Komatsu D155AXi -8 Shop Manual
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Komatsu D155AXi -8 Shop Manual

Komatsu D155AXi -8 Shop Manual

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SEN06521-02
BULLDOZER
D155AXi
-8
100040
SERIAL NUMBERS
and up

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  • Page 1 SEN06521-02 BULLDOZER D155AXi 100040 SERIAL NUMBERS and up...
  • Page 2 Find manuals at https://best-manuals.com...
  • Page 3 00 INDEX AND FOREWORD D155AXI-8 00-1 Find manuals at https://best-manuals.com...

  • Page 4: Table Of Contents

    INDEX 00 INDEX AND FOREWORD INDEX 00 INDEX AND FOREWORD ........................00-1 FOREWORD, SAFETY, BASIC INFORMATION ................... 00-22 HOW TO READ THE SHOP MANUAL................... 00-22 SAFETY NOTICE FOR OPERATION..................... 00-24 PRECAUTIONS TO PREVENT FIRE..................... 00-32 ACTION IF FIRE OCCURS......................00-34 PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS ............
  • Page 5 00 INDEX AND FOREWORD INDEX MACHINE MONITOR SYSTEM ..................... 10-82 KOMTRAX SYSTEM........................10-85 COMPONENT PARTS OF CONTROL SYSTEM................10-86 HYDRAULIC SYSTEM.........................10-121 LAYOUT DRAWING OF HYDRAULIC SYSTEM ................10-121 CLSS ............................10-122 COMPONENT PARTS OF HYDRAULIC SYSTEM ...............10-125 POWER TRAIN SYSTEM ........................10-184 LAYOUT OF POWER TRAIN SYSTEM ..................10-184 OPERATE POWER TRAIN SYSTEM....................10-187 TRANSMISSION, STEERING, AND BRAKE CONTROL ..............10-189 PALM COMMAND CONTROL SYSTEM..................10-192...

  • Page 6: Index

    INDEX 00 INDEX AND FOREWORD TEST EXHAUST GAS TEMPERATURE ..................30-21 TEST EXHAUST GAS COLOR ...................... 30-24 TEST AND ADJUST VALVE CLEARANCE ..................30-26 TEST COMPRESSION PRESSURE....................30-29 TEST BLOWBY PRESSURE ......................30-32 TEST ENGINE OIL PRESSURE ....................30-34 TEST EGR VALVE AND KVGT OIL PRESSURE ................30-36 TEST FUEL PRESSURE .......................
  • Page 7 00 INDEX AND FOREWORD INDEX SET STANDARD ANGLE OF BLADE EDGE ................30-327 METHOD FOR INPUTTING WEAR AMOUNT OF BLADE EDGE AND TRACK SHOE ....30-328 CHECK BLADE ELEVATION, ADJUST..................30-329 TEST STROKE SENSOR FOR LIFT CYLINDER................30-333 TEST AND ADJUST RESET SENSOR FOR LIFT CYLINDER .............30-337 ADJUST WHEN WORK EQUIPMENT CONTROLLER IS REPLACED.........30-339 ADJUST WHEN ICT RELATED DEVICES ARE REPAIRED OR REPLACED.......30-342 Pm CLINIC............................30-347...
  • Page 8 INDEX 00 INDEX AND FOREWORD FAILURE CODE [879GKX] Refrigerant Pressure Input Signal Out of Range ........40-212 FAILURE CODE [989L00] Engine Controller Lock Caution 1 ............40-214 FAILURE CODE [989M00] Engine Controller Lock Caution 2 ............40-215 FAILURE CODE [989N00] Engine Controller Lock Caution 3............40-216 FAILURE CODE [A1U0N3] Hydrocarbon Desorb Request 1............40-217 FAILURE CODE [A1U0N4] Hydrocarbon Desorb Request 2............40-219 FAILURE CODE [AA10NX] Air Cleaner Clogging................40-221...
  • Page 9 00 INDEX AND FOREWORD INDEX FAILURE CODE [CA357] MAF Sensor Low Error .................40-308 FAILURE CODE [CA386] Sensor 1 Supply Voltage High Error .............40-311 FAILURE CODE [CA441] Power Voltage Low Error ..............40-312 FAILURE CODE [CA442] Power Voltage High Error ..............40-315 FAILURE CODE [CA449] Common Rail Pressure High Error 2 ............40-316 FAILURE CODE [CA451] Common Rail Pressure Sensor High Error ...........40-317 FAILURE CODE [CA452] Common Rail Pressure Sensor Low Error ..........40-319 FAILURE CODE [CA515] Common Rail Pressure Sensor Supply Voltage High Error....40-321...
  • Page 10 INDEX 00 INDEX AND FOREWORD FAILURE CODE [CA1977] Fuel Doser Open Circuit Error or Short Circuit Error ......40-424 FAILURE CODE [CA1993] KDPF Differential Pressure Low Error ..........40-427 FAILURE CODE [CA2185] Throttle Sensor Supply Voltage High Error .........40-430 FAILURE CODE [CA2186] Throttle Sensor Supply Voltage Low Error ..........40-432 FAILURE CODE [CA2249] Common Rail Pressure Low Error 2 ...........40-434 FAILURE CODE [CA2265] Fuel Feed Pump Open Circuit Error ...........40-435 FAILURE CODE [CA2266] Fuel Feed Pump Short Circuit Error............40-437...
  • Page 11 00 INDEX AND FOREWORD INDEX FAILURE CODE [CA3314] KDOC Inlet Temperature Sensor High Error ........40-559 FAILURE CODE [CA3315] KDOC Inlet Temperature Sensor In Range Error ........40-560 FAILURE CODE [CA3316] KDOC Outlet Temperature Sensor Low Error ........40-563 FAILURE CODE [CA3317] KDOC Outlet Temperature Sensor High Error ........40-565 FAILURE CODE [CA3318] KDOC Outlet Temperature Sensor In Range Error ......40-566 FAILURE CODE [CA3319] KDPF Outlet Temperature Sensor High Error ........40-569 FAILURE CODE [CA3321] KDPF Outlet Temperature Sensor Low Error ........40-570...
  • Page 12 INDEX 00 INDEX AND FOREWORD FAILURE CODE [CA4161] KDOC and KDPF Temperature Sensor ECU Voltage High Error ..40-704 FAILURE CODE [CA4162] KDOC and KDPF Temperature Sensor ECU Voltage Low Error ..40-707 FAILURE CODE [CA4163] KDOC and KDPF Temperature Sensor ECU Over Temperature Error 40-710 FAILURE CODE [CA4164] SCR Temperature Sensor ECU Voltage High Error ......40-713 FAILURE CODE [CA4165] SCR Temperature Sensor ECU Voltage Low Error ......40-715 FAILURE CODE [CA4166] SCR Temperature Sensor ECU High Temperature Error ....40-717...
  • Page 13 00 INDEX AND FOREWORD INDEX FAILURE CODE [DB9QKR] CAN 2 Defective Communication (W/E Controller) ......40-837 FAILURE CODE [DB9RKR] CAN 1 Defective Communication (W/E Controller)......40-838 FAILURE CODE [DBE0KT] P/T Controller Internal Abnormality ............40-840 FAILURE CODE [DBE1KK] P/T Controller Source Voltage Low Error...........40-841 FAILURE CODE [DBE2KK] P/T Controller Solenoid Power Voltage Low Error ......40-844 FAILURE CODE [DBE5KK] P/T Controller 5V Sensor 0 Power Voltage Out of Range ....40-847 FAILURE CODE [DBE6KK] P/T Controller 24V Sensor Power Voltage Out of Range ....40-849...
  • Page 14 INDEX 00 INDEX AND FOREWORD FAILURE CODE [DFABKA] Ripper Lift Lever Potentiometer 1 Open Circuit .........40-941 FAILURE CODE [DFABKY] Ripper Lift Lever Potentiometer 1 Hot Short Circuit ......40-944 FAILURE CODE [DFACKA] Ripper Lift Lever Potentiometer 2 Open Circuit .........40-946 FAILURE CODE [DFACKY] Ripper Lift Lever Potentiometer 2 Hot Short Circuit ......40-949 FAILURE CODE [DGS1KA] Hydraulic Oil Temperature Sensor Open Circuit ........40-951 FAILURE CODE [DGS1KX] Hydraulic Oil Temperature Sensor Input Signal Out of Range ...40-953 FAILURE CODE [DGT1KA] T/C Oil Temperature Sensor Open Circuit .........40-955...
  • Page 15 00 INDEX AND FOREWORD INDEX FAILURE CODE [DLT3KB] T/M Output Speed Sensor Ground Fault ..........40-1063 FAILURE CODE [DR21KX] Camera 2 Picture Reverse Drive Input Out of Range ......40-1065 FAILURE CODE [DR31KX] Camera 3 Picture Reverse Drive Input Out of Range ......40-1066 FAILURE CODE [DV20KB] Back Alarm Buzzer Short Circuit............40-1067 FAILURE CODE [DW7BKA] Fan Reverse Solenoid Open Circuit ..........40-1069 FAILURE CODE [DW7BKB] Fan Reverse Solenoid Short Circuit..........40-1071...
  • Page 16 INDEX 00 INDEX AND FOREWORD FAILURE CODE [DXHWKB] Ripper Lift Raise EPC Solenoid Short Circuit.........40-1172 FAILURE CODE [DXHWKY] Ripper Lift Raise EPC Solenoid Hot Short Circuit ......40-1173 FAILURE CODE [DXHXKA] Ripper Lift Lower EPC Solenoid Open Circuit .........40-1175 FAILURE CODE [DXHXKB] Ripper Lift Lower EPC Solenoid Short Circuit .........40-1177 FAILURE CODE [DXHXKY] Ripper Lift Lower EPC Solenoid Hot Short Circuit......40-1178 FAILURE CODE [DXHYKA] Ripper Tilt In EPC Solenoid Open Circuit........40-1180 FAILURE CODE [DXHYKB] Ripper Tilt In EPC Solenoid Short Circuit ........40-1182...
  • Page 17 E-48 CONTROL BOX DISPLAYS THE MESSAGE [IMU sensor not connected]......40-1317 E-49 CONTROL BOX DISPLAYS THE MESSAGE [Waiting for satellites...]........40-1318 E-50 CONTROL BOX DISPLAYS THE MESSAGE [Komatsu controller not connected!] ....40-1319 E-51 CONTROL BOX DISPLAYS THE MESSAGE [Cylinder Stroke Reading Abnormal]....40-1321 E-52 CONTROL BOX DISPLAYS THE MESSAGE [Komatsu CAN Comms Abnormal] ....40-1322...
  • Page 18 INDEX 00 INDEX AND FOREWORD E-71 BLADE AUTOMATIC RAISE CONTROL DOES NOT START WHILE AUTO IS DISPLAYED ................................40-1341 E-72 BLADE AUTOMATIC CONTROL FUNCTION IS NOT ACTIVATED WHILE AUTO IS DISPLAYED (BLADE AUTOMATIC CONTROL STOPS)................40-1342 E-73 WHEN CHECKING AND ADJUSTING THE BLADE ELEVATION, THE VALUE IS DIFFERENT FROM ACTUAL MACHINE .....................40-1343 E-74 FINISHED SURFACE IS INACCURATE (THE AVERAGE HEIGHT OF FINISHED SURFACE IS LOWER THAN DESIGNED SURFACE OR BLADE DOES NOT TOUCH THE SURFACE) ..40-1344...
  • Page 19 00 INDEX AND FOREWORD INDEX S-4 ENGINE STARTABILITY IS POOR..................40-1418 S-5 ENGINE DOES NOT PICK UP SMOOTHLY ................40-1420 S-6 ENGINE STOPS DURING OPERATION ................40-1422 S-7 ENGINE RUNS ROUGH OR IS UNSTABLE ................40-1424 S-8 ENGINE LACKS POWER.....................40-1425 S-9 KDPF GETS CLOGGED IN A SHORT TIME ................40-1427 S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE ..............40-1429 S-11 OIL BECOMES CONTAMINATED QUICKLY ..............40-1430 S-12 FUEL CONSUMPTION IS EXCESSIVE ................40-1431...
  • Page 20 INDEX 00 INDEX AND FOREWORD REMOVE AND INSTALL KCCV ASSEMBLY ................50-259 REMOVE AND INSTALL AdBlue/DEF MIXING TUBE ..............50-264 REMOVE AND INSTALL AdBlue/DEF INJECTOR................50-272 REMOVE AND INSTALL AdBlue/DEF PUMP ................50-278 REMOVE AND INSTALL AdBlue/DEF HOSE ................50-286 REMOVE AND INSTALL AIR CLEANER ASSEMBLY..............50-298 REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY ........50-301 REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY ........50-303 POWER TRAIN............................50-307...
  • Page 21 00 INDEX AND FOREWORD INDEX METHOD FOR DISASSEMBLING AND ASSEMBLING BLADE TILT CYLINDER ASSEMBLY..50-616 METHOD FOR DISASSEMBLING AND ASSEMBLING RIPPER CYLINDER ASSEMBLY ...50-622 CAB AND ITS ATTACHMENTS ......................50-629 REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY ............50-629 REMOVE AND INSTALL OPERATOR'S CAB GLASS (ADHERED GLASS) .........50-648 REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY ..........50-655 REMOVE AND INSTALL OPERATOR'S SEAT ................50-668 REMOVE AND INSTALL SEAT BELT ...................50-670...
  • Page 22 INDEX 00 INDEX AND FOREWORD MAINTENANCE STANDARD OF PLUS TYPE TRACK SHOE............60-70 MAINTENANCE STANDARD OF SINGLE SHOE AND HEAVY DUTY SHOE ....... 60-72 HYDRAULIC SYSTEM.......................... 60-73 MAINTENANCE STANDARD OF HYDRAULIC TANK ..............60-73 MAINTENANCE STANDARD OF SCAVENGING PUMP ............... 60-74 MAINTENANCE STANDARD OF STEERING LUBRICATION PUMP AND POWER TRAIN PUMP..
  • Page 23 00 INDEX AND FOREWORD INDEX METHOD FOR TESTING SUNLIGHT SENSOR................80-48 TEST (TRIPLE) PRESSURE SWITCH FOR REFRIGERANT............... 80-49 METHOD FOR TESTING (TRIPLE) PRESSURE SWITCH FOR REFRIGERANT ......80-49 TEST RELAYS............................80-50 METHOD FOR TESTING RELAYS ....................80-50 AIR CONDITIONER TROUBLESHOOTING CHART 1 ................. 80-51 AIR CONDITIONER TROUBLESHOOTING CHART 2 .................

  • Page 24: 00 Index And Foreword

    REMARK • 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.
  • Page 25 00 INDEX AND FOREWORD HOW TO READ THE SHOP MANUAL Symbols Important safety and quality portions are marked with the following symbols so that shop manual is used effec- tively. Symbol Item Remark This signal indicates an extremely hazardous situation which will result in Danger death or serious injury if it is not avoided.

  • Page 26: Safety Notice For Operation

    Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop manuals describe the effective and safe servicing and repair methods recommended by Komatsu. Some of the servicing and repair methods require the use of special tools designed by Komatsu for special purpos- •...
  • Page 27 00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION • Always wear the protective eyeglasses when hitting parts with a hammer. • Always wear the protective eyeglasses when grinding parts with a grinder, etc. • When performing any operation with multiple workers, al- ways agree on the operating procedure before starting.
  • Page 28 SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD • The coolant and oil in the circuits are hot when the engine is shut down. Be careful not to get scalded. Wait for the oil and coolant to cool before performing any work on the oil or coolant circuits.
  • Page 29 00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION • When assembling or installing parts, always tighten them to the specified torques. When installing protec- tive parts such as guards, or parts which vibrate violently or rotate at high speed, check again that they are installed correctly.
  • Page 30 SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD REMARK When slinging a load with 2 or more ropes, the force sub- jected to each rope increases with the hanging angle. The figure below shows the variation of allowable load in kN {kg} when slinging is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1000 kg} ...
  • Page 31 00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION REMARK Weight of component whose weight is heavier than 25 kg is shown with symbol in "DISASSEMBLY AND ASSEMBLY". • Before starting work, check the wire ropes, brake, clutch, controller, rails, over winding prevention device, ground fault circuit interrupter for electric shock prevention, crane collision prevention device, and energiz- ing caution lamp, and check the following safety items.
  • Page 32 SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD Precautions for disconnecting air conditioner piping NOTICE When replacing the air conditioner unit, air conditioner compressor, condenser or receiver drier, etc., collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before disconnecting the air conditioner hoses.
  • Page 33 00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION REMARK • The figure shows an example of fitting of O-ring. • An O-ring is fitted to every joint of the air conditioner piping. For tightening torques, see THE OTHER INFORMATION, "Pre- cautions for disconnection and connection of air conditioner piping".

  • Page 34: Precautions To Prevent Fire

    Fire around the machine due to highly heated exhaust gas This machine is equipped with KDPF (Komatsu Diesel Particulate Filter). KDPF is a system for purifying exhaust gas by removing soot in exhaust gas. In the process of purification (re- generation), the temperature of discharged exhaust gas may be higher than that of conventional models.
  • Page 35 00 INDEX AND FOREWORD PRECAUTIONS TO PREVENT FIRE • When there are thatched houses, dry leaves or pieces of paper near the work site, set the system to disa- ble the regeneration before starting work to prevent fire hazards due to highly heated exhaust gas caused by KDPF regeneration.

  • Page 36: Action If Fire Occurs

    ACTION IF FIRE OCCURS 00 INDEX AND FOREWORD ACTION IF FIRE OCCURS • Turn the starting switch to OFF position to stop the engine. • Use the handrails and steps to get off the machine. • Do not jump off the machine. You may fall and suffer serious injury. •...

  • Page 37: Precautions For Disposing Of Waste Materials

    00 INDEX AND FOREWORD PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS To prevent pollution, pay full attention to the way to dispose of waste materials. • Always drain the oil from your machine in containers. Nev- er drain the oil and coolant directly onto the ground or dump into the sewage system, rivers, seas, or lakes.

  • Page 38: Actions Taken To Meet Exhaust Gas Regulations

    This machine is equipped with the following two exhaust gas treatment systems: • Komatsu Diesel Particulate Filter (hereafter KDPF): A device which captures soot in the exhaust gas to pu- rify exhaust gas. This process performs the combustion of soot referred to as "regeneration".

  • Page 39: Precautions For Def

    00 INDEX AND FOREWORD PRECAUTIONS FOR DEF PRECAUTIONS FOR DEF GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING DEF is a colorless transparent 32.5% aqueous urea solution. Urea as main constituent is a material which is used for cosmetics, medical and pharmaceutical products, and fertilizer, etc. The following situations require im- mediate action: •...

  • Page 40: Store Adblue/Def

    STORE AdBlue/DEF 00 INDEX AND FOREWORD STORE AdBlue/DEF • If the temperature of AdBlue/DEF becomes high, harmful ammonia gas may be generated. Completely seal up its container for storage. Only open containers in a well-ventilated area. • Store AdBlue/DEF avoiding direct sunlight. Always use the original container at the time of purchase. Do not exchange the container of AdBlue/DEF with another one.

  • Page 41: Precautions For Handling Hydraulic Equipment

    00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT Because of the higher pressure and more precise hydraulic components, the most common cause of a failure is dust (foreign material) in the hydraulic circuit. The special care must be taken when adding hydraulic oil, or when disassembling, or assembling the hydraulic components.
  • Page 42 PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 00 INDEX AND FOREWORD Replacing hydraulic oil while its temperature is high • The higher the oil temperature is, the softer the oil is, and the smoother the oil runs. Also, the sludges are easily discharged from the circuit. Perform the replacement while oil temperature is high. •...

  • Page 43: Precautions For Disconnection And Connection Of Pipings

    PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP- 00 INDEX AND FOREWORD INGS PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS When performing "testing and adjusting" of the machine, "removal and installation" and "disassembly and as- sembly" of the components, observe the following precautions. Precautions for removal and disassembling work •...
  • Page 44 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP- INGS 00 INDEX AND FOREWORD Introduction of parts for the disconnection of the taper seal type hoses and tubes Hose side Pipe joint side Nominal No. Plug (1) Nut (2) 07376-50210 07222-00210 07376-50315 07222-00312 07376-50422 07222-00414...
  • Page 45 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP- 00 INDEX AND FOREWORD INGS Bolt pitch (mm) Hose side Tube side Nomi O-ring (4) Bolt (5) Washer (6) Split flange Sleeve head Flange (1) 58.7 30.2 07379-01250 07371-31255 07378-11200 07000-13038 07372-51035 01643-51032 66.7 31.8 07379-01260 07371-51260 07378-11210 07000-13038 01010-81245 01643-51232...
  • Page 46 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP- INGS 00 INDEX AND FOREWORD Introduction of parts for the removal of taper pipe thread type joint Plug (1) Nominal Nominal No. thread size Square head type (A) Hexagonal socket head (B) 07042-00108 07043-00108 07042-00211 07043-00211...
  • Page 47 When the coolant is drained, be sure that the drain valve is securely tightened, then refill the coolant reser- voir with the coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in the piping, and add the coolant to the specified level again.
  • Page 48 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP- INGS 00 INDEX AND FOREWORD Fuel system Check that there is no damage on the pipings, no looseness on mounting bolts, nuts and clamps, and no fuel leak from connecting portion. If there is any looseness, damage, or fuel leak, retighten or repair the part. Check the exhaust equipment and its installation portion for looseness and damage.

  • Page 49: Precautions For Handling Electrical Equipment

    00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT To maintain the performance of the machine over a long period, and to prevent failures or troubles before they occur, correct "operation", "maintenance and inspection" "troubleshooting", and "repairs" must be performed. This section deals particularly with correct repair procedures for mechatronics components and is aimed at im- proving the quality of repairs.
  • Page 50 PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 00 INDEX AND FOREWORD Disconnection in wiring If the wiring harness is pulled to disconnect the connector, or the components are lifted with a crane while the wiring harness is still connected, or a heavy object hits the wiring harness, it may separate the crimping of the connector, or damage the sol- dering, or break the wiring harness.

  • Page 51: Precautions For Handling Fuel System Equipment

    If a filter oth- er than a Komatsu genuine filter is used, fuel system contamination and damage may occur. Therefore Komatsu recommends using only Komatsu fuel filters and install them following the procedures in the shop manual.

  • Page 52: Precautions For Handling Intake System Equipment

    00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT The machines equipped with Komatsu Variable Geometry Turbocharger (KVGT) consists of more precise parts (variable system)than the parts used in the conventional turbocharger. If foreign material enters this system, it may cause a failure.

  • Page 53: Practical Use Of Komtrax

    00 INDEX AND FOREWORD PRACTICAL USE OF KOMTRAX PRACTICAL USE OF KOMTRAX Various information which KOMTRAX system transmits by using the radio communication is useful for KOM- TRAX operator to provide various services for the customers. When KOMTRAX system is installed to the machine and it is enabled, machine information can be checked by KOMTRAX system, and it is used for testing and troubleshooting to be performed efficiently.

  • Page 54: Disconnect And Connect Push-Pull Type Coupler

    DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 00 INDEX AND FOREWORD DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER REMARK • Loosen the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the hydraulic tank. • Provide an oil container to receive oil since some hydraulic oil flows out when the hose is disconnected even after the remaining pressure is released from the hydraulic tank.
  • Page 55 00 INDEX AND FOREWORD DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER After inserting the hose in the mating adapter perfectly, pull it back to check the connecting condition. REMARK When the hose fitting is pulled back, the rubber cap moves approximately 3.5 mm toward the hose, but it is not a prob- lem.
  • Page 56 DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 00 INDEX AND FOREWORD Connection Hold the tightening adapter part, and push body (2) straight un- til sliding prevention ring (1) contacts contact surface (a) of the hexagonal part at the male end. METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER Disconnection Hold the tightening adapter part and push body (2) straight...
  • Page 57 00 INDEX AND FOREWORD DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER Connection Hold the tightening adapter part, and push body (2) straight un- til sliding prevention ring (1) contacts contact surface (a) of the hexagonal part at the male end. D155AXI-8 00-55...

  • Page 58: Precautions For Disconnection And Connection Of Connectors

    PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CON- NECTORS 00 INDEX AND FOREWORD PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNEC- TORS Disconnecting connectors Hold the connectors when disconnecting. When disconnecting the connectors, always hold the con- necting portion. If the connector is fixed with screw, loosen the screw of the connector completely, hold the both of male and female connectors, and pull them out in parallel.
  • Page 59 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CON- 00 INDEX AND FOREWORD NECTORS • Check that there is no deformation, defective contact, corrosion, or damage on the connector pins. • Check that there is no damage or crack on the external surfaces of the connectors. NOTICE •...
  • Page 60 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CON- NECTORS 00 INDEX AND FOREWORD Disconnect the connector and wipe off the water with a dry cloth. NOTICE If the connector is to be blown with dry compressed air, there is the risk that oil in the air may cause defec- tive contact, remove oil and water in the air before starting air blow.
  • Page 61 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CON- 00 INDEX AND FOREWORD NECTORS NOTICE • Controller has been assembled with electronic circuits for control including microcomputers. These electronic circuits inside of the controller must be handled with care since they control the machine. •...

  • Page 62: Method For Disconnecting And Connecting Deutsch Connector

    METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 00 INDEX AND FOREWORD METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNEC- Method for disconnecting Deutsch connector While pressing locks (a) and (b) from each side respectively, pull out female connector (2). Method for connecting Deutsch connector Push in female connector (2) horizontally, and insert it straight until it clicks.

  • Page 63: Method For Disconnecting And Connecting Slide Lock Type Connector

    METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK 00 INDEX AND FOREWORD TYPE CONNECTOR METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR Method for disconnecting slide lock type connector (FRAMATOME-3, FRAMA- TOME-2) Slide lock (L1) to the right. While pressing lock (L2), pull out connector (1) toward you. REMARK If portion A does not float when lock (L2) is pressed, and if connector (1) does not come out when it is pulled toward...
  • Page 64 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 00 INDEX AND FOREWORD While pressing lock (L2), pull out connector (1). REMARK Lock (L2) is located behind connector (1) in the figure. Method for connecting slide lock type connector (FRAMATOME-24) Insert it straight until it clicks.

  • Page 65: Method For Disconnecting And Connecting Connector With Lock To Pull

    METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR 00 INDEX AND FOREWORD WITH LOCK TO PULL METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL Method for disconnecting connector with lock to pull Disconnect the connector (2) by pulling lock (B) (on the wiring harness side) of connector (2) outward.

  • Page 66: Method For Disconnecting And Connecting Connector With Lock To Push

    METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 00 INDEX AND FOREWORD METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH Method for disconnecting connector with lock to push (BOSCH-3) While pressing lock (C), pull out connector (3) in the direction of the arrow. •...
  • Page 67 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR 00 INDEX AND FOREWORD WITH LOCK TO PUSH Method for disconnecting connector with lock to push (AMP-3) While pressing lock (E), pull out connector (5) in the direction of the arrow. Method for connecting connector with lock to push (AMP-3) Insert it straight until it clicks.

  • Page 68: Method For Disconnecting And Connecting Connector With Housing To Rotate

    METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 00 INDEX AND FOREWORD METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE Method for disconnecting connector with housing to rotate Turn housing (H1) to the left, and pull it out. REMARK Housing (H1) is left on the wiring harness side.

  • Page 69: How To Read Electrical Wire Code

    00 INDEX AND FOREWORD HOW TO READ ELECTRICAL WIRE CODE HOW TO READ ELECTRICAL WIRE CODE In the electrical circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electrical wire code is helpful in understanding the electrical circuit diagram. Example) AEX 0.85 L: Indicates heat-resistant, low-voltage blue wire for automobile, having nominal No.
  • Page 70 HOW TO READ ELECTRICAL WIRE CODE 00 INDEX AND FOREWORD Dimensions (Table 2) Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) Number of strands/ 20/0.1 30/0.1 11/0.3 50/0.1 16/0.3 37/0.2 26/0.3 58/0.2 41/0.3 65/0.3 7/0.32 Diameter of strand Conductor Cross-sec- tional area 0.51 0.56...
  • Page 71 00 INDEX AND FOREWORD HOW TO READ ELECTRICAL WIRE CODE Nominal No. 0.5f 0.75f 0.85 1.25f 1.25 ting CAVS Standard REMARK “f” of nominal No. denotes "flexible". Color codes table (Table 3) Color Code Color of wire Color Code Color of wire Black Light green and White Brown...
  • Page 72 HOW TO READ ELECTRICAL WIRE CODE 00 INDEX AND FOREWORD Types of circuits and color codes Type of wire AVS, AV, CAVS Charge Ground Start Light Instrument Signal Type of circuit Others 00-70 D155AXI-8...
  • Page 73 00 INDEX AND FOREWORD EXPLANATION OF TERMS FOR MAINTENANCE STANDARD EXPLANATION OF TERMS FOR MAINTENANCE STANDARD The maintenance standard section shows the judgment criteria whether the equipment or parts should be re- placed or can be reused when the machine is disassembled for the maintenance. The following terms are the descriptions of the judgment criteria.
  • Page 74 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 00 INDEX AND FOREWORD Standard clearance and standard value • The clearance made when new parts are assembled is called the standard clearance, which is indicated by the range from the minimum clearance to the maximum clear- ance.
  • Page 75 00 INDEX AND FOREWORD EXPLANATION OF TERMS FOR MAINTENANCE STANDARD • The parts whose interferences are out of the allowable interference must be replaced or repaired. D155AXI-8 00-73...
  • Page 76 ABBREVIATION LIST 00 INDEX AND FOREWORD ABBREVIATION LIST • This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, compo- nents, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of the meaning.
  • Page 77 00 INDEX AND FOREWORD ABBREVIATION LIST Purpose of use (major ap- Abbrevia- Actual word spelled out plicable machine (*), or Explanation tion component/system) Electronic control device uses the signals from Electronic Control Mod- the sensors on the machine. This signal indicates Electronic control system the optimum actuation to the actuators.
  • Page 78 Inlet Metering Valve Engine discharged volume of supply pump. (Same as IMA) This mechanism separates oil in blowby gas and Komatsu Closed Crank- KCCV Engine returns it to the intake side to combust it there. It case Ventilation primarily consists of filters.

  • Page 79: Urea Scr System

    00 INDEX AND FOREWORD ABBREVIATION LIST Purpose of use (major ap- Abbrevia- Actual word spelled out plicable machine (*), or Explanation tion component/system) Characteristics of electrical or hydraulic circuits. Electrical system, Hydraul- Normally Closed Circuit is normally closed if it is not actuated, and ic system it opens when it is actuated.
  • Page 80 ABBREVIATION LIST 00 INDEX AND FOREWORD PC: Hydraulic excavator WA: Wheel loader List of abbreviations used in the circuit diagrams Abbreviation Actual word spelled out Air Conditioner Analogue-to-Digital Air Mix Damper Accessory Additional Auxiliary Battery Relay Clockwise Counter Clockwise Electronic Control Unit Electronic Control Module Engine EXGND...
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