Komatsu Base Tractor D155CX-8 service & repair manual

Description Komatsu Base Tractor D155CX-8 service & repair manual

Komatsu Base tractor / Pipelayer D155CX-8 pdf workshop service manual

Serial numbers:
150001 and up

Specifications, testing, troubleshooting, maintenance, technical documentation, electrical diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
Index and Foreword
Abbreviation List
Foreword, Safety, Basic Information
How to Read the Shop Manual
Safety Notice for Operation
Precautions to Prevent Fire
Procedures If Fire Occurs
Precautions for Disposing of Waste Materials
Procedures for Exhaust Gas Regulations
Precautions for DEF
Store DEF
Precautions When You Handle Hydraulic Equipment
Precautions When You Disconnect and Connect Pipings
Precautions When You Handle Electrical Equipment
Precautions When You Handle Fuel System Equipment
Precautions When You Handle Intake System Equipment
Practical Use of KOMTRAX
Disconnect and Connect Push-Pull Type Coupler
Precautions for Disconnection and Connection of Connectors
How to Disconnect and Connect Deutsch Connector
How to Disconnect and Connect Slide Lock Type Connector
How to Disconnect and Connect Connector with Lock to Pull
How to Disconnect and Connect Connector with Lock to Push
How to Disconnect and Connect Connector with Housing to Rotate
How to Read the Codes for Electric Cable
Explanation of Terms for Maintenance Standard
Standard Tightening Torque Table
Conversion Table

Specifications
Specification Drawing
Weight Table
How to Use Fuel, Coolant and Lubricants by Ambient Temperature

Structure and Function
Urea SCR System
Layout Drawing of Urea SCR System
Urea SCR System Diagram
Function of Urea SCR System
Component Parts of Urea SCR System
Boot-up System
Layout Drawing of Boot-up System
System Operating Lamp System
Battery Disconnect Switch
Engine System
Layout Drawing of Engine System
Engine Control System
Automatic Idle Stop System
Component Parts of Engine System
Cooling System
Layout Drawing of Cooling System
Component Parts of Cooling System
Control System
Layout Drawing of Control System
Machine Monitor System
KOMTRAX System
Component Parts of Control System
Hydraulic System
Layout Drawing of Hydraulic System
CLSS
Component Parts of Hydraulic System
Power Train System
Layout Drawing of Power Train System
Transmission, Steering, and Brake Control
Palm Command Control System
HSS System
Centralized Pressure Pickup Port
Component Parts of Power Train System
Work Equipment System
Work Equipment Control
Component Parts of Work Equipment System
Undercarriage and Frame
Main Frame
Suspension
Track Frame and Idler Cushion
CAB Related Parts
ROPS CAB
CAB Mount

Standard Value Table
Standard Value Table for Engine
Standard Value Table for Engine: D155CX-8
Standard Value Table for Machine
Standard Value Table for Machine: D155CX-8

Testing and Adjusting
Precautions Before Work
Related Information on Testing and Adjusting
Tools for Testing and Adjusting
Sketch of Tools for Testing and Adjusting
Engine and Cooling System
Examine Engine Speed
Examine Boost Pressure
Examine Exhaust Gas Temperature
Examine Exhaust Gas Color
Examine Mass Air Flow and Temperature Sensor
Examine and Adjust Valve Clearance
Examine Compression Pressure
Examine Blowby Pressure
Examine Engine Oil Pressure
Examine EGR Valve and VGT Oil Pressure
Examine Fuel Pressure
Examine Fuel Return Rate and Leakage
Bleed Air from Fuel System
Examine Fuel Circuit for Leakage
Handle Cylinder Cut-out Mode Operation
Handle No-Injection Cranking Operation
Clean Fuel Doser
Write Injector Compensation Value to Engine Controller
Write Correction for Ash in Soot Accumulation to Engine Controller
Examine SCR Related Functions
Clean DEF Tank
Clean DEF Pump
Adjust Decelerator Pedal
Power Train
Examine Power Train Oil Pressure
Adjust Transmission Output Shaft Speed Sensor
Examine Brake Performance Simply
Examine and Adjust Brake Pedal
Adjust Parking Brake Lever
Move Machine by Parking Brake Release When Machine Does Not Travel
Undercarriage and Frame
Adjust Idler Clearance
Examine and Adjust Track Tension
Hydraulic System
Release Remained Pressure in Hydraulic Circuit
Examine and Adjust Work Equipment and HSS Oil Pressure
Examine Oil Pressure of Control Circuit
Examine Work Equipment Lock Solenoid Valve Outlet Pressure
Examine Outlet Pressure in Solenoid Valve of Rear Work Equipment Switch
Bleed Air from Work Equipment and HSS Pump
Examine Cooling Fan Speed
Examine Cooling Fan Circuit Oil Pressure
Bleed Air in Cooling Fan Pump
Operation When Work Equipment is Disabled
Work Equipment
Adjust Work Equipment Lock Lever
Examine and Adjust Play of Blade Electric Lever
CAB Related Parts
Examine and Adjust Operator Cab
Electrical System
Set and Operate Machine Monitor
How to Start Up KOMTRAX Terminal
Adjust Rearview Camera Angle
Handle Voltage Circuit of Engine Controller
Handle Battery Disconnect Switch
Examine Diodes
Pm Clinic
Pm Clinic Service

Troubleshooting
Precautions Before Work
Related Information to Troubleshooting
General Troubleshooting Points
Troubleshooting Points for Urea SCR System
Sequence of Events in Troubleshooting
Checks Before Troubleshooting
Inspection Procedure Before Troubleshooting
Test in Accordance with Testing Procedure
Procedure for Troubleshooting
Symptom and Troubleshooting Numbers
Information Shown in Troubleshooting Table
Connector List and Layout
Connector Contact Connection Table
T-Branch Box and T-Branch Adapter Table
Fuse Location Table
Precautions When You Clean and Replace KDPF (KCSF and KDOC)
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135])
Failure Code Table
Troubleshooting by Failure Code (Display of Code)
Troubleshooting of Electrical System (E-Mode)
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)
Troubleshooting of Engine (S-Mode)

Disassembly and Assembly
Precautions Before Work
Related Information on Disassembly and Assembly
How to Read This Manual
Coating Materials List
Special Tool List
Sketches of Special Tools
Engine and Cooling System
Remove and Install Supply Pump Assembly
Remove and Install Injector Assembly
Remove and Install Fuel Doser Assembly
Remove and Install Cylinder Head Assembly
Remove and Install EGR Valve Assembly
Remove and Install EGR Cooler Assembly
Remove and Install Starter Assembly
Remove and Install Alternator Belt
Remove and Install Radiator Assembly
Remove and Install Hydraulic Oil Cooler Assembly
Remove and Install Aftercooler Assembly
Remove and Install Cooling Fan Drive Assembly
Remove and Install Cooling Fan Motor Assembly
Remove and Install Engine Assembly
Remove and Install Engine Front Oil Seal
Remove and Install Engine Rear Oil Seal
Remove and Install Engine Hood Assembly
Remove and Install Fuel Tank Assembly
Remove and Install DEF Tank Assembly
Remove and Install DEF Tank Sensor Flange Assembly
Remove and Install DEF Tank Sensor
Remove and Install DEF Tank Strainer
Remove and Install DEF Tank Filler Port Filter
Remove and Install KDPF Assembly
Disassemble and Assemble KDPF Assembly
Remove and Install SCR Assembly
Remove and Install KDPF and SCR Assembly
Remove and Install KCCV Assembly
Remove and Install DEF Mixing Tube
Remove and Install DEF Injector
Remove and Install DEF Pump
Remove and Install DEF Hose
Remove and Install Air Cleaner Assembly
Remove and Install Air Conditioner Compressor Assembly
Remove and Install Air Conditioner Condenser Assembly
Power Train
Remove and Install Damper Assembly
Disassemble and Assemble Damper Assembly
Remove and Install Power Train Unit Assembly
Disconnect and Connect Power Train Unit Assembly
Disassemble and Assemble PTO Assembly
Disassemble and Assemble Torque Converter Assembly
Disassemble and Assemble Transmission Assembly
Disassemble and Assemble HSS Assembly
Remove and Install HSS Motor Assembly
Remove and Install Final Drive Assembly
Disassemble and Assemble Final Drive Assembly
Undercarriage and Frame
Remove and Install Track Frame Assembly
Remove and Install Idler Assembly
Disassemble and Assemble Idler Assembly
Remove and Install Recoil Spring Assembly
Disassemble and Assemble Recoil Spring Assembly
Remove and Install Track Roller Assembly
Disassemble and Assemble Track Roller Assembly
Remove and Install Carrier Roller Assembly
Disassemble and Assemble Carrier Roller Assembly
Remove and Install Pivot Shaft Assembly
Separate and Connect Track Assembly
Disassemble and Assemble Track Assembly Generally
Disassemble and Assemble One Track Link Assembly in Field
Disassemble and Assemble Master Link
Remove and Install Cross Bar Assembly
Remove and Install Sprocket
Remove and Install Center Under Guard Assembly
Hydraulic System
Remove and Install Hydraulic Tank Assembly
Remove and Install Work Equipment Pump and HSS Pump Assembly
Remove and Install Power Train Pump and Steering Lubrication Pump Assembly
Remove and Install Cooling Fan Pump Assembly
Remove and Install Scavenging Pump Assembly
Remove and Install Control Valve Assembly
CAB Related Parts
Remove and Install Operator Cab Assembly
Remove and Install Operator Cab Glass (Adhered Glass)
Remove and Install Air Conditioner Unit Assembly
Remove and Install Operator Seat
How to Remove and Install Seat Belt
Electrical System
Remove and Install Engine Controller Assembly
Remove and Install Power Train Controller Assembly
Remove and Install Work Equipment Controller Assembly
Remove and Install Machine Monitor Assembly
Remove and Install Mass Air Flow and Temperature Sensor
Remove and Install KCCV Crankcase Pressure Sensor
Remove and Install SCR Temperature Sensor
Remove and Install Battery Relay
Remove and Install Gateway Controller Assembly
Remove and Install Communication Terminal
Remove and Install Communication Terminal Wiring Harness

Maintenance Standard
Explanation of Terms for Maintenance Standard
Engine and Cooling System
Maintenance Standard for Engine Mount
Maintenance Standard for Damper
Maintenance Standard for Cooling System
Maintenance Standard for Cooling Fan Pump
Maintenance Standard for Cooling Fan Motor
Power Train
Maintenance Standard for Universal Joint
Maintenance Standard for Power Train Mount
Maintenance Standard for Torque Converter and PTO
Maintenance Standard for Torque Converter Control Valve
Maintenance Standard for ECMV (Lockup Clutch Valve)
Maintenance Standard for ECMV (Stator Clutch Valve)
Maintenance Standard for Transmission
Maintenance Standard for ECMV (Transmission)
Maintenance Standard for Main Relief Valve and Torque Converter Relief Valve
Maintenance Standard for Transmission Lubrication Relief Valve
Maintenance Standard for Bevel Gear Shaft, HSS, and Brake
Maintenance Standard for Brake Control Valve
Maintenance Standard for ECMV (Brake)
Maintenance Standard for Solenoid Valve (Brake)
Maintenance Standard for Sudden Stop Prevention Valve
Maintenance Standard for Final Drive
Maintenance Standard for Sprocket
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing
Undercarriage and Frame
Maintenance Standard for Main Frame
Maintenance Standard for Suspension
Maintenance Standard for Track Frame and Idler Cushion
Maintenance Standard for Idler
Maintenance Standard for Track Roller
Maintenance Standard for Carrier Roller
Maintenance Standard for Track Shoes
Maintenance Standard for Single Shoes
Hydraulic System
Maintenance Standard for Hydraulic Tank
Maintenance Standard for Single Pump (Scavenging)
Maintenance Standard for Duplex Pump (Lubrication, Power Train)
Maintenance Standard for Work Equipment and HSS Pump
Maintenance Standard for PC-EPC Valve
Maintenance Standard for HSS Motor
Maintenance Standard for Control Valve
Maintenance Standard for Self-Pressure Reducing Valve
CAB Related Parts
Maintenance Standard for CAB Mount

Appendix
Precautions Before Work
Air Conditioner System
Precautions for Refrigerant
Air Conditioner Component
Specifications of Air Conditioner
Structure and Function of Refrigeration Cycle
Outline of Refrigeration Cycle
Component Parts of Air Conditioner System
Air Conditioner Unit
Component Parts of Air Conditioner Unit
Air Conditioner Controller
Compressor
Condenser
Receiver Drier
Air Conditioner Related Sensors
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner
Circuit Diagram and Configuration of Connector Pins of Air Conditioner
System Diagram of Air Conditioner
Input and Output Signals of Air Conditioner Controller
Locations of Air Conditioner Parts and Layout of Connectors
Examine Air Leakage (Duct)
How to Examine Air Leakage (Duct)
Examine Air Conditioner with Self-Diagnosis Function
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor
Examine Vent (Mode) Changeover
How to Examine Vent (Mode) Changeover
Examine Fresh/Recirc Air Changeover
How to Examine Fresh/Recirc Air Changeover
Examine Sunlight Sensor
How to Examine Sunlight Sensor
Examine Refrigerant (Triple) Pressure Switch
How to Examine Refrigerant (Triple) Pressure Switch
Examine Relay
How to Examine Relay
Air Conditioner Troubleshooting Chart
Information Shown in Troubleshooting Table
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)
A-4 Troubleshooting for Fresh/Recirc Air Changeover
Troubleshooting by Gauge Pressure
Connect Service Tool
How to Connect Service Tool
Precautions for Disconnection and Connection of Air Conditioner Piping
Handle Compressor Oil

Circuit Diagrams
How to Read the Codes for Electric Cable
Hydraulic Circuit Diagram
Symbols Used in Hydraulic Circuit Diagram
Power Train Hydraulic Circuit Diagram
Electrical Circuit Diagram
Symbols Used in Electric Circuit Diagram

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