIRCUIT IN FUEL INJECTOR NO. 1, NO. 2, NO. 3 SYSTEM) IS DISPLAYED
G-8 [E0459] (SHORT CIRCUIT IN FUEL INJECTOR NO. 4, NO. 5 NO. 6 SYSTEM) IS DISPLAYED
G-9 [E0460] (ABNORMALITY IN CONTROLLER CHASSIS GOUND CIRCUIT) IS DISPLAYED
G-10 [E0461] (DISCONNECTION IN FUEL INJECTOR NO. 1 SYSTEM) IS DISPLAYED
G-11 [E0462] (DISCONNECTION IN FUEL INJECTOR NO. 2 SYSTEM) IS DISPLAYED
G-12 [E0463] (DISCONNECTION IN FUEL INJECTOR NO. 3 SYSTEM) IS DISPLAYED
G-13 [E0464] (DISCONNECTION IN FUEL INJECTOR NO. 4 SYSTEM) IS DISPLAYED
G-14 [E0465] (DISCONNECTION IN FUEL INJECTOR NO. 5 SYSTEM) IS DISPLAYED
G-15 [E0466] (DISCONNECTION IN FUEL INJECTOR NO. 6 SYSTEM) IS DISPLAYED
G-16 [E0468] (OVERCURRENT IN FUEL SUPPLY PUMP PCV1 SYSTEM) IS DISPLAYED
G-17 [E0469] (DISCONNECTION IN FUEL SUPPLY PUMP PCV1 SYSTEM) IS DISPLAYED
G-18 [E0470] (OVERCURRENT IN FUEL SUPPLY PUMP PCV2 SYSTEM) IS DISPLAYED
G-19 [E0471] (DISCONNECTION IN FUEL SUPPLY PUMP PCV2 SYSTEM) IS DISPLAYED
G-20 [E0472] (ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM) IS DISPLAYED
G-21 [E0474] (ABNORMALITY IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM) IS DISPLAYED
G-22 [E0476] (ABNORMALITY IN HIGH ENGINE WATER TEMPERATURE SENSOR SYSTEM) IS DISPLAYED
G-23 [E0478] (ABNORMALITY IN LOW ENGINE WATER TEMPERATURE SENSOR SYSTEM) IS DISPLAYED
G-24 [E0480] (ABNORMALITY IN COMMON RAIL FUEL PRESSURE SYSTEM) IS DISPLAYED
G-25 [E0481] (ABNORMALITY IN HIGH COMMON RAIL FUEL PRESSURE 1 SYSTEM) IS DISPLAYED
[E0482] (ABNORMALITY IN HIGH COMMON RAIL FUEL PRESSURE 2 SYSTEM) IS DISPLAYED
G-26 [E0483] (NO-PRESSURE FEED BY FUEL SUPPLY PUMP 1) IS DISPLAYED
[E0484] (NO-PRESSURE FEED BY FUEL SUPPLY PUMP 2) IS DISPLAYED
G-27 [E0487] (ABNORMALITY IN ENGINE OIL PRESSURE SWITCH SYSTEM) IS DISPLAYED
G-28 [E0488] (ABNORMALITY IN POWER SUPPLY SYSTEM 1) IS DISPLAYED
G-29 [E0489] (ABNORMALITY IN POWER SUPPLY SYSTEM 2) IS DISPLAYED
G-30 [E0490] (ABNORMALITY IN Q REGULATOR SWITCH SIGNAL) IS DISPLAYED
G-31 [E0491] (SHORT CIRCUIT IN STARTING SWITCH C SYSTEM) IS DISPLAYED
TROUBLESHOOTING OF HSS CONTROLLER AND ELECTRICAL SYSTEM (E MODE)
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE
E-1 [E0113] (DROP OF HSS CONTROLLER POWER SUPPLY VOLTAGE) IS DISPLAYED
E-2 [E0143] (ABNORMALITY IN HSS CONTROLER 5V POWER SUPPLY VOLTAGE) IS DISPLAYED
E-3 [E0145] (ABNORMALITY IN HSS CONTROLLER SENSOR POWER SUPPLY VOLTAGE) IS DISPLAYED
E-4 [E0161] (ABNORMALITY IN HSS CONTROLLER MEMORY DATA OF OFFSET CURRENT) IS DISPLAYED
E-5 [E0221] (ABNORMALITY IN GEAR SPEED SWITCH SYSTEM) IS DISPLAYED
E-6 [E0233] (SHORT CIRCUIT IN TRAVEL REVERSE SENSING POTENTIOMETER SYSTEM) IS DISPLAYED
E-7 [E0233] (DISCONNECTION IN TRAVEL REVERSE SENSING POTENTIOMETER SYSTEM) IS DISPLAYED
E-8 [E0237] (ABNORMALITY IN TRANSMISSION NEUTRAL SIGNAL) IS DISPLAYED
E-9 [E0272] (UNEQUALITY BETWEEN TRAVEL REVERSE SENSING POTENTIOMETER SIGNAL AND BACKUP ALARM SWITCH SIGNAL) IS DISPLAYED
E-10 [E0360] (DISCONNECTION IN WORK EQUIPMENT OIL PRESSURE SENSOR SYSTEM) IS DISPLAYED
E-11 [E0361] (SHORT CIRCUIT IN WORK EQUIPMENT OIL PRESSURE SENSOR SYSTEM) IS DISPLAYED
E-12 [E0610] (DISCONNECTION IN BACKUP ALARM RELAY SYSTEM) IS DISPLAYED
E-13 [E0610] (SHORT CIRCUIT IN BACKUP ALARM RELAY SYSTEM) IS DISPLAYED
E-14 [E0730] (ABNORMALITY IN BOTH STEERING POTENTIOMETER SYSTEMS 1 AND 2) IS DISPLAYED
E-15 [E0731] (LARGE DIFFERENCE BETWEEN STEERING POTENTIOMETER SYSTEMS 1 AND 2: CASE I) IS DISPLAYED
E-16 (ABNORMALITY IN STEERING POTENTIOMETER SYSTEM ON SIDE AND LARGE DEVIATION OF NEUTRAL POSITION ON ONE SIDE) IS DISPLAYED
E-17 [E0733] (DISCONNECTION IN STEERING POTENTIOMETER SYSTEM 1) IS DISPLAYED
E-18 [E0733] (SHORT CIRCUIT IN STEERING POTENTIOMETER SYSTEM 1) IS DISPLAYED
E-19 [E0734] (DISCONNECTION IN STEERING POTENTIOMETER SYSTEM 2) IS DISPLAYED
E-20 [E0733] (SHORT CIRCUIT IN STEERING POTENTIOMETER SYSTEM 2) IS DISPLAYED
E-21 [E0735] (LARGE DIFFERENCE BETWEEN STEERING POTENTIOMETER SYSTEMS 1 AND 2: CASE II) IS DISPLAYED
E-22 [E0768] (DISCONNECTION IN STEERING OIL PRESSURE SEMSOR A SYSTEM) IS DISPLAYED
E-23 [E0769] (SHORT CIRCUIT IN STEERING OIL PRESSURE SENSOR A SYSTEM) IS DISPLAYED
E-24 [E0770] (DISCONNECTION IN STEERING OIL PRESSURE SENSOR B SYSTEM) IS DISPLAYED
E-25 [E0771] (SHORT CIRCUIT IN STEERING OIL PRESSURE SENSOR B SYSTEM) IS DISPLAYED
E-26 [E0772] (DISCONNECTION IN HSS PUMP SOLENOID A SYSTEM) IS DISPLAYED
E-27 [E0773] (SHORT CIRCUIT IN HSS PUMP SOLENOID A SYSTEM) IS DISPLAYED
E-28 [E0774] (DISCONNECTION IN HSS PUMP SOLENOID B SYSTEM) IS DISPLAYED
E-29 [E0775] (SHORT CIRCUIT IN HSS PUMP SOLENOID B SYSTEM) IS DISPLAYED
E-30 [E0930] (ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED
E-31 BACKUP ALARM DOES NOT SOUND
E-32 BLADE PITCH MALFUNCTIONS (MACHINE EQUIPPED WITH PITCH DOZER)
E-33 RIPPER PIN PULLER MALFUNCTIONS (MACHINE EQUIPPED WITH GIANT RIPPER)
E-34 ENGINE DOES NOT START (ENGINE DOES NOT ROTATE)

30 DISSASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
PRECAUTIONS WHEN CARRING OUT OPERATION
SPECIAL TOLL LIST
SPECIAL TOOL SKETCH
STARTING MOTOR
REMOVAL AND INSTALLATION
ALTERNATOR
REMOVAL AND INSTALLATION
ENGINE OIL COOLER CORE
REMOVAL AND INSTALLATION
FUEL INJECTION PUMP
REMOVAL
INSTALLATION
WATER PUMP
REMOVAL AND INSTALLATION
TURBOCHARGER
REMOVAL AND INSTALLATION
NOZZLE HOLDER
REMOVAL AND INSTALLATION
FUEL INJECTOR
REMOVAL AND INSTALLATION
ENGINE FRONT SEAL
REMOVAL
INSTALLATION
ENGINE REAR SEAL
REMOVAL
INSTALLATION
CYLINDER HEAD
REMOVAL
INSTALLATION
THERMOSTAT
REMOVAL AND INSTALLATION
AIR CONDITIONER COMPRESSOR
REMOVAL
INSTALLATION
AIR CONDITIONER CONDENSER
REMOVAL AND INSTALLATION
FUEL TANK
REMOVAL AND INSTALLATION
RADIATOR
REMOVAL
INSTALLATION
RADIATOR, OIL COOLER, GUARD
REMOVAL
INSTALLATION
FAN DRIVE
REMOVAL
INSTALLATION
HYDRAULIC COOLER
REMOVAL AND INSTALLATION
ENGINE
REMOVAL
INSTALLATION
DAMPER
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
POWER TRAIN UNIT
REMOVAL
INSTALLATION
SEPARATION
CONNECTION
PTO
DISASSEMBLY
ASSEMBLY
TORQUE CONVERTER
DISASSEMBLY
ASSEMBLY
TORQFLOW TRANSMISSION
DISASSEMBLY
ASSEMBLY
HSS CASE
DISASSEMBLY
ASSEMBLY
HYDRAULIC PUMP
REMOVAL
INSTALLATION
HSS PUMP
DISASSEMBLY
ASSEMBLY
HSS MOTOR
REMOVAL AND INSTALLATION
POWER TRAIN MAIN RELIEF VALVE
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
HSS, PPC, CHARGE VALVE
REMOVAL AND INSTALLATION
PPC, EPC, HMT CHARGE VALVE
DISASSEMBLY
ASSEMBLY
TRANSMISSION CONTROL VALVE
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY
BRAKE VALVE
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
FINAL DRIVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
TRACK FRAME
REMOVAL
INSTALLATION
IDLER ASSEMBLY
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
RECOIL SPRING
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
TRACK ROLLER
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
BOGIE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
CARRIER ROLLER
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
TRACK SHOE
CHECKING BEFORE REMOVAL
REMOVAL (NORMAL)
REMOVAL (WHEN THERE IS ABNORMALITY INSIDE TRACK FRAME)
INSTALLATION
OVERALL DISASSEMBLY
OVERALL ASSEMBLY
PRESS-FITTING JIG DIMENTION TABLE FOR LINK PRESS
ONE LINK
DISASSEMBLY
ASSEMBLY
MASTER LINK
DISASSEMBLY
ASSEMBLY
PIVOT SHAFT
REMOVAL AND INSTALLATION
EQUALIZER BAR
REMOVAL
INSTALLATION
EQUALIZER BAR SIDE BUSHING
REMOVAL AND INSTALLATION
SEGMENT TEETH
REMOVAL AND INSTALLATION
HYDRAULIC TANK
REMOVAL AND INSTALLATION
MAIN CONTROL VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
HSS OIL COOLER BYPASS VALVE
REMOVAL AND INSTALLATION
DISSASSEMBLY, ASSEMBLY OF HMT OIL COOLER BYPASS VALVE
BLADE PPC VALVE
REMOVAL
INSTALLATION
RIPPER PPC VALVE
REMOVAL
INSTALLATION
BLADE PPC VALVE
DISSASSEMBLY
ASSEMBLY
BLADE LIFT CYLINDER
REMOVAL AND INSTALLATION
BLADE TILT CYLINDER
REMOVAL AND INSTALLATION
RIPPER LIFT CYLINDER
REMOVAL AND INSTALLATION
RIPPER TILT CYLINDER
REMOVAL AND INSTALLATION
HYDRAULIC CYCLINDER
DISASSEMBLY
ASSEMBLY
BLADE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
MULTI-SHANK RIPPER
DISASSEMBLY
ASSEMBLY
ROPS GUARD
REMOVAL AND INSTALLATION
OPERATOR CAB
REMOVAL AND INSTALLATION
HOOD
REMOVAL AND INSTALLATION
FLOOR FRAME
REMOVAL
INSTALLATION
DASHBOARD
REMOVAL
INSTALLATION
MONITOR
REMOVAL AND INSTALLATION
HSS CONTROLLER
REMOVAL AND INSTALLATION

40 MAINTENANCE STANDARD
ENGINE MOUNT
POWER TRAIN UNIT MOUNT
DAMPER, UNIVERSAL JOINT
TORQUE CONVERTER, PTO
TRANSMISSION
TRANSMISSION CONTROL VALVE
MAIN RELIEF VALVE
BEVEL GEAR SHAFT, HSS BRAKE
BRAKE VALVE
SCAVENGING PUMP, PPC, HSS CHARGE PUMP
POWER TRAIN PUMP, LUBRICATION PUMP
PPC, HSS CHARGE VALVE
OIL COOLER BYPASS VALVE
FINAL DRIVE
MAIN FRAME
TRACK FRAME
RECOIL SPRING
TRACK ROLLER BOGIE
IDLER
TRACK ROLLER
CARRIER ROLLER
TRACK SHOE
SUSPENSION
WORK EQUIPMENT PUMP
HSS PUMP
HSS MOTOR
PPC VALVE
STEERING LEVER
MAIN CONTROL VALVE
WORK EQUIPMENT CYLINDER
QUICK DROP VALVE
CYLINDER STAY
WORK EQUIPMENT

90 OTHERS
WORK EQUIPMENT HYDRAULIC CIRCUIT AND HSS CIRCUIT DIAGRAM (10-128)
MACHINE EQUIPPED WITH PITCH DOZER (10-129)
ELECTRIC CIRCUIT DIAGRAM (1/3) (SERIAL NO. 70001-75000)
ELECTRIC CIRCUIT DIAGRAM (2/3) (SERIAL NO. 70001-75000)
ELECTRIC CIRCUIT DIAGRAM (3/3) (SERIAL NO. 70001-75000)
ELECTRIC CIRCUIT DIAGRAM (1/3) (SERIAL NO. 75000 AND UP)
ELECTRIC CIRCUIT DIAGRAM (2/3) (SERIAL NO. 75000 AND UP)
ELECTRIC CIRCUIT DIAGRAM (3/3) (SERIAL NO. 75000 AND UP)
ELECTRIC CIRCUIT DIAGRAM INSIDE CAB (SERIAL NO. 75001 AND UP)

-