BULLDOZER
D155AX -6
SERIAL NUMBERS
80001
and up
SEN00598-14
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 4
D155AX-6
SEN00598-14
The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
File overview and other materials in sections in the order shown below and utilize them accordingly.
Section Title
Form Number
SEN00596-14
SEN00597-14
SEN00598-14 q
SEN00599-04
01 Specification
Specification and technical data
SEN00600-05
SEN00601-04 q
SEN00602-05
SEN00603-00
SEN00604-01
SEN00605-02
SEN00606-01
SEN00607-03 q
SEN00608-01
SEN00609-01
SEN00610-03
SEN00611-03
SEN00678-03
SEN00612-05
SEN00679-05
SEN00680-02
SEN00681-04
SEN00682-02
40 Troubleshooting
Failure code table and fuse locations
General information on troubleshooting
Troubleshooting by failure and error codes, Part 1
Troubleshooting by failure and error codes, Part 2
Troubleshooting by failure and error codes, Part 3
Troubleshooting by failure and error codes, Part 4
Troubleshooting by failure and error codes, Part 5
SEN00613-06
SEN04628-02
SEN00851-02
SEN00716-02
SEN00717-03
SEN00718-04
SEN00719-01
SEN00720-02
D155AX-6
SEN00598-14
SEN00721-03
SEN00722-01
SEN00723-01
SEN00807-02
SEN00808-02
SEN00852-02
SEN00614-05
SEN01204-04
SEN01205-05
SEN01206-03
SEN01207-03
SEN02707-01
SEN01208-02
SEN01209-02
SEN01210-01
SEN01211-02
SEN02708-01
80 Air conditioner
Structure, function, testing, adjusting, and troubleshooting
SEN04682-01
SEN04683-01
SEN00615-06
SEN00616-04
SEN00617-05
D155AX-6
q
q
q
SEN00598-14
Table of contents
D155AX-6
SEN00598-14
D155AX-6
SEN00598-14
D155AX-6
SEN00598-14
D155AX-6
SEN00598-14
D155AX-6
SEN00598-14
SEN00598-14
10
D155AX-6
SEN00598-14
11
SEN00598-14
12
D155AX-6
SEN00598-14
16
18
19
20
21
22
24
26
27
28
13
SEN00598-14
14
D155AX-6
SEN00598-14
54
57
58
62
65
70
72
74
76
78
79
80
80
80
81
81
D155AX-6
15
SEN00598-14
D155AX-6 Bulldozer
Form No. SEN00598-14
2012 KOMATSU
All Rights Reserved
Printed in Japan 02-12
16
D155AX-6
SEN00599-04
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
D155AX-6
SEN00599-04
Safety notice
(Rev. 2008/08)
1
General precautions
k Mistakes in operation are extremely
dangerous. Read the Operation and
Maintenance Manual carefully before
operating the machine. In addition,
read this manual and understand its
contents before starting the work.
1) Before carrying out any greasing or
repairs, read all the safety labels stuck to
the machine. For the locations of the
safety labels and detailed explanation of
precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always
keep the tools and parts in their correct
places. Always keep the work area clean
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while
working.
3) When carrying out any operation, always
wear safety shoes and helmet. Do not
wear loose work clothes, or clothes with
buttons missing.
q
Always wear safety glasses when hitting parts with a hammer.
q
Always wear safety glasses when
grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or
more workers, always agree on the operating procedure before starting. Always
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, forklift, service car, etc.
7)
8)
9)
Safety points
1 Good arrangement
2 Correct work clothes
3 Following work standard
4 Making and checking signs
5
D155AX-6
2.
3.
SEN00599-04
6)
11)
D155AX-6
7)
8)
9)
10)
12)
13)
14)
15)
16)
SEN00599-04
4.
8)
D155AX-6
SEN00599-04
13) If the hoist stops because of a power failure, turn the power switch OFF. When
turning on a switch which was turned OFF
by the electric shock prevention earth
leakage breaker, check that the devices
related to that switch are not in operation
state.
14) If you find an obstacle around the hoist,
stop the operation.
15) After finishing the work, stop the hoist at
the specified position and raise the hook
to at least 2 m above the floor. Do not
leave the sling installed to the hook.
5.
6.
D155AX-6
7.
Wire ropes
(Standard Z twist ropes without galvanizing)
(JIS G3525, No. 6, Type 6X37-A)
Nominal
Allowable load
diameter of rope
mm
kN
ton
10
8.8
0.9
12
12.7
1.3
14
17.3
1.7
16
22.6
2.3
18
28.6
2.9
20
35.3
3.6
25
55.3
5.6
30
79.6
8.1
40
141.6
14.4
50
221.6
22.6
60
318.3
32.4
SEN00599-04
8.
Precautions for disconnecting and connecting hoses and tubes in air conditioner
circuit
1) Disconnection
k For the environment, the air conditioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when disconnecting the refrigerant gas circuit and then reuse it.
a Ask professional traders for collecting
and filling operation of refrigerant
(R134a).
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recovering or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2)
Connection
1] When installing the air conditioner circuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not damaged or deteriorated.
4] When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.
D155AX-6
1.
SEN00599-04
Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
Materials and specifications are subject to change without notice.
Shop manuals are divided into the Chassis volume and Engine volume. For the engine unit, see the
engine volume of the engine model mounted on the machine.
D155AX-6
SEN00599-04
2.
3.
Revisions
Revised brochures are shown in the shop manual composition table.
Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol
Item
Safety
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing work.
Weight
Tightening
torque
Coat
Oil, coolant
Drain
Remarks
Special safety precautions are necessary when performing work.
4.
Units
In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
D155AX-6
SEN00599-04
The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the
machine maintenance work. The following terms are used to explain the criteria.
1.
Tolerance
0.022
0.126
Example:
Standard size
60
D155AX-6
Tolerance
Shaft
Hole
0.030
+0.046
0.076
+0
SEN00599-04
2.
3.
Standard interference
q
When the diameter of a hole of a part
shown in the given standard size and tolerance table is smaller than that of the
mating shaft, the difference between those
diameters is called the interference.
q
The range (A B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the standard interference.
q
After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4.
10
5.
Clearance limit
Parts can be used until the clearance
between them is increased to a certain
limit. The limit at which those parts cannot
be used is called the clearance limit.
q
If the clearance between the parts
exceeds the clearance limit, they must be
replaced or repaired.
q
6.
Interference limit
The allowable maximum interference
between the hole of a part and the shaft of
another part to be assembled is called the
interference limit.
q
The interference limit shows the repair
limit of the part of smaller tolerance.
q
If the interference between the parts
exceeds the interference limit, they must
be replaced or repaired.
q
D155AX-6
SEN00599-04
To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on Handling electric equipment and
Handling hydraulic equipment (particularly gear oil and hydraulic oil).
D155AX-6
11
SEN00599-04
12
3)
Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the soldering may be damaged, or the wiring
may be broken.
4)
5)
D155AX-6
3.
SEN00599-04
3]
D155AX-6
13
SEN00599-04
2)
14
Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or damage to the connector pins.
Check that there is no damage or
breakage to the outside of the connector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or breakage, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stopper clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring harness.
For connectors fitted with boots, correct any protrusion of the boot. In
addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position.
a If the connector cannot be corrected easily, remove the clamp
and adjust the position.
q
If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
D155AX-6
3)
D155AX-6
SEN00599-04
Disconnection
Connection (Example of
incomplete setting of (a))
15
SEN00599-04
4)
16
D155AX-6
4.
Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These control all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the controller.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness connectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5.
D155AX-6
SEN00599-04
17
SEN00599-04
1.
2.
3.
Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4.
18
D155AX-6
5.
6.
Flushing operations
After disassembling and assembling the equipment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7.
Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment cannot remove, so it is an extremely effective
device.
D155AX-6
SEN00599-04
19
SEN00599-04
1.
2.
20
D155AX-6
3.
SEN00599-04
114 engine
3)
107 engine
2)
D155AX-6
21
SEN00599-04
4)
4.
1)
2)
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22
D155AX-6
SEN00599-04
The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX
0.85
L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.
Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.
Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indicated.)
1.
(Table 1)
Type
Low-voltage
wire for
automobile
Thin-cover
low-voltage
wire for
automobile
Symbol
AV
AVS
Heat-resistant low-voltAEX
age wire for
automobile
D155AX-6
Material
Conductor
Insulator
Conductor
Insulator
Conductor
Insulator
Using
temperature
range (C)
Example of use
General wiring
(Nominal No. 5 and above)
30 to +60
General wiring
(Nominal No. 3 and below)
General wiring in extremely
50 to +110 cold district, wiring at high-temperature place
23
SEN00599-04
2.
Dimensions
(Table 2)
Nominal No.
0.5f
(0.5)
0.75f
(0.85)
1.25f
(1.25)
2f
2
3f
3
5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51
0.56
0.76
0.88
1.27
1.29
1.96
2.09
3.08
3.30
5.23
area (mm2)
d (approx.)
1.0
1.2
1.5
1.9
1.9
2.3
2.4
3.0
AVS
Standard
2.0
2.2
2.5
2.9
2.9
3.5
3.6
CovAV
Standard
4.6
er D
AEX
Standard
2.0
2.2
2.7
3.0
3.1
3.8
4.6
Nominal No.
Number of
strands/Diameter of strand
Conductor
Sectional
area (mm2)
d (approx.)
AVS
Standard
CovAV
Standard
er D
AEX
Standard
15
20
30
40
50
60
85
100
50/0.45
84/0.45
41/0.80
70/0.80
85/0.80
7.95
13.36
20.61
35.19
42.73
54.29
63.84
84.96
109.1
3.7
5.5
5.3
4.8
7.0
7.0
6.0
8.2
8.2
8.0
10.8
10.8
8.6
11.4
11.4
9.8
13.0
13.0
10.4
13.6
13.6
12.0
16.0
16.0
13.6
17.6
17.6
24
D155AX-6
3.
SEN00599-04
(Table 3)
Color Code
B
Br
BrB
BrR
BrW
BrY
Ch
Dg
G
GB
GL
Gr
GR
GW
GY
L
LB
Lg
LgB
LgR
Color of wire
Color Code
LgW
LgY
LR
LW
LY
O
P
R
RB
RG
RL
RW
RY
Sb
Y
YB
YG
YL
YR
YW
Black
Brown
Brown & Black
Brown & Red
Brown & White
Brown & Yellow
Charcoal
Dark green
Green
Green & Black
Green & Blue
Gray
Green & Red
Green & White
Green & Yellow
Blue
Blue & Black
Light green
Light green & Black
Light green & Red
Color of wire
Light green & White
Light green & Yellow
Blue & Red
Blue & White
Blue & Yellow
Orange
Pink
Red
Red & Black
Red & Green
Red & Blue
Red & White
Red & Yellow
Sky Blue
Yellow
Yellow & Black
Yellow &Green
Yellow & Blue
Yellow & Red
Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: GW means that the background is Green and marking is White.
4.
(Table 4)
Type of wire
Charge
Ground
Start
Light
Instrument
Signal
Type of
circuit
Others
D155AX-6
AVS or AV
R
B
R
RW
Y
G
L
Br
Lg
O
Gr
P
Sb
Dg
Ch
AEX
R
B
R
D
Y
G
L
WG
RB
YR
GW
LW
BrW
LgR
RY
YB
GR
LR
BrR
LgY
RG
YG
GY
LY
BrY
LgB
RL
YL
GB
LB
BrB
LgW
YW
GL
Gr
Br
25
SEN00599-04
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1.
q
q
q
q
q
q
q
q
q
q
26
07376-70210
07376-70315
07376-70422
07376-70522
07376-70628
07376-71034
07376-71234
02789-20210
02789-20315
02789-20422
02789-20522
02789-20628
07221-21034
07221-21234
3)
Split flange
07379-00400
07379-00500
07378-10400
07378-10500
07371-30400
07371-30500
If the part is not under hydraulic pressure, the following corks can be used.
Nominal
number
Part Number
06
08
10
12
14
16
18
20
22
24
07049-00608
07049-00811
07049-01012
07049-01215
07049-01418
07049-01620
07049-01822
07049-02025
07049-02228
07049-02430
Dimensions
D
d
L
6
5
8
8
6.5
11
10
8.5
12
12
10
15
14
11.5
18
16
13.5
20
18
15
22
20
17
25
22
18.5
28
24
20
30
27
07049-02734
27
22.5
34
D155AX-6
2.
q
q
q
q
q
q
q
q
q
q
q
q
q
a
3.
SEN00599-04
D155AX-6
27
SEN00599-04
4)
5)
28
D155AX-6
SEN00599-04
Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1.
Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2.
Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
D155AX-6
29
SEN00599-04
Type 2
1.
Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to disconnect it. (Fig. 8)
2.
Connection
q
Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)
30
D155AX-6
SEN00599-04
Type 3
1.
Disconnection
1) Hold the tightening portion and push body
(9) straight until sliding prevention ring (8)
contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10)
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal portion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to disconnect it. (Fig. 12)
2.
Connection
q
Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)
D155AX-6
31
SEN00599-04
Tightening torque
Nm
11.8 14.7
27 34
59 74
98 123
157 196
245 309
343 427
490 608
662 829
824 1,030
1,180 1,470
1,520 1,910
1,960 2,450
2,450 3,040
2,890 3,630
kgm
1.2 1.5
2.8 3.5
6.0 7.5
10.0 12.5
16 20
25 31.5
35 43.5
50 62
67.5 84.5
84 105
120 150
155 195
200 250
250 310
295 370
Tightening torque
Nm
kgm
5.9 9.8
0.6 1.0
13.7 23.5
1.4 2.4
34.3 46.1
3.5 4.7
74.5 90.2
7.6 9.2
a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
32
D155AX-6
2.
3.
Tightening torque
Nm
59 74
98 123
235 285
kgm
6.0 7.5
10.0 12.5
23.5 29.5
Nominal No.
02
03,04
05,06
10,12
14
4.
SEN00599-04
Thread diameter
mm
14
20
24
33
42
D155AX-6
Thread diameter
mm
8
10
12
14
16
18
20
24
30
33
36
42
52
36
33
SEN00599-04
5.
Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm}
Nominal
No. of
hose
Width
across
flats
02
19
03
04
05
06
(10)
(12)
(14)
6.
22
24
27
32
36
41
46
55
Range
34 54 { 3.5 5.5}
34 63 { 3.5 6.5}
54 93 { 5.5 9.5}
59 98 { 6.0 10.0}
84 132 { 8.5 13.5}
128 186 {13.0 19.0}
177 245 {18.0 25.0}
177 245 {18.0 25.0}
197 294 {20.0 30.0}
246 343 {25.0 35.0}
Target
44 { 4.5}
74 { 7.5}
78 { 8.0}
103 {10.5}
157 {16.0}
216 {22.0}
216 {22.0}
245 {25.0}
294 {30.0}
Taper seal
Thread size
(mm)
14
18
22
24
30
33
36
42
Face seal
Nominal No.
Thread
Number of
diameter (mm)
threads, type of
(Reference)
thread
9/16-18UN
14.3
11/16-16UN
17.5
13/16-16UN
20.6
1-14UNS
25.4
1-3/16-12UN
30.2
Outer
diameter
of pipe
(mm)
Width
across
flats
(mm)
8
10
12
15 (16)
22 (20)
19
22
24 (27)
30 (32)
36
Target
14 16 {1.4 1.6}
24 27 {2.4 2.7}
43 47 {4.4 4.8}
60 68 {6.1 6.8}
90 95 {9.2 9.7}
15 {1.5}
25.5 {2.6}
45 {4.6}
64 {6.5}
92.5 {9.4}
Face seal
Thread diameter
Nominal No.
(mm)
Number of threads,
(Reference)
type of thread
9/16-18UN
14.3
11/16-16UN
17.5
13/16-16UN
20.6
1-14UN
25.4
1-3/16-12UN
30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
7.
Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Bolts and nuts
Thread size
mm
6
8
10
12
14
34
Nm
10 2
24 4
43 6
77 12
kgm
1.02 0.20
2.45 0.41
4.38 0.61
7.85 1.22
D155AX-6
8.
Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size
mm
6
8
10
12
14
9.
SEN00599-04
Tightening torque
Nm
82
10 2
12 2
24 4
36 5
kgm
0.81 0.20
1.02 0.20
1.22 0.20
2.45 0.41
3.67 0.51
Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Material
Thread size (inch)
1/16
1/8
1/4
3/8
1/2
3/4
D155AX-6
Tightening torque
In cast iron or steel
In aluminum
Nm
kgm
Nm
kgm
15 2
1.53 0.20
51
0.51 0.10
20 2
2.04 0.20
15 2
1.53 0.20
25 3
2.55 0.31
20 2
2.04 0.20
35 4
3.57 0.41
25 3
2.55 0.31
55 6
5.61 0.61
35 4
3.57 0.41
75 8
7.65 0.82
45 5
4.59 0.51
35
SEN00599-04
Conversion table
2.
Millimeters to inches
(A)
36
(B)
0
10
20
30
40
0
0
0.394
0.787
1.181
1.575
1
0.039
0.433
0.827
1.220
1.614
2
0.079
0.472
0.866
1.260
1.654
3
0.118
0.512
0.906
1.299
1.693
4
0.157
0.551
0.945
1.339
1.732
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.047
2.441
2.835
3.228
3.622
2.087
2.480
2.874
3.268
3.661
2.126
2.520
2.913
3.307
3.701
5
0.197
0.591
0.984
1.378
1.772
(C)
2.165
2.559
2.953
3.346
3.740
6
0.236
0.630
1.024
1.417
1.811
7
0.276
0.669
1.063
1.457
1.850
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
1 mm = 0.03937 in
8
9
0.315
0.354
0.709
0.748
1.102
1.142
1.496
1.536
1.890
1.929
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
D155AX-6
SEN00599-04
Millimeters to inches
0
10
20
30
40
0
0
0.394
0.787
1.181
1.575
1
0.039
0.433
0.827
1.220
1.614
2
0.079
0.472
0.866
1.260
1.654
3
0.118
0.512
0.906
1.299
1.693
4
0.157
0.551
0.945
1.339
1.732
5
0.197
0.591
0.984
1.378
1.772
6
0.236
0.630
1.024
1.417
1.811
1 mm = 0.03937 in
7
8
9
0.276
0.315
0.354
0.669
0.709
0.748
1.063
1.102
1.142
1.457
1.496
1.536
1.850
1.890
1.929
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.047
2.441
2.835
3.228
3.622
2.087
2.480
2.874
3.268
3.661
2.126
2.520
2.913
3.307
3.701
2.165
2.559
2.953
3.346
3.740
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
1 kg = 2.2046 lb
6
7
8
9
13.23
15.43 17.64
19.84
35.27
37.48 39.68
41.89
57.32
59.53 61.73
63.93
79.37
81.57 83.78
85.98
101.41 103.62 105.82 108.03
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
Kilogram to pound
0
10
20
30
40
0
0
22.05
44.09
66.14
88.18
1
2.20
24.25
46.30
68.34
90.39
2
4.41
26.46
48.50
70.55
92.59
3
6.61
28.66
50.71
72.75
94.80
4
8.82
30.86
51.91
74.96
97.00
5
11.02
33.07
55.12
77.16
99.21
50
60
70
80
90
110.23
132.28
154.32
176.37
198.42
112.44
134.48
156.53
178.57
200.62
114.64
136.69
158.73
180.78
202.83
116.85
138.89
160.94
182.98
205.03
119.05
141.10
163.14
185.19
207.24
121.25
143.30
165.35
187.39
209.44
123.46
145.51
167.55
189.60
211.64
125.66
147.71
169.76
191.80
213.85
127.87
149.91
171.96
194.01
216.05
130.07
152.12
174.17
196.21
218.26
0
10
20
30
40
0
1
2
0
0.264 0.528
2.642
2.906 3.170
5.283
5.548 5.812
7.925
8.189 8.454
10.567 10.831 11.095
3
0.793
3.434
6.076
8.718
11.359
4
1.057
3.698
6.340
8.982
11.624
1 l = 0.2642 U.S.Gal
5
6
7
8
9
1.321
1.585
1.849
2.113
2.378
3.963
4.227
4.491 4.755
5.019
6.604
6.869
7.133 7.397
7.661
9.246
9.510
9.774 10.039 10.303
11.888 12.152 12.416 12.680 12.944
50
60
70
80
90
13.209
15.850
18.492
21.134
23.775
14.001
16.643
19.285
21.926
24.568
14.265
16.907
19.549
22.190
24.832
14.529
17.171
19.813
22.455
25.096
D155AX-6
13.473
16.115
18.756
21.398
24.040
13.737
16.379
19.020
21.662
24.304
14.795
17.435
20.077
22.719
25.361
15.058
17.700
20.341
22.983
25.625
15.322
17.964
20.605
23.247
25.889
15.586
18.228
20.870
23.511
26.153
37
SEN00599-04
0
10
20
30
40
0
0
2.200
4.399
6.599
8.799
1
0.220
2.420
4.619
6.819
9.019
2
0.440
2.640
4.839
7.039
9.239
3
0.660
2.860
5.059
7.259
9.459
4
0.880
3.080
5.279
7.479
9.679
5
1.100
3.300
5.499
7.699
9.899
50
60
70
80
90
10.998
13.198
15.398
17.598
19.797
11.281
13.418
15.618
17.818
20.017
11.438
13.638
15.838
18.037
20.237
11.658
13.858
16.058
18.257
20.457
11.878
14.078
16.278
18.477
20.677
12.098
14.298
16.498
18.697
20.897
1 l = 0.21997 U.K.Gal
6
7
8
9
1.320
1.540 1.760
1.980
3.520
3.740 3.950
4.179
5.719
5.939 6.159
6.379
7.919
8.139 8.359
8.579
10.119 10.339 10.559 10.778
12.318
14.518
16.718
18.917
21.117
12.528
14.738
16.938
19.137
21.337
12.758
14.958
17.158
19.357
21.557
12.978
15.178
17.378
19.577
21.777
kgm to ft.lb
0
10
20
30
40
0
0
72.3
144.7
217.0
289.3
1
7.2
79.6
151.9
224.2
296.6
2
14.5
86.8
159.1
231.5
303.8
3
21.7
94.0
166.4
238.7
311.0
4
28.9
101.3
173.6
245.9
318.3
5
36.2
108.5
180.8
253.2
325.5
6
43.4
115.7
188.1
260.4
332.7
50
60
70
80
90
361.7
434.0
506.3
578.6
651.0
368.9
441.2
513.5
585.9
658.2
376.1
448.5
520.8
593.1
665.4
383.4
455.7
528.0
600.3
672.7
390.6
462.9
535.2
607.6
679.9
397.8
470.2
542.5
614.8
687.1
405.1
477.4
549.7
622.0
694.4
412.3
484.6
556.9
629.3
701.6
419.5
491.8
564.2
636.5
708.8
426.8
499.1
571.4
643.7
716.1
100
110
120
130
140
723.3
730.5 737.8
745.0
752.2 759.5
766.7
773.9 781.2
788.4
795.6
802.9 810.1
817.3
824.6 831.8
839.0
846.3 853.5
860.7
868.0
875.2 882.4
889.7
896.9 904.1
911.4
918.6 925.8
933.1
940.3
947.5 954.8
962.0
969.2 976.5
983.7
990.9 998.2 1005.4
1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150
160
170
180
190
1084.9
1157.3
1129.6
1301.9
1374.3
38
1092.2
1164.5
1236.8
1309.2
1381.5
1099.4
1171.7
1244.1
1316.4
1388.7
1106.6
1179.0
1251.3
1323.6
1396.0
1113.9
1186.2
1258.5
1330.9
1403.2
1121.1
1193.4
1265.8
1338.1
1410.4
1128.3
1200.7
1273.0
1345.3
1417.7
1135.6
1207.9
1280.1
1352.6
1424.9
1142.8
1215.1
1287.5
1359.8
1432.1
1150.0
1222.4
1294.7
1367.0
1439.4
D155AX-6
SEN00599-04
kg/cm2 to lb/in2
0
10
20
30
40
0
0
142.2
284.5
426.7
568.9
1
14.2
156.5
298.7
440.9
583.2
2
28.4
170.7
312.9
455.1
597.4
3
42.7
184.9
327.1
469.4
611.6
4
56.9
199.1
341.4
483.6
625.8
5
71.1
213.4
355.6
497.8
640.1
6
85.3
227.6
369.8
512.0
654.3
50
60
70
80
90
711.2
853.4
995.6
1,138
1,280
725.4
867.6
1,010
1,152
1,294
739.6
881.8
1,024
1,166
1,309
753.8
896.1
1,038
1,181
1,323
768.1
910.3
1,053
1,195
1,337
782.3
924.5
1,067
1,209
1,351
796.5
938.7
1,081
1,223
1,365
810.7
953.0
1,095
1,237
1,380
825.0
967.2
1,109
1,252
1,394
839.2
981.4
1,124
1,266
1,408
100
110
120
130
140
1,422
1,565
1,707
1,849
1,991
1,437
1,579
1,721
1,863
2,005
1,451
1,593
1,735
1,877
2,020
1,465
1,607
1,749
1,892
2,034
1,479
1,621
1,764
1,906
2,048
1,493
1,636
1,778
1,920
2,062
1,508
1,650
1,792
1,934
2,077
1,522
1,664
1,806
1,949
2,091
1,536
1,678
1,821
1,963
2,105
1,550
1,693
1,835
1,977
2,119
150
160
170
180
190
2,134
2,276
2,418
2,560
2,702
2,148
2,290
2,432
2,574
2,717
2,162
2,304
2,446
2,589
2,731
2,176
2,318
2,460
2,603
2,745
2,190
2,333
2,475
2,617
2,759
2,205
2,347
2,489
2,631
2,773
2,219
2,361
2,503
2,646
2,788
2,233
2,375
2,518
2,660
2,802
2,247
2,389
2,532
2,674
2,816
2,262
2,404
2,546
2,688
2,830
200
210
220
230
240
2,845
2,987
3,129
3,271
3,414
2,859
3,001
3,143
3,286
3,428
2,873
3,015
3,158
3,300
3,442
2,887
3,030
3,172
3,314
3,456
2,901
3,044
3,186
3,328
3,470
2,916
3,058
3,200
3,343
3,485
2,930
3,072
3,214
3,357
3,499
2,944
3,086
3,229
3,371
3,513
2,958
3,101
3,243
3,385
3,527
2,973
3,115
3,257
3,399
3,542
D155AX-6
39
SEN00599-04
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1C = 33.8F
F
40.4
37.2
34.4
31.7
28.9
40
35
30
25
20
40.0
31.0
22.0
13.0
4.0
11.7
11.1
10.6
10.0
9.4
11
12
13
14
15
51.8
53.6
55.4
57.2
59.0
7.8
8.3
8.9
9.4
10.0
46
47
48
49
50
114.8
116.6
118.4
120.2
122.0
27.2
27.8
28.3
28.9
29.4
81
82
83
84
85
177.8
179.6
181.4
183.2
185.0
28.3
27.8
27.2
26.7
26.1
19
18
17
16
15
2.2
0.4
1.4
3.2
5.0
8.9
8.3
7.8
7.2
6.7
16
17
18
19
20
60.8
62.6
64.4
66.2
68.0
10.6
11.1
11.7
12.2
12.8
51
52
53
54
55
123.8
125.6
127.4
129.2
131.0
30.0
30.6
31.1
31.7
32.2
86
87
88
89
90
186.8
188.6
190.4
192.2
194.0
25.6
25.0
24.4
23.9
23.3
14
13
12
11
10
6.8
8.6
10.4
12.2
14.0
6.1
5.6
5.0
4.4
3.9
21
22
23
24
25
69.8
71.6
73.4
75.2
77.0
13.3
13.9
14.4
15.0
15.6
56
57
58
59
60
132.8
134.6
136.4
138.2
140.0
32.8
33.3
33.9
34.4
35.0
91
92
93
94
95
195.8
197.6
199.4
201.2
203.0
22.8
22.2
21.7
21.1
20.6
9
8
7
6
5
15.8
17.6
19.4
21.2
23.0
3.3
2.8
2.2
1.7
1.1
26
27
28
29
30
78.8
80.6
82.4
84.2
86.0
16.1
16.7
17.2
17.8
18.3
61
62
63
64
65
141.8
143.6
145.4
147.2
149.0
35.6
36.1
36.7
37.2
37.8
96
97
98
99
100
204.8
206.6
208.4
210.2
212.0
20.0
19.4
18.9
18.3
17.8
4
3
2
1
0
24.8
26.6
28.4
30.2
32.0
0.6
0
0.6
1.1
1.7
31
32
33
34
35
87.8
89.6
91.4
93.2
95.0
18.9
19.4
20.0
20.6
21.1
66
67
68
69
70
150.8
152.6
154.4
156.2
158.0
40.6
43.3
46.1
48.9
51.7
105
110
115
120
125
221.0
230.0
239.0
248.0
257.0
17.2
16.7
16.1
15.6
15.0
1
2
3
4
5
33.8
35.6
37.4
39.2
41.0
2.2
2.8
3.3
3.9
4.4
36
37
38
39
40
96.8
98.6
100.4
102.2
104.0
21.7
22.2
22.8
23.3
23.9
71
72
73
74
75
159.8
161.6
163.4
165.2
167.0
54.4
57.2
60.0
62.7
65.6
130
135
140
145
150
266.0
275.0
284.0
293.0
302.0
14.4
13.9
13.3
12.8
12.2
6
7
8
9
10
42.8
44.6
46.4
48.2
50.0
5.0
5.6
6.1
6.7
7.2
41
42
43
44
45
105.8
107.6
109.4
111.2
113.0
24.4
25.0
25.6
26.1
26.7
76
77
78
79
80
168.8
170.6
172.4
174.2
176.0
68.3
71.1
73.9
76.7
79.4
155
160
165
170
175
311.0
320.0
329.0
338.0
347.0
40
D155AX-6
D155AX-6
SEN00599-04
41
SEN00599-04
D155AX-6 Bulldozer
Form No. SEN00599-04
2008 KOMATSU
All Rights Reserved
Printed in Japan 06-09
42
D155AX-6
SEN00601-04
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
01 Specification
D155AX-6
SEN00601-04
01 Specification
Item
Unit
Overall length
mm
8,225
8,275
mm
3,395
3,395
Overall width
mm
4,060
4,130
Item
Unit
Overall length
mm
8,225
8,275
mm
3,395
3,395
Overall width
mm
4,060
4,130
D155AX-6
01 Specification
SEN00601-04
Specifications
Machine model
D155AX-6
Serial number
80001 and up
Weight
Bare tractor
With HD Sigma-tilt dozer + variable multishank ripper + ROPS cab + air conditioner +
560mm HD shoe + side cover
32,100
41,200
kg
40,800
mm
2.1
Gradeability
deg.
30
deg.
35
Forward
Reverse
Dimensions
Ground pressure
Performance
1st
3.8
2nd
5.6
km/h
7.5
3rd
11.6
1st
4.6
2nd
6.8
km/h
9.2
3rd
14.0
Bare tractor
79.85 {0.81}
kPa
{kg/cm2}
105.84 {1.08}
Bare tractor
With semi U-tilt dozer + tractor
105.84 {1.08}
4,875
mm
6,180
8,225
Bare tractor
2,765
mm
4,130
4,060
3,385
To top of cab
(to top of control lever)
With ROPS cab installed
D155AX-6
mm
2,210
3,395
SEN00601-04
01 Specification
Machine model
D155AX-6
Serial number
80001 and up
Dimensions
Track gauge
2,000
3,050
mm
450
Name
SAA6D140E-5
4-cycle, water-cooled, in-line, vertical type,
direct injection, with turbocharger, aftercooler
and (EGR) cooler
Type of engine
No. of cylinders - Bore x Stroke
mm
6 140 x 165
l {cc}
15.24 {15,240}
kW {HP}/rpm
239 {320}/1,900
Nm {kgm}/rpm
1,715 {175}/1,300
rpm
2,050
rpm
740
g/kWh {g/HPh}
212 {158}
Piston displacement
Performance
Engine
Flywheel horsepower
Max. torque
24V, 11kW
Alternator
24V, 75A
Battery
12V, 170Ah x 2
Torque converter
HSS motor
Bevel gear shaft
HSS
Transmission
MPa
{kg/cm2}
l/min@rpm
MPa
{kg/cm2}
Master brake
Final drive
560
D155AX-6
Undercarriage
01 Specification
SEN00601-04
Machine model
D155AX-6
Serial number
80001 and up
Suspension
Carrier roller
2 each side
Track roller
7 each side
Control valve
+ Ripper tilt
+ Ripper lift
For steering
Hydraulic cylinder
Type
D155AX-6
Cylinder bore
mm
110
mm
75
mm
1,404
mm
2,093
mm
687.5
Cylinder bore
mm
160
mm
90
mm
205
mm
1,395
mm
1,190
Cylinder bore
mm
160
mm
90
mm
210
mm
1,475
mm
1,265
Dimensions of blade
Dimensions of ripper tilt Dimensions of ripper lift (For sigma-tilt dozer tilt and pitch)
Hydraulic cylinder
SEN00601-04
01 Specification
Machine model
D155AX-6
Serial number
80001 and up
Cylinder bore
mm
160
mm
90
mm
165
mm
1,430
mm
1,265
Cylinder bore
mm
180
mm
100
mm
565
mm
1,730
mm
1,165
Cylinder bore
mm
200
mm
110
mm
605
mm
1,815
mm
1,210
Hydraulic tank
MPa
{kg/cm2}
l/min@rpm
MPa
{kg/cm2}
D155AX-6
01 Specification
SEN00601-04
Machine model
D155AX-6
Serial number
80001 and up
Hydraulic sigma-tilt dozer
Hydraulic semi U-tilt dozer
Hydraulic U-tilt dozer
Type
Performance
Dimensions
Performance
Dimensions
Performance
Dimensions
Work equipment
D155AX-6
mm
1,311
mm
627
mm
1,000
deg.
m3
9.4
Blade width
mm
4,060
Blade height
mm
1,790
deg.
46
mm
1,250
mm
590
mm
1,000
deg.
m3
9.4
Blade width
mm
4,130
Blade height
mm
1,790
deg.
52
mm
1,250
mm
590
mm
1,080
deg.
m3
11.9
Blade width
mm
4,225
Blade height
mm
1,790
deg.
52
Performance
Performance
Performance
Dimensions Performance Dimensions Performance
Variable multi-shank ripper Full U-dozer + pitch Semi U-tilt dozer + pitch Sigma-tiltd ozer + pitch
Variable giant ripper
Work equipment
SEN00601-04
01 Specification
Machine model
D155AX-6
Serial number
80001 and up
Max. tilt
mm
1,000
deg.
deg.
Max. tilt
mm
1.000
deg.
deg.
Max. tilt
mm
1,080
deg.
deg.
mm
903
mm
950
30 70
mm
Shank positions
2,320
2
mm
1,255
mm
950
30 70
mm
1,401
Shank positions
No. of holes
D155AX-6
01 Specification
SEN00601-04
Weight table
D155AX-6
Serial number
80001 and up
1,900
Engine assembly
1,759
Damper assembly
120
Universal joint
18
Radiator assembly
(including built-in oil cooler hydraulic cooler and codenser)
333
383
913
2,351
500
Transmission assembly
625
HSS assembly
932
6
16.5
Scavenging pump
20
28
106
HSS motor
67
25
25
1,395 x 2
Sprocket teeth
(12 x 9) x 2
4,426
3,822
Track frame
1,340
Idler assembly
326
508
525 x 3
93 x 4
105 x 3
D155AX-6
45 x 2
SEN00601-04
01 Specification
Unit: kg
Machine model
D155AX-6
Serial number
80001 and up
2,260 x 2
119
136
Equalizer bar
231
99
Control valve
(Blade lift + blade tilt + ripper lift + ripper tilt + steering)
123
Engine underguard
220
Transmission underguard
285
Operators seat
55
Blade
Straight frame
Tilt brace
97 x 1
Center brace
250 x 1
130
Blade
Straight frame
Center brace
250 x 1
130 x 2
Blade
Straight frame
Tilt brace
97 x 1
Center brace
250 x 1
130
165 x 2
4,330
2,300
Shank
266 x 3
184 x 1
252 x 1
10
D155AX-6
01 Specification
SEN00601-04
Unit: kg
Machine model
D155AX-6
Serial number
80001 and up
3,090
1,850
Shank
333 x 1
184 x 1
252 x 1
Cab assembly
410
Dashboard
54
611
Side cover
20
10
D155AX-6
11
SEN00601-04
01 Specification
12
For details of the notes (Note 1, Note 2 - - -) in the table, see Operation and Maintenance Manual.
D155AX-6
01 Specification
SEN00601-04
Unit: l
Refilling points
D155AX-6
Specified capacity
Refill capacity
45
37
Damper case
1.5
1.5
130
90
31
31
Hydraulic system
(with blade, without ripper)
240
91.5
Cooling system
(including reservoir tank)
82
Fuel tank
625
D155AX-6
13
SEN00601-04
01 Specification
D155AX-6 Bulldozer
Form No. SEN00601-04
2012 KOMATSU
All Rights Reserved
Printed in Japan 02-12
14
D155AX-6
SEN00603-00
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
D155AX-6
SEN00603-00
Radiator
D155AX-6
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Overflow hose
Air bleed hose
Inlet hose
Coolant filler cap
Radiator core assembly
Reservoir tank
Inlet hose (for circulating at low coolant
temperature)
Outlet hose
Lower tank (power train oil cooler built-in)
Fan
Drain plug
Cushion
Breather cap
Pressure valve
a:
b:
c:
Aftercooler
Aftercooler outlet hose
Aftercooler inlet hose
SEN00603-00
Outline
q
The reservoir tank is provided for radiator.
q
The power train oil cooler is built in the lower
tank of the radiator.
Radiator
Rectangle
wave fin
Core type
Fin pitch
4.0
(m )
41.99 x 2
Relief
pressure
(MPa {kg/cm2})
0.09 {0.9}
Vacuum
pressure
(MPa {kg/cm2})
0.005 {0.05}
(mm)
2
Specification
Aftercooler: Rectangle wave fin 8.0/2P
D155AX-6
SEN00603-00
Oil cooler
1.
2.
Hydraulic cooler
Power train oil cooler
A:
B:
Outline
q
The power train oil cooler is built in the lower
tank of the radiator.
Core type
Inner fin type
Cooling method
Heat dissipation area (m2)
Power train
oil cooler
Hydraulic
cooler
PTO-OL
Rectangle
wave (4.0P)
TF8-C
TF6-P
Built in lower
tank
Air cooled
2.47
4.51
D155AX-6
SEN00603-00
Engine mount
Unit: mm
No.
Check item
Clearance between bracket
and cushion
Criteria
Standard
size
60
D155AX-6
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
0.1
0.3
+0.046
+0.046
0.1
0.346
Standard clearance
Clearance limit
86
84
Replace
SEN00603-00
Type: LPV45
Servo valve
Air bleeder
D155AX-6
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
SEN00603-00
Shaft
Oil seal
Case
Rocker cam
Shoe
Piston
Cylinder block
Valve plate
Spring
Servo piston
D155AX-6
SEN00603-00
Function
q
The pump converts the engine rotation transmitted to its shaft to oil pressure and delivers
pressurized oil corresponding to the load.
q
It is possible to change the delivery by changing the swash plate angle.
q
q
q
Structure
Cylinder block (7) is supported to shaft by
spline (11).
q
Shaft (1) is supported with front and rear bearings (12).
q
The end of piston (6) has a spherical hollow
and is combined with shoe (5).
q
Piston (6) and shoe (5) form a spherical bearing.
q
Shoe (5) is kept pressed against plane (A) of
rocker cam (4) and slid circularly.
q
Rocker cam (4) slides around ball (13).
q
Piston (6) carries out relative movement in the
axial direction inside each cylinder chamber of
cylinder block (7).
q
D155AX-6
Operation of pump
q
Cylinder block (7) rotates together with shaft
(1), and shoe (5) slides on flat surface (A).
q
At this time, rocker cam (4) slants around ball
(13). As a result, angle (a) between center line
(X) of rocker cam (4) and the axis of cylinder
block (7) changes.
q
Angle (a) is called the swash plate angle.
SEN00603-00
q
q
D155AX-6
SEN00603-00
10
Control of delivery
q
If the swash plate angle (a) becomes larger,
the difference between volumes (E) and (F)
be c o me s la r g er a nd pu m p d el i v er y ( Q )
increases.
q
Swash plate angle (a) is changed with servo
piston (10).
q
Servo piston (10) reciprocates straight according to the signal pressure of the servo valve.
q
This straight motion is transmitted to rocker
cam (4).
q
Rocker cam (4) supported with ball (13) slides
around ball (13).
D155AX-6
SEN00603-00
Servo valve
P:
PE:
PH:
T:
D155AX-6
1.
2.
3.
4.
5.
6.
7.
8.
Plug
Lever
Retainer
Seat
Spool
Piston
Sleeve
Spring
11
SEN00603-00
Function
q
The servo valve controls the current input to
the EPC valve and the pump delivery (Q) so
that they will be related as shown in the diagram.
q
q
12
D155AX-6
SEN00603-00
Type: LMF110(65)
14
Specifications
Type: LMF110(65)
Capacity: 65.1 cc/rev
Rated speed: 1,250 rpm
Rated flow: 81.4 l/mm
Check valve crack pressure: 78.5 kPa {0.8 kg/cm2}
D155AX-6
1.
2.
3.
4.
5.
6.
Output shaft
Case
Thrust plate
Piston assembly
Cylinder block
Valve plate
SEN00603-00
7.
8.
9.
10.
11.
12.
End cover
Center spring
Check valve
Pilot valve
Spool for reversible valve
Safety valve
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
13 Spool return spring
D155AX-6
Repair limit
Installation
load
Free
length
62.66 x 19.8
53.5
146 N
{14.9 kg}
16.4 x 8.9
11.5
13.7 N
{1.4 kg}
Installation
load
Replace spring
if damaged or
117 N
{11.9 kg} deformed.
11.0 N
{1.12 kg}
15
SEN00603-00
1. Hydraulic motor
Function
q
This hydraulic motor is called a swash platetype axial piston motor. It converts the energy
of the pressurized oil sent from the hydraulic
pump into rotary motion.
Principle of operation
q
The oil sent from the hydraulic pump flows
through valve plate (7) into cylinder block (5).
This oil can flow on only one side of the (Y-Y)
line connecting the top dead center and bottom
dead center of the stroke of piston (4).
q
The oil sent to one side of cylinder block (5)
presses piston (4) [4 or 5 pieces], and generates force (F1)[F1 = P x xD2/4].
q
This force is applied to thrust plate (2). Since
thrust plate (2) is fixed to the angle of (a)
degrees to the output shaft(1), the force is
divided into components (F2) and (F3).
q
The radial component (F3) generates torque [T
= F3 x ri] against the (Y-Y) line connecting the
top dead center and bottom dead center.
q
The result of this torque [T = (F3 x ri)] rotates
cylinder block (5) through the piston.
q
Since this cylinder block (5) is splined to the
output shaft, the output shaft revolves to transmit the torque.
16
D155AX-6
SEN00603-00
2. Suction valve
Function
q
If the fan pump stops, the pressurized oil does
not flow into the motor. Since the motor continues revolution because of the force of inertia,
however, the pressure on the outlet side of the
motor rises.
q
When the oil stops flowing in from inlet port (P),
suction valve (1) sucks in the oil on the outlet
side and supplies it to port (MA) where there is
not sufficient oil to prevent cavitation.
Operation
1)
q
2)
q
D155AX-6
17
SEN00603-00
q
q
18
2)
q
q
q
D155AX-6
SEN00603-00
4. Safety valve
Function
q
When the engine is started, the pressure in
port (P) of the fan motor is heightened in some
cases.
q
Safety valve (1) is installed to protect the fan
system circuit.
Operation
q
If the pressure in port (P) rises above the
cracking pressure of safety valve (1), valve (2)
of safety valve (1) opens to release the pressurized oil into port (T).
q
By this operation, generation of abnormal pressure in port (P) is prevented.
D155AX-6
19
SEN00603-00
D155AX-6 Bulldozer
Form No. SEN00603-00
2005 KOMATSU
All Rights Reserved
Printed in Japan 12-05 (02)
20
D155AX-6
SEN00604-01
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
D155AX-6
SEN00604-01
Outline
q
The power generated by engine (1) has its torsional vibration dampened by damper (2), and
then passes through universal joint (3), and is
transmitted to torque converter (8).
q
The power from the engine is transmitted
through the oil by torque converter (8) to the
transmission input shaft (turbine shaft) in
accordance with the change in load. (with L/U)
q
Transmission (9) uses a combination of a planetary gear system and hydraulic clutches to
reduce the speed and shift the gears (3 forward gears and 3 reverse gears). It connects
2 sets of clutches selected according to the
change in load, and transmits the power to
bevel gear (10) from the bevel pinion at the
rear end of the transmission.
D155AX-6
1.
2.
3.
4.
5.
6.
7.
8.
9.
Engine (SAA6D140E-5)
Damper
Universal joint
Scavenging pump (SAR(4)140)
Hydraulic, HSS pump (HPV190)
PTO
Power train lubricating pump
(SAR(3)100+(3)40)
Torque converter
Transmission
D155AX-6
SEN00604-01
10.
11.
12.
13.
14.
15.
16.
17.
18.
Bevel gear
HSS unit
HSS motor (KMF140)
Brake
Final drive
Sprocket
Track shoe
Cooling fan pump (LPV45)
Cooling fan motor (LMF65)
SEN00604-01
D155AX-6
1.
2.
3.
HSS unit
Transmission
Power train, lubricating pump
(SAR(3)100+(3)40)
4. Power train oil strainer
5. HSS motor (KMF140)
6. Main relief, torque converter relief valve
7. Torque converter, PTO
8. Scavenging pump (SAR(4)140)
9. Cooling fan pump (LPV45)
10. Hydraulic, HSS pump (HPV190)
11. Brake control valve
D155AX-6
SEN00604-01
Outline
q
The power train unit can be broadly divided
into torque converter, PTO (7), transmission
(2), and HSS unit (1).
So, a fter the power train unit h as be en
removed, it can be disassembled into the
torque converter, PTO (7), transmission (2),
and HSS unit (1).
q
HSS unit consists of the bevel pinion unit,
bevel gear shaft, HSS motor, planetary gear
and brake.
SEN00604-01
D155AX-6
1.
2.
3.
4.
5.
6.
7.
8.
9.
SEN00604-01
D155AX-6
SEN00604-01
D155AX-6
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
SEN00604-01
Breather
Dipstick
Drain plug
Output shaft
Flywheel
Outer body
Coupling
Universal joint
Cover
Rubber coupling
Inner body
Unit: mm
No.
12
Check item
Clearance between flywheel
housing and cover
13
14
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
511.18
0.022
0.092
+0.070
+0.070
0.022
0.162
0.2
466.72
0.020
0.083
+0.063
+0.070
0.020
0.146
0.2
Standard size
Tolerance
Repair limit
90
0.087
0.087
89.8
Replace
Outline
q
The damper, dampens the torsional vibration
caused by the change in engine torque and
the impact torque generated when accelerating suddenly or when carrying out heavy-duty
digging. In this way, it acts to protect the torque
converter, transmission, and other parts of the
power train.
q
The damper has few component parts: it uses
a rubber coupling, so the vibration is absorbed
by the damping effect of the rubber material.
Operation
q
The motive force from the engine passes
through flywheel (5) and is transmitted to outer
body (6).
The torsional vibration of the engine is absorbed
by rubber coupling (10), and the power is transmitted to inner body (11). It passes through universal joint (8), and is then transmitted to the
torque converter and transmission.
D155AX-6
SEN00604-01
A:
B:
C:
10
D:
E:
F:
D155AX-6
D155AX-6
SEN00604-01
11
SEN00604-01
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
12
D155AX-6
Outline
q
The torque converter is a 3-element, 1-stage,
and 2-phase type, which is integral with the
transmission.
q
The torque converter is equipped with a wet
double disc clutch type torque converter lockup
device and a stator clutch in order to reduce
fuel consumption, to increase the operability,
and to reduce the horsepower consumption by
the engine.
q
For higher efficiency of continuous light dozing
and leveling operation, the torque converter is
locked up and the engine power is transferred
directly to the transmissions input shaft.
q
When the torque converter is locked up (the
pump and turbine is integrated into 1 unit), the
oil is still supplied to the torque converter.
Accordingly, the oil flowing from the pump
through the turbine to the stator is obstructed
by the stator blades and cannot flow in any
direction. As a result, this oil resists the rotation
of the pump and turbine (it is agitated).
q
To reduce the rotating resistance of the pump
and turbine, the stator clutch is disengaged
simultaneously with lockup of the torque converter so that the stator can rotate freely.
As the stator is dragged and turned by the
pump and turbine, the oil returns from the turbine to the pump smoothly against less resistance.
SEN00604-01
Structure
q
Pump (15) is integrated with coupling (6), input
shaft (7), lockup clutch housing (10), and drive
case (12), and rotated by the engine power.
q
Turbine (11) is integrated with turbine boss
(29) and transmission input shaft (25), and
rotated by the oil from pump (15).
q
Stator (14) is integrated with stator shaft (20)
and stator clutch hub (21), and fixed to torque
converter case (5) through the stator clutch
unit.
q
The lockup clutch unit consists of clutch plate
(26) meshed with drive case (12), clutch disc
(27) meshed with turbine boss (29), and clutch
piston (28) which slides inside clutch housing
(10) integrated with drive case (12).
q
The stator clutch unit consists of clutch hub
(21) attached to stator shaft (20) with spline,
clutch disc (23) meshed with clutch hub (21),
clutch plate (22) supported by the pins on
clutch front housing (17) and clutch rear housing (19), and clutch piston (24) which slides
inside clutch front housing (17).
Clutch front housing (17) is fixed to sleeve (35)
with torque converter case (5).
q
The PTO unit consists of input shaft (7), PTO
idler gear (8), PTO gear A(30), PTO gear B(31)
and scavenging pump drive gear (32).
Torque converter
range
Forward
1st
Forward
2nd
Forward
3rd
Max. 1,355rpm
Reverse
1st
Reverse
2nd
Reverse
3rd
D155AX-6
13
SEN00604-01
14
D155AX-6
SEN00604-01
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Tolerance
Repair limit
100
-0.054
-0.054
99.8
35
+0.025
+0.025
35.1
Width
2.56
-0.01
-0.03
2.3
Thickness
1.7
0.1
1.55
65
+0.030
+0.025
65.1
Width
-0.01
-0.03
2.7
Thickness
2.7
0.1
2.55
90
+0.035
+0.025
90.1
Width
-0.01
-0.03
2.7
Thickness
3.7
0.12
3.55
150
+0.040
+0.025
150.5
0.198 0.484
0.198 0.484
0.198 0.484
0.198 0.484
4
Wear of the stator
shaft seal ring
Thickness of the
lockup clutch disc
Replace
Repair by hard
chrome plating
or replace
Replace
0.1
4.5
5.0
0.1
4.5
Overall thickness of
the lockup clutch assembly
15.0
0.17
13.9
5.0
0.1
4.5
5.0
0.1
4.5
15.0
0.17
13.9
D155AX-6
Repair by hard
chrome plating
or replace
Replace
5.0
10 Thickness of the
lockup clutch plate
Repair by hard
chrome plating
or replace
Repair by hard
chrome plating
or replace
Replace
15
SEN00604-01
Unit: mm
No.
Check item
Fitting tolerance
of the PTO idler
12 gear
and bearing
Criteria
Shaft
Hole
Standard
clearance
Clearance
limit
Outer
diameter
140
-0.025
-0.018
-0.008
-0.033
-0.033
0.010
Inner
diameter
80
0.025
-0.019
0
-0.015
-0.015
0.019
Outside
diameter
(cover side)
180
-0.025
-0.025
+0.026
-0.014
-0.014
0.051
120
-0.025
-0.015
+0.022
-0.013
-0.013
0.037
100
+0.035
+0.013
-0.025
-0.020
-0.055
-0.013
65
+0.030
+0.011
-0.025
-0.015
-0.045
-0.011
120
-0.025
-0.015
+0.022
-0.013
-0.013
0.037
120
-0.025
-0.015
+0.022
-0.013
-0.013
0.037
55
+0.030
+0.011
-0.025
-0.015
-0.045
-0.011
Inner
diameter
(case side)
65
+0.030
+0.011
-0.025
-0.015
-0.045
-0.011
Outer
diameter
85
-0.025
-0.015
+0.010
-0.025
-0.025
0.025
Inner
diameter
45
+0.018
+0.002
-0.025
-0.012
-0.030
-0.002
Outside
diameter
(cover side)
Outside
Fitting tolerance of diameter
(case side)
fan pump
drive gear
Inner
bearing
diameter
(cover side)
Fitting tolerance of
the scavenging
15 pump
drive gear
bearing
Standard size
16 Stator clutch
return spring
Replace
Repair limit
Installation Installation
Installation
Free length
Free length
length
load
load
35
16
Remedy
Standard
size
Fitting tolerance of
Outside
HSS, work equipdiameter
ment,
(case side)
power train,
13 steering
Inner
lubrication pump
diameter
drive gear
(cover side)
bearing
Inner
diameter
(case side)
14
Tolerance
27
85.3 N
{8.7 kg}
32.9
72.6 N
{7.4 kg}
D155AX-6
SEN00604-01
D155AX-6
17
SEN00604-01
Oil flow
18
D155AX-6
A:
B:
C:
1.
2.
3.
D155AX-6
SEN00604-01
19
SEN00604-01
A: To clutch
P: From pump
T: Drain
DR: Drain
P1: Clutch oil pressure pickup port
P2: Pilot oil pressure pickup port
1.
2.
3.
4.
5.
6.
7.
20
*1:
Operated clutches
Lockup
E*******
Stator
A*******
D155AX-6
SEN00604-01
Operation
When traveling in torque converter range
D155AX-6
When traveling in torque converter range, current is not supplied to proportional solenoid (1).
Pressure control valve (3) drains the oil from
clutch port (A) through drain port (T), and
lockup clutch is released.
Also at this time, fill switch (5) is turned off
because oil pressure is not applied to pressure
detection valve (4).
21
SEN00604-01
22
Pressure adjustment
D155AX-6
SEN00604-01
Operation
When traveling in direct range
It forms a modulation wave pattern, so the stator clutch is engaged smoothly to reduce the
shock when shifting gear. In addition, it prevents generation of peak torque in the power
train. As a result, it provides a comfortable ride
for the operator and greatly increases the
durability of the power train.
Direct travel o torque converter travel
D155AX-6
23
SEN00604-01
24
When traveling in torque converter range current is supplied to proportional solenoid (1), the
oil pressure force balanced with the solenoid
force is applied to chamber (B) and pushes
pressure control valve (3) to the left.As a
result, pump port (P) and clutch port (A) are
opened and oil starts filling the clutch. If the
clutch is filled with oil, fill switch (5) is turned
on.
Pressure adjustment
D155AX-6
D155AX-6
SEN00604-01
25
SEN00604-01
Transmission control
a
a
1.
2.
3.
4.
5.
26
For steering operation of the Palm Command Steering Control lever (PCCS lever), see Steering, brake
control.
PCCS: Abbreviation for Palm Command Control System
Brake pedal
Lock lever
PCCS lever
(Forward-Reverse, Gear shift)
3A. UP switch
(Gear is shifted up each time this switch is
pressed.)
3B. DOWN switch
(Gear is shifted down each time this switch
is pressed.)
Transmission neutral lock
Transmission control valve
Lever positions
A: Neutral
B: Forward
C: Reverse
D: OFF
E: Shift UP
F: Shift DOWN
G: Free
H: Lock
D155AX-6
SEN00604-01
Outline
q
The transmission is controlled with PCCS lever
(3).
The PCCS lever is used to select the travel
direction and shift the gear.
q
Since the safety mechanism is employed,
transmission neutral safety switch (4) does not
work and the engine does not start unless lock
lever (2) is in the LOCK position.
D155AX-6
27
SEN00604-01
Transmission
28
D155AX-6
A:
B:
C:
D:
E:
F:
G:
H:
J:
D155AX-6
SEN00604-01
K:
L:
M:
N:
P:
R:
S:
T:
U:
To torque converter
To scavenging pump
To torque converter case
From torque converter case
To R clutch
To 3rd clutch
To 1st clutch
To 2nd clutch
To F clutch
29
SEN00604-01
30
D155AX-6
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
Transmission ECMV
Main relief valve and torque converter relief
valve
Transmission case
Sleeve
Transmission input shaft
Tie bolt
R ring gear (hub)
R planetary pinion (number of teeth: 26)
R ring gear (number of internal teeth: 86)
F planetary pinion (number of teeth: 24)
F ring gear (number of internal teeth: 91)
3rd planetary pinion (number of teeth: 35)
3rd ring gear (number of internal teeth: 89)
2nd planetary pinion (number of teeth: 31)
2nd ring gear (number of internal teeth: 91)
1st ring gear (number of internal teeth: 91)
1st planetary pinion (number of teeth: 27)
Transmission output shaft
(3rd sun gear)(number of teeth: 19)
1st clutch housing
1st clutch piston
1st sun gear (number of teeth: 37)
1st carrier
2nd clutch housing
2nd clutch piston
2nd sun gear (number of teeth: 29)
2nd carrier
3rd clutch housing
3rd clutch piston
3rd carrier
F clutch housing
F clutch piston
F carrier
R clutch housing
F sun gear (number of teeth: 44)
R clutch piston
Washer spring
Clutch plate
Clutch disc
Piston return spring
R carrier
Front housing
R sun gear (number of teeth: 34)
D155AX-6
SEN00604-01
Outline
q
The transmission adopted is a forward 3-gear
speed and reverse 3-gear speed transmission
which consists of the planetary gear mechanisms and the disc clutches.
q
Out of the 5 sets of planetary gear mechanisms and disc clutches, 2 clutches are fixed
hydraulically by the operation of ECMV to
select 1 rotation direction and 1 gear speed.
q
The transmission transfers the power received
by the transmission input shaft to the output
shaft while changing the gear speed (forward
1st-3rd or reverse 1st-3rd) by any combination
of the F, R clutches and 3 speed clutches.
Number of plates and disk used
Clutch No.
Number of
plates
Number of discs
R clutch
F clutch
3rd clutch
2nd clutch
1st clutch
Operated clutches
Reduction
ratio
Forward 1st
F x 1st
1.705
Forward 2nd
F x 2nd
1.151
Forward 3rd
F x 3rd
0.540
Neutral
Reverse 1st
R x 1st
1.406
Reverse 2nd
R x 2nd
0.949
Reverse 3rd
R x 3rd
0.445
31
SEN00604-01
32
D155AX-6
SEN00604-01
Unit: mm
No.
Check item
Criteria
Standard size
Free length
Remedy
Repair limit
Installation Installation
Installation
Free length
length
load
load
81.7
72.4
59.8 N
{6.1 kg}
76.8
51.0 N
{5.2 kg}
81.7
76.4
34.3 N
{3.5 kg}
76.8
29.4 N
{3.0 kg}
70.0
50.2
97.1 N
{9.9 kg}
65.8
82.4 N
{8.4 kg}
70.0
51.6
90.2 N
{9.2 kg}
65.8
76.5 N
{7.8 kg}
66.0
51.8
66.7 N
{6.8 kg}
62.0
56.9 N
{5.8 kg}
Standard size
Tolerance
Repair limit
51.6
0.35
48.4
57.0
0.36
53.3
31.2
0.26
29.1
31.2
0.26
29.1
22.6
0.22
21.0
5.4
0.1
4.9
3.2
0.1
2.9
Width
2.56
-0.01
-0.03
2.30
Thickness
1.7
0.1
1.55
Width
3.0
-0.01
-0.03
2.70
Thickness
2.7
0.1
2.55
4.0
-0.01
-0.04
3.60
5.0
0.15
4.85
Width
4.0
-0.01
-0.04
3.60
Thickness
4.0
0.15
3.85
Width
4.0
-0.01
-0.04
3.60
Thickness
4.0
0.15
3.85
D155AX-6
Replace
33
SEN00604-01
Unit: mm
No.
18
Check item
Backlash between
20 sun gear and
planetary pinion
21
Backlash between
planetary pinion and
ring gear
Criteria
Remedy
Standard size
Tolerance
Repair limit
Width
4.0
-0.01
-0.04
3.60
Thickness
4.0
0.15
3.85
Width
4.0
-0.01
-0.04
3.60
Thickness
5.0
0.15
4.85
R, F,
3rd, 1st
0.14 - 0.35
2nd
0.13 - 0.32
0.15 - 0.39
F, 2nd,
1st
0.15 - 0.38
3rd
0.16 - 0.42
Replace
Disc clutch
Structure
q
q
34
Operation
When clutch is engaged (fixed)
D155AX-6
q
q
SEN00604-01
D155AX-6
35
SEN00604-01
36
D155AX-6
SEN00604-01
F ring gear (4) of F clutch and 1st ring gear (19) of 1st clutch are fixed hydraulically.
The power from torque converter
O
Input shaft (1)
O
F sun gear (2)
O
F planetary pinion (3)
O
F carrier (10)
O
3rd carrier (11)
O
3rd planetary pinion (12)
O
3rd ring gear (13)
O
2nd carrier (14)
O
2nd planetary pinion (15)
O
2nd ring gear (16)
O
1st carrier (17)
O
1st planetary pinion (18)
O
1st sun gear (20)
O
Output shaft (22)
D155AX-6
37
SEN00604-01
38
D155AX-6
SEN00604-01
F ring gear (4) of F clutch and 2nd ring gear (16) of 2nd clutch are fixed hydraulically.
The power from torque converter
O
Input shaft (1)
O
F sun gear (2)
O
F planetary pinion (3)
O
F carrier (10)
O
3rd carrier (11)
O
3rd planetary pinion (12)
O
3rd ring gear (13)
O
2nd carrier (14)
O
2nd planetary pinion (15)
O
2nd sun gear (21)
O
Output shaft (22)
D155AX-6
39
SEN00604-01
40
D155AX-6
SEN00604-01
F ring gear (4) of F clutch and 3rd ring gear (13) of 3rd clutch are fixed hydraulically.
The power from torque converter
O
Input shaft (1)
O
F sun gear (2)
O
F planetary pinion (3)
O
F carrier (10)
O
3rd carrier (11)
O
3rd planetary pinion (12)
O
Output shaft (22)
D155AX-6
41
SEN00604-01
42
D155AX-6
SEN00604-01
R ring gear (7) of R clutch and 1st ring gear (19) of 1st clutch are fixed hydraulically.
The power from torque converter
O
Input shaft (1)
O
R sun gear (5)
O
R planetary pinion (6)
O
R ring gear (9)
(R carrier (8) is fixed with R ring gear (7) = R
ring gear (9) rotation direction is opposite to
input shaft (1))
O
F carrier (10)
O
3rd carrier (11)
O
3rd planetary pinion (12)
O
3rd ring gear (13)
O
2nd carrier (14)
O
2nd planetary pinion (15)
O
2nd ring gear (16)
O
1st carrier (17)
O
1st planetary pinion (18)
O
1st sun gear (20)
2nd sun gear (21)
O
Output shaft (22)
D155AX-6
43
SEN00604-01
Transmission ECMV
a
a
44
D155AX-6
SEN00604-01
AF:
AR:
A1:
A2:
A3:
P:
T:
Dr:
PF:
PR:
P1:
P2:
P3:
To F clutch
To R clutch
To 1st clutch
To 2nd clutch
To 3rd clutch
From power train pump
Drain
Drain
F clutch oil pressure pickup port
R clutch oil pressure pickup port
1st clutch oil pressure pickup port
2nd clutch oil pressure pickup port
3rd clutch oil pressure pickup port
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
D155AX-6
sgear
speed
ECMV
N
F1
F2
F3
1st
2nd
3rd
Q
Q
Q
R1
R2
R3
Q
Q
Q
When the directional lever is in (neutral) position, the speed clutch of the speed selected by
gear shift lever activates.
45
SEN00604-01
1.
2.
3.
4.
5.
6.
7.
8.
46
Fill switch
Pressure control valve
Body (upper)
Body (lower)
Proportional solenoid
Filter
Pressure detection valve
Sleeve
D155AX-6
Outline of ECMV
q
The ECMV consists of 1 pressure control valve
and 1 fill switch.
q
Pressure control valve
A proportional solenoid in this valve receives a
current sent from the controller and this valve
converts it to an oil pressure.
q
Fill switch
This switch detects that the clutch is filled with
oil and has the following functions.
1. Outputs a signal (a fill signal) to the controller
to notify that filling is completed when the
clutch is filled with oil.
2. Keeps outputting signals (fill signals) to the
controller to notify whether oil pressure is
applied or not while oil pressure is applied to
the clutch.
SEN00604-01
D155AX-6
47
SEN00604-01
Operation of ECMV
q
ECMV is controlled with the command current
sent from the controller to the proportional
solenoid and the fill switch output signal.
The relationship between the proportional
solenoid command current of ECMV, clutch
input pressure, and fill switch output signal is
shown below.
48
D155AX-6
D155AX-6
SEN00604-01
49
SEN00604-01
Unit: mm
No.
Check item
Clearance between main relief
valve and body
Clearance between the torque converter relief valve and the body
Criteria
Standard
size
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
28
-0.035
-0.045
+0.013
+0.013
0.035
0.058
0.078
22
-0.035
-0.045
+0.013
+0.013
0.035
0.058
0.078
Standard size
3
Remedy
Repair limit
Installation Installation
Installation
Free length
Free length
length
load
load
122
78.0
481 N
{49 kg}
118.3
457 N
{46.6 kg}
108
78.0
368 N
{37.5 kg}
104.8
349 N
{35.6 kg}
50
40.5
182 N
{18.6 kg}
48.5
174 N
{17.7 kg}
6.
7.
8.
9.
10.
50
Body
Piston
Torque converter relief valve
Piston
Main relief valve
Replace
D155AX-6
Outline
SEN00604-01
The oil from the hydraulic pump flows to chamber (F) through the filter, port (C) of the relief
valve and orifice (a) of main relief valve (1).
Operation
Operation of torque converter relief valve
D155AX-6
51
SEN00604-01
Unit: mm
No.
Check item
Criteria
Standard size
Free length
26
2.
3.
4.
F clutch housing
R clutch housing
Piston
A:
B:
C:
Remedy
Repair limit
Installation Installation
Installation
Free length
length
load
load
Replace
23.6
12.5 N
{1.27 kg}
25.2
11.9 N
{1.21 kg}
Outline
q
The oil leaving the torque converter passes
through the power train oil cooler built in the
radiator lower tank. It then goes through the
lubrication relief valve and lubricates the transmission and PTO.
q
The lubrication relief valve is installed to the
right side face of the F clutch housing. It keeps
the lubricating oil pressure below the set pressure.
Specified value
52
Normal pressure
(MPa{kg/cm2})
0.14 0.05
{1.4 0.5}
Cracking pressure
(MPa{kg/cm2})
0.30 0.03
{3.0 0.3}
D155AX-6
SEN00604-01
Scavenging pump
Type: SAR(4)140
Unit: mm
No.
Check item
Side clearance
Delivery amount
Oil: SAE10WCD
Oil temperature: 45 55C
Criteria
Remedy
Standard clearance
Clearance limit
0.11 0.16
0.19
0.06 0.14
0.20
Replace
Standard size
Tolerance
Repair limit
21
-0.5
-0.5
Delivery pressure
MPa{kg/cm2}
Standard
delivery
(l/min)
Delivery
limit
(l/min)
2,200
2.94{30}
300
266
Outline
q
The scavenging pump is installed to the torque
converter case and is driven with the power
from the engine. It returns the oil collected in
the bottom of the transmission case to the
steering case.
D155AX-6
53
SEN00604-01
Type: SAR(3)100+(3)40
1.
2.
54
Outline
q
The power train pump and the steering lubrication pump are installed to the torque converter
case. They are driven by the power from the
engine to supply the oil pressure to the torque
converter, the transmission and the steering
unit.
D155AX-6
SEN00604-01
Unit: mm
No.
Check item
Criteria
Type
Side clearance
SAR(3)100
SAR(3)40
SAR(3)40
SAR(3)100
SAR(3)40
Delivery amount
Oil: SAE10WCD
Oil temperature: 45 55C
D155AX-6
Clearance limit
0.10 - 0.15
0.19
0.06 - 0.15
0.20
SAR(3)100
Type
5
Remedy
Standard clearance
Replace
Standard size
Tolerance
Repair limit
14
-0.5
-0.5
Rotation
speed
(rpm)
Delivery
pressure
(MPa{kg/
cm2})
Standard
delivery
(l/min)
Delivery
limit
(l/min)
SAR(3)100
2,500
2.94{30}
241
96
SAR(3)40
2,500
2.94{30}
239
85
55
SEN00604-01
D155AX-6 Bulldozer
Form No. SEN00604-01
2007 KOMATSU
All Rights Reserved
Printed in Japan 03-07 (02)
56
D155AX-6
SEN00605-02
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
D155AX-6
SEN00605-02
HSS system
D155AX-6
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
PCCS lever
Power train controller
Control valve
Hydraulic, HSS pump
Engine
EPC valve
Hydraulic tank
Sprocket
Final drive
HSS motor
HSS open circuit
Servo valve
Engine throttle controller
A:
B:
C:
D:
E:
D155AX-6
SEN00605-02
Outline
q
HSS system is an abbreviation for the Hydrostatic Steering System.
q
The HSS system consists of a set of control
valve, hydraulic, HSS pump, and HSS motor
as shown in the figure. It turns the machine
continuously without lowering the travel speed
by making a difference in speed between both
tracks.
q
The power train controller controls the EPC
valve of the control valve to control the revolving direction and revolving speed of the HSS
motor according to the tilting direction and
angle of the PCCS lever. The HSS motor acts
on the planetary gear mechanism of the bevel
gear shaft to make a difference in speed
between both sprockets. As a result, the
machine turns.
q
The power train controller senses the engine
speed and oil pressure at each part and controls the hydraulic, HSS pump and control
valve to drive the hydraulic, HSS pump so that
the engine will not stall.
q
The engine speed signal and other engine
control information items are sent and received
through the CAN communication network
which connects the engine throttle controller
and power train controller.
SEN00605-02
HSS motor
Type: KMF140
1.
2.
3.
4.
Outline
q
This motor is composed of the fixed capacity
bent axis type piston motor, the counterbalance valve, the check valve and relief valve.
Specifications
Type: KMF140
Theoretical delivery: 141.1 cm3/rev
Rated output pressure: 41.2 MPa {420 kg/cm2}
Rated rpm: 2,205 rpm
HSS motor
Check valve
Counterbalance valve
Relief valve
D155AX-6
D155AX-6
SEN00605-02
SEN00605-02
D155AX-6
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
SEN00605-02
Drive shaft
Motor case
Piston
Cylinder block
Valve plate
Housing
Cover
Counterbalance valve spool
Check valve
Spool
Safety valve
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
12 Check valve spring
Repair limit
Installation
load
Free
length
Installation
load
62.5 x 20
39
3.04 N
{0.31 kg}
1.96 N
{0.25 kg}
13
43.4 x 35
41
241 N
{24.6 kg}
155 N
{19.7 kg}
14
40.44 x 21.9
38
96.1 N
{9.8 kg}
76.9 N
{7.84 kg}
D155AX-6
Replace spring
if damaged or
deformed.
SEN00605-02
Operation
q
The pressurized oil sent from the main piston
pump enters from the piston motor inlet port,
and the oil pressure is applied to the back of
piston (3), and drive shaft (1) rotates by the
inclination (Q) of piston (3) and cylinder block
(4).
Structure
q
Seven pistons (3) are attached to the disc part
of drive shaft (1) with a manner just like a
spherical joint Pistons (3) forms an specific
agle with drive shaft (1), and stored in cylinder
block (4).
D155AX-6
SEN00605-02
Brake valve
q
1)
Function
When the steering is operated on a downhill
slope, the gravity force tends to make the current driving speed faster than the speed by
motor (engine) rotation.
q
If the steering is operated while the engine is
running at low speed, the motor rotates under
no load and runs away. This may cause an
extremely dangerous condition.
q
These valves control the steering opration in
accordance with the engine speed (pump
delivery) in order to prevent such a dangerous
condition.
q
D155AX-6
SEN00605-02
10
D155AX-6
2)
SEN00605-02
Safety valve
(Both operated safety valve.)
Function
q
When the operation of the steering is finished,
counterbalance valve closes the circuit at the
inlet and outlet ports of the motor.
q
Since the motor is rotated by inertial force,
pressure in the motor outlet port side is abnormally increased, potentially resulting in damages on the motor and piping.
q
The safety valve releases this abnormal pressure to the inlet port side of the motor in order
to prevent damages to the equipment.
Bidirectional action
(1) When pressure in chamber (MB) has become
high (when rotating clockwise)
q
When the operation of the steering is finished,
the check valve of the counterbalance valve
closes the circuit at outlet ports (MB).
q
The motor tries to continue rotation resorting to
inertial force, thus pressure on the outlet port
(MB) is increased.
D155AX-6
11
SEN00605-02
12
D155AX-6
D155AX-6
SEN00605-02
13
SEN00605-02
Type: HPV190
14
D155AX-6
SEN00605-02
Outline
q
This pump consists of a variable displacement
swash plate type piston pump, PC valve, and
EPC valve.
IM: PC mode selector current
PA: Pump discharge port
PB: Pump discharge pressure input port
PD1: Case drain port
PD2: Drain plug
PEN: Control pressure pickup port
PEPC: EPC basic pressure port
PEPCC: EPC basic pressure pickup port
PLS: Load pressure input port
PLSC: Load pressure pickup port
PM: PC mode selector pressure pickup port
PS: Pump suction port
1.
2.
3.
4.
Front pump
LS valve
PC valve
PC-EPC valve
D155AX-6
15
SEN00605-02
1.
2.
3.
4.
5.
6.
7
8.
9.
10.
11.
16
Shaft
Cradle
Case
Rocker cam
Shoe
Piston
Cylinder block
Valve plate
End cap
Servo piston
PC valve
D155AX-6
SEN00605-02
Function
q
The pump converts the engine rotation transmitted to its shaft to oil pressure and delivers
pressurized oil corresponding to the load.
q
It is possible to change the delivery by changing the swash plate angle.
Structure
q
Cylinder block (7) is supported to shaft (1) by
spline (12).
q
Shaft (1) is supported by each bearing (13).
q
The end of piston (6) has a spherical hollow
and is combined with shoe (5).
q
Piston (6) and shoe (5) form a spherical bearing.
q
Rocker cam (4) has flat surface (A), and shoe
(5) is always pressed against this surface while
sliding in a circular movement.
q
Rocker cam (4) conducts high pressure oil to
cylinder surface (B) with cradle (2), which is
secured to the case, and forms a static pressure bearing when it slides.
D155AX-6
q
q
17
SEN00605-02
Operation of pump
q
Cylinder block (7) rotates together with shaft
(1), and shoe (5) slides on flat surface (A).
q
When this happens, rocker cam (4) moves
along cylindrical surface (B), so angle (a)
between center line (X) of rocker cam (4) and
the ax ial di rec tio n of cy li nder b loc k (7)
changes.
q
Angle (a) is called the swash plate angle.
q
q
18
D155AX-6
SEN00605-02
Control of delivery
q
If the swash plate angle (a) becomes larger,
the difference between volumes (E) and (F)
b ec o me s l ar g er a nd pu m p d el i v e r y ( Q )
increases.
q
Swash plate angle (a) is changed with servo
piston (10).
q
Servo piston (10) reciprocates straight according to the signal pressure of the PC and the LS
valve.
q
This straight line movement is transmitted to
rocker cam (4) through slider (14).
q
Being supported by cradle (2) on the cylindrical
surface, rocker cam (4) slides on the surface
while continuing revolving movement.
q
The area receiving the pressure is different at
the left and right sides of servo piston (10), and
the receiving pressure at the small diameter
piston end is always connected with the main
pump discharge pressure (self pressure) (PP).
q
Output pressure (PEN) of the LS valve is
brought to the chamber receiving the pressure
at the large diameter piston end.
q
The movement of servo piston (10) is controlled by the relationship of the size of the
pressure (PP) at the small diameter piston end
and the pressure (PEN) at the large diameter
piston end , and the comparative size of the
ratio of the area receiving the pressure at the
small diameter piston end and large diameter
piston end.
D155AX-6
19
SEN00605-02
1. LS valve
1.
2.
3.
4.
5.
6.
7.
8.
Sleeve
Piston
Spool
Spring
Seat
Sleeve
Plug
Locknut
Function
q
The LS (load sensing) valve detects the load
and controls the delivery.
q
This valve controls pump delivery (Q) according to differential pressure ( PLS) [ = (PP
P L S ) ] ( c a l l e d L S d i ff e r e n ti a l p r e s s u r e )
between pump discharge pressure (PP) and
control valve outlet port pressure (PLS).
q
Pump discharge pressure (PP), pressure
(PLS) [called LS pressure] coming from the
control valve output enter this valve.
q
The relationship between the differential pressure ( PLS) [ = (PP) (PLS)], the difference
between pump discharge pressure (PP) and
LS pressure (PLS), and delivery (Q) is as
shown in the diagram.
20
D155AX-6
SEN00605-02
Operation
1)
q
q
q
q
D155AX-6
21
SEN00605-02
2)
22
D155AX-6
3)
D155AX-6
SEN00605-02
23
SEN00605-02
4)
24
D155AX-6
SEN00605-02
2. PC valve
1.
2.
3.
4.
5.
6.
7.
8.
Wiring
Cover
Seat
Retainer
Spool
Pin
Servo piston assembly
Plug
Function
q
When the pump discharge pressure (PP) is
high, the PC valve controls the pump so that
no more oil than the constant flow (in accordance with the discharge pressure) flows even
if the stroke of the control valve becomes
larger. It carries out equal horsepower control
so that the horsepower absorbed by the pump
does not exceed the engine horsepower.
q
If the load during the operation becomes larger
and the pump discharge pressure (PP) rises, it
reduces the delivery from the pump.
q
If the pump discharge pressure drops, it
increases the delivery from the pump.
q
In this case the relationship between pump discharge pressure (PP) and pump delivery (Q)
with the electric current value (X) given to PCEPC valve solenoid as the parameter is shown
in the diagram.
D155AX-6
25
SEN00605-02
Operation
1)
(1) When the load on the actuator is small and pump discharge pressure (PP) is low
26
D155AX-6
D155AX-6
SEN00605-02
27
SEN00605-02
Action of spring
q
The load of spring (4) at the PC valve is determined by the position of the swash plate.
q
If servo piston (9) moves to the right, spring (4)
is compressed.
q
Spring load changes as servo piston (9) makes
spring (4) elongate or contract.
q
If the command current (X) to PC-EPC valve
solenoid (1) changes, so does the force pushing piston (2).
q
The load of spring (4) also changes according
to the PC-EPC valve solenoid command current (X).
28
D155AX-6
q
q
q
q
q
q
q
SEN00605-02
D155AX-6
29
SEN00605-02
(2) When the load on the actuator is large and pump discharge pressure (PP) is high
Outline
q
When the load is large and pump discharge
pressure (PP) is high, the force pushing spool
(3) to the right becomes larger and spool (3)
moves to the position shown in the diagram
above.
q
As shown in the diagram above, part of the
pressurized oil from port (B) flows out to port
(D) from port (C) through the LS valve, and the
pressure oil flowing from port (C) to the LS
valve becomes approximately half of pump discharge pressure (PP).
30
Operation
q
When port (E) and port (G) of the LS valve are
connected, this pressure from port (J) enters
the large diameter end of servo piston (9),
stopping servo piston (9).
q
If pump discharge pressure (PP) increases further and spool (3) moves further to the right,
pump discharge pressure (PP) flows to port
(C) and acts to make the delivery the minimum.
q
If servo piston (9) moves to the right, spring (4)
is compressed and push back spool (3).
q
When spool (3) moves to the left, the openings
of port (C) and port (D) become larger.
q
The pressure on port (C) (= J) is decreased
and the rightward move of servo piston (9) is
stopped.
q
The position in which servo piston (9) stops
when this happens is further to the right than
the position when pump discharge pressure
(PP) is low.
D155AX-6
D155AX-6
SEN00605-02
31
SEN00605-02
2)
As the emergency pump drive switch is turned on due to failure on the pump controller
q
q
32
D155AX-6
SEN00605-02
q
q
D155AX-6
33
SEN00605-02
3. PC-EPC valve
C:
P:
T:
To PC valve
From self pressure reducing valve
To tank
1.
2.
3.
4.
5.
6.
7.
Connector
Coil
Body
Spring
Spool
Rod
Plunger
34
D155AX-6
Function
q
The EPC valve consists of the proportional
solenoid portion and the hydraulic valve portion.
q
On receiving signal current (i) from the controller, the EPC valve generates EPC output pressure in proportion to the signal current and
outputs it to the PC valve.
SEN00605-02
Operation
1)
q
q
q
D155AX-6
35
SEN00605-02
2)
q
q
q
q
q
q
36
3)
q
q
q
q
D155AX-6
SEN00605-02
1.
2.
3.
Body
Valve
Spring
A:
B:
Outline
q
This valve is installed in the oil cooler inlet circuit. If any abnormal pressure is generated in
the oil flowing to the oil cooler, this valve acts
to return the oil directly to the hydraulic tank.
Set pressure
Cracking pressure ( MPa {kg/cm })
2
D155AX-6
0.5 {5.1}
37
SEN00605-02
38
Regarding the transmission-related description of the operation of the PCCS lever, see Transmission
control.
PCCS: Palm Command Control System
D155AX-6
1.
2.
3.
4.
5.
6.
7.
Potentiometer
Lock lever
PCCS lever (Steering)
Limit switch
Power train controller
Rod (From brake pedal)
Brake pedal
D155AX-6
SEN00605-02
Outline
q
PCCS lever (3) sends electric signals to power
train controller (5). Upon receiving those signals, power train controller (5) sends signals to
the EPC valve of the control valve to change
the delivery of the pump and operate the steering motor.
q
Brake pedal (7) receives signals from potentiometer (1) through rod (6). Then, power train
controller (5) sends signals to the brake valve
to operate the brake.
q
Lock lever (2) is connected to limit switch (4)
and used as the parking brake lever, too.
When it is in lock position "J", power train controller (5) does not send turning signals to the
EPC valve of the control valve.
39
SEN00605-02
Steering unit
40
D155AX-6
A:
B:
C:
D:
E:
SEN00605-02
To transmission case
From scavenging pump, steering lubrication pump
R.H. brake oil pressure pickup port (RB)
L.H. brake oil pressure pickup port (LB)
From the pin puller solenoid valve (Drain)
D155AX-6
41
SEN00605-02
42
D155AX-6
D155AX-6
SEN00605-02
43
SEN00605-02
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
44
D155AX-6
SEN00605-02
Outline
Bevel gear shaft
q
The engine power is transmitted through the
torque converter to the transmission. Then, the
bevel gear shaft system engages bevel pinion
(36) with bevel gear (17) to turn the engine
power at a right angle into the lateral direction
and reduce the rotation speed.
q
The bevel gear shaft system adopts the spiral
bevel gear at bevel pinion (36) and bevel gear
(17), and it adopts the splash lubrication with
the oil from the steering lubrication pump and
the scavenging pump for lubrication.
q
The bevel gear shaft system consists of bevel
pinion (36), bearing (35) which supports bevel
pinion, cage (33), bevel gear (17) which
meshes with the bevel pinion, bevel gear shaft
(16), bearing (25) and (26) which support bevel
shaft gear, and retainer (28).
HSS
HSS is constructed from transfer area which
transmits rotation of HSS motor (39) to gear A
(18) by turning it in reverse direction, and the
planet area which adjusts inputs from ring gear
(22) and sun gear (19) and then outputs to carrier (24).It changes the turning of the machine
by turning off the rotation of HSS motor (39), or
by making it move in normal rotation or reverse
rotation.
q
The transfer unit employs a spur gear speed
reduction mechanism and is lubricated with oil
splashed by the steering lubrication pump and
scavenging pump.
q
Planet area adopts forced lubrication with oil
from steering lubrication pump and scavenging
pump for lubrication.
q
The transfer unit consists of drive gear (40)
connected to the HSS motor (39) by spline,
gear D (41) meshed with the drive gear, gear C
(42) meshed with gear D, gear B (37) connected to shaft (38), gear A (18) supported by
the bearing on the bevel gear shaft and the
steering case to support these parts.
q
The planet area consists of sun gear (19),
planetary pinion (21), pinion shaft (20), ring
gear (22), hub (23) meshed with bevel gear
shaft (16) and ring gear (22), and carrier (24)
attached to brake hub (14).
q
D155AX-6
Brake
q
The brake is connected to the L.H. and R.H.
HSS respectively. It controls the power transmitted from HSS to final drive to brake the
machine.
q
Brake adopts wet multiple disc clutch type and
spring-boosted type, and it is hydraulic actuated type which activates brake control valve
(5) by the operation of brake pedal.
q
It adopts forced lubrication which sends oil
from steering lubrication pump and scavenging
pump to case (7) and brake drum (13) through
passage inside steering case, and then to
brake disc (12) and brake plate (11).
q
When the engine is stopped, back pressure of
brake piston (10) descends even if the brake
pedal is not depressed, which initiates the
brake to operate. However, parking brake
lever must be in lock position, because the
brake is released as the oil pressure within
the circuit rises when the engine is restarted.
q
The brake consists of brake hub (14) attached
to carrier (24), brake disc (12) meshed with the
brake hub, brake drum (13), brake plate (11)
whose outside perimeter meshes with brake
drum (13), brake piston (10) and brake spring
(9) which bring brake disc and brake plate
together, and cylinder (8) which supports all of
them, case (7) and output shaft (6).
Brake drum (13) and case (7) are fixed to the
steering case.
Also, output shaft (6) meshes to brake hub (14)
by spline and is held by spacer (31) in the axial
direction.
45
SEN00605-02
46
D155AX-6
SEN00605-02
Unit: mm
No.
Check item
Criteria
Standard size
Tolerance
Repair limit
Thickness
4.5
0.1
4.0
Strain
0.05
0.14
Repair or
replace
Thickness
2.9
0.1
2.6
Replace
Strain
0.05
0.15
Repair or
replace
41.5
0.33
38.3
100
+0.035
+0.035
100.5
Width
0.01
0.03
2.7
Thickness
0.12
3.85
280
+0.081
+0.081
280.1
220
+0.072
+0.081
220.1
Brake disc
Replace
Brake plate
Large
Inner diameter of the diameter
parts
seal ring
contact surface
Small
of the brake piston
diameter
parts
Standard size
6
Remedy
Brake spring
(2 pieces for 1 set)
Free length
Installation Installation
Installation Replace
Free length
length
load
load
33
19.6
Standard
size
Shaft
+0.019
+0.001
16
Repair limit
32.0
33.9 kN
{3,460 kg}
Hole
Standard
clearance
Clearance
limit
+0.027
+0.027
-0.0190.026
0.026
35.7 kN
{3,640 kg}
Tolerance
0.23 0.42
0.23 0.42
10
0.17 0.52
11
0.17 0.54
12
2.0
13
0.7
14
D155AX-6
Adjust
47
SEN00605-02
48
D155AX-6
SEN00605-02
Unit: mm
No.
Check item
Criteria
0.25 0.33
0.19 0.62
0.18 0.58
0.19 0.61
0.20 0.67
D155AX-6
Remedy
Adjust or
replace
Replace
2.0
49
SEN00605-02
Left turn
Right turn
Stop
Left
*: Counter-rotation
50
D155AX-6
SEN00605-02
When steering operation of PCCS lever is at "neutral", HSS motor (7) is stopped.
The power from transmission
O
Bevel pinion (1)
O
Bevel gear (2)
O
Bevel gear shaft (3)
O
Hub (4)
O
Ring gear (5)
O
Planetary pinion (6)
O
Carrier (15)
O
Brake hub (16)
O
Output shaft (17)
D155AX-6
51
SEN00605-02
52
D155AX-6
SEN00605-02
If PCCS lever shifts the steering operation into "left turn" when traveling forward, HSS motor (7) rotates
counterclockwise, viewing from the left side of the machine body.
The power from transmission
(Forward)
Bevel pinion (1)
O
Bevel gear (2)
O
Bevel gear shaft (3)
O
Hub (4)
O
Ring gear (5)
D155AX-6
53
SEN00605-02
54
D155AX-6
SEN00605-02
If PCCS lever shifts the steering operation into "left turn" when traveling reverse, HSS motor (7) rotates
clockwise, viewing from the left side of the machine body.
The power from transmission
(Reverse)
Bevel pinion (1)
O
Bevel gear (2)
O
Bevel gear shaft (3)
O
Hub (4)
O
Ring gear (5)
Gear C (10)
O
Shaft (11)
O
Gear B (12)
O
R.H. gear A (13)
(Counteclockwise, viewing from
the left side of the machine body.)
O
R.H. sun gear (14)
D155AX-6
55
SEN00605-02
56
D155AX-6
SEN00605-02
If PCCS lever shifts the steering operation into "right turn" when traveling forward, HSS motor (7) rotates
clockwise, viewing from the left side of the machine body.
The power from transmission
(Forward)
Bevel pinion (1)
O
Bevel gear (2)
O
Bevel gear shaft (3)
O
Hub (4)
O
Ring gear (5)
Gear C (10)
O
Shaft (11)
O
Gear B (12)
O
L.H. gear A (13)
R.H. gear A (13)
(Counterclockwise, viewing from
(Counterclockwise, viewing from
the left side of the machine body.) the left side of the machine body.)
O
O
L.H. sun gear (14)
R.H. sun gear (14)
D155AX-6
57
SEN00605-02
58
D155AX-6
SEN00605-02
If PCCS lever shifts the steering operation into "right turn" when traveling reverse, HSS motor (7) rotates
counterclockwise, viewing from the left side of the machine body.
The power from transmission
(Reverse)
Bevel pinion (1)
O
Bevel gear (2)
O
Bevel gear shaft (3)
O
Hub (4)
O
Ring gear (5)
D155AX-6
59
SEN00605-02
Brake operation
When the brake is released
When the PCCS lever is in the neutral position and the brake pedal is released, the maximum brake pressure is applied to the back of
brake piston (1) by the brake control valve.
As the oil pressure rises, brake piston (1) compresses brake spring (2) and moves to the left
to eliminate the pressing force between discs
(3) and plates (4).
The power transmitted from bevel gear shaft
through HSS to brake hub (6) is transmitted to
output shaft (7), then to the final drive.
60
D155AX-6
D155AX-6
SEN00605-02
61
SEN00605-02
62
D155AX-6
P:
L:
D155AX-6
SEN00605-02
Outline
q
The brake control valve consists of 2 ECMVs,
parking brake solenoid valve and the sudden
stop prevention valve installed on the valve
seat, to control the brake.
q
The brake control valve is located in the circuit
between the power train pump and the brake
piston, and consists of 2 sets of brake ECMV
(L.H. and R.H.).
q
The brake control valve sends the oil from the
power train pump to the brake to control leftand-right disc clutches.
q
The controller sends signals to each ECMV
according to the right or left stroke of the
PCCS lever and adjusts the gradual or sharp
turns.
q
If the brake pedal is depressed, the controller
sends commands to the brake ECMV according to the pedal stroke to apply the L.H. and
R.H. brake, thus stopping the machine.
q
The controller, connected electrically to the
PCCS lever and the brake pedal operates the
brake by controlling each ECMV and solenoid
valve.
q
The sudden stop prevention valve is installed
to prevent the machine from stopping suddenly, when an abnormality takes place in the
electric system.
q
When the parking brake lever is set in the
lock position, the controller sends signals to
the parking brake solenoid valve to drain the oil
between the L.H. and R.H. brake ECMV and
the brake pistons to operate the brake. Also
the parking brake solenoid valve is connected
electrically to the brake pedal.
63
SEN00605-02
Brake ECMV
a
a
A: To brake
P: From pump
S: To parking brake solenoid valve
T: Drain
DR: Drain
P1: Brake oil pressure pickup port
1.
2.
3.
4.
5.
6.
7.
64
*1:
Operated clutches
Brake
R*******
Outline
q
The brake ECMV keeps the brake oil pressure
to the set pressure and furthermore changes
the circuit to the piston chamber of brake.
D155AX-6
SEN00605-02
Outline of ECMV
q
The ECMV consists of 1 pressure control valve
and 1 fill switch.
q
Pressure control valve
A proportional solenoid in this valve receives a
current sent from the controller and this valve
converts it to an oil pressure.
q
Fill switch
This is a switch to detect that a clutch or brake
is filled with oil and has the following functions.
1. At the moment when the clutch or brake is
filled with oil, the fill switch outputs the signal
(fill signal) to the controller to notify the finishing of filling.
2. While the oil pressure is applied to the clutch
or brake, the fill switch outputs the signal (fill
signal) to the controller to notify the presence
of the oil pressure.
ECMV and proportional solenoid
q
One proportional solenoid is mounted for
each ECMV.
The propulsion force is generated according to the command current from the controller.
The propulsion force generated by the
proportional solenoid is actuated on the
spool of the pressure control valve and
generates the oil pressure. Accordingly, by
controlling the amount of the command
current, the propulsion force changes and
the pressure control valve is actuated,
then the oil flow and oil pressure is controlled.
ECMV and fill switch
For each ECMV, 1 fill switch is installed.
If the clutch is filled with oil, the fill switch
is turned ON by the pressure of the
clutch. The oil pressure is built up according to this signal.
Operation of ECMV
The ECMV is controlled by the command
current from the controller to the proportional solenoid and the fill switch output
signal.
D155AX-6
65
SEN00605-02
When the PCCS lever is in neutral position, brake pedal is released, and parking brake lever is in
free position: Straight travel
(L.H. and R.H. brake arereleased, parking brake isreleased)
66
D155AX-6
SEN00605-02
When the PCCS lever is in neutral, brake pedal is depressed, and parking brake lever is in free
position: Stop
(L.H. and R.H. brake are operated, parking brake is released)
When the brake pedal is depressed, proportional solenoids (1) of L.H. and R.H. brake
ECMV are de-energized to open the sealing
part of ball (2).
The controller outputs the command current to
proportional solenoids (1) according to the
brake pedal stroke.
Proportional solenoid (1) generates the propulsion force in proportion to the command current. This propulsion force is balanced with the
sum of the propulsion force generated by the
oil pressure in the back pressure port of the
brake piston and the tension of spring (4), then
the brake pressure is set up to adjust the brake
force.
When the brake pedal is depressed fully, the
brake pedal switch is turned ON, and the
parking brake solenoid valve is energized to
drain the pilot pressure of the brake ECMV port
(S).This carries out the same function as when
the parking brake lever is set at the lock position.
D155AX-6
67
SEN00605-02
Solenoid valve
5. Coil (ON-OFF type)
6. Push pin
7. Spring
8. Spool
9. Body
68
D155AX-6
SEN00605-02
When PCCS lever is in neutral position, brake pedal is released, and parking brake lever is
inlock position : Parking
(L.H. and R.H. brake are operated, parking brake is operated)
D155AX-6
69
SEN00605-02
EPC valve
2. Coil (proportional type)
3. Push pin
4. Valve
5. Ball
6. Spool
7. Body
70
D155AX-6
SEN00605-02
Outline
q
The sudden stop prevention valve is installed
to prevent the machine from stopping suddenly
when an abnormality takes place in the electric
system.
q
Sudden stop prevention valve (1) is installed in
the drain circuit of the brake ECMV so that the
sudden oil pressure drop of port (DR) and consequently the sudden brake can be avoided
when coil (2) of brake ECMV is de-energized.
q
If an abnormality takes place in the electric
system, also coil (3) of the sudden stop prevention valve (1) is de-energized. Then, the oil
of port (DR) is drained through orifice (a) so
that the brake is applied gradually.
D155AX-6
71
SEN00605-02
Final drive
Outline
q
The final drive is a single stage spur gear, single stage planetary gear reduction type. The
lubrication is of splash type using the rotation
of the gears. The final drive can be removed
and installed as a single unit.
q
Floating seal (1) is installed to the rotating sliding portion of the sprocket to prevent the entry
of dirt or sand and to prevent leakage of lubricating oil.
72
D155AX-6
D155AX-6
SEN00605-02
73
SEN00605-02
74
D155AX-6
1.
2.
3.
4.
5.
6.
7.
8.
9.
SEN00605-02
Floating seal
Sun gear
Carrier
Sprocket boss
Sprocket teeth
Cover
Planetary gear
Ring gear
Cover
10.
11.
12.
13.
14.
15.
16.
17.
No.1 pinion
Final drive case
Bearing cage
No.1 gear
No.1 gear hub
Shaft
Wear guard
Pivot shaft
Unit: mm
No.
Check item
Criteria
Remedy
Standard clearance
Clearance limit
0.25 0.77
0.77
18
19
0.20 0.55
0.55
20
0.22 0.71
0.71
21
22
23
24
25
26
D155AX-6
Replace
Standard size
Tolerance
Repair limit
95
0.087
0.087
94.913
23
Standard
size
Repair or
replace
22.95
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
68.262
0.015
0.034
0.009
0.039
- 0.024
+ 0.025
(Max.
Replace
clearance)
+ 0.025
90
0.036
0.058
0.066
0.101
- 0.065
- 0.008
0.008
Adjust
Standard size
Repair limit
67
21
Repair or
replace
75
SEN00605-02
76
The power from the bevel gear shaft and steering clutch is transmitted to 1st pinion (10) to
rotate 1st gear (13) meshed with the 1st pinion
and sun gear (2) meshed with the 1st gear.
The rotation of sun gear (2) is transmitted to
planetary gear (7). Since ring gear (8) meshed
with the planetary gear is fixed to cover (6), the
planetary gear (7) rotates along the ring gear
(8) and revolves around the sun gear (2).
D155AX-6
D155AX-6
SEN00605-02
77
SEN00605-02
Sprocket
Unit: mm
No.
Check item
3
4
78
Criteria
Standard clearance
Remedy
Repair limit
351
339
23.7
17.5
83
75
103
95
Rebuid or
replace
D155AX-6
SEN00605-02
D155AX-6
79
SEN00605-02
D155AX-6 Bulldozer
Form No. SEN00605-02
2009 KOMATSU
All Rights Reserved
Printed in Japan 10-09 (02)
80
D155AX-6
SEN00606-01
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
D155AX-6
SEN00606-01
Track frame
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Equalizer bar
Pivot shaft
Idler
Track frame
Carrier roller
Sprocket
Sprocket cover guard
Track roller
Track roller support guard
Minor bogie
Major bogie
First bogie
Outline
q
The track rollers are mounted on an K-shaped
bogie. This increases the actual ground contact area between the track shoes and the
ground on rough surfaces, and helps increase
the drawbar pull.
q
The K-shaped bogies are equipped with rubber
pads to absorb the shock from the ground surface.
Track roller, bogie
Track roller flange type arrangement
1st
2nd
3rd
4th
5th
6th
7th
D: Double
S: Single
D155AX-6
SEN00606-01
Unit: mm
No.
Check item
D155AX-6
Criteria
Remedy
Item
Repair limit
Curvature
Twisting
12
Correct or
replace
SEN00606-01
Recoil spring
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Yoke
Dust seal
Rod
Recoil spring
Wear ring
Lubricator
Nut
Housing
Cylinder
Holder
Bushing
Outline
q
Recoil spring (4) is used to adjust the track tension by pumping in or releasing grease from
lubricator (6) to move rod (3) forward or backward. The recoil spring also acts to dampen
any sudden shock brought to bear on the idler.
D155AX-6
SEN00606-01
Unit: mm
No.
1
11
Check item
Criteria
Tolerance
Recoil spring
D155AX-6
Adjust
Shaft
Hole
Standard
clearance
Clearance
limit
0.036
0.090
+0.277
+0.062
0.098
0.367
1.0
Standard size
4
Remedy
Repair limit
Free length
Installed
length
Installed
load
Free length
Installed
load
859
656
314 kN
{32,000 kg}
804
288 kN
{29,400 kg}
Replace
SEN00606-01
Idler
D155AX-6
SEN00606-01
Unit: mm
No.
Check item
Criteria
Standard size
Remedy
Repair limit
792
750
725
Depth of tread
21
33.5
Thickness of tread
24
11.5
Width of tread
58.5
Overall width
240
Standard
size
140
Standard
size
75
D155AX-6
Tolerance
Rebuild or
replace
Shaft
Hole
Standard
clearance
Clearance
limit
0.350
0.413
+0.265
+0.003
0.353
0.678
Tolerance
Shaft
Hole
+0.046
+0.046
+0.13
0.18
Standard size
Standard Interference
interference
limit
0.130
0.226
Repair limit
0.4 0.9
Replace
bushing
Rebuild or
replace
SEN00606-01
Track roller
D155AX-6
SEN00606-01
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
285
275
250
210
Thickness of tread
57.5
37.5
Overall width
295
Width of tread
(single flange)
61
Width of tread
(double flange)
61
Flange width
(outside of double flange)
25
Flange width
(inside of double flange)
22
10
246
11
12
13
End play
D155AX-6
Standard size
125
Standard size
65
Tolerance
Shaft
Hole
0.350
0.413
+0.260
+0.010
Standard
clearance
0.360 0.673
Replace
Tolerance
Shaft
Hole
+0.046
+0.000
0.15
0.20
Rebuild or
replace
Standard
interference
0.150 0.246
Standard size
Clearance limit
0.44 0.91
Adjust or
replace
SEN00606-01
Carrier roller
10
D155AX-6
SEN00606-01
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
220
190
167
Width of tread
63
Thickness of tread
37.5
26
Width of flange
Interference between
shaft and ring
Clearance between
shaft and support
21
Standard size
70
Standard size
68
D155AX-6
Rebuild or
replace
Tolerance
Shaft
Hole
+0.166
+0.120
+0.030
+0.030
Tolerance
Shaft
Hole
0.2
0.2
+0.300
+0.030
Standard
interference
0.090 0.166
Standard
clearance
Replace
0 0.5
Standard clearance
0.010 0.230
11
SEN00606-01
Track shoe
Dry type
12
SEN00606-01
Unit: mm
No.
1
Check item
Link height
Shoe bolt
Interference between
bushing and link
Remedy
Standard size
Repair limit
228.85
Link pitch
Criteria
When turned
Standard size
Normal load
Impact load
81
75.0
77.0
15.8
9.8
11.8
Standard size
Repair limit
144
128
45.5
29.5
Tightening torque
(Nm {kgm})
Additional tightening
angle (deg.)
120 10
Standard size
Tolerance
Reverse or
replace
Repair or
replace
Retighten
Standard
interference
Shaft
Hole
77.0
+0.404
+0.304
+0.074
+0.074
0.230 0.404
8a
Interference between
regular pin and link
48.5
+0.484
+0.334
0.038
0.100
0.372 0.584
8b
Interference between
master pin and link
48.5
+0.230
+0.200
0.038
0.100
0.238 0.330
Adjust or
replace
Standard clearance
9
D155AX-6
One side
Both side
1.4
2.8
13
SEN00606-01
14
D155AX-6
SEN00606-01
Unit: mm
No.
1
2
3
Check item
Repair limit
228.85
Shoe bolt
Remedy
Standard size
Link pitch
Criteria
Interference between
bushing and link
Interference between
regular pin and link
231.85
When turned
Standard size
Normal load
Impact load
81
72.5
75.0
15.8
7.3
9.8
Standard size
Repair limit
144
128
45.5
29.5
Tightening torque
(Nm {kgm})
Additional tightening
angle (deg.)
120 10
180 10
Tolerance
Standard
size
Reverse or
replace
Repair or
replace
Retighten
Standard
interference
Shaft
Hole
77.0
+0.404
+0.304
+0.074
+0.074
0.230 0.404
48.5
+0.484
+0.334
0.038
0.100
0.372 0.584
Adjust or
replace
Standard clearance
9
D155AX-6
One side
Both side
1.4
2.8
15
SEN00606-01
Unit: mm
No.
1
16
Check item
Criteria
Remedy
Standard size
Repair limit
single
80
30
heavy duty
80
30
97
47
99
49
Height of
grouser
Repair or
replace
D155AX-6
D155AX-6
SEN00606-01
17
SEN00606-01
Main frame
18
D155AX-6
1.
2.
3.
4.
5.
6.
7.
8.
SEN00606-01
Main frame
Cage
Clamp
Cover
Seal
Coupling
Cap
Plate
Unit: mm
No.
10
Check item
Clearance between
equalizer bar shaft
and bushing
Press-fitting force for
equalizer bar shaft
mounting bushing
D155AX-6
Criteria
Standard
size
95
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
0.036
0.090
+0.213
+0.129
0.165
0.303
1.0
Replace
Adjust
19
SEN00606-01
Suspension
20
D155AX-6
1.
2.
3.
4.
5.
SEN00606-01
Equalizer bar
Pivot shaft assembly
Cover
Thrust plate
Thrust plate
6.
7.
8.
10.
11.
Pivot shaft
Seal cage
Seal
Side pin
Center pin
Unit: mm
No.
Check item
12
13
14
15
Interference between
side pin boss and bushing
16
17
18
Criteria
Remedy
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
95
0.036
0.090
+0.279
+0.213
0.249
0.369
1.0
70
0.030
0.060
+0.046
+0.046
0.030
0.106
1.0
Standard
size
Tolerance
Standard Interference
interference
limit
Shaft
Hole
130
+0.033
+0.015
0.028
0.068
0.043
0.101
179
+0.083
+0.043
0.053
0.093
0.096
0.176
Standard
size
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
148
0.145
0.208
+0.099
+0.035
0.180
0.307
1.0
175
0.145
0.208
+0.095
+0.025
0.170
0.303
1.0
Replace
bushing
Outline
q
The front of the track frame rocks up and down
using the rear pivot shafts (6) as a fulcrum.
Equalizer bar (1) rocks using center pin (11) as
a fulcrum. The left and right track frames are
connected by side pin (10).
D155AX-6
21
SEN00606-01
D155AX-6 Bulldozer
Form No. SEN00606-01
2007 KOMATSU
All Rights Reserved
Printed in Japan 03-07 (02)
22
D155AX-6
SEN00607-03
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
Hydraulic system
Work equipment hydraulic piping diagram ...................................................................................................... 2
Work equipment control piping diagram ......................................................................................................... 5
Work equipment control .................................................................................................................................. 8
Hydraulic tank and filter ................................................................................................................................ 10
Accumulator .................................................................................................................................................. 14
PCCS lever ................................................................................................................................................... 15
Work equipment lock valve ........................................................................................................................... 19
Control valve ................................................................................................................................................. 20
Work equipment cylinder .............................................................................................................................. 56
Piston valve................................................................................................................................................... 58
Quick drop valve ........................................................................................................................................... 60
Self pressure reducing valve......................................................................................................................... 65
D155AX-6
SEN00607-03
Semi U-dozer
1.
2.
3.
4.
5.
6.
7.
8.
Hydraulic tank
Hydraulic, HSS pump
L.H. blade lift cylinder
Oil cooler
D155AX-6
SEN00607-03
Multi-shank ripper
1.
2.
3.
4.
Control valve
Divider block
Ripper lift cylinder
Ripper tilt cylinder
D155AX-6
SEN00607-03
Giant ripper
1.
2.
3.
4.
5.
6.
Control valve
Divider block
Ripper lift cylinder
Pin puller cylinder
Ripper tilt cylinder
Pin puller solenoid valve
D155AX-6
SEN00607-03
1.
2.
Accumulator
Control valve
D155AX-6
3.
4.
SEN00607-03
1.
2.
3.
Accumulator
Control valve
Work equipment lock valve
4.
5.
D155AX-6
D155AX-6
SEN00607-03
SEN00607-03
D155AX-6
1.
2.
3.
4.
SEN00607-03
Lever positions
A : Blade HOLD
B : Blade LOWER
B + C :Blade FLOAT
D : Blade RAISE
E : Blade LEFT TILT
F: Blade RIGHT TILT
G : Ripper HOLD
H : Ripper RAISE
J : Ripper LOWER
K : Ripper DECREASE TIP ANGLE
L : Ripper INCREASE TIP ANGLE
M : FREE
N : LOCK
Outline
q
The work equipment control employs a EPC
method which uses a EPC valve to move each
control valve spool.
q
Work equipment lock lever (1) is interconected
with work equipment lock switch (4), and at the
FREE position, the oil in the EPC circuit is
opened.
D155AX-6
SEN00607-03
1.
2.
3.
4.
5.
6.
10
Pressure valve
Drain valve
Drain plug
Cover
Cover
Hydraulic tank
7.
8.
9.
10.
11.
12.
Strainer
Suction valve
Spring
Hydraulic filter element
Oil filler cap
Sight gauge
D155AX-6
SEN00607-03
Specified
value
Tank capacity
Hydraulic
tank
Breather
Level
inside
tank
(l)
125
Hi
(l)
95
Center
(l)
91.5
Low
(l)
75
Cracking pressure
16.76.9
(kPa {kg/cm2}) {0.170.07}
0 0.49
Vacuum valve actuating
pressure
(kPa {kg/cm2}) {0 0.005}
Cracking pressure
(kPa {kg/cm2})
Hydraulic
filter
Mesh size
( m)
20/10/3
Filtering area
(cm2)
13,600
D155AX-6
14729.4
{1.50.31}
(l/min)
550
Mesh size
( m)
105
Filtering area
(cm2)
1,850
11
SEN00607-03
1.
2.
3.
4.
5.
6.
12
Pressure valve
Drain valve
Drain plug
Cover
Cover
Hydraulic tank
7.
8.
9.
10.
11.
12.
Strainer
Suction valve
Spring
Hydraulic filter element
Oil filler cap
Sight gauge
D155AX-6
SEN00607-03
Specified
value
Tank capacity
Hydraulic
tank
Breather
Level
inside
tank
(l)
125
Hi
(l)
95
Center
(l)
91.5
Low
(l)
75
Cracking pressure
16.72.5
(kPa {kg/cm2}) {0.170.025}
2.0 0.3
Vacuum valve actuating
pressure
(kPa {kg/cm2}) {0.02 0.003}
Cracking pressure
(kPa {kg/cm2})
Hydraulic
filter
Mesh size
( m)
20/10/3
Filtering area
(cm2)
13,600
D155AX-6
14729.4
{1.50.31}
(l/min)
550
Mesh size
( m)
105
Filtering area
(cm2)
1,850
13
SEN00607-03
Accumulator
For EPC valve
Function
q
The accumulator is installed between the
redusing valve and the EPC valve. Even if the
engine is started with the work equipment still
raised, the pressure of the nitrogen gas compressed inside the accumulator sends the pilot
pressure to the control valve to actuate it and
enable the work equipment to move down
under its own weight.
Operation
After the engine is stopped, when the EPC
valve is at neutral, chamber (A) inside the bladder is compressed by the oil pressure in chamber (B).
q
When the EPC valve is operated, the oil pressure in chamber (B) goes below 2.9 MPa {30
kg/cm2}, and the pressure of the nitrogen gas
in chamber (A) expands the bladder, so the oil
in chamber (B) acts as the pilot pressure and
actuates the main control valve.
q
1.
2.
3.
4.
5.
6.
Gas plug
Shell
Poppet
Holder
Bladder
Oil port
Specifications
Type of gas: Nitrogen
Gas volume: 500 cc
Max. actuation pressure: 6.86 MPa {70 kg/cm2}
Min. actuation pressure: 0.69 MPa {7 kg/cm2}
14
D155AX-6
PCCS lever
SEN00607-03
Do not disassemble.
Otherwise, adjustments will be required for the characteristics of voltage output and operating efforts.
1.
2.
3.
Boot
Nut
Connector
D155AX-6
15
SEN00607-03
(For steering)
a
Do not disassemble.
Otherwise, adjustments will be required for the characteristics of voltage output and operating efforts.
1.
2.
3.
4.
Boot
Bracket
Plate
Bolt
16
5.
6.
7.
Screw
Lever
Connector
D155AX-6
SEN00607-03
Function
1. Operating effort characteristics
(For blade and ripper)
q
It has the following characteristic for both
longitudinal and lateral operations.
q
Free return (operation effort characteristic
diagram)
2)
q
(For steering)
1) Operation for forward and reverse travel
q
The control lever is held at 3 positions:
forward, neutral and reverse.
D155AX-6
17
SEN00607-03
2.
q
18
D155AX-6
1.
2.
3.
SEN00607-03
Solenoid
Body
Spool
Outline
q
The work equipment lock valve is installed
between the basic pressure valve and control
valve in the work equipment control circuit. If
the work equipment lock lever is set in the
FREE position, the work equipment lock switch
operates and the work equipment lock valve
opens the work equipment control circuit so
that the operator can operate the work equipment.
Operation
q
The solenoid is operated by the electric signal
to move the spool. As a result, the circuit
between port (A) connected to the basic pressure valve and port (B) connected to the control valve is opened.
D155AX-6
19
SEN00607-03
Control valve
Outline
q
This manual explains the 5-spool valve (single
tilt specification) and 6-spool valve (dual tilt
specification).
1.
20
EPC valve
D155AX-6
SEN00607-03
Outside view
5-spool valve (single tilt specification)
D155AX-6
21
SEN00607-03
1.
22
EPC valve
D155AX-6
SEN00607-03
D155AX-6
23
SEN00607-03
Sectional view
(1/8)
5-spool valve
24
D155AX-6
SEN00607-03
(2/8)
6-spool valve
D155AX-6
25
SEN00607-03
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Steering spool
Blade tilt spool
Blade lift spool
Blade tilt (pitch) spool (only for 6-spool valve)
Ripper lift spool
Ripper tilt spool
Valve block
Valve block
Valve block (only for 6-spool valve)
Valve body
Steering priority valve
Load check valve
Pressure compensation valve
Filter
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Free length
Installation
x outer
length
diameter
Repair limit
Installation
load
Free
length
Installation
load
51.7 x 31.3
50
140 N
{14.3 kg}
112 N
{11.4 kg}
76.3 x 30
68.5
224 N
{22.8 kg}
179 N
{18.2 kg}
54.7 x 36.5
33.5
217 N
{22.1 kg}
173 N
{17.7 kg}
18
20.8 x 12.2
13.5
12.7 N
{1.3 kg}
10.2 N
{1.04 kg}
19
Pressure compensation
valve spring
67.04 x 26.5
62.5
468 N
{47.7 kg}
374 N
{38.2 kg}
20
Pressure compensation
valve spring
108.3 x 29.5
81
562 N
{57.3 kg}
450 N
{45.8 kg}
21
Pressure compensation
valve spring
97.7 x 29.5
81
453 N
{46.2 kg}
362 N
{37 kg}
22
Pressure compensation
valve spring
109.4 x 29.5
81
563 N
{57.4 kg}
450 N
{45.9 kg}
23
86.7 x 30
66
192 N
{19.6 kg}
154 N
{15.7 kg}
26
Replace spring
if damaged or
deformed.
D155AX-6
SEN00607-03
(3/8)
5-spool valve
1.
2.
3.
4.
D155AX-6
27
SEN00607-03
(4/8)
6-spool valve
1.
2.
3.
4.
28
D155AX-6
SEN00607-03
(5/8)
1.
2.
No.
3.
4.
Check item
Unload valve
Suction valve
Unit: mm
Remedy
Criteria
Standard size
Free length
Installation
x outer
length
diameter
64.9 x 12.5
D155AX-6
56
Repair limit
Installation
load
Free
length
6.4 N
{0.65 kg}
Installation
Replace spring if
load
damaged or
deformed.
5.1 N
{0.52 kg}
29
SEN00607-03
(6/8)
1.
2.
EPC valve
Suction valve
30
D155AX-6
SEN00607-03
(7/8)
D155AX-6
31
SEN00607-03
1. EPC valve
2. Suction valve
3. LS bypass valve
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Free length
Installation
x outer
length
diameter
46.8 x 7.5
32
40.6
Repair limit
Installation
load
Free
length
5.49 N
{0.56 kg}
Installation
Replace spring if
load
damaged or
deformed.
4.41 N
{0.45 kg}
D155AX-6
SEN00607-03
(8/8)
1.
2.
EPC valve
Suction valve
D155AX-6
33
SEN00607-03
Function
q
When the main spool (1) is at the hold position, it drains the excess oil discharged by the
pump, and prevents the pressure from being
formed in the circuit from rising.
Operation
When the main spool (1) is at the hold position, the pump discharge pressure passes from
chamber A through throttle (4) to chamber
(D).Chambers (C') and (C) are connected to
the drain circuit.
34
q
q
D155AX-6
SEN00607-03
Steering valve
At hold
Function
q
Use of the CLSS circuit (Closed Center Load
Sensing System) makes it possible to control
the oil flow by adjusting the area of opening of
the spool driven by the EPC valve regardless
of the load.
q
q
Operation
q
When the steering spool (1) is at the hold
position, the pump discharge pressure is sent
from chamber (A) through the notch in spool
(3) of the steering priority valve, and passes
through chamber (B) to chamber (C).
D155AX-6
35
SEN00607-03
2)
Operation
q
When the PCCS lever is operated to turn the
machine to the left, pilot pressure (PI) acts
on the right end of steering spool (1) through
the EPC valve.
q
When the pressure becomes greater than the
set load of spring (2), the steering spool (1)
moves to the left. It becomes balanced at a
position that matches pilot pressure (PI).
36
D155AX-6
SEN00607-03
If the oil flow is too large, the differential pressure of steering spool (1) becomes larger, so
pressure compensation valve spool (3) moves
in the direction to throttle the oil flow.
On the other hand, if the oil flow is too small,
pressure compensation valve spool (3) moves
in the direction to increase the oil flow.
LS valve of the pump is controlled so that the
differential pressure between pump discharged
pressure (P) and LS pressure (LS) (LS differential pressure: PLS) remains constant, so a
suitable amount of oil flows to ensure that the
loss of pressure at the control valve ( PLS') is
equal to PLS.
The loss of pressure in the control valve is
determined by the area of the opening of steering spool (1), so the oil flow matches the opening of steering spool (1).
The return oil flow from HSS motor (6) passes
through chamber (E) and chamber (F), and is
drained.
D155AX-6
37
SEN00607-03
2.
a
38
D155AX-6
SEN00607-03
Operation
q
When blade lift spool (1) is at the hold position, the pump discharge pressure (unload
pressure) is sent to chambers (D) and (D').
q
The pressure is not formed in chambers (H)
and (H'), so pressure compensation valve
spool (3) and steering priority valve spool (4)
are pushed completely to the right.
q
The pump pressure passes through chambers
(A) and (B) of steering priority valve spool (4),
and is sent to chamber (C) of the blade lift
valve. From here it goes through chamber (D)
and chamber (E) to chamber (F).
q
In the same way as described in topic (1)
Steering valve, the position of pressure compensation valve spool (3) is determined to
match the opening of blade lift spool (1), and
the oil flow is determined so that the pressure
loss of the control valve becomes equal to the
control differential pressure ( LS) of pump LS
valve.
D155AX-6
39
SEN00607-03
3.
40
Meter-out control when blade moves down under its own weight
D155AX-6
SEN00607-03
Function
q
If the blade moves down under its own weight,
the oil flow of return oil from blade lift cylinder
is controlled by the area of the opening of
blade lift spool (1).
Operation
When the port of blade lift spool (1) is opened
by pilot pressure (PI), because of the weight of
the blade, the oil from the cylinder head side
passes through ports (A), (B), (C) and (D), and
is drained to the tank.
q
The flow of return oil from the blade lift cylinder
is throttled by the area of opening between
ports (A) and (B), so the downward speed is
controlled.
q
The pressurized oil flowing from the blade lift
cylinder head end passes from the drain circuit
through suction valve (2) and is supplied to the
bottom end of the blade lift cylinder.
q
The oil discharged from the pump passes
through ports (A'), (B'), (C'), (D') and (E'), and
is supplied to the blade lift cylinder bottom.
q
D155AX-6
41
SEN00607-03
4.
42
Meter-out control when blade moves down under its own weight
(work equipment lever at float)
D155AX-6
SEN00607-03
Function
q
When the blade lift valve is at float, the cylinder port and drain port are connected to put
the circuit in a no-load condition.
q
When the blade lift valve is in the float condition, the pump passage and cylinder ports (A3)
and (B3) are separated so that the other control valves can be operated.
Operation
When the work equipment control lever is at
the lower position and the float button is
pressed, output pressure (PA3) of the EPC
valve becomes 3.4 MPa {35 kg/cm2 or more
and blade lift spool (1) is moved to the maximum stroke position.
q
Ports (A3) and (B3) and LS passage (O) are all
connected to the drain circuit, so there is no
load on the blade lift cylinder.
q
If the blade lift cylinder is driven by the weight
of the blade, the oil entering from port (A3)
flows to ports (A), (B), (B') and (A'), while the
rest of the pressurized oil flows through ports
(C) and (D), and is drained.
q
The oil flow is throttled by the area of opening
between ports (A) and (B) of blade lift spool
(1), and the cylinder speed is controlled.
q
The pump circuit chamber (E) and ports (A3)
and (B3) are separated, and pump discharge
pressure (P) is formed at chamber (E), so it is
possible to carry out compound operations
with other control valves.
q
D155AX-6
43
SEN00607-03
At relief
1. Steering valve
a The diagram shows the condition at relief for steering LS relief valve (5).
44
D155AX-6
SEN00607-03
Function
q
It sets the maximum pressure when HSS
motor (7) is operated.
Operation
If steering spool (1) is moved and the pressure
of HSS motor (7) becomes higher, the poppet
of steering LS relief valve (5) will start to open
and oil will be drained from LS circuit (O).
(Ports (E), (F), (G), (J), (K) and (L))
q
As a result, there will be a drop in pressure in
LS passage (O) starting from LS sensing hole
(F), and P2 will become larger.
q
For the same reason, if the pressure in chambers (H) and (I) drops, steering priority valve
spool (2) will push against spring (3) and move
to the right, and will make the opening between
chambers (B) and (C) smaller, so the flow to
chambers (B) and (C) will be throttled and P4
will become larger.
q
Because of the pump swash plate control, the
system circuit is balanced at a circuit pressure
which makes the pressure loss generated by
the flow at steering LS relief valve (5), P1 +
P2, equal to LS differential pressure ( LS).
q
When this happens, the pump LS valve
detects the differential pressure generated by
steering LS relief valve (5), and moves the
pump swash plate from the maximum to the
minimum position. The pump swash plate is
balanced at a position where the LS differential
pressure is 2.0 MPa {20 kg/cm2}.
q
When the pump is at the minimum swash plate
angle (minimum oil flow), if the minimum oil
flow is greater than the LS relief oil flow + leakage at any part, the pressure is confined in the
pump circuit (between the pump and chambers
(A) and (B)), so the LS differential pressure
rises.
q
If this differential pressure goes above the set
pressure for unload valve (4), the unload valve
is actuated to relieve the excess oil flow and
balance the circuit.
q
D155AX-6
45
SEN00607-03
2.
a
46
D155AX-6
SEN00607-03
Operation
q
If blade tilt spool (1) is moved and the pressure of the blade tilt cylinder becomes higher,
the poppet of work equipment LS relief valve
(5) will start to open and oil will be drained from
LS circuit (O). (Ports (E), (F), (G), (J), (K) and
(L))
q
As a result, there will be a drop in pressure in
LS passage (O) starting from LS sensing hole
(F), and P2 will become larger.
q
For the same reason, if the pressure in chambers (H) and (I) drops, pressure compensation
valve spool (2) will push against spring (3) and
move to the right, and will make the opening
between chambers (B) and (C) smaller, so the
flow to chambers (B) and (C) will be throttled
and P4 will become larger.
q
Because of the pump swash plate control, the
system circuit is balanced at a circuit pressure
which makes the pressure loss generated by
the flow at work equipment LS relief valve (5),
P1 + P2, equal to LS differential pressure
( LS).
q
When this happens, the pump LS valve
detects the differential pressure generated by
work equipment LS relief valve (5), and moves
the pump swash plate from the maximum to
the minimum position. The pump swash plate
is balanced at a position where the LS differential pressure is 2.0 MPa {20 kg/cm2}.
q
When the pump is at the minimum swash plate
angle (minimum oil flow), if the minimum oil
flow is greater than the LS relief oil flow + leakage at any part, the pressure is confined in the
pump circuit (between the pump and chambers
(A) and (B)), so the LS differential pressure
rises.
q
If this differential pressure goes above the set
pressure for unload valve (4), the unload valve
is actuated to relieve the excess oil flow and
balance the circuit.
D155AX-6
47
SEN00607-03
3.
a
48
D155AX-6
SEN00607-03
= P - P2
PO = Differential pressure between ports (H) and (K)
ressure P2 = LSO + PO
Function
q
When steering spool (1) and blade tilt spool (2)
are relieved at the same time, the pump pressure is separated by pressure compensation
valve spool (3) in the blade tilt valve, and the
port pressure is maintained at a constant
value.
Operation
q
If HSS motor (6) reaches the stall condition,
the load pressure increases and LS relief valve
(4) for the steering valve is actuated, so the
system is cut off.
q
For details, see 1. Steering valve.
q
When this happens, the pump discharge pressure (P) is maintained at 38.2 MPa {390 kg/
cm 2 } and this is sent to chamber (G) of the
blade tilt valve.
q
When blade tilt spool (2) is operated and the
load on the blade tilt valve is greater, blade tilt
valve LS relief valve (5) is actuated, and drain
oil flow (Q1) flows to LS circuit (O).
q
As a result, a differential pressure is generated
on the left and right sides of pressure compensation valve spool (3) by LS throttle (M) of
blade tilt spool (2), and it moves the full stroke
to the right.
q
When this happens, the opening between
chambers (D) and (E) is throttled to the minimum size (pump pressure separated).
q
Oil flow (Q1) is determined by pump discharge
pressure (P) and the total pressure loss (P
LSO) of ports (C), (D), (E), (F), (G), (I), (J) and
(K).
q
Furthermore, pressure (P2) (the pressure in
chamber (H)) becomes the total (LSO + PO)
of the circuit pressure loss of ports (H), (I), (J)
and (K), and the set pressure of work equipment LS relief valve (5).
D155AX-6
49
SEN00607-03
Compound operations
1. Steering and work equipment valve
a The diagram shows the condition when the steering and blade lift valve are operated at the same time.
50
D155AX-6
Function
q
The steering valve is equipped with steering
priority valve spool (3), so if the steering valve
and the downstream work equipment valve are
operated at the same time, priority is given to
the flow of oil to the steering valve, and the rest
of the oil discharged from the pump goes to the
work equipment valve.
Operation
When steering spool (1) is operated by EPC
valve output pressure (PI) and the oil flows, a
differential pressure is created between chambers (C) and (D).
q
Steering priority valve spool (3) is controlled by
this differential pressure, and at the same time,
the pump swash plate angle is controlled at
PLS = 2.0 MPa {20 kg/cm2}, and the flow of
oil to the steering valve is fixed.
q
For details, see 1. Steering valve of Control
of oil flow.
q
In this condition, if downstream work equipment blade lift spool (2) is operated, the pump
discharge pressure momentarily drops.
q
At this point, the differential pressure between
chambers (C) and (D) becomes smaller, and
steering priority valve spool (3) is moved to the
left by the pressure in chamber (E) in the direction to throttle the opening to the work equipment valve.
q
At the same time, PLS becomes smaller, so
the pump swash plate angle moves in the maximum direction to supply an oil flow to make up
the amount that the pressures drops.
q
D155AX-6
SEN00607-03
1)
q
2)
51
SEN00607-03
2.
a
52
D155AX-6
SEN00607-03
Function
q
It consists of a parallel circuit, so when compound operations are carried out, the oil flow is
divided according to the size of each spool
opening.
Operation
When blade tilt spool (1) and blade lift spool (2)
are at the hold position or are operated,
steering priority valve (3) is pushed completely
to the right, and the size of the opening to the
downstream area is at its maximum.
q
Blade tilt spool (1) and blade lift spool (2) are
actuated by PPC valve output pressure (PA2)
and (PB3), and each is balanced at a position
that matches its own EPC valve output pressure.
q
2)
q
D155AX-6
53
SEN00607-03
54
D155AX-6
SEN00607-03
Function
q
This improves the response of the system
including the pump swash plate and pressure
compensation valve by sending the pilot pressure (basic pressure of EPC valve) to the LS
circuit, and compensating the rise of the LS circuit pressure.
Operation
When blade lift valve spool (1) is at the hold
position, pilot pressure (P1) (basic pressure of
EPC valve) is sent through preset check valve
(3) to chamber (F) of the pressure compensation valve. This pressure is called preset pressure (P2).
q
Unload pressure (P) is being sent to chamber
(B), but (P1) + (F0) > (P) (F0: load of spring
(4)), so pressure compensation spool (2)
moves to the left and the size of the opening
between chambers (A) and (B) becomes the
maximum.
q
When blade lift spool (1) is switched, unload
pressure (P) flows immediately through chambers (A), (B), (C), (D) and (E) to the blade lift
cylinder, so the pressure at the port starts to
rise and the time lag becomes smaller.
q
At the same time, preset pressure (P2) is supplied to LS circuit (O), and the pressure in the
LS circuit rises.
q
Unload valve (7) closes, and oil is sent further
to the pump LS valve to improve the response
of the pump swash plate angle. This makes it
possible to reduce the response time for giving
the necessary oil flow.
q
D155AX-6
55
SEN00607-03
Ripper cylinder
56
The piping of the lift cylinder and tilt cylinder of the variable multi-shank ripper is different from the
above.
D155AX-6
SEN00607-03
Unit: mm
No.
Check item
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
75
-0.030
-0.076
+0.279
+0.065
0.095
0.355
0.666
90
-0.036
-0.090
+0.270
+0.061
0.097
0.330
0.695
100
-0.036
-0.090
+0.257
+0.047
0.105
0.375
0.675
Ripper
TILT
110
-0.036
-0.090
+0.261
+0.047
0.105
0.375
0.675
Clearance between
piston rod support
shaft and blade
ball portion
Blade
LIFT
85
+0.3
+0.3
1.0
Clearance between
cylinder support
shaft and bushing
Blade
LIFT
85
-0.100
-0.174
0.100
0.228
0.5
Clearance between
piston rod spherical
surface and cap
Blade
TILT
115
-0.200
-0.300
60
-0.030
-0.050
+0.174
+0.100
0.130
0.224
1.0
Blade
TILT
Clearance between
cylinder bottom sup- Ripper
port shaft and bush- LIFT
ing
Ripper
TILT
90
-0.036
-0.090
+0.207
+0.120
0.156
0.297
1.0
100
-0.036
-0.090
+0.201
+0.119
0.156
0.291
1.0
Ripper
LIFT
90
-0.036
-0.090
+0.207
+0.120
0.156
0.297
1.0
Ripper
TILT
100
-0.036
-0.090
+0.201
+0.119
0.156
0.291
1.0
Blade
LIFT
Clearance between
piston rod and bush- Blade
TILT
ing
Ripper
LIFT
Clearance between
cylinder rod support shaft and bushing
D155AX-6
Replace
57
SEN00607-03
Piston valve
2.
Operation
1. Piston valve CLOSED
Pressurized oil from the hydraulic pump acts
on piston (2) and piston valve (3).
The piston valve (3) is pushed in the direction
of the arrow until piston valve seat (4) comes
into snug contact with the tapered section,
thereby, this causing the pressure in the cylinder to rise and moving piston (2) in the direction of the arrow.
58
D155AX-6
D155AX-6
SEN00607-03
59
SEN00607-03
60
D155AX-6
SEN00607-03
Body
Main spool
Plate
Body
Selector valve spool
EPC valve
Unit: mm
No.
Check item
Clearance between main
spool and valve body
Clearance between selector valve spool and valve
body
Criteria
Tolerance
Remedy
Shaft
Hole
Standard
clearance
36
-0.002
-0.007
+0.010
+0.010
0.008
0.010
0.015
-0.010
-0.022
+0.018
+0.010
0.010
0.015
0.02
Standard
size
Clearance
limit
Replace
Unit: mm
No.
Check item
Criteria
Standard size
10
D155AX-6
Free length
Installation
x outer
length
diameter
Remedy
Repair limit
Installation
load
Free length
76.4 x 27
69.5
449 N
{45.8 kg}
20.9 x 13.8
12.5
97 N
{9.89 kg}
Installation
load
Replace
spring if dam359 N
aged or
{36.6 kg} deformed.
77.6 N
{7.91 kg}
61
SEN00607-03
1.
q
q
No circulating condition
Fine control of lowering blade (Stroke of lever is less than 70%.)
QDV mode: OFF
Outline
QDV: Abbreviation of Quick Drop Valve
q
The quick drop valve is installed between the
control valve and the blade lift cylinder.
q
When the blade control lever is set in lower
position, the quick drop valve prevents a vacuum on the cylinder bottom side and shortens
time lag in starting digging.
q
The blade lowering speed is mostly decided by
the pump delivery. However, it can be heightened by installing the quick drop valve.
62
Since the quick drop valve electronically controls the operation of the PCCS lever, the controller and EPC valve (QDV is built-in), it is
possible to select ON-OFF.
Operation
Because command current (X) from the controller to the EPC valve is 0A, main spool (2) is
not switched.
q
The circuits between port (VH) and port (PH) /
port (VB) and port (PB), are shut off.
q
The pressure oil of the lift cylinder head flows
from port (VH) to tank (T) through the control
valve.
q
D155AX-6
2.
q
q
SEN00607-03
Circulating condition
Lowering blade (Stroke of lever is more than 70%.)
QDV mode: ON
Operation
q
1,000 mA of command current (X) flows from
controller to EPC valve and the pilot pressure
from the EPC valve is taken to chamber (a) at
the main spool.
q
Main spool (1) moves to the right and the circuits between port (VH) and port (PH)/port
(VB) and port (PB), get into circulating condition.
q
Most of the pressurized oil which has been
flowing from port (PH) to port (VH), circulates
and flows to port (PB).
D155AX-6
63
SEN00607-03
3.
q
q
From the circulating condition of lowering blade to the blade tensed condition
Lowering blade (Stroke of lever is more than 70%.)
QDV mode: ON
Operation
q
Under the circulating condition of blade lowering, if the blade gets tensed, the lift cylinder
bottom pressure rises.
q
If the lift cylinder bottom pressure becomes
3.43 MPa {35kg/cm2} or more, selector valve
spool (2) moves to the left.
q
The pilot pressure from the EPC valve is
blocked and pressure chamber (a) of main
spool (1) is connected to drain circuit (TS).
q
Main spool (1) moves to the right by the force
of spring (3).
64
The lift cylinder bottom is connected to the circuit between port (PB) and port (VB), this
enables the blade to be tensed under no circulating condition.
D155AX-6
T:
P1:
P2:
PR:
SEN00607-03
To tank
From pump
To fan motor
Supply to PPC valve and EPC valve
D155AX-6
65
SEN00607-03
1.
2.
3.
4.
5.
66
6.
7.
8.
9.
10.
D155AX-6
SEN00607-03
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
11
Free length
Installation
x outer
length
diameter
Repair limit
Installation
load
Free
length
Installation
load
19.2 x 7.20
16.1
19.6 N
{2.0 kg}
17.7 N
{1.80 kg}
Spring
12 (pressure reduction valve
pilot)
17.8 x 7.20
12.7
28 N
{2.90 kg}
25.6 N
{2.60 kg}
13 Spring
71.0 x 18.0
59.0
200 N
{20.4 kg}
186 N
{19.0 kg}
16.1 x 7.80
13.4
61.7 N
{6.30 kg}
58.8 N
{6.0 kg}
Replace spring
if damaged or
deformed.
Function
q
The self pressure reducing valves reduce the
discharge pressure of the fan pump and supplies it to the PPC valve, the EPC valve, etc. as
the control pressure.
D155AX-6
67
SEN00607-03
Operation
At engine stop (total low pressure)
68
D155AX-6
SEN00607-03
When load pressure (P2) is lower than output pressure (PR) of the self pressure reducing valve.
D155AX-6
69
SEN00607-03
70
D155AX-6
SEN00607-03
D155AX-6
71
SEN00607-03
D155AX-6 Bulldozer
Form No. SEN00607-03
2012 KOMATSU
All Rights Reserved
Printed in Japan 02-12
72
D155AX-6
SEN00608-01
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
Work equipment
Cylinder stay ................................................................................................................................................... 2
Blade............................................................................................................................................................... 4
Cutting edge, end bit....................................................................................................................................... 6
Ripper ............................................................................................................................................................. 8
D155AX-6
SEN00608-01
Cylinder stay
1.
2.
3.
4.
5.
Yoke
Dust seal
Bushing
Bushing
Grease nipple
D155AX-6
SEN00608-01
Unit: mm
No.
Check item
Clearance between cylinder
yoke and bushing
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
125
0.172
0.235
+0.063
+0.046
0.172
0.298
100
0.170
0.224
+0.054
+0.046
0.170
0.278
110
0.172
0.035
+0.054
+0.046
0
0.089
0.5
D155AX-6
Replace
SEN00608-01
Blade
Sigma-tilt dozer
D155AX-6
SEN00608-01
Unit: mm
No.
Check item
Clearance between brace
and pin
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
60
0.3
0.5
+0.174
+0.100
0.4
0.674
60
0.3
0.5
+0.5
+0.2
0.5 1.0
115
0.2
0.3
+0.3
+0.6
0.2 0.6
Clearance between
brace pin and bracket
90
0.3
0.5
+0.3
+0.1
0.4 0.8
90
0.3
0.5
+0.5
+0.3
0.6 1.0
140
0.2
0.7
+0.5
+0.3
0.5 1.2
70
0.5
0.6
+0.3
+0.6
0.5 0.9
70
0.5
0.6
+0.3
+0.6
0.5 0.9
70
0.5
0.6
+0.3
+0.6
0.5 0.9
10
165
0.2
0.3
+0.3
+0.6
0.2 0.6
11
160
0.5
1.0
+0.5
+0.0
0.5 1.5
12
195
0.5
1.0
+0.5
+0.0
0.5 1.5
D155AX-6
Replace
Adjust shims
or replace
Replace
Adjust shims
or replace
Replace
SEN00608-01
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
330
300
235
330
260
640
500
Turn
or replace
Replace
D155AX-6
D155AX-6
SEN00608-01
SEN00608-01
Ripper
D155AX-6
SEN00608-01
Unit: mm
No.
Check item
Criteria
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
110
0.036
0.090
+0.207
+0.120
0.156
0.297
1.5
110
0.036
0.090
+0.459
+0.369
0.405
0.549
1.5
100
0.036
0.090
+0.207
+0.120
0.156
0.297
1.5
100
0.036
0.090
+0.457
+0.370
0.406
0.547
1.5
90
0.036
0.090
+0.207
+0.120
0.156
0.297
1.5
90
0.036
0.090
+0.207
+0.120
0.156
0.297
1.5
Clearance between tilt cylin3,9 der mounting pin and mounting bracket or beam bracket
4,10
Standard
size
Tolerance
13
Shaft 75
Hole 77
+0.300
0.300
+0.300
0.300
1.400
2.600
10.0
14
Shaft 75
Hole 80
+0.300
0.300
+1.000
1.000
3.700
6.300
15.0
15
Wear of point
16
Wear of protector
D155AX-6
Standard size
Repair limit
335
225
115
90
Replace
SEN00608-01
10
D155AX-6
SEN00608-01
Unit: mm
No.
Check item
Criteria
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
110
0.036
0.090
+0.207
+0.120
0.156
0.297
1.5
110
0.036
0.090
+0.459
+0.369
0.405
0.549
1.5
100
0.036
0.090
+0.207
+0.120
0.156
0.297
1.5
100
0.036
0.090
+0.457
+0.370
0.406
0.547
1.5
90
0.036
0.090
+0.207
+0.120
0.156
0.297
1.5
90
0.036
0.090
+0.207
+0.120
0.156
0.297
1.5
Clearance between tilt cylin3,9 der mounting pin and mounting bracket or beam bracket
4,10
Standard
size
Tolerance
13
Shaft 75
Hole 77
+0.300
0.300
+0.300
0.300
1.400
2.600
10.0
14
Shaft 75
Hole 80
+0.300
0.300
+1.000
1.000
3.700
6.300
15.0
15
Wear of point
16
Wear of protector
D155AX-6
Standard size
Repair limit
335
225
115
90
Replace
11
SEN00608-01
D155AX-6 Bulldozer
Form No. SEN00608-01
2007 KOMATSU
All Rights Reserved
Printed in Japan 03-07 (02)
12
D155AX-6
SEN00609-01
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
D155AX-6
SEN00609-01
1.
2.
3.
4.
5.
Support
Damper mount (front)
Damper mount (rear)
ROPS pin (front)
ROPS pin (rear)
Outline
q
Viscous mounts are installed at two places at
the front and two places at the rear to secure
the floor frame and cab.
q
An oil-filled damper mount is used to absorb
the vibration.
q
The ROPS pins are installed to 2 places each
at the front and rear sections to fix the ROPS
(built in the cab) when the machine rolls over.
D155AX-6
ROPS cab
SEN00609-01
Cab assembly
1.
2.
3.
4.
5.
Front wiper
Front glass
Rear wiper
Door
ROPS sub (built in CAB)
D155AX-6
SEN00609-01
Air conditioner
1.
2.
3.
4.
5.
6.
7.
8.
9.
Condenser
Hot water return piping
Hot water pick-up piping
Front window defroster
Side window defroster
Air outlet for face
Air outlet for center
Air outlet for rear
Air conditioner unit
10.
11.
12.
13.
14.
15.
A:
B:
Fresh air
Recirculated air
D155AX-6
D155AX-6
SEN00609-01
SEN00609-01
D155AX-6 Bulldozer
Form No. SEN00609-01
2007 KOMATSU
All Rights Reserved
Printed in Japan 03-07 (02)
D155AX-6
SEN00610-03
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
Electrical system
Engine control ................................................................................................................................................. 2
Engine control system..................................................................................................................................... 3
Deceleration potentiometer............................................................................................................................. 4
Monitor system................................................................................................................................................ 6
Sensors......................................................................................................................................................... 25
Palm command control system..................................................................................................................... 28
KOMTRAX system........................................................................................................................................ 31
D155AX-6
SEN00610-03
Engine control
1.
2.
3.
4.
5.
6.
7.
8.
9.
Decelerator pedal
Decelerator potentiometer
Starter switch
Fuel control dial
Battery relay
Battery
Power train controller
Starter
Fuel supply pump
Outline
q
The throttle signals of the fuel control dial are
sent to the power train controller and processed together with the 3rd throttle signal,
and then sent as the throttle commands
together with the throttle signals of the decelerator pedal to the engine throttle controller. The
engine throttle controller controls the engine
according to the commands.
D155AX-6
SEN00610-03
Outline
q
The engine throttle controller receives the fuel
control dial signal of the 1st throttle, decelerator pedal signal of the 2nd throttle, and 3rd
throttle signal which is the control signal from
the power train controller, and then controls the
fuel supply pump according to the command
signal having the lowest engine speed.
The control signals of the 3rd throttle are as
follows.
(1) Auto deceleration (F3, R3, F2, R2)
(2) Neutral deceleration
q
The power train controller calculates a proper
engine speed from information items (1), (2),
etc.
and sends it as the 3rd throttle signal to the
engine throttle controller.
D155AX-6
SEN00610-03
Deceleration potentiometer
1.
2.
3.
4.
5.
6.
7.
Connector
Lever
Body
Potentiometer
Cuppling
Shaft
Stopper
Outline
q
The deceleration potentiometer is installed to
the inside of the dashboard and connected to
the decelerator pedal by linkage.
q
If the decelerator pedal is pressed, it rotates
the throttle potentiometer shaft through the
linkage and the potentiometer resistance
changes.
Constant voltage is applied between pins (A)
and (C) of the potentiometer and a voltage signal is sent through pin (B) to the engine controller according to the position of the
decelerator pedal.
D155AX-6
D155AX-6
SEN00610-03
SEN00610-03
Monitor system
The monitor system monitors the machine condition with the sensors installed to various
parts of the machine and processes and displays the obtained information on the panel
quickly to notify the operator of the machine
condition.
The main display sections and functions of the
panel are as follows.
1) Monitor unit which turns on the alarm
when the machine has a trouble.
2) Gauge unit which constantly displays the
machine condition (coolant temperature,
torque converter oil temperature, fuel
level, etc.)
3) Function of displaying error codes.
4) Function of monitoring the current and
voltage of the sensors and solenoids,
The CPU (Central Processing Unit) in the monitor panel displays and outputs various information items processed by the power train
controller. The display unit is LCD (Liquid Crystal Display)
D155AX-6
SEN00610-03
Method
Flow of signals
CAN
Method
1. The communication conditions of each sensor, each solenoid, and CAN are displayed.
The item Nos. and device conditions are notified to
CAN
the machine monitor by CAN.
The machine monitor displays the items and each
value.
Flow of signals
Each sensor-controller-machine
monitor
Other items
01
02
03
04
05
06
07
08
09
10
11
12
13
88
89
Method
Flow of signals
D155AX-6
SEN00610-03
Machine monitor
Outline
q
The machine monitor has the functions to display various items and the functions to select
modes and electric parts.
q
The machine monitor has a CPU (Central Processing Unit) in it to process, display, and output the information.
q
The monitor display employs an LCD (Liquid
Crystal Display). The switches are flat sheet
switches.
D155AX-6
Input/
output
1
Battery power (+24V constantly)
Input
2
Battery power (+24V constantly)
Input
3
Battery power GND
4
Battery power GND
Input/
5
Wake-up
Output
6
Relay output
Output
7
Chassis signal GND
8
Hydraulic oil pressure
9
Fuel level
Input
10
NC(*)
11
Charge amount
Input
12
Chassis analog signal GND
13
Light switch
Input
14
Key switch (ACC)
Input
15
Key switch (C)
Input
16
Preheating
Input
17
NC(*)
18
NC(*)
CN-CM02
Input/
output
1
NC(*)
2
NC(*)
3
Coolant level sensor
Input
4
NC(*)
5
NC(*)
6
NC(*)
7
Chassis signal GND
8
CAN terminating resistance
Input/
9
CAN_H
Output
Input/
10
CAN_L
Output
11
NC(*)
12
NC(*)
CN-CM03
Pin No.
CN-CM01
Pin No.
SEN00610-03
Signal name
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Input/
output
RS232C CD for communication terminal Input
RS232C RXD for communication terminal Input
RS232C SG for communication terminal
Signal name
control
Communication terminal selection signal Input
RS232C RTS for communication terminal Output
RS232C TXD for communication terminal Output
RS232C DTR for communication terminal Output
RS232C DTR for communication terminal Input
RS232C CTS for communication terminal
RS232C RI for communication terminal
Power GND for communication terminal
Input CH1 for communication terminal
status
Output for communication terminal
power control
Output CH1 for communication terminal
control
Output CH2 for communication terminal
control
Input CH2 for communication terminal
status
Electric power supply for communication
terminal
Input
Input
Input
Output
Output
Output
Input
Output
CN-CM04
Input/
output
1
NC(*)
2
NC(*)
3
NC(*)
4
NC(*)
5
NC(*)
6
NC(*)
7
NC(*)
8
NC(*)
9
NC(*)
10
NC(*)
11
NC(*)
12
NC(*)
Signal name
CN-CM05
Pin No.
1
2
3
4
5
6
7
8
D155AX-6
Input/
output
Electric power supply for camera
Output
Camera NTSC signal input 1
Input
Camera NTSC signal input 2
Input
Camera NTSC signal input 3
Input
Electric power supply GND for camera
Signal name
SEN00610-03
1.
2.
3.
4.
5.
6.
7.
8.
10
9.
10.
11.
12.
13.
14.
15.
16.
Fuel level
Travel gear speed gear shift mode preset
Guidance icon
Function switch
Custom switch
Custom memory switch
Float mode switch
Air conditioner switch
D155AX-6
D155AX-6
SEN00610-03
11
SEN00610-03
Check
Display
category
Symbol
Display item
Battery charge
Below 49.0kPa
{0.5kg/cm2}
Caution
Pilot
Display method
12
Display range
Above 100C:
Symbol ON
Above 110C:
Symbol ON + buzzer
Maintenance
Preheating
When preheating
D155AX-6
Display
category
Symbol
Display item
SEN00610-03
Display range
Display method
Engine coolant
temperature
Gauges
Fuel level
Service meter
(Hours meter)
D155AX-6
From 0 to 99999
13
SEN00610-03
Gauge
The gauge pointer disappears when information on coolant temperature or hydraulic oil temperature cannot
be obtained due to disconnection of CAN.
Gauge
Engine coolant
temperature
(C)
Hydraulic oil
temperature
(C)
14
Range
A1
A2
A3
A4
A5
A6
B1
B2
B3
B4
B5
B6
C1
C2
C3
C4
C5
C6
D1
D2
D3
D4
D5
D6
Temperature or volume
105
102
100
85
60
30
130
120
118
90
50
0
110
100
98
70
20
0
565
425
310
220
150
75
Indicator
Buzzer sound
Red
Red
Off
Off
Off
White
Red
Red
Off
Off
Off
White
Red
Red
Off
Off
Off
White
Off
Off
Off
Off
Off
Red
D155AX-6
Machine speed
1. 0 km/h
2. 5 km/h
SEN00610-03
Battery voltage
3. 10 km/h
4. 15 km/h
1. 0 V
2. 17 V
3. 20 V
Engine speed
1. 0 MPa
2. 10 MPa
3. 20 MPa
1. 500 rpm
2. 1,000 rpm
3. 1,500 rpm
4. 30 MPa
5. 40 MPa
6. 50 MPa
1. 0.0 MPa
2. 0.2 MPa
3. 0.3 MPa
D155AX-6
4. 25 V
5. 30 V
6. 31 V
4. 2,000 rpm
5. 2,500 rpm
6. 3,000 rpm
Drawbar pull
4. 0.4 MPa
5. 0.5 MPa
6. 0.7 MPa
1. 0 W
2. 0.2 W
3. 0.4 W
4. 0.6 W
5. 0.8 W
6. 1.0 W
15
SEN00610-03
16
Switch
Item
Function
F6
Enter
F5
Return
F4
F5
F6
F3
Select item
Selects item on left side (Selects right end item after left
end item).
F4
Select item
Selects item on right side (Selects left end item after right
end item).
F3
Select item
F4
Select item
F1
Select item
F2
Select item
F2
F1
Start
F1
Stop
F1/F2
Clear
F1
Set
Executes setting.
F1
F2
D155AX-6
SEN00610-03
D155AX-6
17
SEN00610-03
Maintenance function
q
No.
18
01 Engine oil
02 Engine oil filter
03 Fuel main filter
41 Fuel pre filter
04 Hydraulic filter
06 Corrosion resistor
07 Damper case oil
08 Final drive case oil
10 Hydraulic oil
19 P/L oil
20 P/L oil filter
*: If equipped (To be determined)
P/L: Power train
q
Replacement interval
(Hours)
500
500
1000
500
2000
1000(*)
2000
1000
2000
1000
500
Condition
Remaining time for mainteNone
nance for all items is more
than 30 hours.
There is one or more items
Notice display (black symwith less than 30-hour
bol displayed on yellow
remaining time for maintebackground)
nance.
There is one or more items
Warning display (white
with less than 0-hour
symbol displayed on red
remaining time for maintebackground)
nance.
D155AX-6
SEN00610-03
User mode
q
q
q
q
F3 :
F4 :
F5 :
F6 :
D155AX-6
19
SEN00610-03
q
q
Standard display
q
The normal screen is selected.
Load display
q
The horizontal axis indicates the time and the
vertical axis indicates the traction force. The
operation should be carried out in the green
range.
q
The graph on the screen is updated and
scrolled to the left at intervals of several seconds.
No.
Selected item
Remarks
With caution
With caution
Vehicle Speed
HYD Pressure
Battery Voltage
Engine Speed
Traction Force
Clock
With caution
20
D155AX-6
Screen adjustment
q
q
q
SEN00610-03
Clock adjustment
q
For a camera-equipped machine, the brightness, contrast, and illuminance of the camera
screen are also adjustable.
For a camera-equipped machine, selecting
Sc reen adjus tment fro m the us er menu
switches to the screen for selecting a screen
you want to adjust.
1)
Time setting
Set the clock time. If the time setting item
is not highlighted, press F6 to highlight it.
The time display part is highlighted.
F3 : Advances the clock one hour.
F4 : Sets the clock back one hour.
F5 : Cancels changes you made before
confirming them with F6 to return to
the user menu.
F6 : Confirms the changes and moves to
minute setting.
21
SEN00610-03
3)
F3 :
F4 :
F5 :
F6 :
Message display
q
q
q
Language setting
q
22
D155AX-6
Press F6 to enter user mode and select Message display and you can view (open) the
messages.
SEN00610-03
q
q
q
q
D155AX-6
23
SEN00610-03
24
D155AX-6
SEN00610-03
Sensors
Type of sensor
1
Sensor method
When normal
When abnormal
Contact
OFF
ON
Resistance
Resistance
Resistance
Contact
ON
OFF
Fuel level
Resistance
Coolant level
Engine speed sensor
Resistance
Resistance
Resistance
1.
2.
3.
Plug
Contact ring
Contact
4.
5.
6.
Diaphragm
Spring
Terminal
4.
5.
6.
Tube
Wire
Connector
1.
2.
3.
Thermistor
Body
Tube
D155AX-6
25
SEN00610-03
1.
2.
3.
Float
Sensor
Tube
4.
5.
Wire
Connector
1.
2.
3.
4.
5.
6.
7.
26
Connector
Float
Arm
Body
Spring
Contact
Spacer
Function
q
The fuel sensor is installed to the side face of
the fuel tank. The float moves up and down
according go the fuel level. This movement of
the float is transmitted by the arm and actuates
a variable resistance. This sends a signal to
the monitor panel to indicate the remaining fuel
level.
D155AX-6
SEN00610-03
1.
2.
3.
Magnet
Terminal
Case
4.
5.
Boots
Connector
3.
4.
Wire
Connector
1.
2.
Body
Tube
D155AX-6
27
SEN00610-03
1.
2.
3.
4.
5.
6.
7.
8.
28
D155AX-6
SEN00610-03
D155AX-6
29
SEN00610-03
30
D155AX-6
KOMTRAX system
SEN00610-03
D155AX-6
31
SEN00610-03
KOMTRAX terminal
TH300
1.
2.
3.
Outline
The KOMTRAX terminal is a wireless communication device to transmit various kinds of
machine information or GPS position information the monitor obtains from network signals
or input signals in the machine. The terminal
can transmit information via the communication antenna.
q
Use of KOMTRAX terminal must be limited for
the countries in which such communication is
allowed.
q
When using TH300 in Japan or in other countries, the satellite communication company to
contract is different. So, part numbers of
TH300 are different in Japan or in other countries. Also, when using TH300 in countries
other than Japan, you must notify the name of
the country.
q
Signal name
Power (12V)
NC(*1)
NC(*1)
Electric power supply switching
NC(*1)
NC(*1)
GND
GND
NC(*1)
NC(*1)
NC(*1)
NC(*1)
NC(*1)
NC(*1)
Input/
output
Input
Output
Connector B
Input/
output
B-1
Serial signal DCD
Output
B-2
Serial signal RXD
Output
B-3
Serial signal TXD
Input
B-4
Serial signal DTR
Input
B-5
Serial signal SGND
B-6
Serial signal DSR
Output
B-7
NC(*1)
B-8
NC(*1)
B-9
NC(*1)
B-10 NC(*1)
32
Signal name
D155AX-6
D155AX-6
SEN00610-03
33
SEN00610-03
D155AX-6 Bulldozer
Form No. SEN00610-03
2009 KOMATSU
All Rights Reserved
Printed in Japan 02-09 (02)
34
D155AX-6
SEN00678-03
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
D155AX-6
SEN00678-03
Category
Item
Speed
Machine model
D155AX-6
Engine
SAA6D140E-5
Unit
High idle
rpm
2,100 (0/-50)
2,100 (0/-50)
Low idle
rpm
740 (+20/0)
740 (+20/0)
Rated speed
rpm
1,900
1,900
kPa
{mmHg}
Min. 117
{Min. 880}
100
{750}
660
700
Max. 25
(Max. 2.5)
35
{3.5}
Max. 1.0
2.0
Measurement condition
Engine coolant
temperature: Within
operating range
Engine
Valve clearance
Engine coolant
temperature: Within
operating range
Blow-by pressure
High idle
Intake valve
mm
0.35
Exhaust valve
mm
0.57
Min. 1.43
{Min. 14.6}
Min. 1.43
{Min. 14.6}
Min. 1.18
{Min. 12}
Min. 1.18
{Min. 12}
Min. 4.1
{Min. 42}
2.8
{29}
200 250
200 250
Max. 2.94
{Max. 300}
3.92
{400}
MPa
{kg/cm2}
Min. 0.34
{Min. 3.5}
0.21
{2.1}
MPa
{kg/cm2}
Min. 0.10
{Min. 1.0}
0.08
{0.8}
90 110
120
mm
13 16
13 16
mm
Approx. 10
Approx. 10
MPa
{kg/cm2}
MPa
Low idle
{kg/cm2}
Compression MPa
Engine oil
pressure
{kg/cm2}
temperature:
40 60C Engine
rpm
speed
Engine coolant temperature: Within
operating range
kPa
Power train oil temperature: Within
{mmH2O}
operating range
Torque converter: Stalled
High idle
SAE0W30EOS,
SAE5W40EOS,
High idle
SAE10W30DH,
Engine oil pressure
SAE15W40DH
SAE30DH Oil
Engine oil temperature: Low idle
Min. 80 C
Oil temperature
%
(Bosch
index)
(Bosch
index)
Normal temperature
At sharp
acceleration
D155AX-6
SEN00678-03
Machine model
Category
Item
Cooling fan
Engine speed
Decelerator pedal
speed
Auto deceleration
speed
D155AX-6
Unit
rpm
875 50
875 50
rpm
1,875 50
1,875 50
rpm
1,610 50
1,450
rpm
1,550 50
1,395
rpm
1,250 50
1,250 50
mm
30 5
30 5
mm
30 5
30 5
N o Left
mm
40 5
40 5
N o Right
mm
40 5
40 5
mm
50 10
50 10
All stroke
mm
79 10
79 10
Stroke to 0 of
oil pressure
mm
54 4
54 4
Measurement condition
Engine coolant temperature: Within
operating range
Power train oil temperature: Within
operating range
Hydraulic oil temperature: Within
operating range
Engine: High idle
Decelerator pedal speed:
Press pedal
Auto deceleration speed:
Set all levers in neutral
Hydraulic oil
temperature: Within
operating range
Fan: Set in 100%
mode
Engine: High idle
Max. speed
PCCS lever
No
Forward/
Reverse travel
No
Stop engine
Center of lever grip
Forward
Reverse
Steering
Decelerator pedal
Stop engine
Center of pedal
Brake pedal
D155AX-6
SEN00678-03
Machine model
Item
Unit
N o Raise
mm
72 10
72 10
N o Lower
mm
72 10
72 10
N o Left tilt
mm
53 10
53 10
mm
53 10
53 10
N o Raise
mm
75 10
75 10
N o Lower
mm
75 10
75 10
N o In
mm
80 10
80 10
N o Out
mm
80 10
80 10
No
N
{kg}
N
{kg}
N
{kg}
N
{kg}
N
{kg}
N
{kg}
N
{kg}
N
{kg}
N
{kg}
N
{kg}
56.9 6.9
{5.8 0.7}
50.1 6.9
{5.2 0.7}
24.5 4.9
{2.5 0.5}
27.5 4.9
{2.8 0.5}
49.0 9.8
{5.0 1.0}
411.6 78.4
{42.0 8.0}
39.2 5.9
{4.0 0.6}
39.2 9.8
{4.0 1.0}
9.8 4.9
{1.0 0.5}
29.4 5.9
{3.0 0.6}
56.9 6.9
{5.8 0.7}
50.1 6.9
{5.2 0.7}
24.5 4.9
{2.5 0.5}
27.5 4.9
{2.8 0.5}
49.0 9.8
{5.0 1.0}
411.6 78.4
{42.0 8.0}
39.2 5.9
{4.0 0.6}
39.2 9.8
{4.0 1.0}
9.8 4.9
{1.0 0.5}
29.4 5.9
{3.0 0.6}
N
{kg}
29.4 5.9
{3.0 0.6}
29.4 5.9
{3.0 0.6}
N
{kg}
N
{kg}
N
{kg}
N
{kg}
19.6 4.9
{2.0 0.5}
19.6 4.9
{2.0 0.5}
24.5 4.9
{2.5 0.5}
24.5 4.9
{2.5 0.5}
19.6 4.9
{2.0 0.5}
19.6 4.9
{2.0 0.5}
24.5 4.9
{2.5 0.5}
24.5 4.9
{2.5 0.5}
Measurement condition
Stop engine
Center of lever knob
No
PCCS lever
Category
D155AX-6
Stop engine
Center of lever knob
Forward/
Reverse travel
No
Stop engine
Center of lever grip
Right tilt
Forward
Reverse
N o Left
Steering
N o Right
Decelerator pedal
Brake pedal
Stop engine
Center of pedal
Engine: Low idle
Center of pedal
N o Raise
N o Lower
Stop engine
Lower o
Blade control lever/
Center of lever knob
Float
switch
Lower o Float: Switch
N o Left tilt
No
Right tilt
N o Raise
Stop engine
Center of lever knob
N o Lower
N o In
N o Out
D155AX-6
SEN00678-03
Machine model
Category
Item
Torque converter
inlet pressure
Torque converter
outlet pressure
Transmission main
relief pressure
Torque converter
lockup clutch
Transmission 2nd
clutch pressure
0.05 0.49
{0.5 5.0}
Max. 1.0
{Max. 10.0}
0.05 0.49
{0.5 5.0}
Max. 1.0
{Max. 10.0}
0.05 0.29
{0.5 3.0}
0.05 0.29
{0.5 3.0}
0.29 0.69
{3.0 7.0}
2.81 3.11
{28.7 31.7}
0.29 0.69
{3.0 7.0}
Min. 2.62
{Min. 26.7}
3.04 3.33
{31.0 34.0}
Min. 2.84
{Min. 29.0}
1.32 0.20
{13.5 2.0}
1.32 0.20
{13.5 2.0}
1.32 0.20
{13.5 2.0}
2.65 0.20
{27.0 2.0}
1.32 0.20
{13.5 2.0}
2.65 0.20
{27.0 2.0}
2.65 0.20
{27.0 2.0}
2.65 0.20
{27.0 2.0}
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
2.45 2.75
{25.0 28.0}
2.60 2.89
{26.5 29.5}
Min. 2.26
{Min. 23.0}
Min. 2.40
{Min. 24.5}
2.65 2.94
{27.0 30.0}
Min. 2.45
{Min. 25.0}
2.79 3.09
{28.5 31.5}
2.81 3.11
{28.7 31.7}
Min. 2.60
{Min. 26.5}
Min. 2.62
{Min. 26.7}
3.04 3.33
{31.0 34.0}
Min. 2.84
{Min. 29.0}
2.60 2.89
{26.5 29.5}
2.75 3.04
{28.0 31.0}
Min. 2.40
{Min. 24.5}
Min. 2.55
{Min. 26.0}
2.81 3.11
{28.7 31.7}
Min. 2.62
{Min. 26.7}
3.04 3.33
{31.0 34.0}
Min. 2.84
{Min. 29.0}
High idle
MPa
{kg/cm2}
0.05 0.29
{0.5 3.0}
0.05 0.29
{0.5 3.0}
Low idle
MPa
{kg/cm2}
2.75 0.29
{28.0 3.0}
2.75 0.29
{28.0 3.0}
2.16
{22.0}
2.16
{22.0}
2.75 0.29
{28.0 3.0}
2.16
{22.0}
2.75 0.29
{28.0 3.0}
2.16
{22.0}
Low idle
High idle
Low idle
High idle
Low idle
High idle
Low idle
High idle
Low idle
Transmission 3rd
clutch pressure
Transmission lubricating oil pressure
(Reference)
Steering right brake
Power train oil
pressure
temperature: Within
operating range
PCCS lever: Neutral
Steering left brake Brake pedal: Release
pressure
D155AX-6
Low idle
Transmission F
clutch pressure
Transmission 1st
clutch pressure
Measurement condition
Torque converter
stator clutch
pressure
Transmission R
clutch pressure
D155AX-6
High idle
Low idle
High idle
High idle
Low idle
High idle
Unit
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
SEN00678-03
Machine model
Category
Item
Travel speed
Unit
F1
km/h
3.8 0.2
3.8 0.2
F2
km/h
7.5 0.4
7.5 0.4
F3L
km/h
7.5 0.4
7.5 0.4
F3
km/h
11.6 0.6
11.6 0.6
R1
km/h
4.6 0.2
4.6 0.2
R2
km/h
6.8 0.4
6.8 0.4
R3L
km/h
9.2 0.5
9.2 0.5
R3
km/h
14.0 0.7
14.0 0.7
MPa
{kg/cm2}
2.45 (+1.37/0)
2.45 (+1.37/0)
{25 (+14/0)}
{25 (+14/0)}
27.5 1.5
{280 15}
27.5 1.5
{280 15}
27.5 1.5
{280 15}
27.5 1.5
{280 15}
27.5 1.5
{280 15}
27.5 1.5
{280 15}
27.5 1.5
{280 15}
27.5 1.5
{280 15}
25.0 0.98
{255 10}
25.0 0.98
{255 10}
38.2 41.7
{390 425}
38.2 41.7
{390 425}
36.2 38.1
{369 389}
36.2 38.1
{369 389}
MPa
{kg/cm2}
3.97 (+0.49/0)
3.78 4.46
{40.5 (+5/0)}
{38.5 45.5}
MPa
{kg/cm2}
3.82 4.12
{39 42}
3.53
{36}
sec
3.0 4.0
3.0 4.0
sec
1.0 1.7
1.0 1.7
Measurement condition
Flat ground
Engine coolant
temperature: Within
operating range
Power train oil
temperature: Within
operating range
Select manual
gearshift mode
Engine: High idle
Approach run:
10 30 m
Measuring distance:
20 m
(Converted into km/h)
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
Hydraulic oil temperature: Within
{kg/cm2}
operating range
Ripper lift relief
MPa
Engine: High idle
pressure
{kg/cm2}
Cylinder of measured circuit:
Ripper tilt relief
MPa
Stroke end
pressure
{kg/cm2}
Work equipment LS
MPa
relief pressure
{kg/cm2}
HSS relief pressure
HSS LS relief
pressure
pressure
(Reference)
Work equipment speed
Work equipment
Unload pressure
D155AX-6
Blade lift
D155AX-6
SEN00678-03
Machine model
Category
Item
Work equipment
Blade tilt
Ripper lift
Ripper tilt
Time lag
Blade
Ripper
D155AX-6
Measurement condition
Hydraulic oil
temperature: Within
Left tilt
operating range
Engine: High idle
Select P mode
Apply no load to blade
Measure time required
to move blade from left
tilt end to right tilt end Right tilt
For measuring posture,
see Fig. 2
Hydraulic oil
temperature: Within
operating range
Raise
Engine: High idle
Select P mode
Apply no load to ripper
(Shank hole: Lowest)
Measure time required
to move ripper from
ground level to raise
Lower
end
For measuring posture,
see Fig. 3
Hydraulic oil temperature: Within operating
range
Tilt in
Engine: High idle
Select P mode
Apply no load to ripper
Measure time required
to move ripper from tilt
in end to tilt back end Tilt back
For measuring posture,
see Fig. 4
Hydraulic oil temperature: Within
operating range
Engine: Low idle
Select P mode.
Blade control lever: Set to stroke end
Lower blade from max. rising position
and measure time after blade comes
in contact with ground until idler is
lifted
Hydraulic oil temperature: Within
operating range
Engine: Low idle
Select P mode
Ripper control lever: Set to stroke
end
Lower ripper from max. rising position and measure time after ripper
comes in contact with ground until
sprocket is lifted
D155AX-6
Unit
sec
1.8 2.8
3.1
sec
1.8 2.8
3.1
sec
2.0 3.0
4.0
sec
1.5 2.5
3.5
sec
4.5 5.5
6.2
sec
3.7 4.7
6.1
sec
Max. 1.7
2.5
sec
Max. 1.5
1.5
SEN00678-03
Machine model
Category
Item
Work equipment
Hydraulic drift
of lifted blade
Hydraulic drift
of machine
lifted by blade
Hydraulic drift
of machine
tilted by blade
Measurement condition
Hydraulic oil temperature: Within
operating range
Stop engine
Measure reduction of blade bottom
height h in 15 minutes
For measuring posture, see Fig. 5
Hydraulic oil temperature: Within
operating range
Stop engine
Measure reduction of idler center
height h in 5 minutes
For measuring posture, see Fig. 6
Hydraulic oil temperature: Within
operating range
Stop engine
Measure reduction of track shoe
bottom height h in 5 minutes
For measuring posture, see Fig. 7
D155AX-6
Unit
mm
200/15 minutes
mm
70/5 minutes
mm
70/5 minutes
mm
70/5 minutes
cc/min
Max. 3.0
12
cc/min
Max. 2.7
11
cc/min
Max. 2.7
11
D155AX-6
SEN00678-03
D155AX-6
SEN00678-03
10
D155AX-6
D155AX-6
SEN00678-03
11
SEN00678-03
D155AX-6 Bulldozer
Form No. SEN00678-03
2010 KOMATSU
All Rights Reserved
Printed in Japan 11-10
12
D155AX-6
SEN00679-05
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
D155AX-6
SEN00679-05
D155AX-6
SEN00679-05
Symbol
Measuring exhaust
temperature
Part No.
Part name
Measuring blow-by
pressure
1 99.9 1,299C
Commercially
Smoke meter
available
Commercially
Thickness gauge
available
6
Measuring fan speed
795-471-1450
07005-00812
6151-51-8490
6206-71-1770
Commercially
available
Commercially
available
Hose
1 5 mm 2 3 m
Hose
1 15 mm 2 3 m
Commercially
Measuring cylinder
available
Commercially
Stopwatch
available
799-205-1100 Tachometer kit
799-101-5002 Hydraulic tester
D155AX-6
Adapter
Gasket
Spacer
Joint
1
Measuring fan circuit
pressure
Pressure gauge:
2.5, 6, 40, 60 MPa
{25, 60, 400, 600 kg/cm2}
Pressure gauge:
2.5, 6, 40, 60 MPa
{25, 60, 400, 600 kg/cm2}
Pressure gauge: 60 MPa
1
{600 kg/cm2}
Pressure gauge: 1.0 MPa
1
{10 kg/cm2}
1
8 1.25 mm o R1/8
1
1 Inside diameter: 14 mm
1 Inside diameter of joint: 10 mm
Bosch index: 0 9
1
2
795-471-1330 Adapter
6261-71-6150 Gasket
Remarks
799-401-2220 Hose
Q'ty
1
1
1 6.0 99999.9 rpm
Pressure gauge:
2.5, 6, 40, 60 MPa
1
{25, 60, 400, 600 kg/cm2}
Pressure gauge: 60 MPa
1
{600 kg/cm2}
1 Size: 05
1 Size: 10 1.25 mm
Symbol
Part No.
Part name
79A-264-0091
19M-06-32820
1
P
17A-06-41410
2 790-190-1601
799-101-5002
1
Measuring and adjusting
work equipment and HSS Q
790-261-1204
oil pressure
799-101-5220
2
07002-11023
Push-pull scale
Switch assembly
Wiring harness
Pump assembly
Hydraulic tester
Digital hydraulic tester
Nipple
O-ring
T-adapter assembly
T-adapter assembly
T-adapter
T-adapter
T-adapter
Socket
T-adapter
T-adapter
Socket
1
1
1
1
1
1
1
795-799-5530 Socket
Pressure gauge:
2.5, 6, 40, 60 MPa
{25, 60, 400, 600 kg/cm2}
Pressure gauge: 60 MPa
1
{600 kg/cm2}
1 0 490 N {0 50 kg}
1
1
1
Pressure gauge:
2.5, 6, 40, 60 MPa
1
{25, 60, 400, 600 kg/cm2}
Pressure gauge: 60 MPa
1
{600 kg/cm2}
2
Size: 10 1.25 mm
2
Pressure gauge:
2.5, 6, 40, 60 MPa
1
{25, 60, 400, 600 kg/cm2}
Pressure gauge: 60 MPa
1
{600 kg/cm2}
1 Size: 03
Pressure gauge:
2.5, 6, 40, 60 MPa
1
{25, 60, 400, 600 kg/cm2}
Pressure gauge: 60 MPa
1
{600 kg/cm2}
1 Size: 03
1
Adapter
Troubleshooting for
engine
Controller/sensors/actuators
Remarks
Pressure gauge:
2.5, 6, 40, 60 MPa
{25, 60, 400, 600 kg/cm2}
Pressure gauge: 60 MPa
1
{600 kg/cm2}
1 Size: 03
2 799-401-3200
799-601-9000
or
799-601-9300
799-601-4101
or
799-601-4201
799-601-4130
799-601-4150
799-601-4211
799-601-4220
799-601-4240
799-601-4260
799-601-4330
Q'ty
SEN00679-05
Ne sensor
For oil pressure sensor
Engine controller
Engine controller
For ambient pressure sensor
Engine controller
G (Bkup) sensor
Coolant, fuel and oil temperature
1
sensor
D155AX-6
Symbol
SEN00679-05
Q'ty
Remarks
Socket
T-adapter
T-adapter
Socket
1
1
1
1
T-adapter assembly
T-box
1 For ECONO
T-adapter assembly
T-adapter
1 For DT2P
For DT3P
1 (Does not include 799-601-4101 and
799-601-4201)
1 For DT4P
For DT6P
1 (Does not include 799-601-4101 and
799-601-4201)
For DT8PB (Black)
1 (Does not include 799-601-4101 and
799-601-4201)
DT12PGR (Gray)
1 (Does not include 799-601-4101 and
799-601-4201)
For DT12PB (Black)
1 (Does not include 799-601-4101 and
799-601-4201)
For DT12PG (Green)
1 (Does not include 799-601-4101 and
799-601-4201)
Part No.
795-799-5540
799-601-9020
799-601-9420
799-601-9430
799-601-2500
or
799-601-2800
or
799-601-7100
or
799-601-7400
or
799-601-8000
799-601-2600
799-601-4101
or
799-601-4201
or
799-601-9000
or
799-601-9200
799-601-9020
Part name
799-601-9030 T-adapter
799-601-9040 T-adapter
799-601-9050 T-adapter
Troubleshooting for
chassis
Sensors/wiring harnesses
799-601-9070 T-adapter
799-601-9110 T-adapter
799-601-9120 T-adapter
799-601-9130 T-adapter
799-601-7000
or
799-601-7100
or
T-adapter assembly
799-601-7400
or
799-601-8000
799-601-7050 T-adapter
799-601-7110
799-601-9000
or
799-601-9100
799-601-9280
799-601-9290
799-601-9300
799-601-9350
D155AX-6
T-adapter
For SWP6P
(Does not include 799-601-8000)
1 For M3P
T-adapter assembly
T-adapter
T-adapter
T-adapter assembly
T-adapter
1 For HD30-23
1 For HD30-31
1
1 For DRC-401
Symbol
Troubleshooting for
chassis
Sensors/wiring harnesses
Part No.
Part name
Q'ty
SEN00679-05
Remarks
799-601-9360 T-adapter
799-601-7360 T-adapter
799-601-9890 Adapter for multiple
1 For DRC-24
1 For REL-5P
1 For DT2-4 and DTM2
Commercially
Torque wrench
available
1 27 mm deep socket
Commercially
Socket
available
795T-981-1010 Socket
Commercially
Measuring cylinder
available
1 99.9 1,299C
1 0 300 N {0 30 kg}
1 0 500 N {0 50 kg}
Commercially
Ruler
available
Commercially
Stopwatch
available
Commercially
Circuit tester
available
1
1
1
For the model names and part Nos. of the T-boxes and T-adapters used for troubleshooting for the
machine monitor, controllers, sensors, actuators, electrical equipment, and wiring harnesses, see Troubleshooting (Information related to troubleshooting), List of T-boxes and T-adapters.
: Socket
D155AX-6
1.
SEN00679-05
2)
D155AX-6
2.
3.
4.
5.
SEN00679-05
a
6.
7.
3)
4)
5)
6)
k
7)
8)
9)
D155AX-6
SEN00679-05
5.
6.
7.
After finishing measurement, remove the measuring instruments and return the removed parts.
Symbol
A
k
Part No.
799-201-2202
799-401-2220
Part name
Boost gauge kit
Hose
1.
2.
3.
4.
Install nipple [1] of boost gauge kit A and connect gauge [2].
D155AX-6
SEN00679-05
Symbol
Part No.
799-101-1502
Part name
Digital thermometer
1.
2.
3.
10
4.
5.
D155AX-6
2)
3)
4)
5)
6)
7)
SEN00679-05
8)
9)
6.
D155AX-6
Under the condition of step 7), stop relieving the ripper raise system and lower the
exhaust temperature by only stalling the
torque converter (Condition (b) in the figure).
a If the exhaust temperature does not
lower but rises, set the temperature
high in step 7).
After the exhaust temperature is lowered
and stabilized, measure the exhaust temperature (Condition (c) in the figure).
After finishing measurement, remove the measuring instruments and return the removed
parts.
11
SEN00679-05
Symbol
C
k
1.
Part No.
Part name
799-201-9001
Commercially
available
Smoke meter
2)
3)
4)
5)
6)
7)
5)
6)
2.
12
8)
9)
D155AX-6
SEN00679-05
Symbol
Part No.
Commercially
available
1.
Part name
Thickness gauge
2.
5.
6.
7.
3.
4.
D155AX-6
8.
9.
13
SEN00679-05
Measuring compression
pressure
a
1.
Part No.
Part name
795-502-1590
Compression gauge
795-471-1330
Adapter
6261-71-6150
Gasket
5.
6.
3.
Bring the cylinder to be tested to the compression top dead center and remove rocker arm
assembly (2).
a For the procedure for bringing each cylinder to the compression top dead center,
see Adjusting valve clearance.
4.
14
Disconnect the terminal of the injector wiring harness on the injector side and the
bracket on the rocker housing side and
remove the injector wiring harness
(Loosen the 2 terminal nuts alternately).
Pass a wire under the fuel path projected
sideways and pull up the injector (Do not
pry the injector top up).
2.
Symbol
E
D155AX-6
7.
SEN00679-05
a
a
1)
2)
3)
4)
5)
8.
a
1)
2)
3)
4)
a
9.
10. After finishing measurement, remove the measuring instruments and return the removed
parts.
D155AX-6
15
SEN00679-05
Part No.
799-201-1504
Part name
Blow-by checker
1.
2.
3.
16
Symbol
4.
After finishing measurement, remove the measuring instruments and return the removed
parts.
D155AX-6
SEN00679-05
1
2
4.
5.
After finishing measurement, remove the measuring instruments and return the removed
parts.
Symbol
G
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-401-2320
Hydraulic tester
1.
2.
3.
D155AX-6
17
SEN00679-05
G
k
Part No.
4.
5.
After finishing measurement , remove the measuring instruments and return the removed
parts.
q
Remove the gasket sealant remaining on
the threads of the removed plug with a wire
brush and apply new adhesive or gasket
sealant to the plug before installing.
2 Plug: LT2 or LG-5
3 Plug:
9.8 19.6 Nm {1.0 2.0 kgm}
Part name
799-101-5002
Hydraulic tester
790-261-1204
1.
2.
18
Connect hydraulic tester [2] and [3] (Component part of tool G1) to the nipple [1].
Symbol
3.
D155AX-6
SEN00679-05
D155AX-6
Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running.
Low-pressure circuit:
Feed pump Fuel filter Supply pump
High-pressure circuit:
Supply pump Common rail Injector
The pressure in both low-pressure circuit and
high-pressure circuit lowers to a safety level
automatically 30 seconds after the engine is
stopped.
Before the fuel circuit is tested and its parts are
removed, the residual pressure in the fuel circuit must be released completely. Accordingly,
observe the following.
Before testing the fuel system or removing
its parts, wait at for least 30 seconds after
stopping the engine until the residual pressure in the fuel circuit is released. (Do not
start the work just after stopping the engine
since there is residual pressure.)
19
SEN00679-05
1
2
3
k
a
k
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-401-2320
Hydraulic tester
795-471-1450
Adapter
07005-00812
Gasket
Fuel pressure
High idle
1.
2.
20
3.
Symbol
4.
After finishing measurement, remove the measuring instruments and return the removed
parts.
3 Plug: 7.84 9.8 Nm {0.8 1.0 kgm}
D155AX-6
SEN00679-05
Symbol
a
k
Part No.
Part name
6151-51-8490
Spacer
6206-71-1770
Joint
D155AX-6
21
SEN00679-05
1.
Preparation work
1) Open the engine left side cover and left
mudguard.
2) Remove tube (3) between supply pump
(1) and common rail (2).
a In the figure, 1 oil filter is removed
temporarily from the common rail
side.
a Disconnect both ends of the tube,
loosen the clamp, and move the tube
to the opposite side of the cylinder
block.
5)
2.
22
3)
4)
D155AX-6
3)
4)
3.
SEN00679-05
Leakage
(cc/min)
Torque converter
stall
Max. 10
2)
3)
D155AX-6
23
SEN00679-05
4)
5)
4.
24
1,600
960
1,700
1,020
1,800
1,080
1,900
1,140
2,000
1.200
D155AX-6
SEN00679-05
If fuel is used up or if a fuel circuit part is removed and installed, bleed air from the fuel circuit according to the following procedure.
1.
2.
D155AX-6
3.
25
SEN00679-05
7.
4.
5.
6.
26
D155AX-6
a
a
SEN00679-05
9.
Very high pressure is generated in the highpressure circuit of the fuel system. If fuel
leaks while the engine is running, it is dangerous since it can catch fire.
After testing the fuel system or removing and
installing its parts, test it for fuel leakage
according to the following procedure.
Clean and degrease the engine and the parts
around it in advance so that you can test it easily for fuel leakage.
1.
2.
3.
4.
5.
6.
7.
8.
D155AX-6
27
SEN00679-05
6.
7.
Testing
1. Open the engine right side cover and remove
the inspection plate on the right of the radiator
guard.
2.
Adjusting
a If the deflection is out of the standard range,
adjust it according to the following procedure.
1.
2.
3.
4.
5.
28
D155AX-6
SEN00679-05
a
Testing
1. Open the engine left side cover and left mudguard.
2.
5.
Adjusting
a If the deflection is out of the standard range,
adjust it according to the following procedure.
1.
2.
3.
4.
D155AX-6
29
SEN00679-05
Symbol
Part No.
799-205-1100
Part name
Tachometer kit
2.
3.
4.
5.
Hydraulic oil
temperature [C]
Engine speed
[rpm]
Standard value of
fan speed [rpm]
57 2 C
or
77 2 C
Low idle
500 50
High idle
(1675 25)
1250(+50/0)
1.
Take care that the probe will not interfere with the fan.
Rotate the fan with the hand and check
that the probe can sense the rotation of
the reflection tape.
30
For the operation method in the adjustment mode, see "Special functions of
machine monitor (EMMS)".
After finishing measurement, remove the measuring instruments and return the removed
parts.
D155AX-6
SEN00679-05
Symbol
1
L
2
3
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-401-3400
Adapter (05)
799-101-5220
07002-11023
O-ring
1.
2.
3.
4.
D155AX-6
5.
6.
31
SEN00679-05
7.
8.
32
1.
2.
3.
4.
After finishing measurement, remove the measuring instruments and return the removed
parts.
D155AX-6
SEN00679-05
1.
D155AX-6
33
SEN00679-05
2.
Preparation work
1) Remove the right cover of the dashboard
and the right foot rest as a unit.
2) Start the engine and set the machine monitor to Adjusting function of the service
mode.
q
Adjustment code:
0007 (Engine decelerator cut)
a For the operating method, see "Special functions of machine monitor
(EMMS)".
3.
4.
34
5.
D155AX-6
D155AX-6
SEN00679-05
35
SEN00679-05
D155AX-6 Bulldozer
Form No. SEN00679-05
2011 KOMATSU
All Rights Reserved
Printed in Japan 11-11
36
D155AX-6
SEN00680-02
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
D155AX-6
SEN00680-02
D155AX-6
SEN00680-02
Symbol
M
k
Part No.
1
2
3
4
5
6
7
8
9
10
Part name
799-101-5002
Hydraulic tester
790-261-1204
No. Stamp
11
Oil pressure to be
measured
pressure
Torque converter outlet
pressure
TM
D155AX-6
Oil pressure
gauge
(MPa {kg/cm})
6.0 {60}
2.5 {25}
6.0 {60}
6.0 {60}
6.0 {60}
6.0 {60}
6.0 {60}
6.0 {60}
6.0 {60}
6.0 {60}
Machine
monitor
Machine
monitor
SEN00680-02
1.
2)
3)
2.
2)
3)
4)
D155AX-6
SEN00680-02
3.
5)
6)
2)
3)
7)
D155AX-6
SEN00680-02
4.
2)
3)
4)
5)
6)
5.
2)
3)
4)
5)
D155AX-6
SEN00680-02
k
6)
6.
2)
3)
4)
5)
D155AX-6
6)
7.
2)
3)
4)
SEN00680-02
a
a
5)
4)
5)
6)
8.
2)
3)
6)
9.
2)
3)
SEN00680-02
2)
3)
4)
4)
D155AX-6
SEN00680-02
2)
3)
10
D155AX-6
1.
SEN00680-02
2.
3.
4.
D155AX-6
6.
5.
11
SEN00680-02
1.
2.
3.
Set the gearshift mode and preset range as follows with the gearshift mode selector switch
and shiftup or shiftdown switch.
q
Gearshift mode:
Manual gearshift (Ripping)
q
Preset range: F2-R2
4.
While pressing the brake pedal, set the direction of PCCS lever in the forward position.
k
a
a
5.
12
6.
D155AX-6
SEN00680-02
Symbol
N
k
a
a
1.
Part No.
Part name
D155AX-6
2)
3)
4)
13
SEN00680-02
2.
3.
4.
5.
14
D155AX-6
SEN00680-02
a
a
Oil pressure
FREE position
LOCK position
0 MPa {0 kg/cm}
Battery cover: 65 kg
1.
2.
D155AX-6
15
SEN00680-02
3.
2)
16
D155AX-6
SEN00680-02
Symbol
P
1
2
1.
Part No.
Part name
Pump assembly
2)
3)
D155AX-6
17
SEN00680-02
4)
5)
6)
2.
18
2)
3)
Remove the fuel tank undercover and disconnect supply hose (3) of the pin puller
solenoid valve.
4)
5)
D155AX-6
6)
7)
SEN00680-02
D155AX-6
19
SEN00680-02
1.
20
2.
D155AX-6
SEN00680-02
Testing
1. Drive the machine slowly on a level place, then
stop it.
a Do not apply the brake when stopping.
2.
4.
Adjusting
a If the track shoe tension is abnormal, adjust it
according to the following procedure.
1.
2.
3.
D155AX-6
21
SEN00680-02
Symbol
1
Q
2
k
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-101-5220
07002-11023
O-ring
3)
4)
Measuring
a Measure the work equipment and HSS oil
pressure under the following condition.
q
Hydraulic oil temperature: Within operating range
a The unload pressure, work equipment oil pressure, and HSS oil pressure can be checked
with the monitoring function of the service
mode of the machine monitor (See 4).
1.
2.
2)
22
Install nipple Q2 and connect it to oil pressure gauge [1] of hydraulic tester Q1.
a When using an analog oil pressure
gauge, use one of 6.0 MPa {60 kg/
cm}.
D155AX-6
2)
3)
Start the engine and set the work equipment lock lever in the FREE position.
Run the engine at high idle, operate the
blade control lever and ripper control lever
to relieve each cylinder at a stroke end,
and measure the work equipment relief
pressure and work equipment LS relief
pressure.
a The work equipment relief pressure is
measured on the P-stamp side and
the work equipment LS relief pressure is measured on the LS-stamp
side.
k Do not steer the machine with the
oil pressure gauge of 40 MPa {400
kg/cm} installed. If you do so, the
oil pressure gauge will be broken.
4)
5)
SEN00680-02
3.
2)
3)
D155AX-6
23
SEN00680-02
4.
2)
Adjusting
1. Adjusting unload pressure
a The unload pressure cannot be adjusted.
2.
1)
2)
3)
4)
24
D155AX-6
3.
SEN00680-02
1)
2)
3)
4)
D155AX-6
25
SEN00680-02
Symbol
R
1
2
1.
Part No.
Part name
799-101-5002
Hydraulic tester
709-261-1204
799-401-3200
Adapter (03)
The control circuit basic pressure is the pressure lowered by the self-pressure reducing
valve of the fan circuit. It is used commonly for
the EPC valves of the control valve (steering,
blade, and ripper), HSS circuit charge, fan
pump control, and blade lift cylinder quick drop
EPC valve.
Stop the machine on level ground, lower
the work equipment to the ground, stop the
engine, and set the parking brake lever and
work equipment lock lever in the LOCK
position.
Measure the control circuit basic pressure
under the following condition.
q
Hydraulic oil temperature: Within operating range
Run the engine at high idle, set the blade control lever and ripper control lever in neutral,
and measure the control circuit basic pressure.
a The work equipment lock lever may be set
in the LOCK position.
5.
After finishing measurement, remove the measuring instrument and return the removed
parts.
Remove the control valve cover and disconnect accumulator inlet hose (1).
4
2.
3.
Install nipple [1] of hydraulic tester R1 and connect it to oil pressure gauge [2].
a When using an analog oil pressure gauge,
use one of 6.0 MPa {60 kg/cm}.
26
4.
D155AX-6
SEN00680-02
Symbol
S
1
2
1.
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-401-3200
Adapter (03)
4.
Remove the control valve cover and disconnect control valve inlet hose (1).
4
2.
3.
Install nipple [1] of hydraulic tester S1 and connect it oil pressure gauge [2].
a When using an analog oil pressure gauge,
use one of 6.0 MPa {60 kg/cm}.
D155AX-6
5.
Run the engine at high idle, set the work equipment lock lever in the LOCK position and
FREE position, and measure the solenoid
valve output.
a If the output pressure is as follows, the
operation of the work equipment lock solenoid valve is normal.
Work equipment
lock lever
Output pressure
LOCK position
0 MPa {0 kg/cm}
FREE position
After finishing measurement, remove the measuring instrument and return the removed
parts.
27
SEN00680-02
Symbol
T
a
k
1.
2.
Part No.
Disconnect connector WLK of the work equipment lock solenoid valve and connect it to the
male side of wiring harness T.
Part name
If the blade or ripper cannot be moved because of a trouble in the work equipment control s ystem, oper ate it ac cording to the
following procedure.
The engine must be startable for the following
procedure.
Do not turn the starting switch ON or start
the engine before preparing wiring harness
T completely.
Install wiring harness T in the operator's cab
and check where to connect each connector.
q
WLK: To work equipment lock solenoid
under floor
q
WEPW: To power supply connector
above control valve
q
WEPX: To EPC solenoid above control
valve
q
WEPY: To EPC solenoid above control
valve
4.
Connector on wiring
harness T side
WLK (male)
WLK
5.
28
3.
Floor cover: 20 kg
Connector to be connected
Connector on machine
side
Connector on wiring
harness T side
WEPW (female)
WEPW
D155AX-6
6.
SEN00680-02
7.
k
k
8.
Start the engine and operate switch [1] of wiring harness T to move the work equipment.
Before starting the engine, check that
the switch is in neutral.
Since the work equipment cannot be
controlled finely with the switch, keep
the engine speed as low as possible.
After finishing operation of the work equipment, remove the tools used and return the
removed parts.
Connectors to be connected (The following table is for the dual tilt specification.
WEP5 and WEP6 are not connected to
the single tilt specification.)
Connectors on machine side
Device/Operating direction
Blade lift
Blade tilt left
Blade tilt right
Ripper lift
Ripper tilt
No.
Band color
Raise
WEP1
Green
Lower
WEP2
Green/Black
Retract
WEP3
Brown
Extend
WEP4
Brown/Black
Retract
WEP5
Blue
Extend
WEP6
Blue/Black
Raise
WEP7
Yellow
Lower
WEP8
Yellow/Black
In
WEP9
Red
Back
WEPA
Red/Black
D155AX-6
No.
Band color
UP
WEPX
DOWN
WEPY
29
SEN00680-02
Symbol
U
1
2
1.
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-401-3200
Adapter (03)
4.
(1)
(2)
2.
3.
Install nipple [1] of hydraulic tester U1 and connect oil pressure gauge [2].
a When using an analog oil pressure gauge,
use one of 6.0 MPa {60 kg/cm}.
30
5.
Output pressure
Pull-out
Same as transmission
main relief pressure
(See standard value table)
Push-in
0 MPa {0 kg/cm}
Pull-out
0 MPa {0 kg/cm}
Push-in
Same as transmission
main relief pressure
(See standard value table)
After finishing measurement, remove the measuring instrument and return the removed
parts.
D155AX-6
SEN00680-02
1.
2)
3)
D155AX-6
2.
3.
Extend the cylinder to be tested with the corresponding lever and check its movement.
q
If the lowering speed is increased, the cylinder packing is defective.
q
If the lowering speed does not change, the
control valve is defective.
a If the pressure in the accumulator is lost,
run the engine for about 10 seconds to
heighten the pressure in the accumulator.
[Reference]
Reason why the lowering speed is increased when
the cylinder packing is the cause of the hydraulic
drift:
1. If the machine is set in the above position
(where the holding pressure is applied to the
bottom side), the oil leaks from the bottom side
to the head side. Since the volume on the
head side is less than that on the bottom side
by the volume of the rod, the pressure in the
head side is increased by the oil flowing in
from the bottom side.
2. As the pressure in the head side is increased,
it is balanced at a certain level (which depends
on the leakage), then the lowering speed is
lowered.
3. If the circuit on the head side is opened to the
drain circuit by the above operation of the lever
(the bottom side is closed by the check valve
at this time), the oil on the head side flows in
the drain circuit. As a result, the pressure is
unbalanced and the lowering speed is
increased.
31
SEN00680-02
Symbol
Part No.
Commercially
available
a
a
1.
2.
32
Part name
Measuring cylinder
3.
4.
5.
D155AX-6
SEN00680-02
1.
a
1.
2.
3.
4.
2.
3.
4.
Run the engine at low idle for about 10 seconds to increase the pressure in the accumulator, then stop it.
5.
D155AX-6
33
SEN00680-02
a
a
a
a
1.
2.
3.
4.
34
5.
Check that the limit switch signal is input normally when work equipment lock lever (1) is
set in the FREE position and LOCK position.
q
FREE position:
Work equipment lock NC OFF, Work
equipment lock NO ON
q
LOCK position:
Work equipment lock NC ON, Work equipment lock NO OFF
D155AX-6
SEN00680-02
Adjusting blade
a
a
1.
If the blade is removed and installed or disassembled and reassemble, adjust it according
to the following procedure.
The above figure shows the blade of the dual
tilt specification.
Adjusting shims for assembly
1) Adjust the shim of tilting section (1) (1
place).
a After reassembling the tilting section,
supply grease to it.
2 Tilting section: Grease (G2-LI)
Adjusted
point
Adjusted
clearance
Standard
clearance
Standard shim
thickness
See note.
4 mm
D155AX-6
35
SEN00680-02
2)
Adjusted
point
Adjusted
clearance
Standard
clearance
Standard shim
thickness
See note.
4 mm
3)
Dimension
d
2)
Adjust the shim so that the play of the
ball in the axial direction will be less
than 1 mm and the ball can rotate
smoothly.
Dimension
blade
1,292 mm
Semi-U blade
Full-U blade
1,372 mm
1,372 mm
Semi-U blade
Full-U blade
e1
565 mm
570 mm
583 mm
e2
565 mm
570 mm
583 mm
Adjusted
point
Adjusted
clearance
Standard
clearance
Standard shim
thickness
Max. 1 mm
4 mm
36
2.
3)
D155AX-6
SEN00680-02
1.
4)
5)
6)
D155AX-6
2.
7)
Start the engine and set the machine monitor to Adjusting function of the service
mode.
a Adjustment code:
1005 (Fan 100% mode)
a For the operating method, see Special functions of machine monitor
(EMMS).
8)
37
SEN00680-02
4)
4)
5)
3.
4.
2)
3)
4)
38
D155AX-6
5)
6)
SEN00680-02
2)
3)
4)
5)
5.
D155AX-6
39
SEN00680-02
6.
4)
5)
6)
40
D155AX-6
D155AX-6
SEN00680-02
41
SEN00680-02
D155AX-6 Bulldozer
Form No. SEN00680-02
2009 KOMATSU
All Rights Reserved
Printed in Japan 06-09
42
D155AX-6
SEN00681-04
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
D155AX-6
SEN00681-04
D155AX-6
Heater specification
SEN00681-04
D155AX-6
SEN00681-04
Page
Service mode
5p
5p
16 p
01 Monitoring
17 p
Mechanical system "Abnormality
Record"
6p
6p
6p
6p
03 Maintenance Record
36 p
7p
37 p
7p
39 p
7p
Key-on Mode
40 p
7p
Setting of unit
41 p
8p
o 06 Default
42 p
B Customizing operation
8p
Setting of camera
43 p
8p
44 p
8p
8p
9p
9p
Special operations
Page
10 p
10 p
Terminal Status
75 p
11 p
11 p
76 p
12 p
13 Service Message
78 p
12 p
24 p
25 p
07 Adjustment
45 p
08 PM CLINIC
71 p
09 Cylinder Cut-Out
72 p
10 No Injection
73 p
11 Fuel Consumption
74 p
77 p
O (Special operations)
Function of checking display of LCD
D
(Liquid Crystal Display)
14 p
14 p
15 p
D155AX-6
SEN00681-04
Display pattern
a
D155AX-6
SEN00681-04
D155AX-6
D155AX-6
SEN00681-04
SEN00681-04
Customizing operation
While the ordinary screen is displayed, press the
customize switch, and you can change the setting
of the machine.
a If the customize memory switch is operated
while the above screen is displayed, up to 5
settings can be saved.
D155AX-6
SEN00681-04
Heater specification
D155AX-6
SEN00681-04
a
a
a
a
10
Display of clock
D155AX-6
SEN00681-04
To reset the time left after finishing maintenance, more operations are necessary.
[KOMTRAX message]
q
There are 2 types of KOMTRAX message; one
is for the user and the other is for the service.
q
For user:
A message transmitted from the KOMTRAX
base station for the user. If it is received, the
message monitor is displayed on the ordinary
screen. To see the contents of the message,
operate "Message display" in the above user
menu.
D155AX-6
11
SEN00681-04
For service:
A message transmitted from the KOMTRAX
base station for the service. Even if it is
received, nothing is displayed on the ordinary
screen. To see the contents of the message,
operate "KOMTRAX message display" in the
service menu.
12
D155AX-6
SEN00681-04
Remedies given by displayed action codes to operator to take (The following table is an excerpt from the
Operation and Maintenance Manual)
Action
code
Examples of trouble
E01
Action code and failure code are Backup alarm does not sound.
displayed.
Fan speed is kept at maximum.
E02
E03
E04
D155AX-6
13
SEN00681-04
14
D155AX-6
SEN00681-04
1.
2.
3.
4.
5.
D155AX-6
15
SEN00681-04
t Service mode
To change the operator mode to the service mode,
perform the following operation.
This operation is always required when you use the
service mode.
1.
01 Monitoring
Mechanical system "Abnormality
Record"
02 Abnormality
Record
03 Maintenance Record
04 Maintenance Mode Change
05 Phone Number Entry
Key-OFF Mode
Setting of unit
06 Default
07 Adjustment
08 PM CLINIC
09 Cylinder Cut-Out
10 No Injection
11 Fuel Consumption
Terminal Status
12 KOMTRAX
Settings
2.
16
13 Service Message
Items with 2-digit codes are the menus displayed on the Service menu screen. The items
on their right are the menus on the next hierarchy.
D155AX-6
SEN00681-04
Monitoring
The machine monitor can monitor the condition of
the machine in real time by receiving signals from
various switches, sensors, and actuators installed
to many parts of the machine and the information
from the controllers which are controlling switches,
etc.
1.
Selecting menu
Select "01 Monitoring" on the "Service Menu"
screen.
3.
2.
D155AX-6
17
SEN00681-04
4.
Executing monitoring
After the "Monitoring" screen is displayed, perform the necessary operation of the machine
and check the monitoring information.
a Monitoring information is indicated by
value, ON/OFF, or special display.
a The unit of display can be set to SI unit,
metric unit, or inch unit with the Default
function in the service mode.
5.
18
6.
D155AX-6
SEN00681-04
Monitoring item
(Display on screen)
meter
inch
Component
in charge
mV
mV
mV
P/T
mV
mV
mV
P/T
mV
mV
mV
P/T
mA
mA
mA
P/T
mA
mA
mA
P/T
mA
mA
mA
P/T
mA
mA
mA
P/T
mA
mA
mA
P/T
mA
mA
mA
P/T
mA
mA
mA
P/T
P/T
mV
mV
mV
P/T
mV
mV
mV
P/T
mV
mV
mV
P/T
P/T
mV
mV
mV
P/T
ON OFF
P/T
ON OFF
P/T
ON OFF
P/T
ON OFF
P/T
Remarks
mV
mV
mV
P/T
mV
mV
mV
P/T
mA
mA
mA
P/T
mA
mA
mA
P/T
mA
mA
mA
P/T
mA
mA
mA
P/T
mA
mA
mA
P/T
P/T
r/min
rpm
rpm
P/T
MPa
kg/cm
psi
P/T
mV
mV
mV
P/T
MPa
kg/cm
psi
P/T
mV
mV
mV
P/T
mA
mA
mA
P/T
mA
mA
mA
P/T
mV
mV
mV
P/T
km/h
km/h
MP/h
P/T
P/T
D155AX-6
19
SEN00681-04
Monitoring item
(Display on screen)
meter
inch
Component
in charge
mV
mV
mV
P/T
mV
mV
mV
P/T
mA
mA
mA
P/T
r/min
rpm
rpm
P/T
Code
No.
T/M Fill Sw
40906
Input 1
31520
T/M Fill Sw
Input 2
ON OFF
P/T
ON OFF
P/T
SDNC
(Gear shift down sw)
ON OFF
P/T
SDNO
(Gear shift down sw)
ON OFF
P/T
PNC
(Parking brake lever sw)
ON OFF
P/T
PNO
(Parking brake lever sw)
ON OFF
P/T
ON OFF
P/T
ON OFF
P/T
ON OFF
P/T
ON OFF
P/T
ON OFF
P/T
ON OFF
P/T
ON OFF
P/T
ON OFF
P/T
ON OFF
P/T
Fres
(Fan reverse solenoid)
ON OFF
P/T
MPa
kg/cm
psi
W/E
mV
mV
mV
W/E
mA
mA
mA
W/E
mA
mA
mA
W/E
mA
mA
mA
W/E
mA
mA
mA
W/E
mA
mA
mA
W/E
mA
mA
mA
W/E
mA
mA
mA
W/E
mA
mA
mA
W/E
mA
mA
mA
W/E
mA
mA
mA
W/E
mV
mV
mV
W/E
mV
mV
mV
W/E
mV
mV
mV
W/E
20
Remarks
D155AX-6
Monitoring item
(Display on screen)
SEN00681-04
meter
inch
Component
in charge
mV
mV
mV
W/E
mV
mV
mV
W/E
mV
mV
mV
W/E
mV
mV
mV
W/E
mV
mV
mV
W/E
mA
mA
mA
W/E
mA
mA
mA
W/E
Code
No.
ON OFF
W/E
ON OFF
W/E
ON OFF
W/E
ON OFF
W/E
WLNC
(Work equipment lock sw)
ON OFF
W/E
WLNO
(Work equipment lock sw)
ON OFF
W/E
MON
MON
MON
P/T
P/T
P/T
W/E
W/E
W/E
MON
MON
MON
MON
ENG
kPa
kg/cm
psi
ENG
00201 Machine ID
ENG
ENG
ENG
ENG
r/min
rpm
rpm
ENG
ENG
ENG
mV
mV
mV
ENG
D155AX-6
Remarks
ENG
21
SEN00681-04
Monitoring item
(Display on screen)
meter
inch
Component
in charge
MPa
kg/cm
psi
ENG
ENG
MPa
kg/cm
psi
ENG
CA
CA
CA
ENG
ENG
ENG
kPa
kg/cm
psi
ENG
ENG
kPa
kg/cm
psi
ENG
ENG
ENG
l/h
l/h
gal/h
ENG
ENG
ENG
ENG
mg/st
mg/st
mg/st
ENG
CA
CA
CA
ENG
Nm
kgm
lhft
ENG
ENG
ENG
ENG
kPa
kg/cm
psi
ENG
mV
mV
mV
ENG
mm
mm
inch
ENG
mV
mV
mV
ENG
mm
mm
inch
ENG
mV
mV
mV
ENG
Code
No.
a
a
22
R-sig
ON OFF
P/T
Acc
ON OFF
P/T
Eng S
ON OFF
P/T
Eng L
ON OFF
P/T
Eng Sd
ON OFF
P/T
Remarks
D155AX-6
MON
ENG
P/T
W/E
D155AX-6
SEN00681-04
23
SEN00681-04
Selecting menu
Select "02 Abnormality Record" on the "Service Menu" screen.
2.
24
3.
4.
D155AX-6
Selecting menu
Select "02 Abnormality Record" on the "Service Menu" screen.
2.
D155AX-6
SEN00681-04
3.
4.
25
SEN00681-04
2)
3)
26
4)
If the screen to notify completion of deletion is displayed and then the "Electrical
Sys. Error Reset" (delete mode) screen is
displayed, the deletion of the "Abnormality
Record" is completed.
a After a while, the screen returns to
the "Electrical Sys. Error Reset"
screen.
D155AX-6
SEN00681-04
Failure
code
Component
in charge
Category of history
E03
1500L0
P/T
Electrical system
E03
15SAL1
P/T
Electrical system
E03
15SALH
P/T
Electrical system
E03
15SBL1
P/T
Electrical system
E03
15SBLH
P/T
Electrical system
E03
15SEL1
P/T
Electrical system
E03
15SELH
P/T
Electrical system
E03
15SFL1
P/T
Electrical system
E03
15SFLH
P/T
Electrical system
E03
15SGL1
P/T
Electrical system
E03
15SGLH
P/T
Electrical system
E02
15SJL1
P/T
Electrical system
E02
15SJLH
P/T
Electrical system
E04
2301L1
P/T
Electrical system
E04
2301LH
P/T
Electrical system
E04
2302L1
P/T
Electrical system
E04
2302LH
P/T
Electrical system
7RFAKA
P/T
Electrical system
AA10NX
MON
Mechanical system
AB00MA
MON
Mechanical system
B@BAZG
ENG
Mechanical system
B@BCNS
ENG
Mechanical system
B@BCZK
MON
Mechanical system
B@CENS
P/T
Mechanical system
B@HANS
MON
Mechanical system
E04
CA111
ENG
Electrical system
E04
CA115
ENG
Electrical system
E03
CA122
ENG
Electrical system
E03
CA123
ENG
Electrical system
E03
CA131
ENG
Electrical system
E03
CA132
ENG
Electrical system
E02
CA135
ENG
Electrical system
E02
CA141
ENG
Electrical system
E02
CA144
ENG
Electrical system
E02
CA145
ENG
Electrical system
E01
CA153
ENG
Electrical system
D155AX-6
27
SEN00681-04
Action
code
Failure
code
E01
CA154
E03
Component
in charge
Category of history
ENG
Electrical system
CA187
ENG
Electrical system
E03
CA221
ENG
Electrical system
E03
CA222
ENG
Electrical system
E03
CA227
ENG
Electrical system
E03
CA234
Eng Overspeed
ENG
Electrical system
E03
CA238
ENG
Electrical system
E01
CA263
ENG
Electrical system
E01
CA265
ENG
Electrical system
E03
CA271
ENG
Electrical system
E03
CA272
ENG
Electrical system
E03
CA273
ENG
Electrical system
E03
CA274
ENG
Electrical system
E03
CA322
ENG
Electrical system
E03
CA323
ENG
Electrical system
E03
CA324
ENG
Electrical system
E03
CA325
ENG
Electrical system
E03
CA331
ENG
Electrical system
E03
CA332
ENG
Electrical system
E04
CA342
ENG
Electrical system
E03
CA351
ENG
Electrical system
E03
CA352
ENG
Electrical system
E03
CA386
ENG
Electrical system
E04
CA441
ENG
Electrical system
E04
CA442
ENG
Electrical system
E03
CA449
ENG
Electrical system
E03
CA451
ENG
Electrical system
E03
CA452
ENG
Electrical system
E02
CA553
ENG
Electrical system
E03
CA554
ENG
Electrical system
E02
CA559
ENG
Electrical system
E03
CA689
ENG
Electrical system
E03
CA731
ENG
Electrical system
E04
CA757
ENG
Electrical system
E03
CA778
ENG
Electrical system
E02
CA1228
ENG
Electrical system
E03
CA1625
ENG
Electrical system
28
D155AX-6
Action
code
Failure
code
E03
CA1626
E03
SEN00681-04
Component
in charge
Category of history
ENG
Electrical system
CA1627
ENG
Electrical system
E02
CA1628
ENG
Electrical system
E03
CA1629
ENG
Electrical system
E03
CA1631
ENG
Electrical system
E03
CA1632
ENG
Electrical system
E03
CA1633
ENG
Electrical system
E01
CA1642
ENG
Electrical system
E01
CA1653
ENG
Electrical system
E03
CA2185
ENG
Electrical system
E03
CA2186
ENG
Electrical system
E03
CA2249
ENG
Electrical system
E03
CA2271
ENG
Electrical system
E03
C2272
ENG
Electrical system
E03
CA2351
ENG
Electrical system
E03
CA2352
ENG
Electrical system
E01
CA2555
ENG
Electrical system
E01
CA2256
ENG
Electrical system
D110KA
P/T
Electrical system
D110KB
P/T
Electrical system
E02
D130KA
P/T
Electrical system
E02
D130KB
P/T
Electrical system
E01
D161KA
P/T
Electrical system
E01
D161KB
P/T
Electrical system
D190KA
P/T
Electrical system
D190KB
P/T
Electrical system
E03
D5ZKKX
P/T
Electrical system
E03
DAFRKR
CAN Disconnection
MON
Electrical system
E03
DB2RKR
CAN Disconnection
ENG
Electrical system
E04
DB90KK
W/E
Electrical system
E03
DB90KR
P/T
Electrical system
E01
DB90KT
W/E
Electrical system
E03
DB95KK
W/E
Electrical system
E03
DB97KK
W/E
Electrical system
E04
DB99KQ
W/E
Electrical system
E03
DB9RKR
W/E
Electrical system
E03
DBE0KK
P/T
Electrical system
D155AX-6
29
SEN00681-04
Action
code
Failure
code
E01
DBE0KT
E02
Component
in charge
Category of history
P/T
Electrical system
DBE6KK
P/T
Electrical system
E02
DBE7KK
P/T
Electrical system
E04
DBE9KQ
P/T
Electrical system
E02
DD12KA
P/T
Electrical system
E02
D12KB
P/T
Electrical system
E02
D13KA
P/T
Electrical system
E02
DD13KB
P/T
Electrical system
E03
DD14KA
P/T
Electrical system
E03
DD14KB
P/T
Electrical system
E02
DDDDKA
P/T
Electrical system
E02
DDDDKB
P/T
Electrical system
E02
DDDDKX
P/T
Electrical system
E02
DDN7KA
W/E
Electrical system
E02
DDN7KB
W/E
Electrical system
E01
DDN9KA
W/E
Electrical system
E01
DDN9KB
W/E
Electrical system
E03
DDNLKA
W/E
Electrical system
E03
DDNLKB
W/E
Electrical system
E02
DDTSL1
P/T
Electrical system
E02
DDTSLH
W/E
Electrical system
E03
DFA4KX
W/E
Electrical system
E03
DFA4KZ
W/E
Electrical system
E03
DFA4L8
W/E
Electrical system
E03
DFA5KA
BL lever 1: Disconnection
W/E
Electrical system
E03
DFA5KB
W/E
Electrical system
E03
DFA6KA
BL lever 2: Disconnection
W/E
Electrical system
E03
DFA6KB
W/E
Electrical system
E03
DFA7KX
W/E
Electrical system
E03
DFA7KZ
W/E
Electrical system
E03
DFA7L8
W/E
Electrical system
E03
DFA8KA
BT lever 1: Disconnection
W/E
Electrical system
E03
DFA8KB
W/E
Electrical system
E03
DFA9KA
BT lever 2: Disconnection
W/E
Electrical system
E03
DFA9KB
W/E
Electrical system
E03
DFAAKX
W/E
Electrical system
E03
DFAAKZ
W/E
Electrical system
30
D155AX-6
Action
code
Failure
code
E03
DFAAL8
E03
SEN00681-04
Component
in charge
Category of history
W/E
Electrical system
DFABKA
RL lever 1: Disconnection
W/E
Electrical system
E03
DFABKB
W/E
Electrical system
E03
DFACKA
RL lever 2: Disconnection
W/E
Electrical system
E03
DFACKB
W/E
Electrical system
E03
DFADKX
W/E
Electrical system
E03
DFADKZ
W/E
Electrical system
E03
DFADL8
W/E
Electrical system
E03
DFAEKA
RT lever 1: Disconnection
W/E
Electrical system
E03
DFAEKB
W/E
Electrical system
E03
DFAFKA
RT lever 2: Disconnection
W/E
Electrical system
E03
DFAFKB
W/E
Electrical system
E01
DGT1KA
P/T
Electrical system
E01
DGT1KX
P/T
Electrical system
DH21KA
W/E
Electrical system
DH21KB
W/E
Electrical system
E02
DHT5KA
P/T
Electrical system
E02
DHT5KB
P/T
Electrical system
E02
DHT7KA
P/T
Electrical system
E02
DHT7KB
P/T
Electrical system
E03
DK10KX
P/T
Electrical system
E03
DK30KA
ST lever 1: Disconnection
P/T
Electrical system
E03
DK30KB
P/T
Electrical system
E04
DK30KX
P/T
Electrical system
E04
DK30KZ
P/T
Electrical system
E03
DK30L8
P/T
Electrical system
E03
DK31KA
ST lever 2: Disconnection
P/T
Electrical system
E03
DK31KB
P/T
Electrical system
E03
DK40KA
P/T
Electrical system
E03
DK40KB
P/T
Electrical system
E04
DK55KX
P/T
Electrical system
E04
DK55KZ
P/T
Electrical system
E03
DK55L8
P/T
Electrical system
E03
DK56KA
FR lever 1: Disconnection
P/T
Electrical system
E03
DK56KB
P/T
Electrical system
E03
DK57KA
FR lever 2: Disconnection
P/T
Electrical system
E03
DK57KB
P/T
Electrical system
D155AX-6
31
SEN00681-04
Action
code
Failure
code
E03
DKH1KA
E03
Component
in charge
Category of history
P/T
Electrical system
DKH1KB
P/T
Electrical system
E01
DLT3KA
P/T
Electrical system
E01
DLT3KB
P/T
Electrical system
E01
DW7BKA
P/T
Electrical system
E01
DW7BKB
P/T
Electrical system
E03
DWN1KA
P/T
Electrical system
E03
DWN1KB
P/T
Electrical system
E03
DWN1KY
P/T
Electrical system
E03
DWN2KA
P/T
Electrical system
E03
DWN2KB
P/T
Electrical system
E03
DWN2KY
P/T
Electrical system
E04
DWN3KA
P/T
Electrical system
E04
DWN3KB
P/T
Electrical system
E04
DWN3KY
P/T
Electrical system
E01
DWN5KA
P/T
Electrical system
E01
DWN5KB
W/E
Electrical system
E01
DXA0KA
W/E
Electrical system
E01
DXA0KB
W/E
Electrical system
E01
DXA0KY
P/T
Electrical system
E02
DXH1KA
P/T
Electrical system
E02
DXH1KB
P/T
Electrical system
E03
DXH1KY
P/T
Electrical system
E03
DXH4KA
P/T
Electrical system
E03
DXH4KB
P/T
Electrical system
E03
DXH4KY
P/T
Electrical system
E03
DXH5KA
P/T
Electrical system
E03
DXH5KB
P/T
Electrical system
E03
DXH5KY
P/T
Electrical system
E03
DXH6KA
P/T
Electrical system
E03
DXH6KB
P/T
Electrical system
E03
DXH6KY
P/T
Electrical system
E03
DXH7KA
P/T
Electrical system
E03
DXH7KB
P/T
Electrical system
E04
DXH7KY
P/T
Electrical system
E03
DXH8KA
P/T
Electrical system
E03
DXH8KB
P/T
Electrical system
32
D155AX-6
Action
code
Failure
code
E04
DXH8KY
E04
SEN00681-04
Component
in charge
Category of history
P/T
Electrical system
DXHBKA
P/T
Electrical system
E04
DXHBKB
P/T
Electrical system
E04
DXHBKY
P/T
Electrical system
E04
DXHCKA
P/T
Electrical system
E04
DXHCKB
P/T
Electrical system
E04
DXHCKY
P/T
Electrical system
E03
DXHRKA
W/E
Electrical system
E03
DXHRKB
W/E
Electrical system
E03
DXHRKY
W/E
Electrical system
E03
DXHSKA
W/E
Electrical system
E03
DXHSKB
W/E
Electrical system
E03
DXHSKY
W/E
Electrical system
E03
DXHTKA
W/E
Electrical system
E03
DXHTKB
W/E
Electrical system
E03
DXHTKY
W/E
Electrical system
E03
DXHUKA
W/E
Electrical system
E03
DXHUKB
W/E
Electrical system
E03
DXHUKY
W/E
Electrical system
E03
DXHWKA
W/E
Electrical system
E03
DXHWKB
W/E
Electrical system
E03
DXHWKY
W/E
Electrical system
E03
DXHXKA
W/E
Electrical system
E03
DXHXKB
W/E
Electrical system
E03
DXHXKY
W/E
Electrical system
E03
DXHYKA
W/E
Electrical system
E03
DXHYKB
W/E
Electrical system
E03
DXHYKY
W/E
Electrical system
E03
DXHZKA
W/E
Electrical system
E03
DXHZKB
W/E
Electrical system
E03
DXHZKY
W/E
Electrical system
E03
DXJ4KA
W/E
Electrical system
E03
DXJ4KB
W/E
Electrical system
E03
DXJ8KA
W/E
Electrical system
E03
DXJ8KB
W/E
Electrical system
E03
DXJ8KY
W/E
Electrical system
E03
DXJ9KA
W/E
Electrical system
D155AX-6
33
SEN00681-04
Action
code
Failure
code
E03
DXJ9KB
E03
Component
in charge
Category of history
W/E
Electrical system
DXJ9KY
W/E
Electrical system
E01
DXJAKA
W/E
Electrical system
E01
DXJAKB
W/E
Electrical system
E01
DXJAKY
W/E
Electrical system
E02
DXJBKA
P/T
Electrical system
E02
DXJBKB
P/T
Electrical system
E02
DXJBKY
P/T
Electrical system
a
a
34
D155AX-6
Selecting menu
Select "02 Abnormality Record" on the Service
menu screen.
2.
D155AX-6
SEN00681-04
3.
4.
Heater specification
In the heater specification, the display of "Air
conditioner" is replaced with "Heater" and the
items which are not related to the heater are
not displayed.
35
SEN00681-04
Maintenance Record
The machine monitor records the maintenance
information of the filters, oils, etc., which the operator can display and check by the following operations. When maintenance is carried out, if the data
are reset in the operator mode, the number of the
times of maintenance is recorded in this section.
1.
Selecting menu
Select "03 Maintenance Record" on the "Service Menu" screen.
3.
2.
36
D155AX-6
SEN00681-04
1.
Selecting menu
Select "04 Maintenance Mode Change" on the
Service menu screen.
3.
2.
D155AX-6
37
SEN00681-04
4.
q
q
q
q
q
38
5.
q
q
If this operation is executed, the set values of all the maintenance items are set to
default values.
[F5]: Return to Maintenance Mode Change
screen
[F6]: Execute default setting
A while after [F6] is pressed, the default
setting completion screen is displayed.
Then, if the "Maintenance Mode Change"
screen is displayed, default setting is completed.
The default setting of the corrosion resistor is "OFF".
D155AX-6
Selecting menu
Select "05 Phone Number Entry" on the "Service Menu" screen.
2.
a
a
SEN00681-04
a
D155AX-6
39
SEN00681-04
Selecting menu
Select "06 Default" on the "Service Menu"
screen.
2.
40
3.
Selecting mode
After the "Key-on Mode" screen is displayed,
select the mode to be set with the function
switches.
q
Mode at previous key-OFF: Final mode in
previous operation is displayed when
starting switch is turned ON
q
Default Value (ALL OFF): Default setting
of all mode items (Power: E, other 3 items:
OFF) is displayed when starting switch is
turned ON
q
[F3]: Move to lower item
q
[F4]: Move to upper item
q
[F5]: Cancel selection and return to
default screen
q
[F6]: Confirm selection and return to
default screen
a When the machine is delivered, Default
Value (All OFF).
D155AX-6
SEN00681-04
Selecting menu
Select "06 Default" on the "Service Menu"
screen.
2.
3.
Selecting unit
After the "Unit" screen is displayed, select the
unit to be set with the function switches.
q
[F3]: Move to lower unit
q
[F4]: Move to upper unit
q
[F5]: Cancel selection and return to default
screen
q
[F6]: Confirm selection and return to default
screen
a When the machine is delivered, the SI unit
system is set.
D155AX-6
41
SEN00681-04
Selecting menu
Select "06 Default" on the "Service Menu"
screen.
2.
3.
Selecting Enable/Disable
After the "Maintenance Password" screen is
displayed, select the setting with the function
switches.
q
Disable: Password screen is not displayed
q
Enable: Password screen is displayed
q
[F3]: Move to lower item
q
[F4]: Move to upper item
q
[F5]: Cancel selection and return to Initialization screen
42
4.
5.
D155AX-6
SEN00681-04
q
q
q
q
Selecting menu
Select "06 Default" on the "Service Menu"
screen.
a
a
a
a
2.
3.
D155AX-6
43
SEN00681-04
If ECO display is turned ON, ECO is displayed when the screen changes to the
ordinary screen.
Selecting menu
Select "06 Default" on the "Service Menu"
screen.
2.
3.
44
D155AX-6
SEN00681-04
Adjustment
The operator can adjust various items related to the
machine with the machine monitor.
When using an adjustment item, select it according
to the following procedure.
1.
Selecting menu
Select "07 Adjustment" on the "Service Menu"
screen.
3.
2.
D155AX-6
45
SEN00681-04
46
Adjustment item
Remarks
0002
0004
0005
0007
0009
0010
0031
0530
Stall mode
0910
1005
1012
1013
1014
1015
1016
2021
2022
2222
6001
6002
6003
7842
7843
7845
8000
8001
8002
8003
8004
8005
8006
8007
8008
8009
8010
8011
8020
8021
8022
8023
Blade lowering current correction (Fine control mode) Fine adjustment with blade fine control mode ON
8024
8025
9995
9996
9997
9998
D155AX-6
SEN00681-04
Operating method:
1) Press [F6] and check that the alarm
buzzer sounds.
2) Check that the displayed specification
code [CODE] has changed from [5x5] to
[555].
a If specification code [555] is not displayed,
the controller wiring harness or the controller unit may be defective.
a Even if this adjustment code is turned off,
the setting is effective.
Operating method:
1) Press [F3] or [F4] to select the specification value [CODE] of the work equipment
concerned.
CODE
2)
k
D155AX-6
Dual tiltdozer
Single tiltdozer
Mechanical dozer
47
SEN00681-04
48
a
a
This adjustment code is used to stop the autodeceleration function of the engine and check
the high idle speed of the engine unit.
The engine can be driven and tested with the
auto-deceleration reset only while this adjustment code is selected.
Use this adjustment code for testing, adjusting,
or troubleshooting when necessary.
Operating method:
When this adjustment code is displayed, its
function is effective and the auto-deceleration
function is stopped.
a After this adjustment code is turned OFF,
its function is ineffective.
D155AX-6
D155AX-6
SEN00681-04
Operating method:
When this adjustment code is displayed, its
function is effective and the cooling fan speed
is controlled to about 70% of the maximum
speed.
a After this adjustment code is turned OFF,
its function is ineffective.
49
SEN00681-04
Operating method:
When this adjustment code is displayed, its
function is effective and the preset (gear speed
at start) is set to [F3-R3].
k
50
D155AX-6
D155AX-6
SEN00681-04
Operating method:
a When this adjustment code is displayed,
its function is effective and the cooling fan
speed is controlled to about 100% of the
maximum speed.
1) Increase or decrease the adjustment
value by pressing [F3] or [F4].
2) When confirming the adjustment value,
press [F6] and check that the alarm
buzzer sounds.
a After this adjustment code is turned OFF,
its function is ineffective but the set adjustment value is effective.
51
SEN00681-04
Operating method:
1) Check that the PCCS lever is in the neutral position of the steering direction and
keep it in that position.
2) Press [F6] and check that the alarm
buzzer sounds.
a Even if the adjustment is carried out, the
displayed value does not change.
a Even if this adjustment code is turned off,
the adjustment is effective.
a This adjustment code is used to make the
controller recognize the neutral position of
the potentiometer. It is not used to adjust
the steering force.
Operating method:
1) Operate the PCCS lever to the left stroke
end of the steering direction and keep it in
that position.
2) Press [F6] and check that the alarm
buzzer sounds.
a Even if the adjustment is carried out, the
displayed value does not change.
a Even if this adjustment code is turned off,
the adjustment is effective.
a This adjustment code is used to make the
controller recognize the leftmost position
of the potentiometer. It is not used to
adjust the steering force.
52
D155AX-6
D155AX-6
SEN00681-04
Operating method:
1) Increase or decrease the adjustment value by pressing [F3] or [F4].
2) Press [F6] and check that the alarm buzzer sounds.
a If the oil pressure has been adjusted, it is
displayed. It can be adjusted again within
the adjustment range, however.
a It is not necessary to operate the brake
during adjustment. After finishing adjustment, however, operate the brake and
check that there is not a problem in the
actual brake performance.
a Even if this adjustment code is turned off,
the adjustment is effective.
53
SEN00681-04
54
This adjustment code is used to check the constant power supply voltage and switch power
supply voltage applied to the power train controller.
Use this adjustment code for testing, adjusting,
or troubleshooting when necessary.
Operating method:
When this adjustment code is displayed, its
function is effective and the constant power
supply voltage and switch power supply voltage are displayed simultaneously.
a After this adjustment code is turned OFF,
its function is ineffective.
D155AX-6
SEN00681-04
This adjustment code is used to check the constant power supply voltage and switch power
supply voltage applied to the work equipment
controller.
Use this adjustment code for testing, adjusting,
or troubleshooting when necessary.
Operating method:
When this adjustment code is displayed, its
function is effective and the constant power
supply voltage and switch power supply voltage are displayed simultaneously.
a After this adjustment code is turned OFF,
its function is ineffective.
Operating method
1) Set the parking brake lever in the free
position.
2) Tilt the PCCS lever to a right or left position at which the current to be set is indicated and hold it at that position.
q
If the lever is tilted to the left, the current becomes negative.
q
If the lever is tilted to the right, the
current becomes positive.
3) Press [F6] and check that the alarm buzzer sounds.
a The current (mA) varies in the range from
-350 (left end) to 350 (right end).
a As the set current is increased in the positive or negative direction, the turning
radius to start steering is reduced more
(the machine is steered more quickly).
a It is not necessary to steer the machine
during adjustment. After finishing adjustment, however, steer the machine and
check that there is not a problem in the
actual steering feel.
a The following figure shows an example of
reducing the set current for the left steering to increase the turning radius.
D155AX-6
55
SEN00681-04
56
Operating method
1) Increase or decrease the adjustment value by pressing [F3] or [F4].
2) Press [F6] and check that the alarm buzzer sounds.
a If the engine speed has been adjusted, it
is displayed. It can be adjusted again
within the adjustment range, however.
a It is not necessary to drive the machine
during adjustment. After finishing adjustment, however, drive the machine at R1
with the reverse slow mode ON and check
that there is not a problem in the actual
travel speed.
a Even if this adjustment code is turned off,
the adjustment is effective.
D155AX-6
SEN00681-04
Operating method
1) Increase or decrease the adjustment
value by pressing [F3] or [F4].
2) Press [F6] and check that the alarm
buzzer sounds.
a If the engine speed has been adjusted, it
is displayed. It can be adjusted again
within the adjustment range, however.
a It is not necessary to drive the machine
during adjustment. After finishing adjustment, however, drive the machine at R2
with the reverse slow mode ON and check
that there is not a problem in the actual
travel speed.
a Even if this adjustment code is turned off,
the adjustment is effective.
Operating method
1) Increase or decrease the adjustment value by pressing [F3] or [F4].
2) Press [F6] and check that the alarm buzzer sounds.
a If the engine speed has been adjusted, it
is displayed. It can be adjusted again
within the adjustment range, however.
a It is not necessary to drive the machine
during adjustment. After finishing adjustment, however, drive the machine at R3
with the reverse slow mode ON and check
that there is not a problem in the actual
travel speed.
a Even if this adjustment code is turned off,
the adjustment is effective.
D155AX-6
57
SEN00681-04
Operating method:
1) Start the engine and keep its speed in the
specified range of condition with the fuel
control dial.
2) Select a clutch to be corrected manually
with the shift-up or shift-down switches.
3) Increase or decrease the adjustment
value by pressing [F3] or [F4].
4) Press [F6] and check that the alarm
buzzer sounds.
a The machine does not move during the
correction work.
a Even if this adjustment code is turned off,
the correction is effective.
58
Operating method:
1) Start the engine and keep its speed in the
specified range of condition with the fuel
control dial.
2) Press [F6] and start the correction work
and check that [1ST CLUTCH] is displayed newly on the screen.
3) If [END OF TEACHING] is displayed on
the screen, press [F6]. If the alarm buzzer
sounds at this time, correction work is
completed.
a The machine does not move during the
correction work.
a Even if this adjustment code is turned off,
the correction is effective.
This adjustment code is used to carry out correction manually when the correction is not
carried out normally by the operation of IP
automatic correction (Adjustment ID: 7842).
Use this adjustment code after the IP correction work, if necessary.
D155AX-6
SEN00681-04
Operating method
When this adjustment code is displayed, its
function is effective and the correction information is displayed.
a After this adjustment code is turned OFF,
its function is ineffective.
Operating method
1) Check that the blade control lever is in the
neutral position of the lifting direction and
keep it in that position.
2) Press [F6] and check that the alarm
buzzer sounds.
a Even if the adjustment is carried out, the
displayed value does not change.
a Even if this adjustment code is turned off,
the adjustment is effective.
a This adjustment code is used to make the
controller recognize the neutral position of
the potentiometer. It is not used to adjust
the sensitivity of the blade control lever
(For adjustment of the sensitivity of the
blade control lever in the lifting direction,
carry out adjustment codes 8020 8023).
D155AX-6
59
SEN00681-04
Operating method
1) Operate the blade control lever to the raising stroke end of the lifting direction and
keep it in that position.
2) Press [F6] and check that the alarm
buzzer sounds.
a Even if the adjustment is carried out, the
displayed value does not change.
a Even if this adjustment code is turned off,
the adjustment is effective.
a This adjustment code is used to make the
controller recognize the maximum raising
position of the potentiometer. It is not
used to adjust the sensitivity of the blade
control lever (For adjustment of the sensitivity of the blade control lever in the lifting
direction, carry out adjustment codes
8020 8023).
Operating method
1) Operate the blade control lever to the lowering stroke end of the lifting direction and
keep it in that position.
2) Press [F6] and check that the alarm
buzzer sounds.
a Even if the adjustment is carried out, the
displayed value does not change.
a Even if this adjustment code is turned off,
the adjustment is effective.
a This adjustment code is used to make the
controller recognize the maximum lowering position of the potentiometer. It is not
used to adjust the sensitivity of the blade
control lever (For adjustment of the sensitivity of the blade control lever in the lifting
direction, carry out adjustment codes
8020 8023).
60
D155AX-6
SEN00681-04
Operating method
1) Check that the blade control lever is in the
neutral position of the tilting direction and
keep it in that position.
2) Press [F6] and check that the alarm
buzzer sounds.
a Even if the adjustment is carried out, the
displayed value does not change.
a Even if this adjustment code is turned off,
the adjustment is effective.
a This adjustment code is used to make the
controller recognize the neutral position of
the potentiometer. It is not used to adjust
the sensitivity of the blade control lever
(For adjustment of the sensitivity of the
blade control lever in the tilting direction,
carry out adjustment codes 8024 and
8025).
Operating method
1) Operate the blade control lever to the right
stroke end of the tilting direction and keep
it in that position.
2) Press [F6] and check that the alarm
buzzer sounds.
a Even if the adjustment is carried out, the
displayed value does not change.
a Even if this adjustment code is turned off,
the adjustment is effective.
a This adjustment code is used to make the
controller recognize the rightmost position
of the potentiometer. It is not used to
adjust the sensitivity of the blade control
lever (For adjustment of the sensitivity of
the blade control lever in the tilting direction, carry out adjustment codes 8024 and
8025).
D155AX-6
61
SEN00681-04
Operating method
1) Operate the blade control lever to the left
stroke end of the tilting direction and keep
it in that position.
2) Press [F6] and check that the alarm
buzzer sounds.
a Even if the adjustment is carried out, the
displayed value does not change.
a Even if this adjustment code is turned off,
the adjustment is effective.
a This adjustment code is used to make the
controller recognize the leftmost position
of the potentiometer. It is not used to
adjust the sensitivity of the blade control
lever (For adjustment of the sensitivity of
the blade control lever in the tilting direction, carry out adjustment codes 8024 and
8025).
Operating method
1) Check that the ripper control lever is in the
neutral position of the lifting direction and
keep it in that position.
2) Press [F6] and check that the alarm
buzzer sounds.
a Even if the adjustment is carried out, the
displayed value does not change.
a Even if this adjustment code is turned off,
the adjustment is effective.
a This adjustment code is used to make the
controller recognize the neutral position of
the potentiometer. It is not used to adjust
the sensitivity of the ripper control lever.
62
D155AX-6
SEN00681-04
Adjustment ID: 8008 (Ripper lift lever max. lowering position adjustment)
Operating method
1) Operate the ripper control lever to the raising stroke end of the lifting direction and
keep it in that position.
2) Press [F6] and check that the alarm
buzzer sounds.
a Even if the adjustment is carried out, the
displayed value does not change.
a Even if this adjustment code is turned off,
the adjustment is effective.
a This adjustment code is used to make the
controller recognize the maximum raising
position of the potentiometer. It is not
used to adjust the sensitivity of the ripper
control lever.
Operating method
1) Operate the ripper control lever to the lowering stroke end of the lifting direction and
keep it in that position.
2) Press [F6] and check that the alarm
buzzer sounds.
a Even if the adjustment is carried out, the
displayed value does not change.
a Even if this adjustment code is turned off,
the adjustment is effective.
a This adjustment code is used to make the
controller recognize the maximum lowering position of the potentiometer. It is not
used to adjust the sensitivity of the ripper
control lever.
D155AX-6
63
SEN00681-04
Operating method
1) Check that the ripper control lever is in the
neutral position of the tilting direction and
keep it in that position.
2) Press [F6] and check that the alarm
buzzer sounds.
a Even if the adjustment is carried out, the
displayed value does not change.
a Even if this adjustment code is turned off,
the adjustment is effective.
a This adjustment code is used to make the
controller recognize the neutral position of
the potentiometer. It is not used to adjust
the sensitivity of the ripper control lever.
Operating method
1) Operate the ripper control lever to the IN
stroke end of the tilting direction and keep
it in that position.
2) Press [F6] and check that the alarm
buzzer sounds.
a Even if the adjustment is carried out, the
displayed value does not change.
a Even if this adjustment code is turned off,
the adjustment is effective.
a This adjustment code is used to make the
controller recognize the maximum IN position of the potentiometer. It is not used to
adjust the sensitivity of the ripper control
lever.
64
D155AX-6
Operating method
1) Operate the ripper control lever to the
BACK stroke end of the tilting direction
and keep it in that position.
2) Press [F6] and check that the alarm
buzzer sounds.
a Even if the adjustment is carried out, the
displayed value does not change.
a Even if this adjustment code is turned off,
the adjustment is effective.
a This adjustment code is used to make the
controller recognize the maximum BACK
position of the potentiometer. It is not
used to adjust the sensitivity of the ripper
control lever.
D155AX-6
SEN00681-04
This adjustment code is used to adjust the sensitivity of start of blade when the blade control
lever is moved in the raising position with the
blade fine mode OFF.
Use this adjustment code for work when necessary.
Operating method
1) Increase or decrease the adjustment value by pressing [F3] or [F4].
2) Press [F6] and check that the alarm buzzer sounds.
a If the engine speed has been adjusted, it
is displayed. It can be adjusted repeatedly, however.
a It is not necessary to move the blade during adjustment. After finishing adjustment, however, raise the blade and check
that there is not a problem in the actual
operation feel (Check with the blade fine
control mode OFF).
a Even if this adjustment code is turned off,
the adjustment is effective.
65
SEN00681-04
Adjustment ID: 8022 (Blade raising current correction (Fine control mode))
This adjustment code is used to adjust the sensitivity of start of blade when the blade control
lever is moved in the lowering position with the
blade fine mode OFF.
Use this adjustment code for work when necessary.
Operating method
1) Increase or decrease the adjustment value by pressing [F3] or [F4].
2) Press [F6] and check that the alarm buzzer sounds.
a If the engine speed has been adjusted, it
is displayed. It can be adjusted repeatedly, however.
a It is not necessary to move the blade during adjustment. After finishing adjustment, however, lower the blade and check
that there is not a problem in the actual
operation feel (Check with the blade fine
control mode OFF).
a Even if this adjustment code is turned off,
the adjustment is effective.
Operating method
1) Increase or decrease the adjustment value by pressing [F3] or [F4].
2) Press [F6] and check that the alarm buzzer sounds.
a If the engine speed has been adjusted, it
is displayed. It can be adjusted repeatedly, however.
a It is not necessary to move the blade during adjustment. After finishing adjustment, however, raise the blade and check
that there is not a problem in the actual
operation feel (Check with the blade fine
control mode ON).
a Even if this adjustment code is turned off,
the adjustment is effective.
66
This adjustment code is used to adjust the sensitivity of start of blade when the blade control
lever is moved in the raising position with the
blade fine mode ON.
Use this adjustment code for work when necessary.
D155AX-6
Adjustment ID: 8023 (Blade lowering current correction (Fine control mode))
This adjustment code is used to adjust the sensitivity of start of blade when the blade control
lever is moved in the lowering position with the
blade fine mode ON.
Use this adjustment code for work when necessary.
Operating method
1) Increase or decrease the adjustment value by pressing [F3] or [F4].
2) Press [F6] and check that the alarm buzzer sounds.
a If the engine speed has been adjusted, it
is displayed. It can be adjusted repeatedly, however.
a It is not necessary to move the blade during adjustment. After finishing adjustment, however, lower the blade and check
that there is not a problem in the actual
operation feel (Check with the blade fine
control mode ON).
a Even if this adjustment code is turned off,
the adjustment is effective.
D155AX-6
SEN00681-04
This adjustment code is used to adjust the sensitivity of start of blade when the blade control
lever is moved in the tilting left position.
Use this adjustment code for work when necessary.
Operating method
1) Increase or decrease the adjustment value by pressing [F3] or [F4].
2) Press [F6] and check that the alarm buzzer sounds.
a If the engine speed has been adjusted, it
is displayed. It can be adjusted repeatedly, however.
a It is not necessary to move the blade during adjustment. After finishing adjustment, however, tilt the blade to the left and
check that there is not a problem in the
actual operation feel.
a Even if this adjustment code is turned off,
the adjustment is effective.
67
SEN00681-04
68
This adjustment code is used to adjust the sensitivity of start of blade when the blade control
lever is moved in the tilting right position.
Use this adjustment code for work when necessary.
Functions of function switches
[F3]: Increase adjustment value [Current offset]
[F4]: Decrease adjustment value [Current offset]
[F5]: Return to adjustment item selecting
screen (ID inputting screen)
[F6]: Save adjustment value
Operating method
1) Increase or decrease the adjustment value by pressing [F3] or [F4].
2) Press [F6] and check that the alarm buzzer sounds.
a If the engine speed has been adjusted, it
is displayed. It can be adjusted repeatedly, however.
a It is not necessary to move the blade during adjustment. After finishing adjustment, however, tilt the blade to the right
and check that there is not a problem in
the actual operation feel.
a Even if this adjustment code is turned off,
the adjustment is effective.
Operating method
When this adjustment code is displayed, its
function is effective and the control brake (right
and left brake ECMV) is kept released.
a After this adjustment code is turned OFF,
its function is ineffective.
D155AX-6
This adjustment code is used to stop the sudden stop prevent solenoid valve and right and
left brake ECMV to check the operation of the
sudden stop prevent valve.
Use this adjustment code for testing, adjusting,
or troubleshooting when necessary.
Operating method
When this adjustment code is displayed, its
function is effective and the sudden stop prevent solenoid valve and right and left brake
ECMV are kept stopped.
a After this adjustment code is turned OFF,
its function is ineffective.
D155AX-6
SEN00681-04
Operating method
1) Increase or decrease the adjustment value by pressing [F3] or [F4].
2) Press [F6] and check that the alarm buzzer sounds.
a When resetting the limitation of the high
idle speed, set the adjustment value to the
original high idle speed (2,050 rpm).
a Even if this adjustment code is turned off,
the adjustment is effective.
69
SEN00681-04
q
q
This adjustment code is used to limit the maximum transmission gear speed.
The limited gear speed is applied in both automatic gearshift mode and manual gearshift
mode.
Use this adjustment code for work when necessary.
Operating method
1) Increase or decrease the adjustment value by pressing [F3] or [F4].
2) Press [F6] and check that the alarm buzzer sounds.
a When resetting the limitation of the maximum gear speed, set the adjustment
value to the maximum gear speed (3RD).
a Even if this adjustment code is turned off,
the adjustment is effective.
70
D155AX-6
SEN00681-04
Pm Clinic
The machine monitor can check the condition of the
machine without connecting testing tools to assist
the Pm Clinic and other periodic inspections.
1.
2nd screen
Selecting menu
Select "08 PM CLINIC" on the Service menu
screen.
q
q
q
q
3.
2.
D155AX-6
71
SEN00681-04
2.
3.
4.
Selecting menu
Select "09 Cylinder Cut-Out" on the "Service
Menu" screen.
[Reference]
If a normally operating cylinder is disabled, the
following phenomena occur.
1) Lowering of engine speed
2) Increase of final injection rate command
(quantity)
q
If the engine is running near the high idle, however, the engine speed may not lower for the
reason of engine control.
q
In this case, lower the engine speed with the
fuel control dial and judge by increase of the
injection rate command.
q
72
D155AX-6
SEN00681-04
a
Display of No Injection
If the engine is operated after long storage of the
machine, it may be worn or damaged because of
insufficient lubrication with oil. To prevent this, the
function to lubricate the engine before starting it by
cranking it without injecting fuel is installed.
Set the No Injection while the engine is stopped.
1.
2.
3.
Selecting menu
Select "10 No Injection" on the "Service Menu"
screen.
4.
5.
D155AX-6
73
SEN00681-04
Selecting menu
Select "11 Fuel Consumption" on the "Service
Menu" screen.
2.
Starting measurement
After the screen of "Fuel Consumption" is displayed, start measurement with the function
switches.
q
[F1]: Start
q
[F2]: Clear
q
[F5]: Return to Service menu screen
a When the screen of "Fuel Consumption" is
displayed, if a data is indicated, it is the
data of the previous measurement. This
data is not an obstacle to new measurement and can be deleted by pressing [F2].
a If [F1] is pressed, the data is displayed on
the starting date and time side and measurement starts.
a The display unit of the fuel changes
according to the unit set with the initialization (unit setting) function.
SI and meter: l/h,
inch: gal/h
74
3.
4.
Finishing measurement
Press [F1], and measurement is finished and
the data are displayed on the finishing date
and time side.
5.
D155AX-6
Selecting menu
Select "12 KOMTRAX Settings" on the "Service Menu" screen.
2.
3.
D155AX-6
SEN00681-04
75
SEN00681-04
Selecting menu
Select "12 KOMTRAX Settings" on the "Service Menu" screen.
2.
76
3.
D155AX-6
SEN00681-04
Selecting menu
Select "12 KOMTRAX Settings" on the "Service Menu" screen.
2.
3.
D155AX-6
77
SEN00681-04
2.
3.
78
a
a
D155AX-6
D155AX-6
SEN00681-04
79
SEN00681-04
D155AX-6 Bulldozer
Form No. SEN00681-04
2010 KOMATSU
All Rights Reserved
Printed in Japan 08-10
80
D155AX-6
SEN00682-02
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
D155AX-6
SEN00682-02
Before disconnecting or connecting a connector between the engine controller and engine,
be sure to turn the starting switch OFF.
2.
D155AX-6
SEN00682-02
2.
When carrying out troubleshooting of an electric circuit related to the machine monitor,
engine controller, power train controller, or work
equipment controller, expose the related connectors according to the following procedure.
1.
Machine monitor
1) Remove the 4 mounting bolts each from
covers (1) and (2) and remove those covers.
2) Remove the 4 mounting bolts each from
covers (3) and (4) and remove those covers together with the foot rest.
a The 2 bolts on the front window side of the
foot rest are used as the cover mounting
bolts, too.
3) Remove the 4 mounting bolts of machine
monitor (5) and pull out machine monitor
(5) and switch cover together toward the
operator's seat.
4)
Engine controller
1) Open the left engine side cover and left
mudguard.
2) Remove the mounting bolts and cover (6).
3)
D155AX-6
SEN00682-02
3.
4.
2)
D155AX-6
SEN00682-02
Pm Clinic
Machine model
Serial No.
Service meter
D155AX-6
User's name
Date of execution
/
Inspector
Specifications
Blade
Rear attachment
T blade
T Semi-U blade
T Full-U blade
T
T Multi-shank ripper
T Variable giant ripper
T Counterweight (
T
Shoe width
T 560 mm
T 610 mm
T 660 mm
T 710 mm
kg)
Working condition
Quarry/Mining
Construction
Type of soil (Specific gravity:
T Construction/Civil engineering T Rock
T Road
T Gravel
T Tunnel
T Sand
T
T Clay
T Coal
T Gold
T Limestone
T
) Contents of work
T Dozing
T Side cutting
T Ripping
T Travel
%
%
%
%
When necessary
T Damper case oil level
T Power train oil level
Max. range:
Max. range:
Following figure (Left)
Following figure (Right)
Operator's opinion
Ambient temperature
Max.
C/Min.
Altitude
AA10NX
times/1st time
h/last
times/1st time
h/last
AB00MA
times/1st time
h/last
times/1st time
h/last
B@BAZG
times/1st time
h/last
times/1st time
h/last
B@BCNS
times/1st time
h/last
times/1st time
h/last
B@BCZK
times/1st time
h/last
times/1st time
h/last
B@CENS
times/1st time
h/last
times/1st time
h/last
B@HANS
times/1st time
h/last
times/1st time
h/last
CA234
times/1st time
h/last
times/1st time
h/last
D155AX-6
SEN00682-02
Check positions/Method 1
D155AX-6
SEN00682-02
Check positions/Method 2
D155AX-6
SEN00682-02
Check positions/Method 3
D155AX-6
SEN00682-02
Serial No.
Service meter
User's name
Date of execution
Inspector
D155AX-6
Measurement condition
Unit
Low idling
Boost
pressure
Exhaust
temperature
2.
715 765
715 765
rpm
F3 stall
1,560 1,660
1,450
1,500 1,600
1,395
Min. 117
{Min. 880}
100
{750}
660
700
Max. 2.94
{Max. 300}
3.92
{400}
Min. 034
{Min. 3.5}
0.21
{2.1}
Min. 010
{Min. 1.0}
0.08
{0.8}
Standard
value for new
machine
Service limit
value
kPa
{mmHg}
Ambient temperature
F3 stall
C
kPa
{mmH2O}
High idle
Low idle
F3 stall
Measurement result
825 925
Service limit
value
MPa
{kg/cm}
Cooling fan
Item
Measurement condition
Unit
Low idle
Fan
Speed
Circuit
pressure
D155AX-6
Measurement result
Rejected
Engine
Without deceleration
High (Adjustment: 0007)
Engine speed idle Normal (Deceleration)
Decelerator pedal
Standard
value for new
machine
Rejected
Item
Accepted
Engine
Accepted
1.
rpm
1,200 1,300 1,200 1,300
MPa
{kg/cm}
SEN00682-02
Transmission
Item
High idle
Max. 1.0
{Max. 10.0}
Max. 1.0
{Max. 10.0}
Low idle
0.05 0.29
{0.5 3.0}
0.05 0.29
{0.5 3.0}
0.29 0.69
{3.0 7.0}
0.29 0.69
{3.0 7.0}
1.12 1.52
{11.5 15.5}
1.12 1.52
{11.5 15.5}
1.12 1.52
{11.5 15.5}
1.12 1.52
{11.5 15.5}
Low idle
2.45 2.85
{25.0 29.0}
2.45 2.85
{25.0 29.0}
High idle
2.45 2.85
{25.0 29.0}
2.45 2.85
{25.0 29.0}
Standard
value for new
machine
Service limit
value
Low idle
2.81 3.11
{28.7 31.7}
Min. 2.62
{Min. 26.7}
High idle
3.04 3.33
{31.0 34.0}
Min. 2.84
{Min. 29.0}
2.45 2.75
{25.0 28.0}
Min. 2.26
{Min. 23.0}
2.65 2.94
{27.0 30.0}
Min. 2.45
{Min. 25.0}
Monitoring: 32601
Monitoring: 32603
High idle
MPa
{kg/cm}
Measurement condition
Unit
F clutch
pressure
Gear speed: F3
Brake: Applied
Low idle
R clutch
pressure
Gear speed: R3
Brake: Applied
Low idle
1st clutch
pressure
Gear speed: F1
Brake: Applied
Low idle
2.81 3.11
{28.7 31.7}
Min. 2.62
{Min. 26.7}
2nd clutch
pressure
Gear speed: F2
Brake: Applied
Low idle
2.60 2.89
{26.5 29.5}
Min. 2.40
{Min. 24.5}
3rd clutch
pressure
Gear speed: F3
Brake: Applied
Low idle
2.81 3.11
{28.7 31.7}
Min. 2.62
{Min. 26.7}
Standard
value for new
machine
Service limit
value
Low idle
2.46 3.04
{25.0 31.0}
2.16
{22.0}
High idle
2.46 3.04
{25.0 31.0}
2.16
{22.0}
2.46 3.04
{25.0 31.0}
2.16
{22.0}
2.46 3.04
{25.0 31.0}
2.16
{22.0}
Measurement condition
Right brake
pressure
Gear speed: N
Brake: Released
Left brake
pressure
Gear speed: N
Brake: Released
Brake
F2 stall, high idle
performance
Low idle
High idle
MPa
{kg/cm}
Unit
MPa
{kg/cm}
Rejected
0.05 0.49
{0.5 5.0}
Main relief
pressure
Item
Brake
0.05 0.49
{0.5 5.0}
10
Low idle
Measurement result
Measurement result
Rejected
Outlet
pressure
Service limit
value
Unit
Measurement result
Rejected
Torque converter
Inlet
pressure
Standard
value for new
machine
Measurement condition
Accepted
Item
Accepted
Accepted
3.
D155AX-6
Item
Unload
pressure
Work equipment
control lever: All
levers in neutral
Cylinder stroke
Work equip- end relief
ment LS relief
pressure
2.45 3.82
{25 39}
2.45 3.82
{25 39}
High idle
26.0 29.0
{265 295}
26.0 29.0
{265 295}
24.0 26.0
{245 265}
24.0 26.0
{245 265}
38.2 41.5
{390 425}
38.2 41.5
{390 425}
36.2 38.1
{369 389}
36.2 38.1
{369 389}
3.97 4.46
{40.5 45.5}
3.97 4.46
{40.5 45.5}
Standard
value for new
machine
Service limit
value
3.0 4.0
3.0 4.0
High idle
MPa
{kg/cm}
High idle
Brake: Applied
HSS LS relief Steering: Relieved
High idle
pressure
Control
circuit basic
pressure
Work equipment
control lever: All
levers in neutral
High idle
Measurement result
Work
equipment
speed
Blade raise
Unit
High idle
High idle
Ripper lower
High idle
Ripper tilt in
High idle
1.8 2.8
3.1
1.5 2.5
3.5
4.5 5.5
6.2
Unit
Standard
value for new
machine
Service limit
value
mm
Max. 150
200
mm
Max. 50
70
Unit
Standard
value for new
machine
Service limit
value
sec
Measurement result
Rejected
Measurement condition
Accepted
Hydraulic
drift
Hydraulic oil
temperature
Hydraulic drift
of blade lift
Engine: Stopped
Blade lift: 15 minutes
Ripper lift: 5 minutes
Hydraulic drift
of ripper lift
Measurement result
Rejected
Measurement condition
Accepted
Final drive
Item
FD
Final drive
D155AX-6
Measurement condition
Engine: Stopped
Measurement result
Rejected
7.
High idle
HSS relief
pressure
Item
6.
Service limit
value
Unit
Accepted
5.
Standard
value for new
machine
Measurement condition
Rejected
4.
SEN00682-02
11
SEN00682-02
8.
12
Service meter
Repair record
Date
Service meter
Repair record
D155AX-6
SEN00682-02
Serial No.
Service meter
User's name
Date of execution
Inspector
D155AX-6
1.
Bushing temperature
Item
Measurement condition
Measurement result
Accepted Rejected
Under- Bushing
Measure just Left side of machine
carriage temperature after work.
Right side of machine
D155AX-6
13
Item
Measurement condition
Unit
Undercarriage
Left side of
machine
Opening of
track link
Measure
dimension (a).
Clearance
limit
Pin No.
Measurement result
Rejected
Accepted
SEN00682-02
1.4
(Each side)
mm
Right side of
machine
1.4
(Each side)
14
D155AX-6
D155AX-6
SEN00682-02
15
SEN00682-02
D155AX-6 Bulldozer
Form No. SEN00682-02
2010KOMATSU
All Rights Reserved
Printed in Japan 08-10
16
D155AX-6
SEN04628-02
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
40 Troubleshooting
D155AX-6
SEN04628-02
40 Troubleshooting
Failure
code
E03
1500L0
E03
1
Component
in charge
Category of
history
P/T
Electrical system
P/T
Electrical system
E03
P/T
Electrical system
E03
P/T
Electrical system
E03
P/T
Electrical system
E03
P/T
Electrical system
E03
P/T
Electrical system
E03
P/T
Electrical system
E03
P/T
Electrical system
E03
P/T
Electrical system
E03
P/T
Electrical system
E02
15SJL1
P/T
Electrical system
E02
P/T
Electrical system
E04
2301L1
P/T
Electrical system
E04
P/T
Electrical system
E04
2302L1
P/T
Electrical system
E04
P/T
Electrical system
P/T
Electrical system
MON
Mechanical system
MON
Mechanical system
ENG
Mechanical system
ENG
Mechanical system
MON
Mechanical system
P/T
Mechanical system
MON
Mechanical system
E04
CA111
ENG
Electrical system
E04
CA115
ENG
Electrical system
E03
CA122
ENG
Electrical system
E03
CA123
ENG
Electrical system
E03
CA131
ENG
Electrical system
E03
CA132
ENG
Electrical system
E02
CA135
ENG
Electrical system
E02
CA141
ENG
Electrical system
E02
CA144
ENG
Electrical system
E02
CA145
ENG
Electrical system
E01
CA153
ENG
Electrical system
E01
CA154
ENG
Electrical system
E03
CA187
ENG
Electrical system
E03
CA221
ENG
Electrical system
Reference
manual
Troubleshooting
by failure code,
Part 1
SEN00716-02
Troubleshooting
by failure code,
Part 2
SEN00717-02
D155AX-6
40 Troubleshooting
Action
code
Failure
code
E03
CA222
E03
SEN04628-02
Component
in charge
Category of
history
ENG
Electrical system
CA227
ENG
Electrical system
E00
CA234
Eng Overspeed
ENG
Mechanical system
E03
CA238
ENG
Electrical system
E01
CA263
ENG
Electrical system
E01
CA265
ENG
Electrical system
E03
CA271
ENG
Electrical system
E03
CA272
ENG
Electrical system
E03
CA273
ENG
Electrical system
E03
CA274
ENG
Electrical system
E03
CA322
ENG
Electrical system
E03
CA323
ENG
Electrical system
E03
CA324
ENG
Electrical system
E03
CA325
ENG
Electrical system
E03
CA331
ENG
Electrical system
E03
CA332
ENG
Electrical system
E04
CA342
ENG
Electrical system
E03
CA351
ENG
Electrical system
E03
CA352
ENG
Electrical system
E03
CA386
ENG
Electrical system
E04
CA441
ENG
Electrical system
E04
CA442
ENG
Electrical system
E03
CA449
ENG
Electrical system
E03
CA451
ENG
Electrical system
E03
CA452
ENG
Electrical system
E02
CA553
ENG
Electrical system
E03
CA554
ENG
Electrical system
E02
CA559
ENG
Electrical system
E03
CA689
ENG
Electrical system
E03
CA731
ENG
Electrical system
E04
CA757
ENG
Electrical system
E03
CA778
ENG
Electrical system
E02
ENG
Electrical system
E03
ENG
Electrical system
E03
ENG
Electrical system
E03
ENG
Electrical system
E02
ENG
Electrical system
E03
ENG
Electrical system
E03
ENG
Electrical system
E03
ENG
Electrical system
E03
ENG
Electrical system
D155AX-6
Reference
manual
Troubleshooting
by failure code,
Part 2
SEN00717-02
Troubleshooting
by failure code,
Part 3
SEN00718-03
SEN04628-02
Action
code
Failure
code
40 Troubleshooting
Component
in charge
Category of
history
E01
ENG
Electrical system
E01
ENG
Electrical system
E03
ENG
Electrical system
E03
ENG
Electrical system
E03
ENG
Electrical system
E03
ENG
Electrical system
E03
ENG
Electrical system
E03
ENG
Electrical system
E03
ENG
Electrical system
E01
ENG
Electrical system
E01
ENG
Electrical system
P/T
Electrical system
P/T
Electrical system
E02
P/T
Electrical system
E02
P/T
Electrical system
E01
P/T
Electrical system
E01
P/T
Electrical system
P/T
Electrical system
P/T
Electrical system
E03
P/T
Electrical system
E03
MON
Electrical system
E03
ENG
Electrical system
E04
W/E
Electrical system
E03
P/T
Electrical system
E01
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E04
W/E
Electrical system
E03
W/E
Electrical system
E03
P/T
Electrical system
E01
P/T
Electrical system
E02
P/T
Electrical system
E02
P/T
Electrical system
E04
P/T
Electrical system
E02
P/T
Electrical system
E02
P/T
Electrical system
E02
P/T
Electrical system
E02
P/T
Electrical system
E03
P/T
Electrical system
E03
P/T
Electrical system
E02
P/T
Electrical system
Reference
manual
Troubleshooting
by failure code,
Part 3
SEN00718-03
Troubleshooting
by failure code,
Part 4
SEN00719-01
D155AX-6
40 Troubleshooting
Action
code
Failure
code
SEN04628-02
Component
in charge
Category of
history
E02
P/T
Electrical system
E02
P/T
Electrical system
E02
W/E
Electrical system
E02
W/E
Electrical system
E01
W/E
Electrical system
E01
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E02
P/T
Electrical system
E02
P/T
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E01
P/T
Electrical system
E01
P/T
Electrical system
W/E
Electrical system
D155AX-6
Reference
manual
Troubleshooting
by failure code,
Part 4
SEN00719-01
Troubleshooting
by failure code,
Part 5
SEN00720-02
SEN04628-02
Action
code
Failure
code
40 Troubleshooting
Component
in charge
Category of
history
W/E
Electrical system
E02
P/T
Electrical system
E02
P/T
Electrical system
E02
P/T
Electrical system
E02
P/T
Electrical system
E03
ENG
Electrical system
E03
P/T
Electrical system
E03
P/T
Electrical system
E04
P/T
Electrical system
E04
P/T
Electrical system
E03
P/T
Electrical system
E03
P/T
Electrical system
E03
P/T
Electrical system
E03
P/T
Electrical system
E03
P/T
Electrical system
E04
P/T
Electrical system
E04
P/T
Electrical system
E03
P/T
Electrical system
E03
P/T
Electrical system
E03
P/T
Electrical system
E03
P/T
Electrical system
E03
P/T
Electrical system
E03
P/T
Electrical system
E03
P/T
Electrical system
E01
P/T
Electrical system
E01
P/T
Electrical system
E01
P/T
Electrical system
E01
P/T
Electrical system
E03
P/T
Electrical system
E03
P/T
Electrical system
E03
P/T
Electrical system
E03
P/T
Electrical system
E03
P/T
Electrical system
E03
P/T
Electrical system
E04
P/T
Electrical system
E04
P/T
Electrical system
E04
P/T
Electrical system
E01
P/T
Electrical system
E01
P/T
Electrical system
E01
W/E
Electrical system
E01
W/E
Electrical system
Reference
manual
Troubleshooting
by failure code,
Part 5
SEN00720-02
Troubleshooting
by failure code,
Part 6
SEN00721-03
D155AX-6
40 Troubleshooting
Action
code
Failure
code
SEN04628-02
Component
in charge
Category of
history
E01
W/E
Electrical system
E02
P/T
Electrical system
E02
P/T
Electrical system
E03
P/T
Electrical system
E03
P/T
Electrical system
E03
P/T
Electrical system
E03
P/T
Electrical system
E03
P/T
Electrical system
E03
P/T
Electrical system
E03
P/T
Electrical system
E03
P/T
Electrical system
E03
P/T
Electrical system
E03
P/T
Electrical system
E03
P/T
Electrical system
E03
P/T
Electrical system
E04
P/T
Electrical system
E03
P/T
Electrical system
E03
P/T
Electrical system
E04
P/T
Electrical system
E04
P/T
Electrical system
E04
P/T
Electrical system
E04
P/T
Electrical system
E04
P/T
Electrical system
E04
P/T
Electrical system
E04
P/T
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
D155AX-6
Reference
manual
Troubleshooting
by failure code,
Part 6
SEN00721-03
Troubleshooting
by failure code,
Part 7
SEN00722-01
SEN04628-02
Action
code
Failure
code
40 Troubleshooting
Component
in charge
Category of
history
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E01
W/E
Electrical system
E01
W/E
Electrical system
E01
W/E
Electrical system
E02
P/T
Electrical system
E02
P/T
Electrical system
E02
P/T
Electrical system
Reference
manual
Troubleshooting
by failure code,
Part 7
SEN00722-01
Troubleshooting
by failure code,
Part 8
SEN00723-01
D155AX-6
40 Troubleshooting
SEN04628-02
Fuse locations
CB105
(Accessory power
supply)
CB30
(Unswitched power
supply)
Circuit
breaker
capacity
Destination of power
CB9
20A
CB1
20A
CB2
20A
CB3
20A
CB4
20A
CB5
20A
CB6
20A
CB7
20A
Starting switch
Engine hold relay
Machine monitor
Power train controller
Work equipment controller
CB8
30A
Fuse No.
Fuel
capacity
CB30
(Unswitched power
supply)
20A
5A
20A
20A
5A
CB105H
(Unswitched power
supply)
Engine controller
Engine electrical intake air heater
CB105
(Accessory power
supply)
Starting switch (ACC)
D155AX-6
Destination of power
SEN04628-02
40 Troubleshooting
Fuse No.
Fuel
capacity
CB30
(Unswitched power
supply)
5A
5A
CB105
(Accessory power
supply)
10
Destination of power
20A
5A
Horn
20A
D155AX-6
40 Troubleshooting
SEN04628-02
Locations of circuit breakers CB30, CB105, and CB105H (In battery room)
Locations of circuit breakers CB1 CB9 and fuse boxes FS1 and FS2 (In battery room)
D155AX-6
11
SEN04628-02
40 Troubleshooting
Fuse box
Power circuit fuse
(Type of power supply)
FS1-1
(Unswitched power
supply)
FS1-3
(Accessory power
supply)
Fuse No.
Fuel
capacity
Destination of power
Radio
10A
20A
20A
FS1-4
(Accessory power
supply)
12
Room lamp
20A
10A
10A
Cigarette lighter
Windshield wiper (Via intermittent relay)
D155AX-6
40 Troubleshooting
SEN04628-02
a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully.
Action code
Failure code
Display on
Display on machine
machine monimonitor
tor
Contents of
trouble
Trouble
Action of
Action taken by machine monitor or controller to protect system or devices when they detect
machine monitrouble
tor or controller
Problem that
appears on
machine
Problem that appears on machine as result of action taken by machine monitor or controller
(shown above)
Related information
Cause
Possible causes
and standard
value in normal
state
D155AX-6
13
SEN04628-02
40 Troubleshooting
14
D155AX-6
40 Troubleshooting
D155AX-6
SEN04628-02
15
SEN04628-02
40 Troubleshooting
D155AX-6 Bulldozer
Form No. SEN04628-02
2011 KOMATSU
All Rights Reserved
Printed in Japan 11-11
16
D155AX-6
SEN00851-02
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
40 Troubleshooting
D155AX-6
SEN00851-02
40 Troubleshooting
Stop the machine in a level ground, and check that the lock pin, blocks, and parking brake are
securely fitted.
When carrying out the operation with two or more workers, keep strictly to the agreed signals,
and do not allow any unauthorized person to come near.
If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative () terminal of the battery first.
When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and function.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1.
2.
3.
3)
4)
5)
4.
Confirming failure
q
Confirm the extent of the failure yourself,
and judge whether to handle it as a real
failure or as a problem with the method of
operation, etc.
a When operating the machine to reenact the troubleshooting symptoms, do
not carry out any investigation or
measurement that may make the
problem worse.
5.
Troubleshooting
q
Use the results of the investigation and
inspection in Items 2 4 to narrow down
the causes of failure, then use the troubleshooting flowchart to locate the position of
the failure exactly.
a The basic procedure for troubleshooting is as follows.
1) Start from the simple points.
2) Start from the most likely points.
3) Investigate other related parts or
information.
6.
D155AX-6
40 Troubleshooting
SEN00851-02
D155AX-6
SEN00851-02
40 Troubleshooting
Lubricating
oil/Coolant
Hydraulic/
Mechanical
equipment
Criterion
Remedy
Add fuel
Between H L
Add oil
Between H L
Add oil
Between H L
Add oil
Between H L
Add oil
Add coolant
Clean or replace
Adjust
Repair
Repair
3. Bleeding air
Bleed air
Retighten or replace
Retighten or replace
Retighten or replace
20 30 V
Charge or replace
Between H L
Add or replace
Repair or replace
Repair
Dry
Replace
Replace
Replace
D155AX-6
40 Troubleshooting
SEN00851-02
Contents
Troubleshooting by failure code
E mode
H mode
S mode
Procedure for troubleshooting to be taken when action code and failure code are displayed on
machine monitor:
If a action code and a failure code are displayed on the machine monitor, carry out the troubleshooting
for the corresponding "Display of code" according to the displayed failure code.
2.
When electrical system failure code or mechanical system failure code is recorded in fault history:
If a action code and a failure code are not displayed on the machine monitor, check for a mechanical
system failure code and an electrical system failure code with the fault history function of the machine
monitor.
If a failure code is recorded, carry out troubleshooting for the corresponding "Display of code" according to that code.
a If an electrical system failure code is recorded, delete all the codes and reproduce them, and then
see if the trouble is still detected.
a A failure code of the mechanical system cannot be deleted.
a If a trouble is displayed in the air conditioner fault history or heater fault history by the fault history
function, carry out the corresponding troubleshooting in "E mode".
3.
When action code or failure code is not displayed and no failure code is recorded in fault
history:
If a action code or a failure code is not displayed on the machine monitor and no failure code is recorded
in the fault history, a trouble that the machine cannot find out by itself may have occurred in the electrical
system or hydraulic and mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from
the table of "Phenomena looking like troubles and troubleshooting Nos.", and then carry out troubleshooting corresponding to that phenomenon in the "E mode", "H mode", or "S mode".
D155AX-6
SEN00851-02
40 Troubleshooting
Display
of code
E mode
H mode
S mode
According to displayed
code
E-20
S-1
E-3
S-2
S-3
S-4
S-5
S-6
S-7
S-8
S-9
S-10
15 Oil is in coolant (or coolant spurts back or coolant level goes down)
S-11
S-12
S-13
S-14
S-15
20 Vibration is excessive
S-16
E-4
Phenomena related to power train
H-1
H-2
H-3
H-4
H-5
H-6
H-7
H-8
H-9
31 Abnormal sound comes out from around HSS pump or HSS motor
H-10
H-11
H-12
H-13
H-14
D155AX-6
40 Troubleshooting
SEN00851-02
Troubleshooting
No.
Display
of code
E mode
H mode
H-15
H-16
H-17
H-18
H-19
H-20
H-21
H-22
S mode
E-1
E-2
E-5
E-6
E-7
E-8
E-9
E-10
E-11
E-12
50
E-13
E-14
E-15
E-16
E-17
E-18
E-19
E-20
E-21
E-22
E-23
E-24
E-25
E-26
Other phenomena
68 KOMTRAX system does not operate normally
D155AX-6
E-27
SEN00851-02
40 Troubleshooting
(Rev. 2009.04)
The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
D155AX-6
40 Troubleshooting
D155AX-6
SEN00851-02
SEN00851-02
10
40 Troubleshooting
D155AX-6
40 Troubleshooting
D155AX-6
SEN00851-02
11
SEN00851-02
12
40 Troubleshooting
D155AX-6
40 Troubleshooting
D155AX-6
SEN00851-02
13
SEN00851-02
14
40 Troubleshooting
D155AX-6
40 Troubleshooting
D155AX-6
SEN00851-02
15
SEN00851-02
16
40 Troubleshooting
D155AX-6
40 Troubleshooting
D155AX-6
SEN00851-02
17
SEN00851-02
18
40 Troubleshooting
D155AX-6
40 Troubleshooting
D155AX-6
SEN00851-02
19
SEN00851-02
20
40 Troubleshooting
D155AX-6
40 Troubleshooting
D155AX-6
SEN00851-02
21
SEN00851-02
22
40 Troubleshooting
D155AX-6
40 Troubleshooting
D155AX-6
SEN00851-02
23
SEN00851-02
24
40 Troubleshooting
D155AX-6
40 Troubleshooting
D155AX-6
SEN00851-02
25
SEN00851-02
26
40 Troubleshooting
D155AX-6
40 Troubleshooting
D155AX-6
SEN00851-02
27
SEN00851-02
28
40 Troubleshooting
D155AX-6
40 Troubleshooting
D155AX-6
SEN00851-02
29
SEN00851-02
30
40 Troubleshooting
D155AX-6
40 Troubleshooting
D155AX-6
SEN00851-02
31
SEN00851-02
32
40 Troubleshooting
D155AX-6
40 Troubleshooting
D155AX-6
SEN00851-02
33
SEN00851-02
34
40 Troubleshooting
D155AX-6
40 Troubleshooting
D155AX-6
SEN00851-02
35
SEN00851-02
36
40 Troubleshooting
D155AX-6
40 Troubleshooting
D155AX-6
SEN00851-02
37
SEN00851-02
38
40 Troubleshooting
D155AX-6
40 Troubleshooting
D155AX-6
SEN00851-02
39
SEN00851-02
40
40 Troubleshooting
D155AX-6
40 Troubleshooting
D155AX-6
SEN00851-02
41
SEN00851-02
42
40 Troubleshooting
D155AX-6
40 Troubleshooting
D155AX-6
SEN00851-02
43
SEN00851-02
40 Troubleshooting
(Rev. 2009.03)
1
q q
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-2800
Identification
symbol
799-601-2700
Part name
T-adapter kit
799-601-2500
Part No.
Number of pins
The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
21
37
37
q
q
24
MS-24P
24
MS-24P
17
MS-17P
17
MS-17P
q
q
MS-5P
10
MS-10P
MS-5P
17
MS-17P
19
MS-19P
14
MS-14P
q
q
799-601-3470 Case
799-601-2710 Adapter for MIC
MIC-5P
q q
13
MIC-13P
q q
17
MIC-17P
q q q
21
MIC-21P
q q q
MIC-9P
ECONO2P
q q
ECONO3P
q q
ECONO4P
q q
ECONO8P
q q
12 ECONO12P q q
DLI-8P
q q
12
DLI-12P
q q
16
DLI-16P
q q
12 ECONO12P q q
q
q q
q q
q q q
799-601-2850 Case
799-601-4350 T-box (for DRC 60, ECONO)
60
799-601-4360 Case
799-601-7010 Adapter for X (T-adapter)
X2P
q q q
X3P
q q q
X4P
q q q
SW6P
q q q
SW8P
q q q
12
SW12P
q
M2P
q q q
M3P
q q q
14
SW14P
16
SW16P
44
q
q
D155AX-6
40 Troubleshooting
SEN00851-02
10
S10P
q q q
12
S12P
q q q
16
S16P
q q q
Out of kit
799-601-4201
q q q
799-601-4101
S8P
799-601-9300
799-601-9200
799-601-9100
M8P
799-601-9000
799-601-8000
q
799-601-7500
q q q
799-601-7400
q q q
M6P
799-601-7100
M4P
799-601-7000
799-601-2800
Part name
799-601-2700
Identification
symbol
Part No.
799-601-2500
Number of pins
T-adapter kit
q
q
16
S16PW
12
S12PW
A8P
12
A12P
16
A16P
q q q
20
A20P
q q q
q q q
q q
799-601-7240 Case
799-601-7270 Case
799-601-7510 Adapter for 070
10
07-10
12
07-12
14
07-14
18
07-18
20
07-20
REL-5P
REL-6P
DTM2
DT2
DT3
DT4
DT6
DT8GR
DT8B
DT8G
DT8BR
12
DT12GR
12
DT12B
12
DT12G
12
DT12BR
D18-8
q q
14
D18-14
q q
20
D18-20
q q
21
D18-21
q q
D24-9
q q
16
D24-16
q q
21
D24-21
q q
23
D24-23
q q
31
D24-31
q q
D155AX-6
24
q q
q q
q q
q q
45
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-2800
Identification
symbol
799-601-2700
Part name
T-adapter kit
799-601-2500
Part No.
40 Troubleshooting
Number of pins
SEN00851-02
799-601-9330 Case
799-601-9340 Case
799-601-9350 Adapter for DRC
40
DRC-40
24
DRC-24
A3
q q
q q
1,2,3
q q
q q
799-601-9430*
795-799-5540*
q
q
ITT3N
q q
FCIN
q q
FCIG
q q
FCIB
q q
4160
q q
4180
q q
1,2,3L
q q
1,2,3,4C
q q
1,2,3A
q q
1,2,3B
q q
1,2,3,G
q q
2,PA
q q
1,2,3,4T
DTP4
799-601-4140
799-601-4230*
799-601-4380*
q
q q
50
DRC50
60
DRC60
60
121
16
HST16A
16
HST16B
26
HST26A
2,
3,
4,
799-601-9890
Multi-adapter for
DT2 4 and DTM2
46
D155AX-6
SEN00851-02
40 Troubleshooting
47
D155AX-6
SEN00851-02
40 Troubleshooting
D155AX-6 Bulldozer
Form No. SEN00851-02
2009 KOMATSU
All Rights Reserved
Printed in Japan 06-09
48
D155AX-6
SEN00716-02
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
40 Troubleshooting
D155AX-6
SEN00716-02
40 Troubleshooting
D155AX-6
40 Troubleshooting
SEN00716-02
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Failure code
1500L0
Trouble
Among failure codes related to transmission clutch, 2 or more of following failure codes occurred
similarly.
1) Either [DXH4KA] or [DXH4KB]
2) Either [DXH5KA] or [DXH5KB]
3) Either [DXH6KA] or [DXH6KB]
Among failure codes related to transmission clutch, following combinations of failure codes
occurred similarly.
1) [15SAL1] and [15SBL1]
2) [15SALH] and [15SBLH]
3) 2 or all of [15SEL1], [15SFL1], and [15SGL1]
4) 2 or all of [15SELH], [15SFLH], and [15SGLH]
Limits operation of engine and transmission.
Auto-shift-down function does not operate.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to specific gear speed.
Method of reproducing failure code: Start engine + Travel.
Cause
Standard value in normal state/Remarks on troubleshooting
Possible causes
and standard If other failure codes are displayed, carry out troubleshooting for them.
value in normal [15SAL1], [15SALH], [15SBL1], [15SBLH], [15SEL1], [15SELH], [15SFL1], [15SFLH],
state
[15SGL1], [15SGLH], [DXH4KA], [DXH4KB], [DXH5KA], [DXH5KB], [DXH6KA], [DXH6KB]
D155AX-6
SEN00716-02
40 Troubleshooting
Failure code
E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
15SAL1
Trouble
When output to transmission F clutch ECMV solenoid circuit is turned OFF, fill switch signal is
turned ON.
Sets transmission in neutral when operator sets it in reverse position (Prevention of double engagement).
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1.
State of F clutch ECMV fill switch signal can be checked with monitoring function.
(Code: 40906 T/M Fill Sw Input 1)
Method of reproducing failure code: Start engine + Set transmission in neutral.
Cause
FFT (male)
Between (1) chassis ground
Possible causes
and standard
value in normal
state
PCCS lever
(Travel gear speed)
Resistance
Min. 1 Mz
F1, F2, F3
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between STC2 (female) (35)
FFT (female) (1) and chassis ground
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then start engine and carry
out troubleshooting.
3
STC2
Between (35) chassis ground
PCCS lever
(Travel gear speed)
Voltage
5 11 V
F1, F2, F3
Max. 1 V
If causes 1 3 are not detected in electrical system, hydraulic system may be defective. Carry out related troubleshooting (H mode).
D155AX-6
40 Troubleshooting
SEN00716-02
Failure code
E03
15SALH
Trouble
Contents of
trouble
When output to transmission F clutch ECMV solenoid circuit is turned ON, fill switch signal is turned
OFF.
Action of
controller
Sets transmission in neutral when operator sets it in forward position (Prevention of double engagement).
Limits operation of engine and transmission.
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
FFT (male)
Between (1) chassis ground
PCCS lever
(Travel gear speed)
Resistance
Min. 1 Mz
F1, F2, F3
Max. 1 z
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
ness (Disconnection in wiring
2
or defective contact in con- Wiring harness between STC2 (female) (35)
ResisMax. 1 z
nector)
FFT (female) (1)
tance
a Prepare with starting switch OFF, then start engine and carry
out troubleshooting.
3
STC2
Between (35) chassis ground
PCCS lever
(Travel gear speed)
Voltage
5 11 V
F1, F2, F3
Max. 1 V
If causes 1 3 are not detected in electrical system, hydraulic system may be defective. Carry out related troubleshooting (H mode).
D155AX-6
SEN00716-02
40 Troubleshooting
Failure code
E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
15SBL1
Trouble
When output to transmission R clutch ECMV solenoid circuit is turned OFF, fill switch signal is
turned ON.
Sets transmission in neutral when operator sets it in forward position (Prevention of double engagement).
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to R1.
State of R clutch ECMV fill switch signal can be checked with monitoring function.
(Code: 40906 T/M Fill Sw Input 1)
Method of reproducing failure code: Start engine + Set transmission in neutral.
Cause
FRT (male)
Between (1) chassis ground
Possible causes
and standard
value in normal
state
PCCS lever
(Travel gear speed)
Resistance
Min. 1 Mz
R1, R2, R3
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
2 ness (Contact with GND cirWiring harness between STC2 (female) (25)
Resiscuit)
Min. 1 Mz
FRT (female) (1) and chassis ground
tance
a Prepare with starting switch OFF, then start engine and carry
out troubleshooting.
3
STC2
Between (25) chassis ground
PCCS lever
(Travel gear speed)
Voltage
5 11 V
R1, R2, R3
Max. 1 V
If causes 1 3 are not detected in electrical system, hydraulic system may be defective. Carry out related troubleshooting (H mode).
D155AX-6
40 Troubleshooting
SEN00716-02
Failure code
E03
15SBLH
Trouble
Contents of
trouble
When output to transmission R clutch ECMV solenoid circuit is turned ON, fill switch signal is turned
OFF.
Action of
controller
Sets transmission in neutral when operator sets it in reverse position (Prevention of double engagement).
Limits operation of engine and transmission.
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
FRT (male)
Between (1) chassis ground
PCCS lever
(Travel gear speed)
Resistance
Min. 1 Mz
R1, R2, R3
Max. 1 z
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
ness (Disconnection in wiring
2
or defective contact in con- Wiring harness between STC2 (female) (25)
ResisMax. 1 z
nector)
FRT (female) (1)
tance
a Prepare with starting switch OFF, then start engine and carry
out troubleshooting.
3
STC2
Between (25) chassis ground
PCCS lever
(Travel gear speed)
Voltage
5 11 V
R1, R2, R3
Max. 1 V
If causes 1 3 are not detected in electrical system, hydraulic system may be defective. Carry out related troubleshooting (H mode).
D155AX-6
SEN00716-02
40 Troubleshooting
Failure code
E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
15SEL1
Trouble
When output to transmission 1st clutch ECMV solenoid circuit is turned OFF, fill switch signal is
turned ON.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1 and R1.
State of 1st clutch ECMV fill switch signal can be checked with monitoring function.
(Code: 40906 T/M Fill Sw Input 1)
Method of reproducing failure code: Start engine + Set transmission in neutral.
Cause
Possible causes
and standard
value in normal
state
F1T (male)
Between (1) chassis ground
PCCS lever
(Travel gear speed)
Resistance
Min. 1 Mz
F1, R1
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
2 ness (Contact with GND cirWiring harness between STC3 (female) (19)
Resiscuit)
Min. 1 Mz
F1T (female) (1) and chassis ground
tance
a Prepare with starting switch OFF, then start engine, select
manual gearshift mode, and carry out troubleshooting.
3
STC3
Between (19) chassis ground
PCCS lever
(Travel gear speed)
Voltage
5 11 V
F1, R1
Max. 1 V
If causes 1 3 are not detected in electrical system, hydraulic system may be defective. Carry out related troubleshooting (H mode).
D155AX-6
40 Troubleshooting
SEN00716-02
Failure code
E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
15SELH
Trouble
When output to transmission 1st clutch ECMV solenoid circuit is turned ON, fill switch signal is
turned OFF.
Limits operation of engine and transmission.
Auto-shift-down function does not operate.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F2 and R2.
State of 1st clutch ECMV fill switch signal can be checked with monitoring function.
(Code: 40906 T/M Fill Sw Input 1)
Method of reproducing failure code: Start engine + Set transmission in F1 or R1 position (in manual
gearshift mode).
Cause
Possible causes
and standard
value in normal
state
F1T (male)
Between (1) chassis ground
PCCS lever
(Travel gear speed)
Resistance
Min. 1 Mz
F1, R1
Max. 1 z
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
ness (Disconnection in wiring
2
or defective contact in con- Wiring harness between STC3 (female) (19)
ResisMax. 1 z
nector)
F1T (female) (1)
tance
a Prepare with starting switch OFF, then start engine, select
manual gearshift mode, and carry out troubleshooting.
3
STC3
Between (19) chassis ground
PCCS lever
(Travel gear speed)
Voltage
5 11 V
F1, R1
Max. 1 V
If causes 1 3 are not detected in electrical system, hydraulic system may be defective. Carry out related troubleshooting (H mode).
D155AX-6
SEN00716-02
40 Troubleshooting
Failure code
E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
15SFL1
Trouble
When output to transmission 2nd clutch ECMV solenoid circuit is turned OFF, fill switch signal is
turned ON.
Limits operation of engine and transmission.
Auto-shift-down function does not operate.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F2 and R2.
State of 2nd clutch ECMV fill switch signal can be checked with monitoring function.
(Code: 40906 T/M Fill Sw Input 1)
Method of reproducing failure code: Start engine + Set transmission in neutral.
Cause
Possible causes
and standard
value in normal
state
F2T (male)
Between (1) chassis ground
PCCS lever
(Travel gear speed)
Resistance
Min. 1 Mz
F2, R2
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
2 ness (Contact with GND cirWiring harness between STC3 (female) (29)
Resiscuit)
Min. 1 Mz
F2T (female) (1) and chassis ground
tance
a Prepare with starting switch OFF, then start engine, select
manual gearshift mode, and carry out troubleshooting.
3
STC3
Between (29) chassis ground
PCCS lever
(Travel gear speed)
Voltage
5 11 V
F2, R2
Max. 1 V
If causes 1 3 are not detected in electrical system, hydraulic system may be defective. Carry out related troubleshooting (H mode).
10
D155AX-6
40 Troubleshooting
SEN00716-02
Failure code
E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
15SFLH
Trouble
When output to transmission 2nd clutch ECMV solenoid circuit is turned ON, fill switch signal is
turned OFF.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1 and R1.
State of 2nd clutch ECMV fill switch signal can be checked with monitoring function.
(Code: 40906 T/M Fill Sw Input 1)
Method of reproducing failure code: Start engine + Set transmission in F2 or R2 position (in manual
gearshift mode).
Cause
Possible causes
and standard
value in normal
state
F2T (male)
Between (1) chassis ground
PCCS lever
(Travel gear speed)
Resistance
Min. 1 Mz
F2, R2
Max. 1 z
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
ness (Disconnection in wiring
2
or defective contact in con- Wiring harness between STC3 (female) (29)
ResisMax. 1 z
nector)
F2T (female) (1)
tance
a Prepare with starting switch OFF, then start engine, select
manual gearshift mode, and carry out troubleshooting.
3
STC3
Between (29) chassis ground
PCCS lever
(Travel gear speed)
Voltage
5 11 V
F2, R2
Max. 1 V
If causes 1 3 are not detected in electrical system, hydraulic system may be defective. Carry out related troubleshooting (H mode).
D155AX-6
11
SEN00716-02
40 Troubleshooting
Failure code
E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
15SGL1
Trouble
When output to transmission 3rd clutch ECMV solenoid circuit is turned OFF, fill switch signal is
turned ON.
Limits operation of engine and transmission.
Auto-shift-down function does not operate.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F3 and R3.
State of 3rd clutch ECMV fill switch signal can be checked with monitoring function.
(Code: 40906 T/M Fill Sw Input 1)
Method of reproducing failure code: Start engine + Set transmission in neutral.
Cause
Possible causes
and standard
value in normal
state
F3T (male)
Between (1) chassis ground
PCCS lever
(Travel gear speed)
Resistance
Min. 1 Mz
F3, R3
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
2 ness (Contact with GND cirWiring harness between STC3 (female) (39)
Resiscuit)
Min. 1 Mz
F3T (female) (1) and chassis ground
tance
a Prepare with starting switch OFF, then start engine, select
manual gearshift mode, and carry out troubleshooting.
3
STC3
Between (39) chassis ground
PCCS lever
(Travel gear speed)
Voltage
5 11 V
F3, R3
Max. 1 V
If causes 1 3 are not detected in electrical system, hydraulic system may be defective. Carry out related troubleshooting (H mode).
12
D155AX-6
40 Troubleshooting
SEN00716-02
Failure code
E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
15SGLH
Trouble
When output to transmission 3rd clutch ECMV solenoid circuit is turned ON, fill switch signal is
turned OFF.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1 and R1.
State of 3rd clutch ECMV fill switch signal can be checked with monitoring function.
(Code: 40906 T/M Fill Sw Input 1)
Method of reproducing failure code: Start engine + Set transmission in F3 or R3 position (in manual
gearshift mode).
Cause
Possible causes
and standard
value in normal
state
F3T (male)
Between (1) chassis ground
PCCS lever
(Travel gear speed)
Resistance
Min. 1 Mz
F3, R3
Max. 1 z
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
ness (Disconnection in wiring
2
or defective contact in con- Wiring harness between STC3 (female) (39)
ResisMax. 1 z
nector)
F3T (female) (1)
tance
a Prepare with starting switch OFF, then start engine, select
manual gearshift mode, and carry out troubleshooting.
3
STC3
Between (39) chassis ground
PCCS lever
(Travel gear speed)
Voltage
5 11 V
F3, R3
Max. 1 V
If causes 1 - 3 are not detected in electrical system, hydraulic system may be defective. Carry out related troubleshooting (H mode).
D155AX-6
13
SEN00716-02
40 Troubleshooting
Failure code
E02
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
15SJL1
Trouble
When output to torque converter lockup clutch ECMV solenoid circuit is turned OFF, fill switch signal is turned ON.
None in particular.
Engine may stall during travel.
State of lockup clutch ECMV fill switch signal can be checked with monitoring function.
(Code: 31520 T/M Fill Sw Input 2)
Method of reproducing failure code: Start engine + Set transmission in forward position (in automatic gearshift mode).
Cause
Possible causes
and standard
value in normal
state
FLUC (male)
Between (1) chassis ground
PCCS lever
(Travel gear speed)
Resistance
Min. 1 Mz
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
2 ness (Contact with GND cirWiring harness between STC2 (female) (36)
Resiscuit)
Min. 1 Mz
FLUC (female) (1) and chassis ground
tance
a Prepare with starting switch OFF, then start engine, select
automatic gearshift mode, and carry out troubleshooting.
3
14
STC2
PCCS lever
(Travel gear speed)
N
Between (36) chasLocked up at F1, F2,
sis ground
or F3
Voltage
5 11 V
Max. 1 V
If causes 1 3 are not detected in electrical system, hydraulic system may be defective. Carry out related troubleshooting (H mode).
D155AX-6
40 Troubleshooting
SEN00716-02
D155AX-6
15
SEN00716-02
40 Troubleshooting
Failure code
E02
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
15SJLH
Trouble
When output to torque converter lockup clutch ECMV solenoid circuit is turned ON, fill switch signal
is turned OFF.
None in particular.
Engine may stall during travel.
State of lockup clutch ECMV fill switch signal can be checked with monitoring function.
(Code: 31520 T/M Fill Sw Input 2)
Method of reproducing failure code: Start engine + Set transmission in forward position (in automatic gearshift mode).
Cause
Possible causes
and standard
value in normal
state
FLUC (male)
Between (1) chassis ground
PCCS lever
(Travel gear speed)
Resistance
Min. 1 Mz
Max. 1 z
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
ness (Disconnection in wiring
2
or defective contact in con- Wiring harness between STC2 (female) (36)
ResisMax. 1 z
nector)
FLUC (female) (1)
tance
a Prepare with starting switch OFF, then start engine, select
automatic gearshift mode, and carry out troubleshooting.
3
16
STC2
PCCS lever
(Travel gear speed)
N
Between (36) chasLocked up at F1, F2,
sis ground
or F3
Voltage
5 11 V
Max. 1 V
If causes 1 3 are not detected in electrical system, hydraulic system may be defective. Carry out related troubleshooting (H mode).
D155AX-6
40 Troubleshooting
SEN00716-02
D155AX-6
17
SEN00716-02
40 Troubleshooting
Failure code
E04
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
2301L1
Trouble
When output to steering case right brake ECMV solenoid circuit is turned OFF, fill switch signal is
turned ON.
Limits operation of engine, transmission, and brake.
Applies brake lightly during travel.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, machine cannot travel at all.
State of right brake ECMV fill switch signal can be checked with monitoring function.
(Code: 31521 S/T Fill Sw Input)
Method of reproducing failure code: Start engine + Operate parking brake lever (Free) + Operate
brake pedal (Press).
Cause
Defective right brake ECMV
1 fill switch (Internal short circuit)
Possible causes
and standard
value in normal
state
Brake pedal
Resistance
Released
Max. 1 z
Pressed
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
2 ness (Contact with GND cirWiring
harness between STC2 (female) (38)
Resiscuit)
Min. 1 Mz
FBRR (female) (1) and chassis ground
tance
a Prepare with starting switch OFF, then start engine, set parking
brake lever in Free position, and carry out troubleshooting.
3
STC2
Brake pedal
Voltage
Released
Max. 1 V
Pressed
5 11V
If causes 1 3 are not detected in electrical system, hydraulic system may be defective. Carry out related troubleshooting (H mode).
18
D155AX-6
40 Troubleshooting
SEN00716-02
Failure code
E04
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
2301LH
Trouble
When output to steering case right brake ECMV solenoid circuit is turned ON, fill switch signal is
turned OFF.
Limits operation of engine, transmission, and brake.
Applies brake lightly during travel.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, machine cannot travel at all.
State of right brake ECMV fill switch signal can be checked with monitoring function.
(Code: 31521 S/T Fill Sw Input)
Method of reproducing failure code: Start engine + Operate parking brake lever (Free) + Operate
brake pedal (Press).
Cause
Defective right brake ECMV
1 fill switch (Internal short circuit)
Possible causes
and standard
value in normal
state
Brake pedal
Resistance
Released
Max. 1 z
Pressed
Min. 1 Mz
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
ness (Disconnection in wiring
2
or defective contact in con- Wiring harness between STC2 (female) (38)
ResisMax. 1 z
nector)
FBRR (female) (1)
tance
a Prepare with starting switch OFF, then start engine, set parking
brake lever in Free position, and carry out troubleshooting.
3
STC2
Brake pedal
Voltage
Released
Max. 1 V
Pressed
5 11 V
If causes 1 3 are not detected in electrical system, hydraulic system may be defective. Carry out related troubleshooting (H mode).
D155AX-6
19
SEN00716-02
40 Troubleshooting
Failure code
E04
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
2302L1
Trouble
When output to steering case left brake ECMV solenoid circuit is turned OFF, fill switch signal is
turned ON.
Limits operation of engine, transmission, and brake.
Applies brake lightly during travel.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, machine cannot travel at all.
State of left brake ECMV fill switch signal can be checked with monitoring function.
(Code: 31521 S/T Fill Sw Input)
Method of reproducing failure code: Start engine + Operate parking brake lever (Free) + Operate
brake pedal (Press).
Cause
Possible causes
and standard
value in normal
state
FBRL (male)
Brake pedal
Resistance
Released
Max. 1 z
Pressed
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
2 ness (Contact with GND cirWiring
harness between STC2 (female) (2)
Resiscuit)
Min. 1 Mz
FBRL (female) (1) and chassis ground
tance
a Prepare with starting switch OFF, then start engine, set parking
brake lever in Free position, and carry out troubleshooting.
3
STC2
Brake pedal
Voltage
Released
Max. 1 V
Pressed
5 11 V
If causes 1 3 are not detected in electrical system, hydraulic system may be defective. Carry out related troubleshooting (H mode).
20
D155AX-6
40 Troubleshooting
SEN00716-02
Failure code
E04
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
2302LH
Trouble
When output to steering case left brake ECMV solenoid circuit is turned ON, fill switch signal is
turned OFF.
Limits operation of engine, transmission, and brake.
Applies brake lightly during travel.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, machine cannot travel at all.
State of left brake ECMV fill switch signal can be checked with monitoring function.
(Code: 31521 S/T Fill Sw Input)
Method of reproducing failure code: Start engine + Operate parking brake lever (Free) + Operate
brake pedal (Press).
Cause
Possible causes
and standard
value in normal
state
FBRL (male)
Brake pedal
Resistance
Released
Max. 1 z
Pressed
Min. 1 Mz
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
ness (Disconnection in wiring
2
or defective contact in con- Wiring harness between STC2 (female) (2)
ResisMax. 1 z
nector)
FBRL (female) (1)
tance
a Prepare with starting switch OFF, then start engine, set parking
brake lever in Free position, and carry out troubleshooting.
3
STC2
Brake pedal
Voltage
Released
Max. 1 V
Pressed
5 11 V
If causes 1 3 are not detected in electrical system, hydraulic system may be defective. Carry out related troubleshooting (H mode).
D155AX-6
21
SEN00716-02
40 Troubleshooting
Failure code
7RFAKA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When ground circuit of engine cut relay circuit is disconnected to turn output ON, no current flows.
None in particular.
When engine cut mechanism is installed, engine cannot be cut (stopped).
State of engine cut relay circuit signal can be checked with monitoring function.
(Code: 40912 P/T Sw Input)
Method of reproducing failure code: Start engine.
This failure code detects abnormality on primary side (coil side) of engine cut relay but does not
detect abnormality on secondary side (contact side).
Cause
Resistance
200 400 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC2 (female) (19)
2
or defective contact in con- ACT (female) (2)
nector)
Wiring harness between ACT (female) (1)
terminal 270.
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Short circuit in wiring harWiring harness between STC2 (female) (19)
3 ness (Contact with GND cir- ACT (female) (2) and chassis ground
cuit)
Wiring harness between ACT (female) (1),
(3) terminal 270, circuit branch end and
chassis ground.
Defective power train con4
troller
22
Resistance
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Voltage
20 30 V
D155AX-6
40 Troubleshooting
SEN00716-02
D155AX-6
23
SEN00716-02
40 Troubleshooting
Failure code
Contents of
trouble
AA10NX
Trouble
While engine was running, air cleaner clogging switch signal circuit detected clogging of air cleaner
(opening of sensor contact).
Action of
None in particular.
machine monitor
Problem that
appears on
machine
Related
information
Cause
1
Possible causes
and standard
value in normal
state
AF1 (male)
Air cleaner
Resistance
Max. 1 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between CM02 (female) (4)
3
or defective contact in con- AF1 (female) (1)
nector)
Wiring harness between CM01 (female) (7),
CM02 (female) (7) AF1 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then start engine and carry
out troubleshooting.
Defective power train con4
troller
CM02
Air cleaner
Voltage
Max. 1 V
20 30 V
24
D155AX-6
40 Troubleshooting
SEN00716-02
D155AX-6
25
SEN00716-02
40 Troubleshooting
Failure code
AB00MA
Contents of
trouble
Trouble
While engine was running, alternator signal circuit detected that battery charge voltage was low.
Action of
Displays charge level monitor red on machine monitor.
machine monitor
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
26
Engine
Voltage
Above medium
speed
27.5 29.5 V
D155AX-6
40 Troubleshooting
SEN00716-02
D155AX-6
27
SEN00716-02
40 Troubleshooting
Failure code
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
B@BAZG
Trouble
While engine was running, engine oil pressure sensor signal circuit detected that engine oil pressure was abnormally low.
Displays engine oil pressure monitor red on machine monitor.
If machine is used as it is, engine may be seized.
Engine oil pressure sensor signal is input to engine controller and then transmitted to machine monitor through communication system.
Engine oil pressure can be checked with monitoring function.
(Code: 37200 Engine Oil Pressure)
Method of reproducing failure code: Start engine.
Cause
Possible causes
and standard
value in normal
state
Failure code
B@BCNS
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
28
While engine was running, engine coolant temperature sensor signal circuit detected that engine
coolant was overheated.
Displays engine coolant temperature monitor red on machine monitor.
If machine is used as it is, engine may be seized.
Engine coolant temperature sensor signal is input to engine controller and then transmitted to
machine monitor through communication system.
Engine coolant temperature can be checked with monitoring function.
(Code: 04107 Coolant Temperature)
Method of reproducing failure code: Start engine.
Cause
Possible causes
and standard
value in normal
state
D155AX-6
40 Troubleshooting
SEN00716-02
Failure code
Contents of
trouble
B@BCZK
Trouble
While starting switch was ON (and engine was stopped) or engine was running, radiator coolant
level switch signal circuit detected that radiator coolant level was low (sensor contact was open).
Action of
Displays radiator coolant level monitor red on machine monitor.
machine monitor
Problem that
appears on
machine
Related
information
Cause
Possible causes
and standard
value in normal
state
Failure code
B@CENS
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
D155AX-6
While engine was running, torque converter oil temperature sensor signal circuit detected that
power train oil was overheated.
Displays torque converter oil temperature monitor red on machine monitor.
If machine is used as it is, power train components may be damaged.
Torque converter oil temperature sensor signal is input to power train controller and then transmitted to machine monitor through communication system.
Power train oil temperature can be checked with monitoring function.
(Code: 30100 T/C Oil Temperature)
Method of reproducing failure code: Start engine.
Cause
Possible causes
and standard
value in normal
state
29
SEN00716-02
40 Troubleshooting
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Failure code
B@HANS
Trouble
30
While engine was running, hydraulic oil temperature sensor signal circuit detected that hydraulic oil
was overheated.
Displays hydraulic oil temperature monitor red on machine monitor.
If machine is used as it is, work equipment and HSS circuit components may be damaged.
Hydraulic oil temperature can be checked with monitoring function.
(Code: 04401 Hyd Oil Temperature)
Method of reproducing failure code: Start engine.
Cause
Possible causes
and standard
value in normal
state
D155AX-6
40 Troubleshooting
D155AX-6
SEN00716-02
31
SEN00716-02
40 Troubleshooting
D155AX-6 Bulldozer
Form No. SEN00716-02
2008 KOMATSU
All Rights Reserved
Printed in Japan 10-08 (02)
32
D155AX-6
SEN00717-03
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
40 Troubleshooting
D155AX-6
SEN00717-03
40 Troubleshooting
D155AX-6
40 Troubleshooting
D155AX-6
SEN00717-03
SEN00717-03
40 Troubleshooting
Failure code
E04
CA111
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Engine runs normally but may stop during operation or may not be able to start.
Source voltage of engine controller can be checked with monitoring function.
(Code: 03203 Battery Power Supply)
Cause
1
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
EGC3
Starting switch
Voltage
ON
20 30 V
D155AX-6
40 Troubleshooting
SEN00717-03
D155AX-6
SEN00717-03
40 Troubleshooting
Failure code
E04
CA115
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Trouble occurred in Ne speed sensor circuit and Bkup speed sensor circuit simultaneously.
None in particular.
Engine cannot be started (if engine has been stopped).
Engine stops (if engine has been running).
Related
information
Cause
Possible causes
and standard
value in normal
state
Ne speed sensor system may be defective. Carry out troubleshooting for code [CA689].
Bkup speed sensor system may be defective. Carry out troubleshooting for code [CA778].
Defective mount of Ne speed Check mount of Ne speed sensor directly for defect (defective
sensor
installation of sensor, internal trouble of flywheel, etc.)
Defective connection (Wrong Check Ne speed sensor and Bkup speed sensor directly for defecconnection) of sensor
tive connection (wrong connection).
If causes 1 5 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried
out.)
D155AX-6
40 Troubleshooting
D155AX-6
SEN00717-03
SEN00717-03
40 Troubleshooting
Failure code
E03
CA122
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Defective sensor power sup- If code [CA187] or [CA227] is indicated, carry out troubleshooting
1
ply system
for it first.
a Prepare with starting switch OFF, then turn starting switch ON
or start engine and carry out troubleshooting.
2
PIM
Between (1) (2)
Voltage
Power supply
4.75 5.25 V
Pressure sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness
and controller, too, for another cause of trouble, and then judge.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring
3
or defective contact in connector)
Possible causes
and standard
value in normal
state
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG (female) (37)
Ground fault in wiring har PIM (female) (1) and chassis ground
4 ness (Contact with GND cirWiring harness between ENG (female) (47)
cuit)
PIM (female) (2) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
ENG
Between (37) (47)
Voltage
Power supply
4.75 5.25 V
D155AX-6
40 Troubleshooting
SEN00717-03
D155AX-6
SEN00717-03
40 Troubleshooting
Failure code
E03
CA123
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
10
Trouble
Acceleration performance of engine lowers or black smoke is produced more during acceleration.
State of charge pressure sensor can be checked with monitoring function.
(Code: 36500 Charge Pressure-Abs)
Cause
D155AX-6
40 Troubleshooting
D155AX-6
SEN00717-03
11
SEN00717-03
40 Troubleshooting
Failure code
E03
CA131
Contents of
trouble
Action of
controller
Trouble
Problem that
appears on
machine
Related
information
State of decelerator pedal optimum operation range signal can be checked with monitoring function.
(Code: 03001 Throttle Pos Sens Volt)
Cause
1
Defective sensor power sup- If code [CA2185] or [CA2186] is indicated, carry out troubleshootply system
ing for it first.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
DCL (male)
Resistance
1.5 2.5 kz
0 3 kz
0 3 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between EGC2 (female) (9)
Ground fault in wiring har DCL (female) (A) and chassis ground
4 ness (Contact with GND cirWiring harness between EGC2 (female)
cuit)
(22) DCL (female) (B) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
12
EGC2
Voltage
Power supply
4.75 5.25 V
Signal
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00717-03
D155AX-6
13
SEN00717-03
40 Troubleshooting
Failure code
E03
CA132
Trouble
Contents of
trouble
Action of
controller
Sets throttle position with fuel control dial signal and continues operation.
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
14
State of decelerator pedal optimum operation range signal can be checked with monitoring function.
(Code: 03001 Throttle Pos Sens Volt)
Cause
D155AX-6
40 Troubleshooting
D155AX-6
SEN00717-03
15
SEN00717-03
40 Troubleshooting
Failure code
E02
CA135
Contents of
trouble
Action of
controller
Trouble
Problem that
appears on
machine
Related
information
State of engine oil pressure sensor can be checked with monitoring function.
(Code: 37201 Eng Oil Press Sens Volt)
Cause
1
Defective sensor power sup- If code [CA187] or [CA227] is indicated, carry out troubleshooting
ply system
for it first.
a Prepare with starting switch OFF, then turn starting switch ON
or start engine and carry out troubleshooting.
POIL
Between (1) (2)
Voltage
Power supply
4.75 5.25 V
Possible causes
and standard
value in normal
state
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG (female) (37)
Ground fault in wiring har POIL (female) (1) and chassis ground
4 ness (Contact with GND cirWiring harness between ENG (female) (47)
cuit)
POIL (female) (2) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
ENG
Between (37) (47)
16
Voltage
Power supply
4.75 5.25 V
D155AX-6
40 Troubleshooting
SEN00717-03
D155AX-6
17
SEN00717-03
40 Troubleshooting
Failure code
E02
CA141
Contents of
trouble
Action of
controller
Trouble
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
18
State of engine oil pressure sensor can be checked with monitoring function.
(Code: 37201 Eng Oil Press Sens Volt)
Cause
D155AX-6
40 Troubleshooting
D155AX-6
SEN00717-03
19
SEN00717-03
40 Troubleshooting
Failure code
E02
CA144
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Possible causes
and standard
value in normal
state
Coolant temperature
Resistance
0C
30 37 kz
25C
9.3 10.7 kz
50C
3.2 3.8 kz
80C
1.0 1.3 kz
95C
700 800 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female) (15)
Resis2
Max. 1 z
or defective contact in con- TWTR (female) (A)
tance
nector)
Wiring harness between ENG (female) (38)
ResisMax. 1 z
TWTR (female) (B)
tance
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
3 ness (Contact with GND cirWiring harness between ENG (female) (15)
Resiscuit)
Min. 1 Mz
TWTR (female) (A) and chassis ground
tance
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
ENG (female)
4 Defective engine controller
Between (15) (38)
20
Coolant temperature
Resistance
0C
30 37 kz
25C
9.3 10.7 kz
50C
3.2 3.8 kz
80C
1.0 1.3 kz
95C
700 800 z
D155AX-6
40 Troubleshooting
SEN00717-03
D155AX-6
21
SEN00717-03
40 Troubleshooting
Failure code
E02
CA145
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
22
Trouble
D155AX-6
40 Troubleshooting
D155AX-6
SEN00717-03
23
SEN00717-03
40 Troubleshooting
Failure code
E01
CA153
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Intake air
temperature
Resistance
0C
29 36 kz
25C
9 11 kz
40C
4.9 5.8 kz
100C
600 700 z
All range
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female) (23)
2
or defective contact in con- TIM (female) (A)
nector)
Wiring harness between ENG (female) (47)
TIM (female) (B)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
3 ness (Contact with GND cirWiring harness between ENG (female) (23)
Resiscuit)
Min. 1 Mz
TIM (female) (A) and chassis ground
tance
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
ENG (female)
4 Defective engine controller
Between (23) (47)
24
Intake air
temperature
Resistance
0C
29 36 kz
25C
9 11 kz
40C
4.9 5.8 kz
100C
600 700 z
D155AX-6
40 Troubleshooting
SEN00717-03
D155AX-6
25
SEN00717-03
40 Troubleshooting
Failure code
E01
CA154
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Possible causes
and standard
value in normal
state
Cause
Failure code
E03
CA187
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Related
information
Possible causes
and standard
value in normal
state
26
Cause
D155AX-6
40 Troubleshooting
D155AX-6
SEN00717-03
27
SEN00717-03
40 Troubleshooting
Failure code
E03
CA221
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Defective sensor power sup- If code [CA187] or [CA227] is indicated, carry out troubleshooting
1
ply system
for it first.
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
PAMB
2
Voltage
Power supply
Signal
4.75 5.25 V
Possible causes
and standard
value in normal
state
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG (female) (37)
Ground fault in wiring har PAMB (female) (1) and chassis ground
4 ness (Contact with GND cirWiring harness between ENG (female) (38)
cuit)
PAMB (female) (2) and chassis ground
Wiring harness between ENG (female) (3)
PAMB (female) (3) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
ENG
Voltage
4.75 5.25 V
28
D155AX-6
40 Troubleshooting
SEN00717-03
D155AX-6
29
SEN00717-03
40 Troubleshooting
Failure code
E03
CA222
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
30
Trouble
D155AX-6
40 Troubleshooting
D155AX-6
SEN00717-03
31
SEN00717-03
40 Troubleshooting
Failure code
E03
CA227
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Related
information
Cause
1 Defective related system
Possible causes
and standard
value in normal
state
Disconnect devices
at right in order. If
"E" of failure code
disappears when a
device is disconnected, that device
has trouble in it.
G connector
POIL connector
Ambient pressure
sensor
PAMB connector
Charge pressure
sensor
PIM connector
PEVA connector
SEGR connector
SBP connector
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female) (37)
Resis3
Max. 1 z
or defective contact in con- each sensor (female)
tance
nector)
Wiring harness between ENG (female) (47)
ResisMax. 1 z
each sensor (female)
tance
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between ENG (female) (37)
4 ness (Contact with GND cir each sensor (female) and chassis ground
cuit)
Wiring harness between ENG (female) (47)
each sensor (female) and chassis ground
Short circuit in wiring har5 ness (with another wiring
harness)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG (female) (37)
each sensor (female) and between ENG
(female) (47) each sensor (female)
Resistance
Min. 1 Mz
32
ENG
Voltage
4.75 5.25 V
D155AX-6
40 Troubleshooting
SEN00717-03
D155AX-6
33
SEN00717-03
40 Troubleshooting
Failure code
CA234
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
34
Eng Overspeed
(Engine controller system)
Possible causes
and standard
value in normal
state
If causes 1 2 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried
out.)
D155AX-6
40 Troubleshooting
D155AX-6
SEN00717-03
35
SEN00717-03
40 Troubleshooting
Failure code
E03
CA238
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Related
information
Cause
Disconnect devices
at right in order. If
"E" of failure code
disappears when a
device is disconnected, that device
has trouble in it.
Engine Ne speed
sensor
NE connector
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female) (16)
2
or defective contact in con- NE (female) (1)
nector)
Wiring harness between ENG (female) (48)
NE (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between ENG (female) (16)
3 ness (Contact with GND cir NE (female) (1) and chassis ground
cuit)
Wiring harness between ENG (female) (48)
NE (female) (2) and chassis ground
Short circuit in wiring har4 ness (with another wiring
harness)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG (female) (16)
NE (female) (1) and between ENG
(female) (48) NE (female) (2)
Resistance
Min. 1 Mz
36
ENG
Voltage
4.75 5.25 V
D155AX-6
40 Troubleshooting
SEN00717-03
D155AX-6
37
SEN00717-03
40 Troubleshooting
Failure code
E01
CA263
Contents of
trouble
Action of
controller
Trouble
Problem that
appears on
machine
Related
information
State of fuel temperature sensor signal can be checked with monitoring function.
(Code: 14201 Fuel Temp Sens Volt)
Cause
Possible causes
and standard
value in normal
state
Fuel temperature
Resistance
0C
30 37 kz
25C
9.3 10.7 kz
50C
3.2 3.8 kz
80C
1.0 1.3 kz
95C
700 800 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female) (30)
Resis2
Max. 1 z
or defective contact in con- TFUEL (female) (A)
tance
nector)
Wiring harness between ENG (female) (47)
ResisMax. 1 z
TFUEL (female) (B)
tance
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
3 ness (Contact with GND cirWiring harness between ENG (female) (30)
Resiscuit)
Min. 1 Mz
TFUEL (female) (A) and chassis ground
tance
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
ENG (female)
4 Defective engine controller
Between (30) (47)
38
Fuel temperature
Resistance
0C
30 37 kz
25C
9.3 10.7 kz
50C
3.2 3.8 kz
80C
1.0 1.3 kz
95C
700 800 z
D155AX-6
40 Troubleshooting
SEN00717-03
D155AX-6
39
SEN00717-03
40 Troubleshooting
Failure code
E01
CA265
Contents of
trouble
Action of
controller
Trouble
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
40
Cause
D155AX-6
40 Troubleshooting
SEN00717-03
Failure code
E03
CA271
Contents of
trouble
Action of
controller
Trouble
Problem that
appears on
machine
Related
information
Cause
PCV1 (male)
Resistance
2.3 5.3 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Hot short (Short circuit with Wiring harness between ENG (female) (4)
24V circuit) in wiring harness PCV1 (female) (1) and chassis ground
Voltage
Max. 1 V
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4 Defective engine controller
ENG (female)
Resistance
2.3 5.3 z
Min. 1 Mz
D155AX-6
41
SEN00717-03
40 Troubleshooting
Failure code
E03
CA272
Contents of
trouble
Action of
controller
Trouble
Problem that
appears on
machine
Related
information
Cause
PCV1 (male)
Resistance
2.3 5.3 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female) (4)
2
or defective contact in con- PCV1 (female) (1)
nector)
Wiring harness between ENG (female) (5)
PCV1 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between ENG (female) (4)
3 ness (Contact with GND cir PCV1 (female) (1) and chassis ground
cuit)
Wiring harness between ENG (female) (5)
PCV1 (female) (2) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4 Defective engine controller
ENG (female)
Resistance
2.3 5.3 z
Min. 1 Mz
42
D155AX-6
40 Troubleshooting
SEN00717-03
Failure code
E03
CA273
Contents of
trouble
Action of
controller
Trouble
Problem that
appears on
machine
Related
information
Cause
PCV2 (male)
Resistance
2.3 5.3 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Hot short (Short circuit with Wiring harness between ENG (female) (9)
24V circuit) in wiring harness PCV2 (female) (1) and chassis ground
Wiring harness between ENG (female) (10)
PCV2 (female) (2) and chassis ground
Voltage
Max. 1 V
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4 Defective engine controller
ENG (female)
Resistance
2.3 5.3 z
Min. 1 Mz
D155AX-6
43
SEN00717-03
40 Troubleshooting
Failure code
E03
CA274
Contents of
trouble
Action of
controller
Trouble
Problem that
appears on
machine
Related
information
Cause
PCV2 (male)
Resistance
2.3 5.3 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female) (9)
2
or defective contact in con- PCV2 (female) (1)
nector)
Wiring harness between ENG (female) (10)
PCV2 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between ENG (female) (9)
3 ness (Contact with GND cir PCV2 (female) (1) and chassis ground
cuit)
Wiring harness between ENG (female) (10)
PCV2 (female) (2) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4 Defective engine controller
ENG (female)
Resistance
2.3 5.3 z
Min. 1 Mz
44
D155AX-6
40 Troubleshooting
SEN00717-03
D155AX-6
45
SEN00717-03
40 Troubleshooting
Failure code
E03
CA322
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Related
information
Cause
CN1 (male)
Resistance
0.4 1.1 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female) (45)
2
or defective contact in con- CN1 (female) (1)
nector)
Wiring harness between ENG (female) (53)
CN1 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between ENG (female) (45)
3 ness (Contact with GND cir CN1 (female) (1) and chassis ground
cuit)
Wiring harness between ENG (female) (53)
CN1 (female) (2) and chassis ground
4
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
46
ENG (female)
Resistance
0.4 1.1 z
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00717-03
D155AX-6
47
SEN00717-03
40 Troubleshooting
Failure code
E03
CA323
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Related
information
Cause
CN5 (male)
Resistance
0.4 1.1 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female) (46)
2
or defective contact in con- CN5 (female) (1)
nector)
Wiring harness between ENG (female) (60)
CN5 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between ENG (female) (46)
3 ness (Contact with GND cir CN5 (female) (1) and chassis ground
cuit)
Wiring harness between ENG (female) (60)
CN5 (female) (2) and chassis ground
4
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
48
ENG (female)
Resistance
0.4 1.1 z
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00717-03
D155AX-6
49
SEN00717-03
40 Troubleshooting
Failure code
E03
CA324
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Related
information
Cause
CN3 (male)
Resistance
0.4 1.1 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female) (55)
2
or defective contact in con- CN3 (female) (1)
nector)
Wiring harness between ENG (female) (52)
CN3 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between ENG (female) (55)
3 ness (Contact with GND cir CN3 (female) (1) and chassis ground
cuit)
Wiring harness between ENG (female) (52)
CN3 (female) (2) and chassis ground
4
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
50
ENG (female)
Resistance
0.4 1.1 z
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00717-03
D155AX-6
51
SEN00717-03
40 Troubleshooting
Failure code
E03
CA325
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Related
information
Cause
CN6 (male)
Resistance
0.4 1.1 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female) (57)
2
or defective contact in con- CN6 (female) (1)
nector)
Wiring harness between ENG (female) (59)
CN6 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between ENG (female) (57)
3 ness (Contact with GND cir CN6 (female) (1) and chassis ground
cuit)
Wiring harness between ENG (female) (59)
CN6 (female) (2) and chassis ground
4
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
52
ENG (female)
Resistance
0.4 1.1 z
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00717-03
D155AX-6
53
SEN00717-03
40 Troubleshooting
Failure code
E03
CA331
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Related
information
Cause
CN2 (male)
Resistance
0.4 1.1 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female) (54)
2
or defective contact in con- CN2 (female) (1)
nector)
Wiring harness between ENG (female) (51)
CN2 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between ENG (female) (54)
3 ness (Contact with GND cir CN2 (female) (1) and chassis ground
cuit)
Wiring harness between ENG (female) (51)
CN2 (female) (2) and chassis ground
4
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
54
ENG (female)
Resistance
0.4 1.1 z
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00717-03
D155AX-6
55
SEN00717-03
40 Troubleshooting
Failure code
E03
CA332
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Related
information
Cause
CN4 (male)
Resistance
0.4 1.1 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female) (56)
2
or defective contact in con- CN4 (female) (1)
nector)
Wiring harness between ENG (female) (58)
CN4 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between ENG (female) (56)
3 ness (Contact with GND cir CN4 (female) (1) and chassis ground
cuit)
Wiring harness between ENG (female) (58)
CN4 (female) (2) and chassis ground
4
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
56
ENG (female)
Resistance
0.4 1.1 z
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00717-03
D155AX-6
57
SEN00717-03
40 Troubleshooting
Failure code
E04
CA342
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Engine continues operation normally, but it may stop during operation or may not be able to start.
Related
information
Possible causes
and standard
value in normal
state
58
Cause
D155AX-6
40 Troubleshooting
D155AX-6
SEN00717-03
59
SEN00717-03
40 Troubleshooting
Failure code
E03
CA351
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Disconnection in wiring harness (Disconnection in wiring Wiring harness between CB8 (1) CB30
3
or defective contact in con- (B30S)
nector)
Wiring harness between CB30 (B30L) terminal BRB
Wiring harness between EGC3 (female) (1),
(2) chassis ground (GND20)
Possible causes
and standard
value in normal
state
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between EGC3 (female) (3),
(4) CB8 (2) and chassis ground
Wiring harness between CB8 (1) CB30
Ground fault in wiring har(B30S) or circuit branch end and chassis
4 ness (Contact with GND cirground
cuit)
Wiring harness between CB30 (B30L) terminal BRB and chassis ground
Wiring harness between EGC3 (female) (1),
(2) chassis ground (GND20) and chassis
ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
60
EGC3
Voltage
20 30 V
D155AX-6
40 Troubleshooting
SEN00717-03
D155AX-6
61
SEN00717-03
40 Troubleshooting
Failure code
E03
CA352
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Signal voltage in sensor power supply 1 (5 V) circuit of engine controller is abnormally low.
Limits common rail pressure sensor output and continues operation (Limits common rail pressure).
Related
information
Possible causes
and standard
value in normal
state
62
Cause
D155AX-6
40 Troubleshooting
D155AX-6
SEN00717-03
63
SEN00717-03
40 Troubleshooting
Failure code
E03
CA386
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Related
information
Cause
1 Defective related system
Disconnect devices
at right in order. If
"E" of failure code
disappears when a
device is disconnected, that device
has trouble in it.
PFUEL connector
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female) (33)
3
or defective contact in con- PFUEL (female) (1)
nector)
Wiring harness between ENG (female) (47)
PFUEL (female) (3)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between ENG (female) (33)
4 ness (Contact with GND cir PFUEL (female) (1) and chassis ground
cuit)
Wiring harness between ENG (female) (47)
PFUEL (female) (3) and chassis ground
Short circuit in wiring har5 ness (with another wiring
harness)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG (female) (33)
PFUEL (female) (1) and between ENG
(female) (47) PFUEL (female) (3)
Resistance
Min. 1 Mz
64
ENG
Voltage
4.75 5.25 z
D155AX-6
40 Troubleshooting
SEN00717-03
D155AX-6
65
SEN00717-03
40 Troubleshooting
Failure code
E04
CA441
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Trouble
Engine continues operation normally, but it may stop during operation or may not be able to start.
Source voltage of engine controller can be checked with monitoring function.
(Code: 03203 Battery Power Supply)
Cause
Failure code
E04
CA442
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
66
Trouble
Engine continues operation normally, but it may stop during operation or may not be able to start.
Source voltage of engine controller can be checked with monitoring function.
(Code: 03203 Battery Power Supply)
Cause
D155AX-6
40 Troubleshooting
SEN00717-03
Failure code
E03
CA449
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
D155AX-6
Trouble
Common rail pressure sensor circuit detected abnormally high pressure (level 2).
Limits engine output and continues operation (Limits common rail pressure).
67
SEN00717-03
40 Troubleshooting
Failure code
E03
CA451
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Defective sensor power sup- If code [CA352] or [CA386] is indicated, carry out troubleshooting
ply system
for it first.
a Prepare with starting switch OFF, then turn starting switch ON
or start engine and carry out troubleshooting.
PFUEL
Voltage
Power supply
4.75 5.25 V
Signal
0.26 4.6 V
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG (female) (33)
Ground fault in wiring har PFUEL (female) (1) and chassis ground
4 ness (Contact with GND cirWiring harness between ENG (female) (25)
cuit)
PFUEL (female) (2) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
68
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00717-03
Cause
Possible causes
and standard
value in normal
state
Voltage
4.75 5.25 V
0.26 4.6 V
D155AX-6
69
SEN00717-03
40 Troubleshooting
Failure code
E03
CA452
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Possible causes
and standard
value in normal
state
Cause
Failure code
E02
CA553
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
70
Common rail pressure sensor circuit detected abnormally high pressure (level 1).
None in particular.
Possible causes
and standard
value in normal
state
Defective electrical system of Common rail pressure sensor may have electric trouble. Carry out
common rail pressure sensor troubleshooting for failure code [CA451].
Check overflow valve directly for broken spring, worn seat, and
stuck ball.
D155AX-6
40 Troubleshooting
SEN00717-03
Failure code
E03
CA554
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
D155AX-6
Trouble
71
SEN00717-03
40 Troubleshooting
Failure code
E02
CA559
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
4 Clogging of filter/strainer
Possible causes
and standard
value in normal
state
a For contents of troubleshooting, see Note 1. For check of pressure in fuel low-pressure circuit, see Testing and adjusting,
Testing fuel pressure.
Pressure in fuel low-pressure circuit (At high idle or under the
load equivalent to rating (Stalling))
Defective electrical system of Supply pump PCV may have electric trouble. Carry out troublesupply pump PCV
shooting for following codes; [CA271], [CA272], [CA273], [CA274].
Defective common rail pres- Common rail pressure sensor may be defective. Check wiring harsure sensor
ness for damage.
a For testing of leakage from pressure limiter, see Testing and
adjusting, Measuring fuel return rate and fuel leakage.
Max. 10 cc/min
8 Defective injector
1,600 rpm
960 cc/min
1,700 rpm
1,020 cc/min
1,800 rpm
1,080 cc/min
1,900 rpm
1,140 cc/min
2,000 rpm
1,200 cc/min
72
D155AX-6
40 Troubleshooting
SEN00717-03
Note 1: Check the low-pressure circuit parts for the following items.
1) Fuel level
2) Clogging of fuel tank breather
3) Sticking and wear of feed pump and clogging of filter
4) Leakage through and clogging of low-pressure fuel piping
5) Defective operation of bypass valve and installation of wrong part (See Fig. 1)
6) Clogging of fuel filter
7) Fuel in oil pan (Fuel leakage inside head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
Overflow valve (1): Spring is seen through both holes.
Bypass valve (2): Spring is seen through hole on nut side.
Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
D155AX-6
73
SEN00717-03
40 Troubleshooting
Work No.
SAA6D140E-5
Service meter
Date of check
Engine
Engine serial No.
D155AX-6
/
h
Worker's name
A. Visual check
Good NG
B. Check with machine monitor (02 Fault history, 01 monitoring, and 09 reduced cylinder mode operation) Good NG
3 Check of failure code
Displayed item
31706
Final accelerator
position
ISO unit
Standard value
(Reference value)
Low idle
r/min
715 765
High idle
r/min
1,825 1,925
r/min
1,560 1,660
Low idle
High idle
100
mg/st
Checking condition
Measured
value
Good NG
36200
MPa
36400
MPa
Low idle
CA
High idle
CA
CA
kPa
ISO unit
Standard value
(Reference value)
No. 1 cylinder
r/min
No. 2 cylinder
Reduce No. 3 cylinder
each
cylinder No. 4 cylinder
No. 5 cylinder
r/min
r/min
r/min
r/min
No. 6 cylinder
r/min
Low idle
74
Reduced cylinder
Checking condition
Measured
value
Good NG
D155AX-6
40 Troubleshooting
SEN00717-03
Checking condition
At high idle or under the
load equivalent to rating
(Stalling)
Unit
Standard value
(Reference value)
MPa
{kg/cm2}
Min. 0.15
{Min. 1.5}
Measured
value
Good NG
Good NG
D155AX-6
Unit
Standard value
(Reference value)
cc/min
Max. 10
cc/min
960
cc/min
1,020
cc/min
1,080
cc/min
1,140
cc/min
1,200
Checking condition
Measured
value
Good NG
Speed:
Leakage
75
SEN00717-03
40 Troubleshooting
Failure code
E03
CA689
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Related
information
Cause
1
Defective sensor power supIf code [CA238] is indicated, carry out troubleshooting for it first.
ply system
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG (female) (16)
Ground fault in wiring har NE (female) (1) and chassis ground
3 ness (Contact with GND cirWiring harness between ENG (female) (48)
cuit)
NE (female) (2) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Possible causes
and standard
value in normal
state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Defective mount of sensor or Check Ne speed sensor directly for defective mount (defective
5 defective rotation sensing
clearance) or check rotation sensing part (flywheel) directly for
part
defect.
Defective engine Ne speed
sensor
If causes 1 5 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried
out.)
76
D155AX-6
40 Troubleshooting
SEN00717-03
D155AX-6
77
SEN00717-03
40 Troubleshooting
D155AX-6 Bulldozer
Form No. SEN00717-03
2010 KOMATSU
All Rights Reserved
Printed in Japan 08-10
78
D155AX-6
SEN00718-04
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
40 Troubleshooting
D155AX-6
SEN00718-04
40 Troubleshooting
Failure code [CA2185] Throt Sens Sup Volt High Error ................................................................................ 24
Failure code [CA2186] Throt Sens Sup Volt Low Error................................................................................. 26
Failure code [CA2249] Rail Press Very Low Error ........................................................................................ 26
Failure code [CA2271] EGR Valve Pos Sens High Error .............................................................................. 28
Failure code [CA2272] EGR Valve Pos Sens Low Error ............................................................................... 30
Failure code [CA2351] EGR Valve Sol Current High Error ........................................................................... 32
Failure code [CA2352] EGR Valve Sol Current Low Error ............................................................................ 34
Failure code [CA2555] Grid Htr Relay Volt Low Error ................................................................................... 35
Failure code [CA2556] Grid Htr Relay Volt High Error .................................................................................. 36
Failure code [D110KA] Battery relay: Disconnection .................................................................................... 38
Failure code [D110KB] Battery Relay: Drive Short Circuit ............................................................................ 40
Failure code [D130KA] Neutral relay: Disconnection .................................................................................... 42
Failure code [D130KB] Neutral relay: Short circuit........................................................................................ 44
Failure code [D161KA] Back-up alarm relay: Disconnection ........................................................................ 46
Failure code [D161KB] Back-up alarm relay: Short circuit ............................................................................ 48
Failure code [D190KA] ACC signal relay: Disconnection.............................................................................. 50
Failure code [D190KB] ACC signal relay: Short circuit ................................................................................. 52
Failure code [D5ZKKX] Throttle Dial: Out of normal range ........................................................................... 54
Failure code [DAFRKR] CAN Disconnection (Monitor) ................................................................................. 56
Failure code [DB2RKR] CAN Disconnection (Engine controller) .................................................................. 58
Failure code [DB90KK] WE controller: Source voltage reduction ................................................................. 60
Failure code [DB90KR] PT controller: Can communication lost.................................................................... 62
D155AX-6
40 Troubleshooting
SEN00718-04
Failure code
E03
CA731
Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Cause
Possible causes
and standard
value in normal
state
Engine Ne speed sensor may be defective. Carry out troubleshooting for failure code [CA689].
Engine Bkup speed sensor may be defective. Carry out troubleshooting for failure code [CA778].
Failure code
E04
CA757
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Engine continues operation normally, but it may stop during operation or may not be able to start.
Related
information
Possible causes
and standard
value in normal
state
D155AX-6
Cause
SEN00718-04
40 Troubleshooting
Failure code
E03
CA778
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Related
information
Cause
1
Defective sensor power sup- If code [CA187] or [CA227] is indicated, carry out troubleshooting
ply system
for it first.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG (female) (37)
Ground fault in wiring har G (female) (1) and chassis ground
3 ness (Contact with GND cirWiring harness between ENG (female) (47)
cuit)
G (female) (2) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Possible causes
and standard
value in normal
state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Defective mount of sensor or Check Bkup speed sensor directly for defective mount (defective
5 defective rotation sensing
clearance) or check rotation sensing part (in supply pump) directly
part
for defect.
6
D155AX-6
40 Troubleshooting
SEN00718-04
D155AX-6
SEN00718-04
40 Troubleshooting
Failure code
E02
CA1228
Contents of
trouble
Action of
controller
Trouble
Problem that
appears on
machine
Related
information
Engine speed
Low idle
High idle
Engine
Low idle
High idle
If engine oil pressure is abnormal, carry out troubleshooting for "S12 Oil pressure lowers" in S mode.
Check oil pump and relief valve for EGR valve circuit directly.
If causes 1 7 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried
out.)
D155AX-6
40 Troubleshooting
SEN00718-04
Failure code
E03
CA1625
Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
D155AX-6
SEN00718-04
40 Troubleshooting
Failure code
E03
CA1626
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Related
information
Cause
Defective bypass valve sole1
noid (Internal trouble)
Resistance
10 21 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female) (31)
Resis2
Max. 1 z
or defective contact in con- BP (female) (1)
tance
nector)
Wiring harness between ENG (female) (11)
ResisMax. 1 z
BP (female) (2)
tance
Possible causes
and standard
value in normal
state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between ENG (female) (31)
3 ness (Contact with GND cir BP (female) (1) and chassis ground
cuit)
Wiring harness between ENG (female) (11)
BP (female) (2) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Hot short (Short circuit with Wiring harness between ENG (female) (31)
24V circuit) in wiring harness - BP (female) (1) and chassis ground
Voltage
Max. 1 V
Voltage
Max. 1 V
ENG (female)
Resistance
10 21 z
D155AX-6
40 Troubleshooting
SEN00718-04
D155AX-6
SEN00718-04
40 Troubleshooting
Failure code
E03
CA1627
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Related
information
Possible causes
and standard
value in normal
state
10
Cause
D155AX-6
40 Troubleshooting
SEN00718-04
Failure code
E02
CA1628
Contents of
trouble
Action of
controller
Trouble
Problem that
appears on
machine
Related
information
Engine speed
Low idle
High idle
Engine
Low idle
High idle
D155AX-6
Check oil pump and relief valve for bypass valve circuit directly.
If causes 1 7 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried
out.)
11
SEN00718-04
40 Troubleshooting
Failure code
E03
CA1619
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
12
Trouble
D155AX-6
40 Troubleshooting
D155AX-6
SEN00718-04
13
SEN00718-04
40 Troubleshooting
Failure code
E03
CA1631
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Defective sensor power sup- If code [CA187] or [CA227] is indicated, carry out troubleshooting
ply system
for it first.
a Prepare with starting switch OFF, then turn starting switch ON
or start engine and carry out troubleshooting.
SBP
Between (1) (2)
Voltage
Power supply
4.75 5.25 V
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG (female) (37)
Ground fault in wiring har SBP (female) (1) and chassis ground
4 ness (Contact with GND cirWiring harness between ENG (female) (38)
cuit)
SBP (female) (2) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
14
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00718-04
Cause
Possible causes
and standard
value in normal
state
ENG
Voltage
4.75 5.25 V
D155AX-6
15
SEN00718-04
40 Troubleshooting
Failure code
E03
CA1632
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
16
Trouble
D155AX-6
40 Troubleshooting
D155AX-6
SEN00718-04
17
SEN00718-04
40 Troubleshooting
Failure code
CA1633
Trouble
Trouble occurred in KOMNET (CAN) communication circuit between engine controller and machine
monitor, power train controller, and work equipment controller.
Operates in default mode or maintains condition when abnormality occurs.
Problem that
appears on
machine
Related
information
Cause
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Min. 1 Mz
Resistance
Min. 1 Mz
18
Resistance
Voltage
Max. 1 V
Voltage
Max. 1 V
Resistance
Approx. 120 z
If causes 1 4 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried
out.)
D155AX-6
40 Troubleshooting
SEN00718-04
D155AX-6
19
SEN00718-04
40 Troubleshooting
Failure code
E01
CA1642
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
20
Trouble
D155AX-6
40 Troubleshooting
D155AX-6
SEN00718-04
21
SEN00718-04
40 Troubleshooting
Failure code
E01
CA1653
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Defective sensor power sup- If code [CA187] or [CA227] is indicated, carry out troubleshooting
1
ply system
for it first.
a Prepare with starting switch OFF, then turn starting switch ON
or start engine and carry out troubleshooting.
2
PEVA
Between (1) (2)
Voltage
Power supply
4.75 5.25 V
Possible causes
and standard
value in normal
state
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG (female) (37)
Ground fault in wiring har PEVA (female) (1) and chassis ground
4 ness (Contact with GND cirWiring harness between ENG (female) (47)
cuit)
PEVA (female) (2) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
22
ENG
Voltage
4.75 5.25 V
D155AX-6
40 Troubleshooting
SEN00718-04
D155AX-6
23
SEN00718-04
40 Troubleshooting
Failure code
E03
CA2185
Contents of
trouble
Action of
controller
Trouble
Problem that
appears on
machine
Related
information
Cause
Disconnect devices
at right in order. If
"E" of failure code
disappears when a
device is disconnected, that device
has trouble in it.
Decelerator pedal
potentiometer
DCL connector
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between EGC2 (female)
2
or defective contact in con- (22) DCL (female) (B)
nector)
Wiring harness between EGC2 (female)
(23) DCL (female) (C)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between EGC2 (female)
3 ness (Contact with GND cir(22) DCL (female) (B) and chassis ground
cuit)
Wiring harness between EGC2 (female)
(23) DCL (female) (C) and chassis ground
Short circuit in wiring har4 ness (with another wiring
harness)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between EGC2 (female)
(22) DCL (female) (B) and between EGC2
(female) (23) DCL (female) (C)
Resistance
Min. 1 Mz
24
EGC2
Voltage
4.75 5.25 V
D155AX-6
40 Troubleshooting
SEN00718-04
D155AX-6
25
SEN00718-04
40 Troubleshooting
Failure code
E03
CA2186
Contents of
trouble
Action of
controller
Trouble
Signal voltage in throttle sensor power supply (5 V) circuit of engine controller is abnormally low.
Sets throttle position with signal of fuel control dial and continues operation.
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Cause
Failure code
E03
CA2249
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Related
information
Possible causes
and standard
value in normal
state
26
Cause
D155AX-6
40 Troubleshooting
D155AX-6
SEN00718-04
27
SEN00718-04
40 Troubleshooting
Failure code
E03
CA2271
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Defective sensor power sup- If code [CA187] or [CA227] is indicated, carry out troubleshooting
1
ply
for it first.
a Prepare with starting switch OFF, then turn starting switch ON
or start engine and carry out troubleshooting.
2
SEGR
Between (1) (2)
Voltage
Power supply
4.75 5.25 V
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG (female) (37)
SEGR (female) (1) and chassis ground
Ground fault in wiring har4 ness (Contact with GND cir- Wiring harness between ENG (female) (47)
cuit)
SEGR (female) (2) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
28
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00718-04
Cause
Possible causes
and standard
value in normal
state
ENG
Voltage
4.75 5.25 V
D155AX-6
29
SEN00718-04
40 Troubleshooting
Failure code
E03
CA2272
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
30
Trouble
D155AX-6
40 Troubleshooting
D155AX-6
SEN00718-04
31
SEN00718-04
40 Troubleshooting
Failure code
E03
CA2351
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Related
information
Cause
Defective EGR valve sole1
noid (Internal trouble)
Resistance
10 21 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female) (22)
Resis2
Max. 1 z
or defective contact in con- EGR (female) (1)
tance
nector)
Wiring harness between ENG (female) (11)
ResisMax. 1 z
EGR (female) (2)
tance
Possible causes
and standard
value in normal
state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between ENG (female) (22)
3 ness (Contact with GND cir EGR (female) (1) and chassis ground
cuit)
Wiring harness between ENG (female) (11)
EGR (female) (2) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Hot short (Short circuit with Wiring harness between ENG (female) (22)
24V circuit) in wiring harness EGR (female) (1) and chassis ground
Voltage
Max. 1 V
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
5 Defective engine controller
32
ENG (female)
Resistance
10 21 z
D155AX-6
40 Troubleshooting
SEN00718-04
D155AX-6
33
SEN00718-04
40 Troubleshooting
Failure code
E03
CA2352
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Related
information
Possible causes
and standard
value in normal
state
34
Cause
D155AX-6
40 Troubleshooting
SEN00718-04
Failure code
E01
CA2555
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
D155AX-6
Trouble
35
SEN00718-04
40 Troubleshooting
Failure code
E01
CA2556
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Resistance
200 400 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between EGC2 (female)
2
or defective contact in con- (40) PHR (female) (1)
nector)
Wiring harness between PHR (female) (2)
chassis ground (GND03)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
3 ness (Contact with GND cirWiring harness between EGC2 (female)
Resiscuit)
Min. 1 Mz
(40) PHR (female) (1) and chassis ground
tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
4 Defective engine controller
36
EGC2
Coolant temperature
Voltage
-5 C or higher
Max. 1 V
Below -5 C
20 30 V
D155AX-6
40 Troubleshooting
SEN00718-04
D155AX-6
37
SEN00718-04
40 Troubleshooting
Failure code
D110KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Problem may occur in writing data into ROM (non-volatile memory) of each controller.
State of battery relay holding circuit signal can be checked with monitoring function.
(Code: 60600 BR Hold Relay)
Method of reproducing failure code: Turn starting switch ON o OFF.
Cause
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective battery relay (Inter1
nal disconnection)
Battery relay
Continuity
Between terminals SW BRE
There is continuity
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC3 (female) (4)
2
or defective contact in con- terminal SW
nector)
Wiring harness between terminal BRE and
chassis ground
Resistance
Max. 1 z
Resistance
Max. 1 z
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4
38
STC3
Starting switch
Voltage
OFF
Max. 1 V
D155AX-6
40 Troubleshooting
SEN00718-04
D155AX-6
39
SEN00718-04
40 Troubleshooting
Failure code
D110KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal was output to battery relay circuit, abnormal current flowed.
Turns signal to battery relay holding circuit OFF.
Problem may occur in writing data into ROM (non-volatile memory) of each controller.
State of battery relay holding circuit signal can be checked with monitoring function.
(Code: 60600 BR Hold Relay)
Method of reproducing failure code: Turn starting switch ON o OFF.
Cause
Possible causes
and standard
value in normal
state
Battery relay
Continuity/Resistance
There is continuity
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring har2 ness (Contact with GND cir- Wiring harness between STC3 (female) (4)
Resiscuit)
terminal SW, terminal 260 or RSD
Min. 1 Mz
tance
(female) (1) and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
3
40
STC3
Starting switch
Voltage
ON
20 30 V
D155AX-6
40 Troubleshooting
SEN00718-04
D155AX-6
41
SEN00718-04
40 Troubleshooting
Failure code
E02
D130KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When ground circuit of neutral safety relay circuit is disconnected, no current flows.
Turns output of neutral safety relay circuit OFF.
Possible causes
and standard
value in normal
state
Resistance
300 600 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC2 (female) (8)
Resis3
Max. 1 z
or defective contact in con- NSF (female) (2)
tance
nector)
Wiring harness between NSF (female) (1)
ResisMax. 1 z
FS21 (5)
tance
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between STC2 (female) (8)
4 ness (Contact with GND cir- NSF (female) (2) and chassis ground
cuit)
Wiring harness between NSF (female) (1)
FS21 (5) or circuit branch end and chassis
ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
42
STC2
Voltage
Lock
Max. 1 V
Free
20 30 V
D155AX-6
40 Troubleshooting
SEN00718-04
D155AX-6
43
SEN00718-04
40 Troubleshooting
Failure code
E02
D130KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When ground circuit of neutral safety relay was disconnected, abnormal current flowed.
Turns output of neutral safety relay circuit OFF.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective neutral safety relay
1
(Internal short circuit)
NSF (male)
Resistance
300 600 z
44
STC2
Voltage
Lock
Max. 1 V
Free
20 30 V
D155AX-6
40 Troubleshooting
SEN00718-04
D155AX-6
45
SEN00718-04
40 Troubleshooting
Failure code
E01
D161KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When ground circuit of back-up alarm relay circuit is disconnected, no current flows.
Turns output of back-up alarm relay circuit OFF.
Possible causes
and standard
value in normal
state
Resistance
300 600 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC2 (female) (18)
Resis3
Max. 1 z
or defective contact in con- BKA (female) (2)
tance
nector)
Wiring harness between BKA (female) (1)
ResisMax. 1 z
FS12 (2)
tance
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between STC2 (female) (18)
4 ness (Contact with GND cir- BKA (female) (2) or circuit branch end and
cuit)
chassis ground
Wiring harness between BKA (female) (1),
(3) FS12 (2) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
STC2
Between (18) chassis ground
46
PCCS lever
(Directional)
Voltage
20 30 V
R (Reverse)
Max. 1 V
D155AX-6
40 Troubleshooting
SEN00718-04
D155AX-6
47
SEN00718-04
40 Troubleshooting
Failure code
E01
D161KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When ground circuit of back-up alarm relay was disconnected, abnormal current flowed.
Turns output of back-up alarm relay circuit OFF.
Possible causes
and standard
value in normal
state
Resistance
300 600 z
Voltage
Max. 1 V
STC2
Between (18) chassis ground
48
PCCS lever
(Directional)
Voltage
20 30 V
R (Reverse)
Max. 1 V
D155AX-6
40 Troubleshooting
SEN00718-04
D155AX-6
49
SEN00718-04
40 Troubleshooting
Failure code
D190KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When ground circuit of ACC signal drive relay circuit is disconnected, no current flows.
Turns signal to ACC signal drive relay circuit OFF.
Turbo-timer function does not operate (if turbo-timer is installed).
Machine is not affected particularly (if turbo-timer is not installed).
State of ACC signal drive relay circuit signal can be checked with monitoring function.
(Code: 60500 ENG Hold Relay)
Method of reproducing failure code: Turn starting switch ON o OFF (if turbo-timer is installed).
This failure code detects abnormality on primary side (coil side) of ACC signal drive relay but does
not detect abnormality on secondary side (contact side).
Cause
Resistance
200 400 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC2 (female) (9)
2
or defective contact in con- EHL (female) (2)
nector)
Wiring harness between EHL (female) (1)
branch point (J)
50
Resistance
Max. 1 z
Resistance
Max. 1 z
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
STC2 (female)
Resistance
200 400 z
D155AX-6
40 Troubleshooting
SEN00718-04
D155AX-6
51
SEN00718-04
40 Troubleshooting
Failure code
D190KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Resistance
200 400 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
2 ness (Contact with GND cirWiring
harness between STC2 (female) (9)
Resiscuit)
1 Mz
EHL (female) (2) and chassis ground
tance
52
When ground circuit of ACC signal drive relay was disconnected, abnormal current flowed.
Cause
Possible causes
and standard
value in normal
state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
STC2 (female)
Resistance
200 400 z
D155AX-6
40 Troubleshooting
SEN00718-04
D155AX-6
53
SEN00718-04
40 Troubleshooting
Failure code
E03
D5ZKKX
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
If failure code [DBE7KK] is also displayed, carry out troubleshooting for it first.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
DIAL (male)
Resistance
4.0 6.0 kz
0.25 7.0 kz
0.25 7.0 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC1 (female) (22)
3
or defective contact in con- DIAL (female) (1)
nector)
Wiring harness between STC1 (female) (1)
DIAL (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
4 ness (Contact with GND cirWiring
harness between STC1 (female) (1)
Resiscuit)
Min. 1 Mz
DIAL (female) (2) and chassis ground
tance
Hot short (Short circuit with
5 24 V circuit) in wiring harness
54
Voltage
Max. 1 V
Voltage
0.30 4.33 V
D155AX-6
40 Troubleshooting
SEN00718-04
D155AX-6
55
SEN00718-04
40 Troubleshooting
Failure code
DAFRKR
Trouble
Machine monitor cannot recognize engine controller, power train controller, or work equipment controller in CAN communication circuit.
Limits operation of engine and transmission.
System may not operate normally.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1 and R1.
Method of reproducing failure code: Turn starting switch ON.
Cause
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Min. 1 Mz
Resistance
Min. 1 Mz
Voltage
Max. 1 V
Voltage
Max. 1 V
56
Resistance
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
CA1 (male)
Resistance
Approx. 120 z
If causes 1 4 are not detected, machine monitor, engine controller, power train controller or work equipment controller may be
defective. (Since trouble is in system, troubleshooting cannot be
carried out.)
D155AX-6
40 Troubleshooting
SEN00718-04
D155AX-6
57
SEN00718-04
40 Troubleshooting
Failure code
E03
DB2RKR
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Power train controller cannot recognize engine controller in CAN communication circuit.
Limits operation of engine and transmission.
System may not operate normally.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1 and R1.
Method of reproducing failure code: Turn starting switch ON.
Cause
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Min. 1 Mz
Resistance
Min. 1 Mz
58
Resistance
Voltage
Max. 1 V
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
CA1 (male)
Resistance
Approx. 120 z
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40 Troubleshooting
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SEN00718-04
40 Troubleshooting
Failure code
E04
DB90KK
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Source voltage of work equipment controller can be checked with adjusting function. (Code: 2022)
Method of reproducing failure code: Turn starting switch ON.
Cause
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between CB30 (B30L) terDisconnection in wiring har- minal BRB
ness (Disconnection in wiring
2
or defective contact in con- Wiring harness between WEC3 (female) (2),
(12), (22) CB2 (2)
nector)
Wiring harness between CB2 (1) CB105
(B105S)
Possible causes
and standard
value in normal
state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between WEC3 (female) (1),
(11) CB7 (2) or circuit branch end and
chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Ground fault in wiring harWiring harness between CB30 (B30L) ter3 ness (Contact with GND cirminal BRB and chassis ground
cuit)
Wiring harness between WEC3 (female) (2),
(12), (22) CB2 (2) or WEPW (female) (A)
and chassis ground
60
D155AX-6
40 Troubleshooting
SEN00718-04
Cause
Possible causes
and standard
value in normal
state
WEC3
Starting switch
Voltage
OFF
20 30 V
ON
20 30 V
D155AX-6
61
SEN00718-04
40 Troubleshooting
Failure code
DB90KR
Trouble
Power train controller cannot recognize machine monitor, engine controller or work equipment controller in CAN communication circuit.
Limits operation of engine and transmission.
System may not operate normally.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1 and R1.
Method of reproducing failure code: Turn starting switch ON.
Cause
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Min. 1 Mz
Resistance
Min. 1 Mz
62
Resistance
Voltage
Max. 1 V
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
CA1 (male)
Resistance
Approx. 120 z
If causes 1 4 are not detected, machine monitor, engine controller, power train controller or work equipment controller may be
defective. (Since trouble is in system, troubleshooting cannot be
carried out.)
D155AX-6
40 Troubleshooting
SEN00718-04
D155AX-6
63
SEN00718-04
40 Troubleshooting
D155AX-6 Bulldozer
Form No. SEN00718-04
2010 KOMATSU
All Rights Reserved
Printed in Japan 08-10
64
D155AX-6
SEN00719-01
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
40 Troubleshooting
D155AX-6
SEN00719-01
40 Troubleshooting
D155AX-6
40 Troubleshooting
SEN00719-01
Action code
Failure code
E01
DB90KT
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Cause
Possible causes
and standard
value in normal
state
Turn Adjustment function in service mode ON and perform operation of reproducing trouble. If "E" of failure code disappears at this
Defective adjustment of work
time, system is normal.
1
equipment controller
Adjustment code: 0031
(Initialization of work equipment controller)
2
D155AX-6
SEN00719-01
40 Troubleshooting
Failure code
E03
DB95KK
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Voltage of 5V power supply circuit for work equipment controller sensors is below 4.5 V or above
5.5 V.
Abnormal current flowed in 5V power supply circuit for work equipment controller sensors.
Turns output of 5V power supply circuit OFF, if abnormal current flows.
Limits operation of engine and transmission.
System may not operate normally.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1 and R1.
Method of reproducing failure code: Turn starting switch ON.
Cause
Possible causes
and standard
value in normal
state
Disconnect devices
at right in order. If
"E" of failure code
disappears when a
device is disconnected, that device
has trouble in it.
Work equipment
pump oil pressure
sensor
Connector HHP
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between WEC3 (female)
(34) HHP (female) (B) and chassis ground
Resistance
Min. 1 Mz
Voltage
4.5 5.5 V
D155AX-6
40 Troubleshooting
SEN00719-01
D155AX-6
SEN00719-01
40 Troubleshooting
Failure code
E03
DB97KK
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Voltage of 5V power supply circuit for work equipment controller sensors is below 4.5 V or above
5.5 V.
Abnormal current flowed in 5V power supply circuit for work equipment controller sensors.
Turns output of 5V power supply circuit OFF, if abnormal current flows.
Limits operation of engine and transmission.
System may not operate normally.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1 and R1.
Method of reproducing failure code: Turn starting switch ON.
Cause
Disconnect devices
Defective blade control lever at right in order.If "E" Blade control lever
1 or ripper control lever (Inter- of failure code disapnal trouble)
pears when a device
is disconnected, that
Ripper control
device has trouble in
lever
it.
Connector WLV1
Connector WLV2
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Voltage
Max. 1 V
Voltage
Max. 1 V
Voltage
4.5 5.5 V
D155AX-6
40 Troubleshooting
SEN00719-01
D155AX-6
SEN00719-01
40 Troubleshooting
Failure code
E04
DB99KQ
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Specification setting in work equipment controller does not match to specification setting signal
(Work equipment controller cannot be recognized).
Turns all outputs of work equipment controller OFF.
Limits operation of engine and transmission.
Machine does not move at all.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, it cannot travel at all.
Method of reproducing failure code: Turn starting switch ON.
Cause
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
ness (Disconnection in wiring
2
or defective contact in con- Wiring harness between WEC3 (female)
ResisMax. 1 z
nector)
(30) chassis ground (GND11)
tance
Voltage
Max. 1 V
Circuit diagram related to work equipment controller type select power supply
D155AX-6
SEN00719-01
40 Troubleshooting
Failure code
E03
DB9RKR
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Work equipment controller cannot recognize machine monitor, engine controller or power train controller in CAN communication circuit.
Limits operation of engine and transmission.
System may not operate normally.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1 and R1.
Method of reproducing failure code: Turn starting switch ON.
Cause
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Min. 1 Mz
Resistance
Min. 1 Mz
10
Resistance
Voltage
Max. 1 V
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
CA1 (male)
Resistance
Approx. 120 z
If causes 1 4 are not detected, machine monitor, engine controller, power train controller or work equipment controller may be
defective. (Since trouble is in system, troubleshooting cannot be
carried out.)
D155AX-6
40 Troubleshooting
SEN00719-01
D155AX-6
11
SEN00719-01
40 Troubleshooting
Failure code
E03
DBE0KK
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Source voltage of power train controller can be checked with adjusting function. (Code: 2121)
Method of reproducing failure code: Turn starting switch ON.
Cause
1
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between CB30 (B30L) terDisconnection in wiring har- minal BRB
ness (Disconnection in wiring
2
or defective contact in con- Wiring harness between STC3 (female) (2),
(12), (22) CB1 (2)
nector)
Wiring harness between CB1 (1) CB105
(B105S)
Possible causes
and standard
value in normal
state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between STC3 (female) (1),
(11) CB7 (2) or circuit branch end and
chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Ground fault in wiring harWiring harness between CB30 (B30L) ter3 ness (Contact with GND cirminal BRB and chassis ground
cuit)
Wiring harness between STC3 (female) (2),
(12), (22) CB1 (2) or PL1 (female) (68)
and chassis ground
12
D155AX-6
40 Troubleshooting
SEN00719-01
Cause
Possible causes
and standard
value in normal
state
STC3
Starting switch
Voltage
OFF
20 30 V
ON
20 30 V
D155AX-6
13
SEN00719-01
40 Troubleshooting
Failure code
E01
DBE0KT
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Defective adjustment of
1
power train controller
14
Cause
Possible causes
and standard
value in normal
state
D155AX-6
SEN00719-01
40 Troubleshooting
Failure code
E02
DBE6KK
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Voltage of 24V power supply circuit for power train controller sensors is below 17 V or above 30 V.
Abnormal current flowed in 24V power supply circuit for power train controller sensors.
Turns output of 24V power supply circuit OFF, if abnormal current flows.
Limits operation of engine and transmission.
System may not operate normally.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1 and R1.
Method of reproducing failure code: Turn starting switch ON.
Cause
Disconnect devices
Defective pitch angle sensor at right in order. If
1 or torque converter pressure "E" of failure code
sensor (Internal trouble)
disappears when a
device is disconnected, that device
has trouble in it.
Possible causes
and standard
value in normal
state
Connector PT1
Torque converter
inlet pressure sensor
Connector TIP
Connector TOP
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between STC1 (female) (16)
PT1 (female) (C) [Pitch angle sensor system]
Ground fault in wiring har2 ness (Contact with GND cir- Wiring harness between STC1 (female) (16)
cuit)
PIT (female) (B) [Torque converter inlet
pressure sensor system]
Wiring harness between STC1 (female) (16)
TOP (female) (B) [Torque converter outlet
pressure sensor system]
Defective power train con3
troller
16
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Voltage
20 30 V
D155AX-6
40 Troubleshooting
SEN00719-01
Circuit diagram related to power train controller 24V sensor power supply
D155AX-6
17
SEN00719-01
40 Troubleshooting
Failure code
E02
DBE7KK
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Voltage of 5V power supply circuit for power train controller sensors is below 4.5 V or above 5.5 V.
Abnormal current flowed in 5V power supply circuit for power train controller sensors.
Turns output of 5V power supply circuit OFF, if abnormal current flows.
Limits operation of engine and transmission.
System may not operate normally.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1 and R1.
Method of reproducing failure code: Turn starting switch ON.
Cause
Disconnect devices
Defective brake pedal poten- at right in order. If
1 tiometer, fuel control dial or "E" of failure code
PCCS lever (Internal trouble) disappears when a
device is disconnected, that device
has trouble in it.
Brake pedal
potentiometer
Connector BRK
Connector DIAL
PCCS lever
Connector TLV1
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between STC1 (female) (22)
BRK (female) (C) and chassis ground
[Brake pedal potentiometer system]
Possible causes
and standard
value in normal
state
Ground fault in wiring har2 ness (Contact with GND cir- Wiring harness between STC1 (female) (22)
cuit)
DIAL (female) (1) and chassis ground
[Fuel control dial system]
Wiring harness between STC1 (female) (22)
TLV1 (female) (4), (5) and chassis ground
[PCCS lever system]
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
18
Voltage
Max. 1 V
Voltage
Max. 1 V
Voltage
Max. 1 V
Voltage
4.5 5.5 V
D155AX-6
40 Troubleshooting
SEN00719-01
D155AX-6
19
SEN00719-01
40 Troubleshooting
Failure code
E04
DBE9KQ
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Specification setting in power train controller does not match to specification setting signal
(Power train controller cannot be recognized).
Turns all outputs of power train controller OFF.
Limits operation of engine and transmission.
Machine does not move at all.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, it cannot travel at all.
Method of reproducing failure code: Turn starting switch ON.
Possible causes
and standard
value in normal
state
Trouble
Cause
Defective adjustment of
power train controller
Turn Adjustment function in service mode ON and perform operation of reproducing trouble. If "E" of failure code disappears at this
time, system is normal.
Adjustment code: 0002 (Initialization of power train controller)
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
ness (Disconnection in wiring
2
or defective contact in con- Wiring harness between STC3 (female) (30)
ResisMax. 1 z
nector)
chassis ground (GND11)
tance
Voltage
Max. 1 V
Circuit diagram related to work equipment controller type select power supply
20
D155AX-6
SEN00719-01
40 Troubleshooting
Failure code
E02
DD12KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Signals of 2 systems of shift-up switch circuit are turned OFF (opened) simultaneously.
Recognizes that shift-up switch is not pressed.
Transmission gear cannot be shifted up.
Auto shift-down function does not operate.
"NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error.
State of shift-up switch signal can be checked with monitoring function.
(Code: 40905 T/M Sw Input 1)
Method of reproducing failure code: Turn starting switch ON + Operate shift-up switch.
Cause
SFTU (male)
Shift-up switch
OFF (Released)
ON (Pressed)
Resistance between
(3) (2)
Max. 1 z
Min. 1 Mz
Resistance between
(1) (2)
Min. 1 Mz
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Voltage
Max. 1 V
Voltage
Max. 1 V
22
Shift-up switch
OFF (Released)
ON (Pressed)
Voltage between
STC1 (12) STC1
(4)
Max. 1 V
5 11 V
Voltage between
STC3 (9) STC1 (4)
5 11 V
Max. 1 V
D155AX-6
40 Troubleshooting
SEN00719-01
D155AX-6
23
SEN00719-01
40 Troubleshooting
Failure code
E02
DD12KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Possible causes
and standard
value in normal
state
SFTU (male)
Shift-up switch
OFF (Released)
ON (Pressed)
Resistance between
(3) (2)
Max. 1 z
Min. 1 Mz
Resistance between
(1) (2)
Min. 1 Mz
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
24
STC1 ,STC3
Shift-up switch
OFF (Released)
ON (Pressed)
Voltage between
STC1 (12) STC1 (4)
Max. 1 V
5 11 V
Voltage between
STC3 (9) STC1 (4)
5 11 V
Max. 1 V
D155AX-6
40 Troubleshooting
SEN00719-01
D155AX-6
25
SEN00719-01
40 Troubleshooting
Failure code
E02
DD13KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Signals of 2 systems of shift-down switch circuit are turned OFF (opened) simultaneously.
Recognizes that shift-down switch is not pressed.
Transmission gear cannot be shifted down.
Auto shift-down function does not operate.
"NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error.
State of shift-down switch signal can be checked with monitoring function.
(Code: 40905 T/M Sw Input 1)
Method of reproducing failure code: Turn starting switch ON + Operate shift-down switch.
Cause
SFTD (female)
Shift-down switch
OFF (Released)
ON (Pressed)
Resistance between
(3) (2)
Max. 1 z
Min. 1 Mz
Resistance between
(1) (2)
Min. 1 Mz
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Hot short (Short circuit with Wiring harness between STC1 (female) (18)
24V circuit) in wiring harness SFTD (female) (1) and chassis ground
Voltage
Max. 1 V
Voltage
Max. 1 V
26
STC1
Shift-down switch
OFF (Released)
ON (Pressed)
Voltage between
(24) - (4)
Max. 1 V
5 11 V
Voltage between
(18) (4)
5 11 V
Max. 1 V
D155AX-6
40 Troubleshooting
SEN00719-01
D155AX-6
27
SEN00719-01
40 Troubleshooting
Failure code
E02
DD13KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Possible causes
and standard
value in normal
state
SFTD (female)
Shift-down switch
OFF (Released)
ON (Pressed)
Resistance between
(3) (2)
Max. 1 z
Min. 1 Mz
Resistance between
(1) (2)
Min. 1 Mz
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
28
STC1
Shift-down switch
OFF (Released)
ON (Pressed)
Voltage between
(24) (4)
Max. 1 V
5 11 V
Voltage between
(18) (4)
5 11 V
Max. 1 V
D155AX-6
40 Troubleshooting
SEN00719-01
D155AX-6
29
SEN00719-01
40 Troubleshooting
Failure code
E03
DD14KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Signals of 2 systems of parking brake lever switch circuit are turned OFF (opened) simultaneously.
Recognizes that parking brake lever is in FREE position.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1 and R1.
"NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error.
State of parking brake lever switch signal can be checked with monitoring function.
(Code: 40905 T/M Sw Input 1)
Method of reproducing failure code: Turn starting switch ON + Operate parking brake lever.
Cause
1 Defective fuse (FS2-5)
PKSW (male)
Defective parking brake lever
2 switch (Internal disconnecResistance between
tion)
(A) (B)
Resistance between
(A) (C)
LOCK position
Max. 1 z
Min. 1 Mz
Min. 1 Mz
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between FS22 (2) PKSW
(female) (A) and chassis ground
Ground fault in wiring har4 ness (Contact with GND cir- Wiring harness between STC1 (female) (23)
cuit)
PKSW (female) (B) and chassis ground
Wiring harness between STC1 (female) (17)
PKSW (female) (C), PKS (female) (1) or
PKD (female) (1) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
30
STC1
LOCK position
20 30 V
Max. 1 V
Max. 1 V
20 30 V
D155AX-6
40 Troubleshooting
SEN00719-01
Circuit diagram related to parking brake lever switch and solenoid valve
D155AX-6
31
SEN00719-01
40 Troubleshooting
Failure code
E03
DD14KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Signals of 2 systems of parking brake lever switch circuit are turned ON (closed) simultaneously.
Recognizes that parking brake lever is in FREE position.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1 and R1.
"NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error.
State of parking brake lever switch signal can be checked with monitoring function.
(Code: 40905 T/M Sw Input 1)
Method of reproducing failure code: Turn starting switch ON + Operate parking brake lever.
Cause
Possible causes
and standard
value in normal
state
LOCK position
Max. 1 z
Min. 1 Mz
Min. 1 Mz
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
2
Voltage
Max. 1 V
Voltage
Max. 1 V
32
STC1
LOCK position
20 30 V
Max. 1 V
Max. 1 V
20 30 V
D155AX-6
40 Troubleshooting
SEN00719-01
Circuit diagram related to parking brake lever switch and solenoid valve
D155AX-6
33
SEN00719-01
40 Troubleshooting
Failure code
E02
DDDDKA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Signals of 2 systems of brake pedal switch circuit are turned OFF (opened) simultaneously.
Recognizes that brake pedal is not pressed.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1 and R1.
"NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error.
State of brake pedal switch signal can be checked with monitoring function.
(Code: 40905 T/M Sw Input1)
Method of reproducing failure code: Turn starting switch ON + Operate brake pedal.
Cause
1 Defective fuse (FS2-1)
Brake pedal
Released
Pressed
Max. 1 z
Min. 1 Mz
Min. 1 Mz
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between FS22 (1) BKSW
(female) (A) and chassis ground
Ground fault in wiring har4 ness (Contact with GND cir- Wiring harness between STC1 (female) (11)
cuit)
BKSW (female) (B) and chassis ground
Wiring harness between STC1 (female) (5)
BKSW (female) (C), PBS (female) (1) or
PBD (female) (1) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
34
STC1
Brake pedal
Released
Pressed
20 30 V
Max. 1 V
Max. 1 V
20 30 V
D155AX-6
40 Troubleshooting
SEN00719-01
D155AX-6
35
SEN00719-01
40 Troubleshooting
Failure code
E02
DDDDKB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Signals of 2 systems of brake pedal switch circuit are turned ON (closed) simultaneously.
Recognizes that brake pedal is not pressed.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1 and R1.
"NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error.
State of brake pedal switch signal can be checked with monitoring function.
(Code: 40905 T/M Sw Input 1)
Method of reproducing failure code: Turn starting switch ON + Operate brake pedal.
Cause
Possible causes
and standard
value in normal
state
Brake pedal
Released
Pressed
Max. 1 z
Min. 1 Mz
Min. 1 Mz
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
2
Voltage
Max. 1 V
Voltage
Max. 1 V
36
STC1
Brake pedal
Released
Pressed
20 30 V
Max. 1 V
Max. 1 V
20 30 V
D155AX-6
40 Troubleshooting
SEN00719-01
D155AX-6
37
SEN00719-01
40 Troubleshooting
Failure code
E02
DDDDKX
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
None in particular.
Backup brake may not operate.
State of brake pedal potentiometer signal can be checked with monitoring function.
(Code: 50400 Brake Pedal Potentio)
Method of reproducing failure code: Turn starting switch ON + Operate brake pedal.
Defective brake pedal switch If failure code [DDDDKA] or [DDDDKB] is also displayed, carry out
system
troubleshooting for it first.
38
Brake pedal potentiometer signal does not match to brake pedal switch signal.
Cause
Possible causes
and standard
value in normal
state
D155AX-6
SEN00719-01
40 Troubleshooting
Failure code
E02
DDN7KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Signals of 2 systems of blade pitch switch circuit are turned OFF (opened) simultaneously.
Recognizes that blade pitch switch is not pressed.
Blade pitch function does not operate.
"NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error.
State of blade pitch switch signal can be checked with monitoring function.
(Code: 70300 Blade Sw Input)
Method of reproducing failure code: Turn starting switch ON + Operate blade pitch switch.
Cause
BNSL (female)
ON (Pressed)
Resistance between
(3) (2)
Max. 1 z
Min. 1 Mz
Resistance between
(1) (2)
Min. 1 Mz
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Voltage
Max. 1 V
Voltage
Max. 1 V
40
ON (Pressed)
Voltage between
WEC2 (6) WEC1 (4)
Max. 1 V
5 11 V
Voltage between
WEC2 (16)
WEC1 (4)
5 11 V
Max. 1 V
D155AX-6
40 Troubleshooting
SEN00719-01
Circuit diagram related to blade float switch and blade pitch switch
D155AX-6
41
SEN00719-01
40 Troubleshooting
Failure code
E02
DDN7KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Signals of 2 systems of blade pitch switch circuit are turned ON (closed) simultaneously.
Recognizes that blade pitch switch is not pressed.
Blade pitch function does not operate.
"NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error.
State of blade pitch switch signal can be checked with monitoring function.
(Code: 70300 Blade Sw Input)
Method of reproducing failure code: Turn starting switch ON + Operate blade pitch switch.
Cause
Possible causes
and standard
value in normal
state
BNSL (female)
ON (Pressed)
Resistance between
(3) (2)
Max. 1 z
Min. 1 Mz
Resistance between
(1) (2)
Min. 1 Mz
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between WEC2 (female)
2 ness (Contact with GND cir- (16) BNSL (female) (1) and chassis
cuit)
ground
Wiring harness between WEC2 (female) (6)
BNSL (female) (3) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
42
ON (Pressed)
Voltage between
WEC2 (6) WEC1 (4)
Max. 1 V
5 11 V
Voltage between
WEC2 (16)
WEC1 (4)
5 11 V
Max. 1 V
D155AX-6
40 Troubleshooting
SEN00719-01
Circuit diagram related to blade float switch and blade pitch switch
D155AX-6
43
SEN00719-01
40 Troubleshooting
Failure code
E01
DDN9KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Signals of 2 systems of blade float switch circuit are turned OFF (opened) simultaneously.
Recognizes that blade float switch is not pressed.
Blade float function does not operate.
"NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error.
State of blade float switch signal can be checked with monitoring function.
(Code: 70300 Blade Sw Input)
Method of reproducing failure code: Turn starting switch ON + Operate blade float switch.
Cause
BNSU (male)
ON (Pressed)
Resistance between
(3) (2)
Max. 1 z
Min. 1 Mz
Resistance between
(1) (2)
Min. 1 Mz
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring
2
or defective contact in connector)
Possible causes
and standard
value in normal
state
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Voltage
Max. 1 V
Voltage
Max. 1 V
44
ON (Pressed)
Voltage between
WEC2 (26)
WEC1 (4)
Max. 1 V
5 11 V
Voltage between
WEC2 (36)
WEC1 (4)
5 11 V
Max. 1 V
D155AX-6
40 Troubleshooting
SEN00719-01
Circuit diagram related to blade float switch and blade pitch switch
D155AX-6
45
SEN00719-01
40 Troubleshooting
Failure code
E01
DDN9KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Signals of 2 systems of blade float switch circuit are turned ON (closed) simultaneously.
Recognizes that blade float switch is not pressed.
Blade float function does not operate.
"NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error.
State of blade float switch signal can be checked with monitoring function.
(Code: 70300 Blade Sw Input)
Method of reproducing failure code: Turn starting switch ON + Operate blade float switch.
Cause
BNSU (male)
ON (Pressed)
Resistance between
(3) (2)
Max. 1 z
Min. 1 Mz
Resistance between
(1) (2)
Min. 1 Mz
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
46
ON (Pressed)
Voltage between
WEC2 (26)
WEC1 (4)
Max. 1 V
5 11 V
Voltage between
WEC2 (36)
WEC1 (4)
5 11 V
Max. 1 V
D155AX-6
40 Troubleshooting
SEN00719-01
Circuit diagram related to blade float switch and blade pitch switch
D155AX-6
47
SEN00719-01
40 Troubleshooting
Failure code
E03
DDNLKA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Signals of 2 systems of work equipment lock lever switch circuit are turned OFF (opened) simultaneously.
Recognizes that work equipment lock lever is in FREE position.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1 and R1.
"NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error.
State of blade float switch signal can be checked with monitoring function.
(Code: 70300 Blade Sw Input)
Method of reproducing failure code: Turn starting switch ON + Operate work equipment lock lever.
Cause
WELK (male)
LOCK position
Resistance between
(B) (A)
Max. 1 z
Min. 1 Mz
Resistance between
(C) (A)
Min. 1 Mz
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring
2
or defective contact in connector)
Possible causes
and standard
value in normal
state
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Voltage
Max. 1 V
Voltage
Max. 1 V
48
LOCK position
Voltage between
WEC2 (5)
WEC1 (10)
Max. 1 V
5 11 V
Voltage between
WEC2 (15)
WEC1 (10)
5 11 V
Max. 1 V
D155AX-6
40 Troubleshooting
SEN00719-01
D155AX-6
49
SEN00719-01
40 Troubleshooting
Failure code
E03
DDNLKB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Signals of 2 systems of work equipment lock lever switch circuit are turned ON (closed) simultaneously.
Recognizes that work equipment lock lever is in FREE position.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1 and R1.
"NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error.
State of blade float switch signal can be checked with monitoring function.
(Code: 70300 Blade Sw Input)
Method of reproducing failure code: Turn starting switch ON + Operate work equipment lock lever.
Cause
WELK (male)
LOCK position
Resistance between
(B) (A)
Max. 1 z
Min. 1 Mz
Resistance between
(C) (A)
Min. 1 Mz
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
50
LOCK position
Voltage between
WEC2 (5)
WEC1 (10)
Max. 1 V
5 11 V
Voltage between
WEC2 (15)
WEC1 (10)
5 11 V
Max. 1 V
D155AX-6
40 Troubleshooting
SEN00719-01
D155AX-6
51
SEN00719-01
40 Troubleshooting
Failure code
E02
DDTSL1
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal is not output to solenoid circuit of torque converter stator clutch ECMV, fill switch signal
is turned ON.
None in particular.
Travel torque may not be obtained sufficiently.
State of fill switch signal of stator clutch ECMV can be checked with monitoring function.
(Code: 31520 T/M Fill Sw Input 2)
Method of reproducing failure code: Start engine + Set travel lever in N (Neutral).
Cause
Possible causes
and standard
value in normal
state
FSTC (male)
PCCS lever
(Travel gear speed)
N
Between (1) chasLocked up at F1, F2,
sis ground
or F3
Resistance
Max. 1 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
2 ness (Contact with GND cirWiring harness between STC2 (female) (26)
Resiscuit)
Min. 1 Mz
FSTC (female) (1) and chassis ground
tance
a Prepare with starting switch OFF, then start engine, select
automatic gearshift mode, and carry out troubleshooting.
3
52
STC2
PCCS lever
(Travel gear speed)
N
Between (26) chasLocked
up
at F1, F2,
sis ground
or F3
Voltage
Max. 1 V
5 11 V
If causes 1 3 are not detected in electrical system, hydraulic system may be defective. Carry out related troubleshooting (H mode).
D155AX-6
40 Troubleshooting
SEN00719-01
D155AX-6
53
SEN00719-01
40 Troubleshooting
Failure code
E02
DDTSLH
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal is output to solenoid circuit of torque converter stator clutch ECMV, fill switch signal is
turned OFF.
None in particular.
Travel torque may not be obtained sufficiently.
State of fill switch signal of stator clutch ECMV can be checked with monitoring function.
(Code: 31520 T/M Fill Sw Input 2)
Method of reproducing failure code: Start engine + Set travel lever in F (Forward) (Automatic gearshift mode).
Cause
Possible causes
and standard
value in normal
state
FSTC (male)
PCCS lever
(Travel gear speed)
N
Between (1) chasLocked up at F1, F2,
sis ground
or F3
Resistance
Max. 1 z
Min. 1 Mz
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
ness (Disconnection in wiring
2
or defective contact in con- Wiring harness between STC2 (female) (26)
ResisMax. 1 z
nector)
FSTC (female) (1)
tance
a Prepare with starting switch OFF, then start engine, select
automatic gearshift mode, and carry out troubleshooting.
3
54
STC2
PCCS lever
(Travel gear speed)
N
Between (26) chasLocked up at F1, F2,
sis ground
or F3
Voltage
Max. 1 V
5 11 V
If causes 1 3 are not detected in electrical system, hydraulic system may be defective. Carry out related troubleshooting (H mode).
D155AX-6
40 Troubleshooting
SEN00719-01
D155AX-6
55
SEN00719-01
40 Troubleshooting
D155AX-6 Bulldozer
Form No. SEN00719-01
2006 KOMATSU
All Rights Reserved
Printed in Japan 05-06 (02)
56
D155AX-6
SEN00720-02
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
40 Troubleshooting
D155AX-6
SEN00720-02
40 Troubleshooting
D155AX-6
40 Troubleshooting
SEN00720-02
Possible causes
and standard
value in normal
state
Failure code
DFA4KX
Trouble
In blade control lever lift potentiometer 1 and 2 systems, either of failure codes [DFA5KA] and
[DFA5KB] and either of failure codes [DFA6KA] and [DFA6KB] occurred simultaneously.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1 and R1.
State of blade control lever lift potentiometer signal can be checked with monitoring function.
(Code: 73400 Blade Lift Lever A Potentio)
(Code: 73401 Blade Lift Lever B Potentio)
Method of reproducing failure code: Turn starting switch ON + Operate blade control lever
(in lifting direction).
Cause
Carry out troubleshooting for failure codes [DFA5KA], [DFA5KB], [DFA6KA], and [DFA6KB].
Failure code
E03
DFA4KZ
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
D155AX-6
Trouble
In blade control lever lift potentiometer 1 and 2 systems, when starting switch is turned ON, only
either side is abnormal and then either of failure codes [DFA5KA] and [DFA5KB] and either of failure codes [DFA6KA] and [DFA6KB] occurred simultaneously.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1 and R1.
State of blade control lever lift potentiometer signal can be checked with monitoring function.
(Code: 73400 Blade Lift Lever A Potentio)
(Code: 73401 Blade Lift Lever B Potentio)
Method of reproducing failure code: Turn starting switch ON + Operate blade control lever
(in lifting direction).
Cause
Carry out troubleshooting for failure codes [DFA5KA], [DFA5KB], [DFA6KA], and [DFA6KB].
SEN00720-02
40 Troubleshooting
DFA4L8
Trouble
Contents of
trouble
In blade control lever lift potentiometer 1 and 2 systems, total of both signal voltages is below 4.41 V
or above 5.59 V.
Action of
controller
Continues control with signal of normal one of blade control lever lift potentiometer 1 and 2 systems.
Limits operation of engine and transmission.
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Failure code
Carry out troubleshooting for failure codes [DFA5KA], [DFA5KB], [DFA6KA], and [DFA6KB].
D155AX-6
40 Troubleshooting
D155AX-6
SEN00720-02
SEN00720-02
40 Troubleshooting
Failure code
E03
DFA5KA
Trouble
BL lever 1: Disconnection
(Work equipment controller system)
Contents of
trouble
Signal voltage of blade control lever lift potentiometer 1 system is below 0.5 V.
Action of
controller
Continues control with signal of blade control lever lift potentiometer 2 system.
Limits operation of engine and transmission.
Problem that
appears on
machine
Related
information
WLV1 (male)
3.2 kz 40 %
Neutral
Resistance
1 5 kz
1 5 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between WEC1 (female)
3
or defective contact in con- (22) WLV1 (female) (4)
nector)
Wiring harness between WEC1 (female) (2)
WLV1 (female) (3)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
4 ness (Contact with GND cirWiring harness between WEC1 (female) (2)
Resiscuit)
Min. 1 Mz
WLV1 (female) (3) and chassis ground
tance
Defective work equipment
5
controller
Voltage
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
SEN00720-02
40 Troubleshooting
Failure code
E03
DFA5KB
Trouble
Contents of
trouble
Signal voltage of blade control lever lift potentiometer 1 system is above 4.5 V.
Action of
controller
Continues control with signal of blade control lever lift potentiometer 2 system.
Limits operation of engine and transmission.
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Resistance
3.2 kz 40 %
Neutral
1 5 kz
1 5 kz
WLV1 (male)
Voltage
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
SEN00720-02
40 Troubleshooting
Failure code
E03
DFA6KA
Trouble
BL lever 2: Disconnection
(Work equipment controller system)
Contents of
trouble
Signal voltage of blade control lever lift potentiometer 2 system is below 0.5 V.
Action of
controller
Continues control with signal of blade control lever lift potentiometer 1 system.
Limits operation of engine and transmission.
Problem that
appears on
machine
Related
information
WLV1 (male)
3.2 kz 40 %
Neutral
Resistance
1 5 kz
1 5 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between WEC1 (female)
3
or defective contact in con- (22) WLV1 (female) (4)
nector)
Wiring harness between WEC1 (female)
(19) WLV1 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring har4 ness (Contact with GND cir- Wiring harness between WEC1 (female)
Resiscuit)
(19) WLV1 (female) (2) and chassis
Min. 1 Mz
tance
ground
10
Voltage
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
11
SEN00720-02
40 Troubleshooting
Failure code
E03
DFA6KB
Trouble
Contents of
trouble
Signal voltage of blade control lever lift potentiometer 2 system is above 4.5 V.
Action of
controller
Continues control with signal of blade control lever lift potentiometer 1 system.
Limits operation of engine and transmission.
Problem that
appears on
machine
Related
information
Resistance
3.2 kz 40 %
Neutral
1 5 kz
1 5 kz
12
WLV1 (male)
Voltage
Max. 1 V
Voltage
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
13
SEN00720-02
40 Troubleshooting
Possible causes
and standard
value in normal
state
Failure code
DFA7KX
Trouble
In blade control lever tilt potentiometer 1 and 2 systems, either of failure codes [DFA8KA] and
[DFA8KB] and either of failure codes [DFA9KA] and [DFA9KB] occurred simultaneously.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1 and R1.
State of blade control lever tilt potentiometer signal can be checked with monitoring function.
(Code: 73500 Blade Tilt Lever A Potentio)
(Code: 73501 Blade Tilt Lever B Potentio)
Method of reproducing failure code: Turn starting switch ON + Operate blade control lever
(in tilting direction).
Cause
Carry out troubleshooting for failure codes [DFA8KA], [DFA8KB], [DFA9KA], and [DFA9KB].
Failure code
E03
DFA7KZ
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
14
Trouble
In blade control lever tilt potentiometer 1 and 2 systems, when starting switch is turned ON, only
either side is abnormal and then either of failure codes [DFA8KA] and [DFA8KB] and either of failure codes [DFA9KA] and [DFA9KB] occurred simultaneously.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1 and R1.
State of blade control lever tilt potentiometer signal can be checked with monitoring function.
(Code: 73500 Blade Tilt Lever A Potentio)
(Code: 73501 Blade Tilt Lever B Potentio)
Method of reproducing failure code: Turn starting switch ON + Operate blade control lever
(in tilting direction).
Cause
Carry out troubleshooting for failure codes [DFA8KA], [DFA8KB], [DFA9KA], and [DFA9KB].
D155AX-6
40 Troubleshooting
SEN00720-02
Failure code
DFA7L8
Trouble
Contents of
trouble
In blade control lever tilt potentiometer 1 and 2 systems, total of both signal voltages is below 4.41 V
or above 5.59 V.
Action of
controller
Continues control with signal of normal one of blade control lever tilt potentiometer 1 and 2 systems.
Limits operation of engine and transmission.
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
D155AX-6
Carry out troubleshooting for failure codes [DFA8KA], [DFA8KB], [DFA9KA], and [DFA9KB].
15
SEN00720-02
40 Troubleshooting
Failure code
E03
DFA8KA
Trouble
BT lever 1: Disconnection
(Work equipment controller system)
Contents of
trouble
Signal voltage of blade control lever tilt potentiometer 1 system is below 0.5 V.
Action of
controller
Continues control with signal of blade control lever tilt potentiometer 2 system.
Limits operation of engine and transmission
Problem that
appears on
machine
Related
information
WLV1 (male)
3.2 kz 40 %
Neutral
Resistance
1 5 kz
1 5 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between WEC1 (female)
3
or defective contact in con- (22) WLV1 (female) (8)
nector)
Wiring harness between WEC1 (female)
(13) WLV1 (female) (7)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring har4 ness (Contact with GND cir- Wiring harness between WEC1 (female)
Resiscuit)
(13) WLV1 (female) (7) and chassis
Min. 1 Mz
tance
ground
16
Voltage
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
17
SEN00720-02
40 Troubleshooting
Failure code
E03
DFA8KB
Trouble
Contents of
trouble
Signal voltage of blade control lever tilt potentiometer 1 system is above 4.5 V.
Action of
controller
Continues control with signal of blade control lever tilt potentiometer 2 system.
Limits operation of engine and transmission.
Problem that
appears on
machine
Related
information
Resistance
3.2 kz 40 %
Neutral
1 5 kz
1 5 kz
18
WLV1 (male)
Voltage
Max. 1 V
Voltage
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
19
SEN00720-02
40 Troubleshooting
Failure code
E03
DFA9KA
Trouble
BT lever 2: Disconnection
(Work equipment controller system)
Contents of
trouble
Signal voltage of blade control lever tilt potentiometer 2 system is below 0.5 V.
Action of
controller
Continues control with signal of blade control lever tilt potentiometer 1 system.
Limits operation of engine and transmission.
Problem that
appears on
machine
Related
information
WLV1 (male)
3.2 kz 40 %
Neutral
Resistance
1 5 kz
1 5 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between WEC1 (female)
3
or defective contact in con- (22) WLV1 (female) (8)
nector)
Wiring harness between WEC1 (female) (7)
WLV1 (female) (6)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
4 ness (Contact with GND cirWiring harness between WEC1 (female) (7)
Resiscuit)
Min. 1 Mz
WLV1 (female) (6) and chassis ground
tance
Defective work equipment
5
controller
20
Voltage
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
21
SEN00720-02
40 Troubleshooting
Failure code
E03
DFA9KB
Trouble
Contents of
trouble
Signal voltage of blade control lever tilt potentiometer 2 system is above 4.5 V.
Action of
controller
Continues control with signal of blade control lever tilt potentiometer 1 system.
Limits operation of engine and transmission.
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Resistance
3.2 kz 40 %
Neutral
1 5 kz
1 5 kz
22
WLV1 (male)
Voltage
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
23
SEN00720-02
40 Troubleshooting
Possible causes
and standard
value in normal
state
Failure code
DFAAKX
Trouble
In ripper control lever lift potentiometer 1 and 2 systems, either of failure codes [DFABKA] and
[DFABKB] and either of failure codes [DFACKA] and [DFACKB] occurred simultaneously.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1 and R1.
State of ripper control lever lift potentiometer signal can be checked with monitoring function.
(Code: 73700 Ripper Lift Lever A Potentio)
(Code: 73701 Ripper Lift Lever B Potentio)
Method of reproducing failure code: Turn starting switch ON + Operate ripper control lever
(in lifting direction).
Cause
Carry out troubleshooting for failure codes [DFABKA], [DFABKB], [DFACKA], and [DFACKB].
Failure code
E03
DFAAKZ
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
24
Trouble
In ripper control lever lift potentiometer 1 and 2 systems, when starting switch is turned ON, only
either side is abnormal and then either of failure codes [DFABKA] and [DFABKB] and either of failure codes [DFACKA] and [DFACKB] occurred simultaneously.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1 and R1.
State of ripper control lever lift potentiometer signal can be checked with monitoring function.
(Code: 73700 Ripper Lift Lever A Potentio)
(Code: 73701 Ripper Lift Lever B Potentio)
Method of reproducing failure code: Turn starting switch ON + Operate ripper control lever
(in lifting direction).
Cause
Carry out troubleshooting for failure codes [DFABKA], [DFABKB], [DFACKA], and [DFACKB].
D155AX-6
40 Troubleshooting
SEN00720-02
Possible causes
and standard
value in normal
state
D155AX-6
Failure code
DFAAL8
Trouble
In ripper control lever lift potentiometer 1 and 2 systems, total of both signal voltages is below 4.41
V or above 5.59 V.
Continues control with signal of normal one of ripper control lever lift potentiometer 1 and 2 systems.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1 and R1.
State of ripper control lever lift potentiometer signal can be checked with monitoring function.
(Code: 73700 Ripper Lift Lever A Potentio)
(Code: 73701 Ripper Lift Lever B Potentio)
Method of reproducing failure code: Turn starting switch ON + Operate ripper control lever
(in lifting direction).
Cause
Carry out troubleshooting for failure codes [DFABKA], [DFABKB], [DFACKA], and [DFACKB].
25
SEN00720-02
40 Troubleshooting
Failure code
E03
DFABKA
Trouble
RL lever 1: Disconnection
(Work equipment controller system)
Contents of
trouble
Signal voltage of ripper control lever lift potentiometer 1 system is below 0.5 V.
Action of
controller
Continues control with signal of ripper control lever lift potentiometer 2 system.
Limits operation of engine and transmission.
Problem that
appears on
machine
Related
information
WLV2 (male)
3.2 kz 40 %
Neutral
Resistance
1 5 kz
1 5 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between WEC1 (female)
3
or defective contact in con- (22) WLV2 (female) (8)
nector)
Wiring harness between WEC1 (female)
(14) WLV2 (female) (7)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring har4 ness (Contact with GND cir- Wiring harness between WEC1 (female)
Resiscuit)
(14) WLV2 (female) (7) and chassis
Min. 1 Mz
tance
ground
26
Voltage
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
27
SEN00720-02
40 Troubleshooting
Failure code
E03
DFABKB
Trouble
Contents of
trouble
Signal voltage of ripper control lever lift potentiometer 1 system is above 4.5 V.
Action of
controller
Continues control with signal of ripper control lever lift potentiometer 2 system.
Limits operation of engine and transmission.
Problem that
appears on
machine
Related
information
Resistance
3.2 kz 40 %
Neutral
1 5 kz
1 5 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
28
WLV2 (male)
Resistance
Min. 1 Mz
Voltage
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
29
SEN00720-02
40 Troubleshooting
Failure code
E03
DFACKA
Trouble
RL lever 2: Disconnection
(Work equipment controller system)
Contents of
trouble
Signal voltage of ripper control lever lift potentiometer 2 system is below 0.5 V.
Action of
controller
Continues control with signal of ripper control lever lift potentiometer 1 system.
Limits operation of engine and transmission.
Problem that
appears on
machine
Related
information
WLV2 (male)
3.2 kz 40 %
Neutral
Resistance
1 5 kz
1 5 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between WEC1 (female)
3
or defective contact in con- (22) WLV2 (female) (8)
nector)
Wiring harness between WEC1 (female) (8)
WLV2 (female) (6)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
4 ness (Contact with GND cirWiring harness between WEC1 (female) (8)
Resiscuit)
Min. 1 Mz
WLV2 (female) (6) and chassis ground
tance
Defective work equipment
5
controller
30
Voltage
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
31
SEN00720-02
40 Troubleshooting
Failure code
E03
DFACKB
Trouble
Contents of
trouble
Signal voltage of ripper control lever lift potentiometer 2 system is above 4.5 V.
Action of
controller
Continues control with signal of ripper control lever lift potentiometer 1 system.
Limits operation of engine and transmission.
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Resistance
3.2 kz 40 %
Neutral
1 5 kz
1 5 kz
32
WLV2 (male)
Voltage
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
33
SEN00720-02
40 Troubleshooting
Possible causes
and standard
value in normal
state
Failure code
DFADKX
Trouble
In ripper control lever tilt potentiometer 1 and 2 systems, either of failure codes [DFAEKA] and
[DFAEKB] and either of failure codes [DFAFKA] and [DFAFKB] occurred simultaneously.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1 and R1.
State of ripper control lever tilt potentiometer signal can be checked with monitoring function.
(Code: 73600 Ripper Tilt Lever A Potentio)
(Code: 73601 Ripper Tilt Lever B Potentio)
Method of reproducing failure code: Turn starting switch ON + Operate ripper control lever
(in tilting direction).
Cause
Carry out troubleshooting for failure codes [DFAEKA], [DFAEKB], [DFAFKA], and [DFAFKB].
Failure code
E03
DFADKZ
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
34
Trouble
In ripper control lever tilt potentiometer 1 and 2 systems, when starting switch is turned ON, only
either side is abnormal and then either of failure codes [DFAEKA] and [DFAEKB] and either of failure codes [DFAFKA] and [DFAFKB] occurred simultaneously.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1 and R1.
State of ripper control lever tilt potentiometer signal can be checked with monitoring function.
(Code: 73600 Ripper Tilt Lever A Potentio)
(Code: 73601 Ripper Tilt Lever B Potentio)
Method of reproducing failure code: Turn starting switch ON + Operate ripper control lever
(in tilting direction).
Cause
Carry out troubleshooting for failure codes [DFAEKA], [DFAEKB], [DFAFKA], and [DFAFKB].
D155AX-6
40 Troubleshooting
SEN00720-02
Possible causes
and standard
value in normal
state
D155AX-6
Failure code
DFADL8
Trouble
In ripper control lever tilt potentiometer 1 and 2 systems, total of both signal voltages is
below 4.41 V or above 5.59 V.
Continues control with signal of normal one of ripper control lever tilt potentiometer 1 and 2 systems.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1 and R1.
State of ripper control lever tilt potentiometer signal can be checked with monitoring function.
(Code: 73600 Ripper Tilt Lever A Potentio)
(Code: 73601 Ripper Tilt Lever B Potentio)
Method of reproducing failure code: Turn starting switch ON + Operate ripper control lever
(in tilting direction).
Cause
Carry out troubleshooting for failure codes [DFAEKA], [DFAEKB], [DFAFKA], and [DFAFKB].
35
SEN00720-02
40 Troubleshooting
Failure code
E03
DFAEKA
Trouble
RL lever 1: Disconnection
(Work equipment controller system)
Contents of
trouble
Signal voltage of ripper control lever tilt potentiometer 1 system is below 0.5 V.
Action of
controller
Continues control with signal of ripper control lever tilt potentiometer 2 system.
Limits operation of engine and transmission.
Problem that
appears on
machine
Related
information
WLV2 (male)
3.2 kz 40 %
Neutral
Resistance
1 5 kz
1 5 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between WEC1 (female)
3
or defective contact in con- (22) WLV2 (female) (4)
nector)
Wiring harness between WEC1 (female) (3)
WLV2 (female) (3)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
4 ness (Contact with GND cirWiring harness between WEC1 (female) (3)
Resiscuit)
Min. 1 Mz
WLV2 (female) (3) and chassis ground
tance
Defective work equipment
5
controller
36
Voltage
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
37
SEN00720-02
40 Troubleshooting
Failure code
E03
DFAEKB
Trouble
Contents of
trouble
Signal voltage of ripper control lever tilt potentiometer 1 system is above 4.5 V.
Action of
controller
Continues control with signal of ripper control lever tilt potentiometer 2 system.
Limits operation of engine and transmission.
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Resistance
3.2 kz 40 %
Neutral
1 5 kz
1 5 kz
38
WLV2 (male)
Voltage
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
39
SEN00720-02
40 Troubleshooting
Failure code
E03
DFAFKA
Trouble
RL lever 2: Disconnection
(Work equipment controller system)
Contents of
trouble
Signal voltage of ripper control lever tilt potentiometer 2 system is below 0.5 V.
Action of
controller
Continues control with signal of ripper control lever tilt potentiometer 1 system.
Limits operation of engine and transmission.
Problem that
appears on
machine
Related
information
WLV2 (male)
3.2 kz 40 %
Neutral
Resistance
1 5 kz
1 5 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between WEC1 (female)
3
or defective contact in con- (22) WLV2 (female) (4)
nector)
Wiring harness between WEC1 (female)
(20) WLV2 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring har4 ness (Contact with GND cir- Wiring harness between WEC1 (female)
Resiscuit)
(20) WLV2 (female) (2) and chassis
Min. 1 Mz
tance
ground
40
Voltage
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
41
SEN00720-02
40 Troubleshooting
Failure code
E03
DFAFKB
Trouble
Contents of
trouble
Signal voltage of ripper control lever tilt potentiometer 2 system is above 4.5 V.
Action of
controller
Continues control with signal of ripper control lever tilt potentiometer 1 system.
Limits operation of engine and transmission.
Problem that
appears on
machine
Related
information
Resistance
3.2 kz 40 %
Neutral
1 5 kz
1 5 kz
42
WLV2 (male)
Voltage
Max. 1 V
Voltage
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
43
SEN00720-02
40 Troubleshooting
Failure code
E01
DGT1KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Resistance
1 50 kz
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC1 (female) (9)
2
or defective contact in con- TCT (female) (1)
nector)
Wiring harness between STC1 (female) (21)
TCT (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
3 ness (Contact with GND cirWiring harness between STC1 (female) (9)
Resiscuit)
Min. 1 Mz
TCT (female) (1) and chassis ground
tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
Hot short (Short circuit with
4
24V circuit) in wiring harness Wiring harness between STC1 (female) (9)
Voltage Max. 1 V
TCT (female) (1) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
5
44
STC1 (female)
Resistance
1 50 kz
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
45
SEN00720-02
40 Troubleshooting
Failure code
E01
DGT1KX
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Resistance
1 50 kz
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC1 (female) (9)
2
or defective contact in con- TCT (female) (1)
nector)
Wiring harness between STC1 (female) (21)
TCT (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
3 ness (Contact with GND cirWiring harness between STC1 (female) (9)
Resiscuit)
Min. 1 Mz
TCT (female) (1) and chassis ground
tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
Hot short (Short circuit with
4
24V circuit) in wiring harness Wiring harness between STC1 (female) (9)
Voltage Max. 1 V
TCT (female) (1) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
5
46
STC1 (female)
Resistance
1 50 kz
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
47
SEN00720-02
40 Troubleshooting
Failure code
DH21KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Signal voltage of work equipment pump oil pressure sensor is below 0.5 V.
None in particular.
Oil pressure of work equipment pump cannot be monitored.
State of work equipment pump oil pressure sensor can be checked with monitoring function.
(Code: 70701 Hydraulic Pressure Sensor 1)
Method of reproducing failure code: Turn starting switch ON.
Cause
If failure code [DB95KK] is also displayed, carry out troubleshooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON
or start engine and carry out troubleshooting in each case.
HHP
Voltage
Power supply
4.5 5.5 V
Signal
0.5 6.0 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring
3
or defective contact in connector)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
4 ness (Contact with GND cirWiring
harness between WEC1 (female) (1)
Resiscuit)
Min. 1 Mz
HHP (female) (C) and chassis ground
tance
5
48
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
49
SEN00720-02
40 Troubleshooting
Failure code
DH21KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Signal voltage of work equipment pump oil pressure sensor is below 6.0 V.
None in particular.
Oil pressure of work equipment pump cannot be monitored.
State of work equipment pump oil pressure sensor can be checked with monitoring function.
(Code: 70701 Hydraulic Pressure Sensor 1)
Method of reproducing failure code: Turn starting switch ON.
Cause
If failure code [DB95KK] is also displayed, carry out troubleshooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON
or start engine and carry out troubleshooting in each case.
Possible causes
and standard
value in normal
state
HHP
Voltage
Power supply
4.5 5.5 V
Signal
0.5 6.0 V
50
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
51
SEN00720-02
40 Troubleshooting
Failure code
E02
DHT5KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Defective sensor 24 V power If failure code [DBE6KK] is also displayed, carry out troubleshoot1
supply system
ing for it first.
a Prepare with starting switch OFF, then turn starting switch ON
or start engine and carry out troubleshooting in each case.
Defective torque converter
2 inlet pressure sensor (Internal trouble)
TIP
Voltage
Power supply
20 30 V
Signal
0.5 6.0 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring
3
or defective contact in connector)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between STC1 (female) (16)
4 ness (Contact with GND cir- TIP (female) (B) or circuit branch end and
cuit)
chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
52
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
53
SEN00720-02
40 Troubleshooting
Failure code
E02
DHT5KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Defective sensor 24 V power If failure code [DBE6KK] is also displayed, carry out troubleshoot1
supply system
ing for it first.
a Prepare with starting switch OFF, then turn starting switch ON
or start engine and carry out troubleshooting in each case.
Defective torque converter
2 inlet pressure sensor (Internal trouble)
Voltage
Power supply
20 30 V
Signal
0.5 6.0 V
Possible causes
and standard
value in normal
state
54
TIP
Voltage
Max. 1 V
Voltage
Max. 1 V
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
55
SEN00720-02
40 Troubleshooting
Failure code
E02
DHT7KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Defective sensor 24 V power If failure code [DBE6KK] is also displayed, carry out troubleshoot1
supply system
ing for it first.
a Prepare with starting switch OFF, then turn starting switch ON
or start engine and carry out troubleshooting in each case.
Defective torque converter
2 outlet pressure sensor (Internal trouble)
TOP
Voltage
Power supply
20 30 V
Signal
0.5 6.0 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring
3
or defective contact in connector)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
56
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
57
SEN00720-02
40 Troubleshooting
Failure code
E02
DHT7KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Defective sensor 24 V power If failure code [DBE6KK] is also displayed, carry out troubleshoot1
supply system
ing for it first.
a Prepare with starting switch OFF, then turn starting switch ON
or start engine and carry out troubleshooting in each case.
Possible causes
and standard
value in normal
state
Voltage
Power supply
20 30 V
Signal
0.5 6.0 V
58
TOP
Hot short (Short circuit with Wiring harness between STC1 (female) (21)
24V circuit) in wiring harness TOP (female) (A) or circuit branch end
Voltage
Max. 1 V
Voltage
Max. 1 V
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
59
SEN00720-02
40 Troubleshooting
Failure code
E03
DK10KX
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
DIAL (male)
Resistance
4.0 6.0 kz
0.25 7.0 kz
0.25 7.0 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring
3
or defective contact in connector)
Possible causes
and standard
value in normal
state
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between STC1 (female) (22)
4 ness (Contact with GND cir- DIAL (female) (1) or circuit branch end
cuit)
and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Voltage
Max. 1 V
Voltage
Max. 1 V
Voltage
Max. 1 V
60
STC1
Voltage
4.6 5.4 V
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
61
SEN00720-02
40 Troubleshooting
D155AX-6 Bulldozer
Form No. SEN00720-02
2008 KOMATSU
All Rights Reserved
Printed in Japan 10-08 (02)
62
D155AX-6
SEN00721-03
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
40 Troubleshooting
D155AX-6
SEN00721-03
40 Troubleshooting
D155AX-6
40 Troubleshooting
D155AX-6
SEN00721-03
SEN00721-03
40 Troubleshooting
Failure code
E03
DK30KA
Trouble
ST lever1: Disconnection
(Power train controller system)
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Sensor
output
0.96 to
4.04 V
Voltage
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC1 (female) (22)
3
or defective contact in con- TLV1 (female) (5)
nector)
Wiring harness between STC1 (female) (2)
TLV1 (female) (7)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
4 ness (Contact with GND cirWiring harness between STC1 (female) (2)
Resiscuit)
Min. 1 Mz
TLV1 (female) (7) and chassis ground
tance
Voltage
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00721-03
D155AX-6
SEN00721-03
40 Troubleshooting
Failure code
E03
DK30KB
Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Sensor
output
0.96 to
4.04 V
Voltage
Voltage
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00721-03
D155AX-6
SEN00721-03
40 Troubleshooting
Related
information
Possible causes
and standard
value in normal
state
Failure code
DK30KX
Trouble
In PCCS lever steering potentiometer 1 and 2 systems, either of failure codes [DK30KA] and
[DK30KB] and either of failure codes [DK31KA] and [DK31KB] occurred simultaneously.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1 and R1.
State of PCCS lever steering potentiometer signal can be checked with monitoring function.
(Code: 50300 S/T Lever 1 Potentio)
(Code: 50301 S/T Lever 2 Potentio)
Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (in steering
direction).
Cause
Carry out troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
Failure code
E04
DK30KZ
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Trouble
In PCCS lever steering potentiometer 1 and 2 systems, when starting switch is turned ON, only
either side is abnormal and then either of failure codes [DK30KA] and [DK30KB] and either of failure codes [DK31KA] and [DK31KB] occurred simultaneously.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, it cannot travel at all.
State of PCCS lever steering potentiometer signal can be checked with monitoring function.
(Code: 50300 S/T Lever 1 Potentio)
(Code: 50301 S/T Lever 2 Potentio)
Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (in steering
direction).
Cause
Carry out troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
D155AX-6
40 Troubleshooting
SEN00721-03
Failure code
DK30L8
Trouble
Contents of
trouble
In PCCS lever steering potentiometer 1 and 2 systems, total of both signal voltages is below 4.41 V
or above 5.59 V.
Action of
controller
Continues control with signal of normal one of PCCS lever steering potentiometer 1 and 2 systems.
Limits operation of engine and transmission.
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
D155AX-6
Carry out troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
SEN00721-03
40 Troubleshooting
Failure code
E03
DK31KA
Trouble
ST lever 2: Disconnection
(Power train controller system)
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Sensor
output
0.96 to
4.04 V
Voltage
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC1 (female) (22)
3
or defective contact in con- TLV1 (female) (5)
nector)
Wiring harness between STC1 (female) (19)
TLV1 (female) (6)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
4 ness (Contact with GND cirWiring harness between STC1 (female) (19)
Resiscuit)
Min. 1 Mz
TLV1 (female) (6) and chassis ground
tance
10
Voltage
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00721-03
D155AX-6
11
SEN00721-03
40 Troubleshooting
Failure code
E03
DK31KB
Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Sensor
output
0.96 to
4.04 V
Voltage
12
Voltage
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00721-03
D155AX-6
13
SEN00721-03
40 Troubleshooting
Failure code
E03
DK40KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
If failure code [DBE7KK] is also displayed, carry out troubleshooting for it first.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
BRK (male)
Resistance
4.0 6.0 kz
0.25 7.0 kz
0.25 7.0 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between STC1 (female) (3)
4 ness (Contact with GND cir- BRK (female) (B) and chassis ground
cuit)
Wiring harness between STC1 (female) (22)
BRK (female) (C) or circuit branch end
and chassis ground
Defective power train con5
troller
14
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Voltage
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00721-03
D155AX-6
15
SEN00721-03
40 Troubleshooting
Failure code
E03
DK40KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
If failure code [DBE7KK] is also displayed, carry out troubleshooting for it first.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Resistance
4.0 6.0 kz
0.25 7.0 kz
0.25 7.0 kz
16
BRK (male)
Voltage
Max. 1 V
Voltage
Max. 1 V
Voltage
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00721-03
D155AX-6
17
SEN00721-03
40 Troubleshooting
Related
information
Possible causes
and standard
value in normal
state
Failure code
DK55KX
Trouble
In PCCS lever F-R potentiometer 1 and 2 systems, either of failure codes [DK56KA] and [DK56KB]
and either of failure codes [DK57KA] and [DK57KB] occurred simultaneously.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, it cannot travel at all.
State of PCCS lever F-R potentiometer signal can be checked with monitoring function.
(Code: 50200 T/M Lever 1 Potentio)
(Code: 50201 T/M Lever 2 Potentio)
Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (in F-R direction).
Cause
Carry out troubleshooting for failure codes [DK56KA], [DK56KB], [DK57KA], and [DK57KB].
Failure code
E04
DK55KZ
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
18
Trouble
In PCCS lever F-R potentiometer 1 and 2 systems, when starting switch is turned ON, only either
side is abnormal and then either of failure codes [DK56KA] and [DK56KB] and either of failure
codes [DK57KA] and [DK57KB] occurred simultaneously.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, it cannot travel at all.
State of PCCS lever F-R potentiometer signal can be checked with monitoring function.
(Code: 50200 T/M Lever 1 Potentio)
(Code: 50201 T/M Lever 2 Potentio)
Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (in F-R direction).
Cause
Carry out troubleshooting for failure codes [DK56KA], [DK56KB], [DK57KA], and [DK57KB].
D155AX-6
40 Troubleshooting
SEN00721-03
Related
information
Possible causes
and standard
value in normal
state
D155AX-6
Failure code
DK55L8
Trouble
In PCCS lever F-R potentiometer 1 and 2 systems, total of both signal voltages is below 4.41 V or
above 5.59 V.
Continues control with signal of normal one of PCCS lever F-R potentiometer 1 and 2 systems.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1 and R1.
State of PCCS lever F-R potentiometer signal can be checked with monitoring function.
(Code: 50200 T/M Lever 1 Potentio)
(Code: 50201 T/M Lever 2 Potentio)
Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (in F-R direction).
Cause
Carry out troubleshooting for failure codes [DK56KA], [DK56KB], [DK57KA], and [DK57KB].
19
SEN00721-03
40 Troubleshooting
Failure code
E03
DK56KA
Trouble
FR lever 1: Disconnection
(Power train controller system)
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Sensor
output
0.96 to
4.04 V
Voltage
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC1 (female) (22)
Resis3
Max. 1 z
or defective contact in con- TLV1 (female) (4)
tance
nector)
Wiring harness between STC1 (female) (13)
ResisMax. 1 z
TLV1 (female) (3)
tance
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
4 ness (Contact with GND cirWiring harness between STC1 (female) (13)
Resiscuit)
Min. 1 Mz
TLV1 (female) (3) and chassis ground
tance
20
Voltage
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00721-03
D155AX-6
21
SEN00721-03
40 Troubleshooting
Failure code
E03
DK56KB
Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Sensor
output
0.96 to
4.04 V
Voltage
22
Voltage
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00721-03
D155AX-6
23
SEN00721-03
40 Troubleshooting
Failure code
E03
DK57KA
Trouble
FR lever 2: Disconnection
(Power train controller system)
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Sensor
output
0.96 to
4.04 V
Voltage
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC1 (female) (22)
Resis3
Max. 1 z
or defective contact in con- TLV1 (female) (4)
tance
nector)
Wiring harness between STC1 (female) (7)
ResisMax. 1 z
TLV1 (female) (2)
tance
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
4 ness (Contact with GND cirWiring harness between STC1 (female) (7)
Resiscuit)
Min. 1 Mz
TLV1 (female) (2) and chassis ground
tance
24
Voltage
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00721-03
D155AX-6
25
SEN00721-03
40 Troubleshooting
Failure code
E03
DK57KB
Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Sensor
output
0.96 to
4.04 V
Voltage
26
Voltage
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00721-03
D155AX-6
27
SEN00721-03
40 Troubleshooting
Failure code
E03
DKH1KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Defective sensor 24V power If failure code [DBE6KK] is also displayed, carry out troubleshoot1
supply system
ing for it first.
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
PT1
2
Voltage
Power supply
20 30 V
Signal
0.15 4.85 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring
3
or defective contact in connector)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
4 ness (Contact with GND cirWiring
harness between STC1 (female) (8)
Resiscuit)
Min. 1 Mz
PT1 (female) (B) and chassis ground
tance
5
28
D155AX-6
40 Troubleshooting
SEN00721-03
D155AX-6
29
SEN00721-03
40 Troubleshooting
Failure code
E03
DKH1KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Defective sensor 24V power If failure code [DBE6KK] is also displayed, carry out troubleshoot1
supply system
ing for it first.
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
PT1
Possible causes
and standard
value in normal
state
Voltage
Power supply
20 30 V
Signal
0.15 4.85 V
30
D155AX-6
40 Troubleshooting
SEN00721-03
D155AX-6
31
SEN00721-03
40 Troubleshooting
Failure code
E01
DLT3KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Possible causes
and standard
value in normal
state
Resistance
500 1,000 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC2 (female) (30)
3
or defective contact in con- BVRV (female) (1)
nector)
Wiring harness between STC2 (female) (29)
BVRV (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
4 ness (Contact with GND cirWiring harness between STC2 (female) (30)
Resiscuit)
Min. 1 Mz
BVRV (female) (1) and chassis ground
tance
5
32
D155AX-6
40 Troubleshooting
SEN00721-03
Failure code
E01
DLT3KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Possible causes
and standard
value in normal
state
Resistance
500 1,000 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC2 (female) (30)
2
or defective contact in con- BVRV (female) (1)
nector)
Wiring harness between STC2 (female) (29)
BVRV (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
3 ness (Contact with GND cirWiring harness between STC2 (female) (30)
Resiscuit)
Min. 1 Mz
BVRV (female) (1) and chassis ground
tance
4
D155AX-6
33
SEN00721-03
40 Troubleshooting
Failure code
E01
DW7BKA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Resistance
34 44 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC3 (female) (18)
2
or defective contact in con- FAR (female) (1)
nector)
Wiring harness between STC3 (female) (13)
FAR (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
34
D155AX-6
40 Troubleshooting
SEN00721-03
Failure code
E01
DW7BKB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal was output to fan reverse solenoid circuit, abnormal current flowed.
Turns signal to fan reverse solenoid circuit OFF.
Possible causes
and standard
value in normal
state
FAR (male)
Resistance
34 44 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
2 ness (Contact with GND cirWiring harness between STC3 (female) (18)
Resiscuit)
Min. 1 Mz
FAR (female) (1) and chassis ground
tance
Short circuit in wiring har3 ness (with another wiring
harness)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between STC3 (female) (18)
FAR (female) (1) and between STC3
(female) (13) FAR (female) (2)
Resistance
Min. 1 Mz
D155AX-6
35
SEN00721-03
40 Troubleshooting
Failure code
E03
DWN1KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal is output to HSS left EPC solenoid circuit, no current flows.
Turns signal to HSS left EPC solenoid circuit OFF.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1 and R1.
Output to HSS left EPC solenoid can be checked with monitoring function.
(Code: 50600 HSS Solenoid LH (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (Left steering)
Cause
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective HSS left EPC sole1
noid (Internal disconnection)
HSL (male)
Resistance
Between (1) (2)
4.5 14.5 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC3 (female) (25)
2
or defective contact in con- HSL (female) (1)
nector)
Wiring harness between STC3 (female) (3)
HSL (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
Voltage
Max. 1 V
36
D155AX-6
40 Troubleshooting
SEN00721-03
Failure code
E03
DWN1KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal is output to HSS left EPC solenoid circuit, abnormal current flowed.
Turns signal to HSS left EPC solenoid circuit OFF.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1 and R1.
Output to HSS left EPC solenoid can be checked with monitoring function.
(Code: 50600 HSS Solenoid LH (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (Left steering).
Cause
Possible causes
and standard
value in normal
state
HSL (male)
Resistance
4.5 14.5 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
2 ness (Contact with GND cirWiring harness between STC3 (female) (25)
Resiscuit)
Min. 1 Mz
HSL (female) (1) and chassis ground
tance
Short circuit in wiring har3 ness (with another wiring
harness)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between STC3 (female) (25)
HSL (female) (1) and between STC3
(female) (3) HSL (female) (2)
Resistance
Min. 1 Mz
D155AX-6
37
SEN00721-03
40 Troubleshooting
Failure code
E03
DWN1KY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal is output to HSS left EPC solenoid circuit, abnormal current flowed.
Turns signal to HSS left EPC solenoid circuit OFF.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1 and R1.
Output to HSS left EPC solenoid can be checked with monitoring function.
(Code: 50600 HSS Solenoid LH (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (Left steering).
Cause
Possible causes
and standard
value in normal
state
HSL (male)
Resistance
4.5 14.5 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between STC3 (female) (25)
HSL (female) (1) and between STC3
(female) (3) HSL (female) (2)
Resistance
Min. 1 Mz
38
D155AX-6
40 Troubleshooting
SEN00721-03
Failure code
E03
DWN2KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal is output to HSS right EPC solenoid circuit, no current flows.
Turns signal to HSS right EPC solenoid circuit OFF.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1 and R1.
Output to HSS right EPC solenoid can be checked with monitoring function.
(Code: 50601 HSS Solenoid RH (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (Right steering).
Cause
Defective HSS right EPC
1 solenoid (Internal disconnection)
Resistance
4.5 14.5 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC3 (female) (35)
2
or defective contact in con- HSR (female) (1)
nector)
Wiring harness between STC3 (female) (3)
HSR (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
Voltage
Max. 1 V
D155AX-6
39
SEN00721-03
40 Troubleshooting
Failure code
E03
DWN2KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal is output to HSS right EPC solenoid circuit, abnormal current flowed.
Turns signal to HSS right EPC solenoid circuit OFF.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1 and R1.
Output to HSS right EPC solenoid can be checked with monitoring function.
(Code: 50601 HSS Solenoid RH (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (Right steering).
Cause
Possible causes
and standard
value in normal
state
Resistance
4.5 14.5 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
2 ness (Contact with GND cirResisWiring harness between STC3 (female) (35)
cuit)
Min. 1 Mz
HSR (female) (1) and chassis ground
tance
Short circuit in wiring har3 ness (with another wiring
harness)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between STC3 (female) (35)
HSR (female) (1) and between STC3
(female) (3) HSR (female) (2)
Resistance
Min. 1 Mz
40
D155AX-6
40 Troubleshooting
SEN00721-03
Failure code
E03
DWN2KY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal is output to HSS right EPC solenoid circuit, abnormal current flowed.
Turns signal to HSS right EPC solenoid circuit OFF.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1 and R1.
Output to HSS right EPC solenoid can be checked with monitoring function.
(Code: 50601 HSS Solenoid RH (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (Right steering).
Cause
Possible causes
and standard
value in normal
state
Resistance
4.5 14.5 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between STC3 (female) (35)
HSR (female) (1) and between STC3
(female) (3) HSR (female) (2)
Resistance
Min. 1 Mz
D155AX-6
41
SEN00721-03
40 Troubleshooting
Failure code
E04
DWN3KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal is output to sudden stop prevent solenoid circuit, no current flows.
Limits operation of engine, transmission, and brake.
Brake is applied lightly during travel.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, it cannot travel at all.
Output to sudden stop prevent solenoid can be checked with monitoring function.
(Code: 31628 SSP Solenoid)
Method of reproducing failure code: Turn starting switch ON.
Cause
Defective sudden stop pre1 vent solenoid (Internal disconnection)
Resistance
3.5 12.5 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC3 (female) (7)
2
or defective contact in con- SSP (female) (1)
nector)
Wiring harness between STC3 (female) (23)
SSP (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
42
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
STC3 (female)
Resistance
3.5 12.5 z
D155AX-6
40 Troubleshooting
SEN00721-03
D155AX-6
43
SEN00721-03
40 Troubleshooting
Failure code
E04
DWN3KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal was output to sudden stop prevent solenoid circuit, abnormal current flowed.
Limits operation of engine, transmission, and brake.
Brake is applied lightly during travel.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, it cannot travel at all.
Output to sudden stop prevent solenoid can be checked with monitoring function.
(Code: 31628 SSP Solenoid)
Method of reproducing failure code: Turn starting switch ON.
Cause
Possible causes
and standard
value in normal
state
Resistance
3.5 12.5 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
2 ness (Contact with GND cirWiring harness between STC3 (female) (7)
Resiscuit)
Min. 1 Mz
SSP (female) (1) and chassis ground
tance
Short circuit in wiring har3 ness (with another wiring
harness)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between STC3 (female) (7)
SSP (female) (1) and between STC3
(female) (23) SSP (female) (2)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4
44
STC3 (female)
Resistance
3.5 12.5 z
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00721-03
D155AX-6
45
SEN00721-03
40 Troubleshooting
Failure code
E04
DWN3KY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal was output to sudden stop prevent solenoid circuit, abnormal current flowed.
Limits operation of engine, transmission, and brake.
Brake is applied lightly during travel.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, it cannot travel at all.
Output to sudden stop prevent solenoid can be checked with monitoring function.
(Code: 31628 SSP Solenoid)
Method of reproducing failure code: Turn starting switch ON.
Cause
Possible causes
and standard
value in normal
state
Resistance
3.5 12.5 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between STC3 (female) (7)
SSP (female) (1) and between STC3
(female) (23) SSP (female) (2)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4
46
STC3 (female)
Resistance
3.5 12.5 z
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00721-03
D155AX-6
47
SEN00721-03
40 Troubleshooting
Failure code
E01
DWN5KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal is output to fan pump EPC solenoid circuit, no current flows.
Turns signal to fan pump EPC solenoid circuit OFF.
Resistance
2 12 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC3 (female) (36)
2
or defective contact in con- FAC (female) (1)
nector)
Wiring harness between STC3 (female) (23)
FAC (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
Voltage
Max. 1 V
48
D155AX-6
40 Troubleshooting
SEN00721-03
Failure code
E01
DWN5KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal was output to fan pump EPC solenoid circuit, abnormal current flowed.
Turns signal to fan pump EPC solenoid circuit OFF.
Possible causes
and standard
value in normal
state
Resistance
2 12 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
2 ness (Contact with GND cirWiring harness between STC3 (female) (36)
Resiscuit)
Min. 1 Mz
FAC (female) (1) and chassis ground
tance
Short circuit in wiring har3 ness (with another wiring
harness)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between STC3 (female) (36)
FAC (female) (1) and between STC3
(female) (23) FAC (female) (2)
Resistance
Min. 1 Mz
D155AX-6
49
SEN00721-03
40 Troubleshooting
Failure code
E01
DXA0KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal is output to work equipment-HSS pump TVC solenoid circuit, no current flows.
Turns signal to work equipment-HSS pump TVC solenoid circuit OFF.
Resistance
2 12 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between WEC3 (female) (7)
2
or defective contact in con- TVC (female) (1)
nector)
Wiring harness between WEC3 (female) (3)
TVC (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
WEC3 (female)
Resistance
2 12 z
50
D155AX-6
40 Troubleshooting
SEN00721-03
Failure code
E01
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
DXA0KB
Trouble
When signal was output to work equipment-HSS pump TVC solenoid circuit, abnormal current
flowed.
Turns signal to work equipment-HSS pump TVC solenoid circuit OFF.
Possible causes
and standard
value in normal
state
Resistance
2 12 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
2 ness (Contact with GND cirWiring harness between WEC3 (female) (7)
Resiscuit)
Min. 1 Mz
TVC (female) (1) and chassis ground
tance
Short circuit in wiring har3 ness (with another wiring
harness)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between WEC3 (female) (7)
TVC (female) (1) and between WEC3
(female) (3) TVC (female) (2)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4
WEC3 (female)
Resistance
2 12 z
Min. 1 Mz
D155AX-6
51
SEN00721-03
40 Troubleshooting
Failure code
E01
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
DXA0KY
Trouble
When signal was output to work equipment-HSS pump TVC solenoid circuit, abnormal current
flowed.
Turns signal to work equipment-HSS pump TVC solenoid circuit OFF.
Possible causes
and standard
value in normal
state
Resistance
2 12 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between WEC3 (female) (7)
TVC (female) (1) and between WEC3
(female) (3) TVC (female) (2)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4
WEC3 (female)
Resistance
2 12 z
Min. 1 Mz
52
D155AX-6
40 Troubleshooting
D155AX-6
SEN00721-03
53
SEN00721-03
40 Troubleshooting
Failure code
E02
DXH1KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal is output to torque converter lockup clutch ECMV solenoid circuit, no current flows.
Turns signal to torque converter lockup clutch ECMV solenoid circuit OFF.
Resistance
3.5 12.5 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC3 (female) (17)
2
or defective contact in con- SLUC (female) (1)
nector)
Wiring harness between STC3 (female) (13)
SLUC (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
54
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
STC3 (female)
Resistance
3.5 12.5 z
D155AX-6
40 Troubleshooting
SEN00721-03
D155AX-6
55
SEN00721-03
40 Troubleshooting
Failure code
E02
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
DXH1KB
Trouble
When signal was output to torque converter lockup clutch ECMV solenoid circuit, abnormal current
flowed.
Turns signal to torque converter lockup clutch ECMV solenoid circuit OFF.
Possible causes
and standard
value in normal
state
Resistance
3.5 12.5 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
2 ness (Contact with GND cirWiring harness between STC3 (female) (17)
Resiscuit)
Min. 1 Mz
SLUC (female) (1) and chassis ground
tance
Short circuit in wiring har3 ness (with another wiring
harness)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between STC3 (female) (17)
SLUC (female) (1) and between STC3
(female) (13) SLUC (female) (2)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4
56
STC3 (female)
Resistance
3.5 12.5 z
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00721-03
D155AX-6
57
SEN00721-03
40 Troubleshooting
Failure code
E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
DXH1KY
Trouble
When signal was output to torque converter lockup clutch ECMV solenoid circuit, abnormal current
flowed.
Turns signal to torque converter lockup clutch ECMV solenoid circuit OFF.
Torque converter lockup function operates constantly.
Engine may stall during travel.
Output to lockup clutch ECMV solenoid can be checked with monitoring function.
(Code: 31642 L/U ECMV (F/B))
Method of reproducing failure code: Start engine + Drive in auto gearshift mode (while lockup is in
operation).
Cause
Possible causes
and standard
value in normal
state
Resistance
3.5 12.5 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between STC3 (female) (17)
SLUC (female) (1) and between STC3
(female) (13) SLUC (female) (2)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4
58
STC3 (female)
Resistance
3.5 12.5 z
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00721-03
D155AX-6
59
SEN00721-03
40 Troubleshooting
Failure code
E03
DXH4KA
Contents of
trouble
Trouble
When signal is output to transmission 1st clutch ECMV solenoid circuit, no current flows.
Action of
controller
Problem that
appears on
machine
Related
information
Output to 1st clutch ECMV solenoid can be checked with monitoring function.
(Code: 31602 T/M Clutch 1st ECMV (F/B))
Method of reproducing failure code: Start engine + Set gear to F1 or R1.
Cause
Resistance
3.5 12.5 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC3 (female) (6)
2
or defective contact in con- S1T (female) (1)
nector)
Wiring harness between STC3 (female) (23)
S1T (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
Voltage
Max. 1 V
60
D155AX-6
40 Troubleshooting
D155AX-6
SEN00721-03
61
SEN00721-03
40 Troubleshooting
D155AX-6 Bulldozer
Form No. SEN00721-03
2011 KOMATSU
All Rights Reserved
Printed in Japan 11-11
62
D155AX-6
SEN00722-01
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
40 Troubleshooting
D155AX-6
SEN00722-01
40 Troubleshooting
D155AX-6
40 Troubleshooting
SEN00722-01
Action code
Failure code
E03
DXH4KB
Contents of
trouble
Trouble
When signal was output to transmission 1st clutch ECMV solenoid circuit, abnormal current flowed.
Action of
controller
Problem that
appears on
machine
Related
information
Output to 1st clutch ECMV solenoid can be checked with monitoring function.
(Code: 31602 T/M Clutch 1st ECMV (F/B))
Method of reproducing failure code: Start engine + Set gear to F1 or R1.
Cause
Defective 1st clutch ECMV
1 solenoid (Internal short circuit)
Possible causes
and standard
value in normal
state
Resistance
3.5 12.5 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
2 ness (Contact with GND cirWiring harness between STC3 (female) (6)
Resiscuit)
Min. 1 Mz
S1T (female) (1) and chassis ground
tance
Short circuit in wiring har3 ness (with another wiring
harness)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between STC3 (female) (6)
S1T (female) (1) and between STC3
(female) (23) S1T (female) (2)
Resistance
Min. 1 Mz
D155AX-6
SEN00722-01
40 Troubleshooting
Failure code
E03
DXH4KY
Contents of
trouble
Trouble
When signal was output to transmission 1st clutch ECMV solenoid circuit, abnormal current flowed.
Action of
controller
Problem that
appears on
machine
Related
information
Output to 1st clutch ECMV solenoid can be checked with monitoring function.
(Code: 31602 T/M Clutch 1st ECMV (F/B))
Method of reproducing failure code: Start engine + Set gear to F1 or R1.
Cause
Defective 1st clutch ECMV
1 solenoid (Internal short circuit)
Possible causes
and standard
value in normal
state
Resistance
3.5 12.5 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between STC3 (female) (6)
S1T (female) (1) and between STC3
(female) (23) S1T (female) (2)
Resistance
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code
E03
DXH5KA
Contents of
trouble
Trouble
When signal is output to transmission 2nd clutch ECMV solenoid circuit, no current flows.
Action of
controller
Problem that
appears on
machine
Related
information
Output to 2nd clutch ECMV solenoid can be checked with monitoring function.
(Code: 31603 T/M Clutch 2nd ECMV (F/B))
Method of reproducing failure code: Start engine + Set gear to F2 or R2.
Cause
Defective 2nd clutch ECMV
1 solenoid (Internal disconnection)
Resistance
3.5 12.5 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC3 (female) (16)
2
or defective contact in con- S2T (female) (1)
nector)
Wiring harness between STC3 (female) (23)
S2T (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
Voltage
Max. 1 V
D155AX-6
SEN00722-01
40 Troubleshooting
Failure code
E03
DXH5KB
Contents of
trouble
Trouble
When signal was output to transmission 2nd clutch ECMV solenoid circuit, abnormal current flowed.
Action of
controller
Problem that
appears on
machine
Related
information
Output to 2nd clutch ECMV solenoid can be checked with monitoring function.
(Code: 31603 T/M Clutch 2nd ECMV (F/B))
Method of reproducing failure code: Start engine + Set gear to F2 or R2.
Cause
Defective 2nd clutch ECMV
1 solenoid (Internal short circuit)
Possible causes
and standard
value in normal
state
Resistance
3.5 12.5 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
2 ness (Contact with GND cirWiring harness between STC3 (female) (16)
Resiscuit)
Min. 1 Mz
S2T (female) (1) and chassis ground
tance
Short circuit in wiring har3 ness (with another wiring
harness)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between STC3 (female) (16)
S2T (female) (1) and between STC3
(female) (23) S2T (female) (2)
Resistance
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code
E03
DXH5KY
Contents of
trouble
Trouble
When signal was output to transmission 2nd clutch ECMV solenoid circuit, abnormal current flowed.
Action of
controller
Problem that
appears on
machine
Related
information
Output to 2nd clutch ECMV solenoid can be checked with monitoring function.
(Code: 31603 T/M Clutch 2nd ECMV (F/B))
Method of reproducing failure code: Start engine + Set gear to F2 or R2.
Cause
Defective 2nd clutch ECMV
1 solenoid (Internal short circuit)
Possible causes
and standard
value in normal
state
Resistance
3.5 12.5 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between STC3 (female) (16)
S2T (female) (1) and between STC3
(female) (23) S2T (female) (2)
Resistance
Min. 1 Mz
D155AX-6
SEN00722-01
40 Troubleshooting
Failure code
E03
DXH6KA
Contents of
trouble
Trouble
When signal is output to transmission 3rd clutch ECMV solenoid circuit, no current flows.
Action of
controller
Problem that
appears on
machine
Related
information
Output to 3rd clutch ECMV solenoid can be checked with monitoring function.
(Code: 31604 T/M Clutch 3rd ECMV (F/B))
Method of reproducing failure code: Start engine + Set gear to F3 or R3.
Cause
Defective 3rd clutch ECMV
1 solenoid (Internal disconnection)
Resistance
3.5 12.5 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC3 (female) (26)
2
or defective contact in con- S3T (female) (1)
nector)
Wiring harness between STC3 (female) (23)
S3T (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
Voltage
Max. 1 V
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code
E03
DXH6KB
Contents of
trouble
Trouble
When signal was output to transmission 3rd clutch ECMV solenoid circuit, abnormal current flowed.
Action of
controller
Problem that
appears on
machine
Related
information
Output to 3rd clutch ECMV solenoid can be checked with monitoring function.
(Code: 31604 T/M Clutch 3rd ECMV (F/B))
Method of reproducing failure code: Start engine + Set gear to F3 or R3.
Cause
Defective 3rd clutch ECMV
1 solenoid (Internal short circuit)
Possible causes
and standard
value in normal
state
Resistance
3.5 12.5 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
2 ness (Contact with GND cirResisWiring harness between STC3 (female) (26)
cuit)
Min. 1 Mz
S3T (female) (1) and chassis ground
tance
Short circuit in wiring har3 ness (with another wiring
harness)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between STC3 (female) (26)
S3T (female) (1) and between STC3
(female) (23) S3T (female) (2)
Resistance
Min. 1 Mz
D155AX-6
SEN00722-01
40 Troubleshooting
Failure code
E03
DXH6KY
Contents of
trouble
Trouble
When signal was output to transmission 3rd clutch ECMV solenoid circuit, abnormal current flowed.
Action of
controller
Problem that
appears on
machine
Related
information
Output to 3rd clutch ECMV solenoid can be checked with monitoring function.
(Code: 31604 T/M Clutch 3rd ECMV (F/B))
Method of reproducing failure code: Start engine + Set gear to F3 or R3.
Cause
Defective 3rd clutch ECMV
1 solenoid (Internal short circuit)
Possible causes
and standard
value in normal
state
Resistance
3.5 12.5 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between STC3 (female) (26)
S3T (female) (1) and between STC3
(female) (23) S3T (female) (2)
Resistance
Min. 1 Mz
10
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code
E03
DXH7KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal is output to transmission R clutch ECMV solenoid circuit, no current flows.
Turns signal to transmission R clutch ECMV solenoid circuit OFF.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1.
Output to R clutch ECMV solenoid can be checked with monitoring function.
(Code: 31616 T/M Clutch R ECMV (F/B))
Method of reproducing failure code: Start engine + Set gear to R (Reverse).
Cause
Defective R clutch ECMV
1 solenoid (Internal disconnection)
Resistance
3.5 12.5 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC3 (female) (37)
2
or defective contact in con- SRT (female) (1)
nector)
Wiring harness between STC3 (female) (13)
SRT (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
Voltage
Max. 1 V
D155AX-6
11
SEN00722-01
40 Troubleshooting
Failure code
E03
DXH7KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal was output to transmission R clutch ECMV solenoid circuit, abnormal current flowed.
Turns signal to transmission R clutch ECMV solenoid circuit OFF.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1.
Output to R clutch ECMV solenoid can be checked with monitoring function.
(Code: 31616 T/M Clutch R ECMV (F/B))
Method of reproducing failure code: Start engine + Set gear to R (Reverse).
Cause
Defective R clutch ECMV
1 solenoid (Internal short circuit)
Possible causes
and standard
value in normal
state
Resistance
3.5 12.5 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
2 ness (Contact with GND cirResisWiring harness between STC3 (female) (37)
cuit)
Min. 1 Mz
SRT (female) (1) and chassis ground
tance
Short circuit in wiring har3 ness (with another wiring
harness)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between STC3 (female) (37)
SRT (female) (1) and between STC3
(female) (13) SRT (female) (2)
Resistance
Min. 1 Mz
12
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code
E04
DXH7KY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal was output to transmission R clutch ECMV solenoid circuit, abnormal current flowed.
Turns signal to transmission R clutch ECMV solenoid circuit OFF.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to F1.
Output to R clutch ECMV solenoid can be checked with monitoring function.
(Code: 31616 T/M Clutch R ECMV (F/B))
Method of reproducing failure code: Start engine + Set gear to R (Reverse).
Cause
Defective R clutch ECMV
1 solenoid (Internal short circuit)
Possible causes
and standard
value in normal
state
Resistance
3.5 12.5 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between STC3 (female) (37)
SRT (female) (1) and between STC3
(female) (13) SRT (female) (2)
Resistance
Min. 1 Mz
D155AX-6
13
SEN00722-01
40 Troubleshooting
Failure code
E03
DXH8KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal is output to transmission F clutch ECMV solenoid circuit, no current flows.
Turns signal to transmission F clutch ECMV solenoid circuit OFF.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to R1.
Output to F clutch ECMV solenoid can be checked with monitoring function.
(Code: 31622 T/M Clutch F ECMV (F/B))
Method of reproducing failure code: Start engine + Set gear to F (Forward).
Cause
Defective F clutch ECMV
1 solenoid (Internal disconnection)
Resistance
3.5 12.5 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC3 (female) (27)
2
or defective contact in con- SFT (female) (1)
nector)
Wiring harness between STC3 (female) (13)
SFT (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
Voltage
Max. 1 V
14
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code
E03
DXH8KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal was output to transmission F clutch ECMV solenoid circuit, abnormal current flowed.
Turns signal to transmission F clutch ECMV solenoid circuit OFF.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to R1.
Output to F clutch ECMV solenoid can be checked with monitoring function.
(Code: 31622 T/M Clutch F ECMV (F/B))
Method of reproducing failure code: Start engine + Set gear to F (Forward).
Cause
Defective F clutch ECMV
1 solenoid (Internal short circuit)
Possible causes
and standard
value in normal
state
Resistance
3.5 12.5 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
2 ness (Contact with GND cirResisWiring harness between STC3 (female) (27)
cuit)
Min. 1 Mz
SFT (female) (1) and chassis ground
tance
Short circuit in wiring har3 ness (with another wiring
harness)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between STC3 (female) (27)
SFT (female) (1) and between STC3
(female) (13) SFT (female) (2)
Resistance
Min. 1 Mz
D155AX-6
15
SEN00722-01
40 Troubleshooting
Failure code
E04
DXH8KY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal was output to transmission F clutch ECMV solenoid circuit, abnormal current flowed.
Turns signal to transmission F clutch ECMV solenoid circuit OFF.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to R1.
Output to F clutch ECMV solenoid can be checked with monitoring function.
(Code: 31622 T/M Clutch F ECMV (F/B))
Method of reproducing failure code: Start engine + Set gear to F (Forward).
Cause
Defective F clutch ECMV
1 solenoid (Internal short circuit)
Possible causes
and standard
value in normal
state
Resistance
3.5 12.5 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between STC3 (female) (27)
SFT (female) (1) and between STC3
(female) (13) SFT (female) (2)
Resistance
Min. 1 Mz
16
D155AX-6
SEN00722-01
40 Troubleshooting
Failure code
E04
DXHBKA
Contents of
trouble
Trouble
When signal is output to steering case right brake ECMV solenoid circuit, no current flows.
Action of
controller
Turns signal to steering case right brake ECMV solenoid circuit OFF.
Limits operation of engine and transmission.
Problem that
appears on
machine
Related
information
Output to right brake ECMV solenoid can be checked with monitoring function.
(Code: 31618 Brake RH ECMV (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate parking brake lever (Free).
Cause
Defective right brake ECMV
1 solenoid (Internal disconnection)
Resistance
3.5 12.5 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC3 (female) (15)
2
or defective contact in con- SBRR (female) (1)
nector)
Wiring harness between STC3 (female) (3)
SBRR (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
18
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
STC3 (female)
Resistance
3.5 12.5 z
D155AX-6
40 Troubleshooting
SEN00722-01
D155AX-6
19
SEN00722-01
40 Troubleshooting
Failure code
E04
Contents of
trouble
DXHBKB
Trouble
When signal was output to steering case right brake ECMV solenoid circuit, abnormal current
flowed.
Action of
controller
Turns signal to steering case right brake ECMV solenoid circuit OFF.
Limits operation of engine and transmission.
Problem that
appears on
machine
Related
information
Output to right brake ECMV solenoid can be checked with monitoring function.
(Code: 31618 Brake RH ECMV (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate parking brake lever (Free).
Cause
Defective right brake ECMV
1 solenoid (Internal short circuit)
Possible causes
and standard
value in normal
state
Resistance
3.5 12.5 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
2 ness (Contact with GND cirWiring harness between STC3 (female) (15)
Resiscuit)
Min. 1 Mz
SBRR (female) (1) and chassis ground
tance
Short circuit in wiring har3 ness (with another wiring
harness)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between STC3 (female) (15)
SBRR (female) (1) and between STC3
(female) (3) SBRR (female) (2)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4
20
STC3 (female)
Resistance
3.5 12.5 z
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00722-01
D155AX-6
21
SEN00722-01
40 Troubleshooting
Failure code
E04
Contents of
trouble
DXHBKY
Trouble
When signal was output to steering case right brake ECMV solenoid circuit, abnormal current
flowed.
Action of
controller
Turns signal to steering case right brake ECMV solenoid circuit OFF.
Limits operation of engine and transmission.
Problem that
appears on
machine
Related
information
Output to right brake ECMV solenoid can be checked with monitoring function.
(Code: 31618 Brake RH ECMV (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate parking brake lever (Free).
Cause
Defective right brake ECMV
1 solenoid (Internal short circuit)
Possible causes
and standard
value in normal
state
Resistance
3.5 12.5 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between STC3 (female) (15)
SBRR (female) (1) and between STC3
(female) (3) SBRR (female) (2)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4
22
STC3 (female)
Resistance
3.5 12.5 z
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00722-01
D155AX-6
23
SEN00722-01
40 Troubleshooting
Failure code
E04
DXHCKA
Contents of
trouble
Trouble
When signal is output to steering case left brake ECMV solenoid circuit, no current flows.
Action of
controller
Turns signal to steering case left brake ECMV solenoid circuit OFF.
Limits operation of engine and transmission.
Problem that
appears on
machine
Related
information
Output to left brake ECMV solenoid can be checked with monitoring function.
(Code: 31619 Brake LH ECMV (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate parking brake lever (Free).
Cause
Defective left brake ECMV
1 solenoid (Internal disconnection)
Resistance
3.5 12.5 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC3 (female) (5)
2
or defective contact in con- SBRL (female) (1)
nector)
Wiring harness between STC3 (female) (3)
SBRL (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
24
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
STC3 (female)
Resistance
3.5 12.5 z
D155AX-6
40 Troubleshooting
SEN00722-01
D155AX-6
25
SEN00722-01
40 Troubleshooting
Failure code
E04
DXHCKB
Contents of
trouble
Trouble
When signal was output to steering case left brake ECMV solenoid circuit, abnormal current flowed.
Action of
controller
Turns signal to steering case left brake ECMV solenoid circuit OFF.
Limits operation of engine and transmission.
Problem that
appears on
machine
Related
information
Output to left brake ECMV solenoid can be checked with monitoring function.
(Code: 31619 Brake LH ECMV (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate parking brake lever (Free).
Cause
Defective left brake ECMV
1 solenoid (Internal short circuit)
Possible causes
and standard
value in normal
state
Resistance
3.5 12.5 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
2 ness (Contact with GND cirWiring harness between STC3 (female) (5)
Resiscuit)
Min. 1 Mz
SBRL (female) (1) and chassis ground
tance
Short circuit in wiring har3 ness (with another wiring
harness)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between STC3 (female) (5)
SBRL (female) (1) and between STC3
(female) (3) SBRL (female) (2)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4
26
STC3 (female)
Resistance
3.5 12.5 z
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00722-01
D155AX-6
27
SEN00722-01
40 Troubleshooting
Failure code
E04
DXHCKY
Contents of
trouble
Trouble
When signal was output to steering case left brake ECMV solenoid circuit, abnormal current flowed.
Action of
controller
Turns signal to steering case left brake ECMV solenoid circuit OFF.
Limits operation of engine and transmission.
Problem that
appears on
machine
Related
information
Output to left brake ECMV solenoid can be checked with monitoring function.
(Code: 31619 Brake LH ECMV (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate parking brake lever (Free).
Cause
Defective left brake ECMV
1 solenoid (Internal short circuit)
Possible causes
and standard
value in normal
state
Resistance
3.5 12.5 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between STC3 (female) (5)
SBRL (female) (1) and between STC3
(female) (3) SBRL (female) (2)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4
28
STC3 (female)
Resistance
3.5 12.5 z
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00722-01
D155AX-6
29
SEN00722-01
40 Troubleshooting
Failure code
E03
DXHRKA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal is output to blade lift-up EPC solenoid circuit, no current flows.
Turns signal to blade lift-up EPC solenoid circuit OFF.
Limits operation of engine and transmission.
Blade cannot be lifted up.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to R1.
Output to blade lift-up EPC solenoid can be checked with monitoring function.
(Code: 71001 Blade Raise EPC (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate blade control lever (Raise).
Cause
Defective blade lift-up EPC
1 solenoid (Internal disconnection)
Possible causes
and standard
value in normal
state
Resistance
4.5 14.5 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between WEC3 (female) (6)
2
or defective contact in con- WEP1 (female) (1)
nector)
Wiring harness between WEC3 (female)
(13) WEP1 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
WEC3 (female)
Resistance
4.5 14.5 z
30
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code
E03
DXHRKB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal was output to blade lift-up EPC solenoid circuit, abnormal current flowed.
Turns signal to blade lift-up EPC solenoid circuit OFF.
Limits operation of engine and transmission.
Blade cannot be lifted up.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to R1.
Output to blade lift-up EPC solenoid can be checked with monitoring function.
(Code: 71001 Blade Raise EPC (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate blade control lever (Raise).
Cause
Defective blade lift-up EPC
1 solenoid (Internal short circuit)
Possible causes
and standard
value in normal
state
Resistance
4.5 14.5 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
2 ness (Contact with GND cirWiring harness between WEC3 (female) (6)
Resiscuit)
Min. 1 Mz
WEP1 (female) (1) and chassis ground
tance
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3
WEC3 (female)
Resistance
4.5 14.5 z
Min. 1 Mz
D155AX-6
31
SEN00722-01
40 Troubleshooting
Failure code
E03
DXHRKY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal was output to blade lift-up EPC solenoid circuit, abnormal current flowed.
Turns signal to blade lift-up EPC solenoid circuit OFF.
Limits operation of engine and transmission.
Blade cannot be lifted up.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to R1.
Output to blade lift-up EPC solenoid can be checked with monitoring function.
(Code: 71001 Blade Raise EPC (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate blade control lever (Raise).
Cause
Defective blade lift-up EPC
1 solenoid (Internal short circuit)
Possible causes
and standard
value in normal
state
Resistance
4.5 14.5 z
Min. 1 Mz
WEC3 (female)
Resistance
4.5 14.5 z
Min. 1 Mz
32
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code
E03
DXHSKA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal is output to blade lift-down EPC solenoid circuit, no current flows.
Turns signal to blade lift-down EPC solenoid circuit OFF.
Limits operation of engine and transmission.
Blade cannot be lifted down.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to R1.
Output to blade lift-down EPC solenoid can be checked with monitoring function.
(Code: 71003 Blade Down EPC (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate blade control lever (Lower).
Cause
Defective blade lift-down
1 EPC solenoid (Internal disconnection)
Possible causes
and standard
value in normal
state
Resistance
4.5 14.5 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between WEC3 (female)
2
or defective contact in con- (16) WEP2 (female) (1)
nector)
Wiring harness between WEC3 (female)
(13) WEP2 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
WEC3 (female)
Resistance
4.5 14.5 z
D155AX-6
33
SEN00722-01
40 Troubleshooting
Failure code
E03
DXHSKB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal was output to blade lift-down EPC solenoid circuit, abnormal current flowed.
Turns signal to blade lift-down EPC solenoid circuit OFF.
Limits operation of engine and transmission.
Blade cannot be lifted down.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to R1.
Output to blade lift-down EPC solenoid can be checked with monitoring function.
(Code: 71003 Blade Down EPC (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate blade control lever (Lower).
Cause
Defective blade lift-down
1 EPC solenoid (Internal short
circuit)
Possible causes
and standard
value in normal
state
Resistance
4.5 14.5 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring har2 ness (Contact with GND cir- Wiring harness between WEC3 (female)
Resiscuit)
(16) WEP2 (female) (1) and chassis
Min. 1 Mz
tance
ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3
WEC3 (female)
Resistance
4.5 14.5 z
Min. 1 Mz
34
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code
E03
DXHSKY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal was output to blade lift-down EPC solenoid circuit, abnormal current flowed.
Turns signal to blade lift-down EPC solenoid circuit OFF.
Limits operation of engine and transmission.
Blade cannot be lifted down.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to R1.
Output to blade lift-down EPC solenoid can be checked with monitoring function.
(Code: 71003 Blade Down EPC (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate blade control lever (Lower).
Cause
Defective blade lift-down
1 EPC solenoid (Internal short
circuit)
Possible causes
and standard
value in normal
state
Resistance
4.5 14.5 z
Min. 1 Mz
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3
WEC3 (female)
Resistance
4.5 14.5 z
Min. 1 Mz
D155AX-6
35
SEN00722-01
40 Troubleshooting
Failure code
E03
DXHTKA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal is output to blade tilt right head EPC solenoid circuit, no current flows.
Turns signal to blade tilt right head EPC solenoid circuit OFF.
Limits operation of engine and transmission.
Blade tilt cylinder or pitch right cylinder cannot be retracted.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to R1.
Output to blade tilt right head EPC solenoid can be checked with monitoring function.
(Code: 90800 Blade Tilt RH-H EPC (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate blade control lever (Pitch
back).
Cause
Defective blade tilt right head
1 EPC solenoid (Internal disconnection)
Possible causes
and standard
value in normal
state
Resistance
2 12 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between WEC3 (female)
2
or defective contact in con- (26) WEP5 (female) (1)
nector)
Wiring harness between WEC3 (female)
(23) WEP5 (female) (2)
Defective work equipment
3
controller
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
WEC3 (female)
Resistance
2 12 z
36
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code
E03
DXHTKB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal was output to blade tilt right head EPC solenoid circuit, abnormal current flowed.
Turns signal to blade tilt right head EPC solenoid circuit OFF.
Limits operation of engine and transmission.
Blade tilt cylinder or pitch right cylinder cannot be retracted.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to R1.
Output to blade tilt right head EPC solenoid can be checked with monitoring function.
(Code: 90800 Blade Tilt RH-H EPC (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate blade control lever (Pitch
back).
Cause
Defective blade tilt right head
1 EPC solenoid (Internal short
circuit)
Possible causes
and standard
value in normal
state
Resistance
2 12 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring har2 ness (Contact with GND cir- Wiring harness between WEC3 (female)
Resiscuit)
(26) WEP5 (female) (1) and chassis
Min. 1 Mz
tance
ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3
WEC3 (female)
Resistance
2 12 z
Min. 1 Mz
D155AX-6
37
SEN00722-01
40 Troubleshooting
Failure code
E03
DXHTKY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal was output to blade tilt right head EPC solenoid circuit, abnormal current flowed.
Turns signal to blade tilt right head EPC solenoid circuit OFF.
Limits operation of engine and transmission.
Blade tilt cylinder or pitch right cylinder cannot be retracted.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to R1.
Output to blade tilt right head EPC solenoid can be checked with monitoring function.
(Code: 90800 Blade Tilt RH-H EPC (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate blade control lever (Pitch
back).
Cause
Defective blade tilt right head
1 EPC solenoid (Internal short
circuit)
Possible causes
and standard
value in normal
state
Resistance
2 12 z
Min. 1 Mz
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3
WEC3 (female)
Resistance
2 12 z
Min. 1 Mz
38
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code
E03
DXHUKA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal is output to blade tilt right bottom EPC solenoid circuit, no current flows.
Turns signal to blade tilt right bottom EPC solenoid circuit OFF.
Limits operation of engine and transmission.
Blade tilt cylinder or pitch right cylinder cannot be retracted.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to R1.
Output to blade tilt right bottom EPC solenoid can be checked with monitoring function.
(Code: 90801 Blade Tilt RH-B EPC (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate blade control lever (Pitch
forward).
Cause
Defective blade tilt right bot1 tom EPC solenoid (Internal
disconnection)
Possible causes
and standard
value in normal
state
Resistance
2 12 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between WEC3 (female)
2
or defective contact in con- (36) WEP6 (female) (1)
nector)
Wiring harness between WEC3 (female)
(23) WEP6 (female) (2)
Defective work equipment
3
controller
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
WEC3 (female)
Resistance
2 12 z
D155AX-6
39
SEN00722-01
40 Troubleshooting
Failure code
E03
DXHUKB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal was output to blade tilt right bottom EPC solenoid circuit, abnormal current flowed.
Turns signal to blade tilt right bottom EPC solenoid circuit OFF.
Limits operation of engine and transmission.
Blade tilt cylinder or pitch right cylinder cannot be retracted.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to R1.
Output to blade tilt right bottom EPC solenoid can be checked with monitoring function.
(Code: 90801 Blade Tilt RH-B EPC (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate blade control lever (Pitch
forward).
Cause
Defective blade tilt right bot1 tom EPC solenoid (Internal
short circuit)
Possible causes
and standard
value in normal
state
Resistance
2 12 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring har2 ness (Contact with GND cir- Wiring harness between WEC3 (female)
Resiscuit)
(36) WEP6 (female) (1) and chassis
Min. 1 Mz
tance
ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3
WEC3 (female)
Resistance
2 12 z
Min. 1 Mz
40
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code
E03
DXHUKY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal was output to blade tilt right bottom EPC solenoid circuit, abnormal current flowed.
Turns signal to blade tilt right bottom EPC solenoid circuit OFF.
Limits operation of engine and transmission.
Blade tilt cylinder or pitch right cylinder cannot be retracted.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to R1.
Output to blade tilt right bottom EPC solenoid can be checked with monitoring function.
(Code: 90801 Blade Tilt RH-B EPC (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate blade control lever (Pitch
forward).
Cause
Defective blade tilt right bot1 tom EPC solenoid (Internal
short circuit)
Possible causes
and standard
value in normal
state
Resistance
2 12 z
Min. 1 Mz
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3
WEC3 (female)
Resistance
2 12 z
Min. 1 Mz
D155AX-6
41
SEN00722-01
40 Troubleshooting
Failure code
E03
DXHWKA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal is output to ripper lift-up EPC solenoid circuit, no current flows.
Turns signal to ripper lift-up EPC solenoid circuit OFF.
Limits operation of engine and transmission.
Ripper cannot be lifted up.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to R1.
Output to ripper lift-up EPC solenoid can be checked with monitoring function.
(Code: 71101 Ripper Raise EPC (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate ripper control lever (Raise).
Cause
Defective ripper lift-up EPC
1 solenoid (Internal disconnection)
Possible causes
and standard
value in normal
state
Resistance
2 12 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between WEC3 (female) (5)
2
or defective contact in con- WEP7 (female) (1)
nector)
Wiring harness between WEC3 (female)
(23) WEP7 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
WEC3 (female)
Resistance
2 12 z
42
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code
E03
DXHWKB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal was output to ripper lift-up EPC solenoid circuit, abnormal current flowed.
Turns signal to ripper lift-up EPC solenoid circuit OFF.
Limits operation of engine and transmission.
Ripper cannot be lifted up.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to R1.
Output to ripper lift-up EPC solenoid can be checked with monitoring function.
(Code: 71101 Ripper Raise EPC (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate ripper control lever (Raise).
Cause
Defective ripper lift-up EPC
1 solenoid (Internal short circuit)
Possible causes
and standard
value in normal
state
Resistance
2 12 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
2 ness (Contact with GND cirWiring harness between WEC3 (female) (5)
Resiscuit)
Min. 1 Mz
WEP7 (female) (1) and chassis ground
tance
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3
WEC3 (female)
Resistance
2 12 z
Min. 1 Mz
D155AX-6
43
SEN00722-01
40 Troubleshooting
Failure code
E03
DXHWKY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal was output to ripper lift-up EPC solenoid circuit, abnormal current flowed.
Turns signal to ripper lift-up EPC solenoid circuit OFF.
Limits operation of engine and transmission.
Ripper cannot be lifted up.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to R1.
Output to ripper lift-up EPC solenoid can be checked with monitoring function.
(Code: 71101 Ripper Raise EPC (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate ripper control lever (Raise).
Cause
Defective ripper lift-up EPC
1 solenoid (Internal short circuit)
Possible causes
and standard
value in normal
state
Resistance
2 12 z
Min. 1 Mz
WEC3 (female)
Resistance
2 12 z
Min. 1 Mz
44
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code
E03
DXHXKA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal is output to ripper lift-down EPC solenoid circuit, no current flows.
Turns signal to ripper lift-down EPC solenoid circuit OFF.
Limits operation of engine and transmission.
Ripper cannot be lifted down.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to R1.
Output to ripper lift-down EPC solenoid can be checked with monitoring function.
(Code: 71103 Ripper Down EPC (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate ripper control lever (Lower).
Cause
Defective ripper lift-down
1 EPC solenoid (Internal disconnection)
Possible causes
and standard
value in normal
state
Resistance
2 12 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between WEC3 (female)
2
or defective contact in con- (15) WEP8 (female) (1)
nector)
Wiring harness between WEC3 (female)
(23) WEP8 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
WEC3 (female)
Resistance
2 12 z
D155AX-6
45
SEN00722-01
40 Troubleshooting
Failure code
E03
DXHXKB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal was output to ripper lift-down EPC solenoid circuit, abnormal current flowed.
Turns signal to ripper lift-down EPC solenoid circuit OFF.
Limits operation of engine and transmission.
Ripper cannot be lifted down.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to R1.
Output to ripper lift-down EPC solenoid can be checked with monitoring function.
(Code: 71103 Ripper Down EPC (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate ripper control lever (Lower).
Cause
Defective ripper lift-down
1 EPC solenoid (Internal short
circuit)
Possible causes
and standard
value in normal
state
Resistance
2 12 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring har2 ness (Contact with GND cir- Wiring harness between WEC3 (female)
Resiscuit)
(15) WEP8 (female) (1) and chassis
Min. 1 Mz
tance
ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3
WEC3 (female)
Resistance
2 12 z
Min. 1 Mz
46
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code
E03
DXHXKY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal was output to ripper lift-down EPC solenoid circuit, abnormal current flowed.
Turns signal to ripper lift-down EPC solenoid circuit OFF.
Limits operation of engine and transmission.
Ripper cannot be lifted down.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to R1.
Output to ripper lift-down EPC solenoid can be checked with monitoring function.
(Code: 71103 Ripper Down EPC (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate ripper control lever (Lower).
Cause
Defective ripper lift-down
1 EPC solenoid (Internal short
circuit)
Possible causes
and standard
value in normal
state
Resistance
2 12 z
Min. 1 Mz
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3
WEC3 (female)
Resistance
2 12 z
Min. 1 Mz
D155AX-6
47
SEN00722-01
40 Troubleshooting
Failure code
E03
DXHYKA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal is output to ripper tilt-in EPC solenoid circuit, no current flows.
Turns signal to ripper tilt-in EPC solenoid circuit OFF.
Limits operation of engine and transmission.
Ripper cannot be tilted in.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to R1.
Output to ripper tilt-in EPC solenoid can be checked with monitoring function.
(Code: 71105 Ripper Tilt In EPC (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate ripper control lever (Tilt in).
Cause
Defective ripper tilt-in EPC
1 solenoid (Internal disconnection)
Possible causes
and standard
value in normal
state
Resistance
2 12 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between WEC3 (female)
2
or defective contact in con- (25) WEP9 (female) (1)
nector)
Wiring harness between WEC3 (female)
(23) WEP9 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
WEC3 (female)
Resistance
2 12 z
48
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code
E03
DXHYKB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal was output to ripper tilt-in EPC solenoid circuit, abnormal current flowed.
Turns signal to ripper tilt-in EPC solenoid circuit OFF.
Limits operation of engine and transmission.
Ripper cannot be tilted in.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to R1.
Output to ripper tilt-in EPC solenoid can be checked with monitoring function.
(Code: 71105 Ripper Tilt In EPC (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate ripper control lever (Tilt in).
Cause
Defective ripper tilt-in EPC
1 solenoid (Internal short circuit)
Possible causes
and standard
value in normal
state
Resistance
2 12 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring har2 ness (Contact with GND cir- Wiring harness between WEC3 (female)
Resiscuit)
(25) WEP9 (female) (1) and chassis
Min. 1 Mz
tance
ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3
WEC3 (female)
Resistance
2 12 z
Min. 1 Mz
D155AX-6
49
SEN00722-01
40 Troubleshooting
Failure code
E03
DXHYKY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal was output to ripper tilt-in EPC solenoid circuit, abnormal current flowed.
Turns signal to ripper tilt-in EPC solenoid circuit OFF.
Limits operation of engine and transmission.
Ripper cannot be tilted in.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to R1.
Output to ripper tilt-in EPC solenoid can be checked with monitoring function.
(Code: 71105 Ripper Tilt In EPC (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate ripper control lever (Tilt in).
Cause
Defective ripper tilt-in EPC
1 solenoid (Internal short circuit)
Possible causes
and standard
value in normal
state
Resistance
2 12 z
Min. 1 Mz
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3
WEC3 (female)
Resistance
2 12 z
Min. 1 Mz
50
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code
E03
DXHZKA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal is output to ripper tilt-back EPC solenoid circuit, no current flows.
Turns signal to ripper tilt-back EPC solenoid circuit OFF.
Limits operation of engine and transmission.
Ripper cannot be tilted back.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to R1.
Output to ripper tilt-back EPC solenoid can be checked with monitoring function.
(Code: 71107 Ripper Tilt Back EPC (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate ripper control lever (Tilt
back).
Cause
Defective ripper tilt-back
1 EPC solenoid (Internal disconnection)
Possible causes
and standard
value in normal
state
Resistance
2 12 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between WEC3 (female)
2
or defective contact in con- (35) WEPA (female) (1)
nector)
Wiring harness between WEC3 (female)
(23) WEPA (female) (2)
Defective work equipment
3
controller
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
WEC3 (female)
Resistance
2 12 z
D155AX-6
51
SEN00722-01
40 Troubleshooting
Failure code
E03
DXHZKB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal was output to ripper tilt-back EPC solenoid circuit, abnormal current flowed.
Turns signal to ripper tilt-back EPC solenoid circuit OFF.
Limits operation of engine and transmission.
Ripper cannot be tilted back.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to R1.
Output to ripper tilt-back EPC solenoid can be checked with monitoring function.
(Code: 71107 Ripper Tilt Back EPC (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate ripper control lever (Tilt
back).
Cause
Defective ripper tilt-back
1 EPC solenoid (Internal short
circuit)
Possible causes
and standard
value in normal
state
Resistance
2 12 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring har2 ness (Contact with GND cir- Wiring harness between WEC3 (female)
Resiscuit)
(35) WEPA (female) (1) and chassis
Min. 1 Mz
tance
ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3
WEC3 (female)
Resistance
2 12 z
Min. 1 Mz
52
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code
E03
DXHZKY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal was output to ripper tilt-back EPC solenoid circuit, abnormal current flowed.
Turns signal to ripper tilt-back EPC solenoid circuit OFF.
Limits operation of engine and transmission.
Ripper cannot be tilted back.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to R1.
Output to ripper tilt-back EPC solenoid can be checked with monitoring function.
(Code: 71107 Ripper Tilt Back EPC (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate ripper control lever (Tilt
back).
Cause
Defective ripper tilt-back
1 EPC solenoid (Internal short
circuit)
Possible causes
and standard
value in normal
state
Resistance
2 12 z
Min. 1 Mz
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3
WEC3 (female)
Resistance
2 12 z
Min. 1 Mz
D155AX-6
53
SEN00722-01
40 Troubleshooting
Failure code
E03
DXJ4KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal is output to work equipment lock solenoid circuit, no current flows.
Turns signal to work equipment lock solenoid circuit OFF.
Blade and ripper cannot be operated.
Method of reproducing failure code: Turn starting switch ON + Operate work equipment lock lever
(Free).
Cause
Defective work equipment
1 lock solenoid (Internal disconnection)
Possible causes
and standard
value in normal
state
Resistance
20 60 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between WEC3 (female) (8)
Resis2
Max. 1 z
or defective contact in con- WLK (female) (1)
tance
nector)
Wiring harness between WEC3 (female) (3)
ResisMax. 1 z
WLK (female) (2)
tance
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
WEC3 (female)
Resistance
20 60 z
54
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code
E03
DXJ4KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal was output to work equipment lock solenoid circuit, abnormal current flowed.
Turns signal to work equipment lock solenoid circuit OFF.
Blade and ripper cannot be operated.
Method of reproducing failure code: Turn starting switch ON + Operate work equipment lock lever
(Free).
Cause
Defective work equipment
1 lock solenoid (Internal short
circuit)
Possible causes
and standard
value in normal
state
Resistance
20 60 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring har2 ness (Contact with GND cirWiring harness between WEC3 (female) (8)
cuit)
WLK (female) (1) and chassis ground
Resistance
Min. 1 Mz
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4
WEC3 (female)
Resistance
20 60 z
Min. 1 Mz
D155AX-6
55
SEN00722-01
40 Troubleshooting
D155AX-6 Bulldozer
Form No. SEN00722-01
2006 KOMATSU
All Rights Reserved
Printed in Japan 05-06 (02)
56
D155AX-6
SEN00723-01
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
40 Troubleshooting
D155AX-6
SEN00723-01
40 Troubleshooting
Action code
Failure code
E03
DXJ8KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal is output to blade tilt left bottom EPC solenoid circuit, no current flows.
Turns signal to blade tilt left bottom EPC solenoid circuit OFF.
Limits operation of engine and transmission.
Blade tilt cylinder or pitch left cylinder cannot be extended.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to R1.
Output to blade tilt left bottom EPC solenoid can be checked with monitoring function.
(Code: 71007 Blade Tilt LH-B EPC (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate blade control lever (Pitch
forward).
Cause
Defective blade tilt left bot1 tom EPC solenoid (Internal
disconnection)
Possible causes
and standard
value in normal
state
Resistance
2 12 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between WEC3 (female)
2
or defective contact in con- (38) WEP4 (female) (1)
nector)
Wiring harness between WEC3 (female)
(13) WEP4 (female) (2)
Defective work equipment
3
controller
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
WEC3 (female)
Resistance
2 12 z
D155AX-6
40 Troubleshooting
SEN00723-01
Failure code
E03
DXJ8KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal was output to blade tilt left bottom EPC solenoid circuit, abnormal current flowed.
Turns signal to blade tilt left bottom EPC solenoid circuit OFF.
Limits operation of engine and transmission.
Blade tilt cylinder or pitch left cylinder cannot be extended.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to R1.
Output to blade tilt left bottom EPC solenoid can be checked with monitoring function.
(Code: 71007 Blade Tilt LH-B EPC (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate blade control lever (Pitch
forward).
Cause
Defective blade tilt left bot1 tom EPC solenoid (Internal
short circuit)
Possible causes
and standard
value in normal
state
Resistance
2 12 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring har2 ness (Contact with GND cir- Wiring harness between WEC3 (female)
Resiscuit)
(38) WEP4 (female) (1) and chassis
Min. 1 Mz
tance
ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3
WEC3 (female)
Resistance
2 12 z
Min. 1 Mz
D155AX-6
SEN00723-01
40 Troubleshooting
Failure code
E03
DXJ8KY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal was output to blade tilt left bottom EPC solenoid circuit, abnormal current flowed.
Turns signal to blade tilt left bottom EPC solenoid circuit OFF.
Limits operation of engine and transmission.
Blade tilt cylinder or pitch left cylinder cannot be extended.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to R1.
Output to blade tilt left bottom EPC solenoid can be checked with monitoring function.
(Code: 71007 Blade Tilt LH-B EPC (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate blade control lever (Pitch
forward).
Cause
Defective blade tilt left bot1 tom EPC solenoid (Internal
short circuit)
Possible causes
and standard
value in normal
state
Resistance
2 12 z
Min. 1 Mz
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3
WEC3 (female)
Resistance
2 12 z
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00723-01
Failure code
E03
DXJ9KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal is output to blade tilt left head EPC solenoid circuit, no current flows.
Turns signal to blade tilt left head EPC solenoid circuit OFF.
Limits operation of engine and transmission.
Blade tilt cylinder or pitch left cylinder cannot be retracted.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to R1.
Output to blade tilt left head EPC solenoid can be checked with monitoring function.
(Code: 71005 Blade Tilt LH-H EPC (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate blade control lever (Pitch
back).
Cause
Defective blade tilt left head
1 EPC solenoid (Internal disconnection)
Possible causes
and standard
value in normal
state
Resistance
2 12 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between WEC3 (female)
2
or defective contact in con- (28) WEP3 (female) (1)
nector)
Wiring harness between WEC3 (female)
(13) WEP3 (female) (2)
Defective work equipment
3
controller
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
WEC3 (female)
Resistance
2 12 z
D155AX-6
SEN00723-01
40 Troubleshooting
Failure code
E03
DXJ9KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal was output to blade tilt left head EPC solenoid circuit, abnormal current flowed.
Turns signal to blade tilt left head EPC solenoid circuit OFF.
Limits operation of engine and transmission.
Blade tilt cylinder or pitch left cylinder cannot be retracted.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to R1.
Output to blade tilt left head EPC solenoid can be checked with monitoring function.
(Code: 71005 Blade Tilt LH-H EPC (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate blade control lever (Pitch
back).
Cause
Defective blade tilt left head
1 EPC solenoid (Internal disconnection)
Possible causes
and standard
value in normal
state
Resistance
2 12 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring har2 ness (Contact with GND cir- Wiring harness between WEC3 (female)
Resiscuit)
(28) WEP3 (female) (1) and chassis
Min. 1 Mz
tance
ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3
WEC3 (female)
Resistance
2 12 z
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00723-01
Failure code
E03
DXJ9KY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal was output to blade tilt left head EPC solenoid circuit, abnormal current flowed.
Turns signal to blade tilt left head EPC solenoid circuit OFF.
Limits operation of engine and transmission.
Blade tilt cylinder or pitch left cylinder cannot be retracted.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to R1.
Output to blade tilt left head EPC solenoid can be checked with monitoring function.
(Code: 71005 Blade Tilt LH-H EPC (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate blade control lever (Pitch
back).
Cause
Defective blade tilt left head
1 EPC solenoid (Internal short
circuit)
Possible causes
and standard
value in normal
state
Resistance
2 12 z
Min. 1 Mz
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3
WEC3 (female)
Resistance
2 12 z
Min. 1 Mz
D155AX-6
SEN00723-01
40 Troubleshooting
Failure code
E01
DXJAKA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Resistance
4.5 14.5 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between WEC3 (female)
2
or defective contact in con- (37) QDP (female) (1)
nector)
Wiring harness between WEC3 (female) (3)
QDP (female) (2)
When signal is output to blade quick drop EPC solenoid circuit, no current flows.
Cause
Possible causes
and standard
value in normal
state
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
WEC3 (female)
Resistance
4.5 14.5 z
D155AX-6
40 Troubleshooting
SEN00723-01
D155AX-6
SEN00723-01
40 Troubleshooting
Failure code
E01
DXJAKB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal was output to blade quick drop EPC solenoid circuit, abnormal current flowed.
Turns signal to blade quick drop EPC solenoid circuit OFF.
Blade quick drop function does not operate.
Output to blade quick drop EPC solenoid can be checked with monitoring function.
(Code: 90900 Quick Drop Solenoid (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate blade control lever (Lower).
Cause
Defective blade quick drop
1 EPC solenoid (Internal short
circuit)
Possible causes
and standard
value in normal
state
Resistance
4.5 14.5 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
2 ness (Contact with GND cirResisWiring harness between WEC3 (female)
cuit)
Min. 1 Mz
(37) QDP (female) (1) and chassis ground
tance
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3
10
WEC3 (female)
Resistance
4.5 14.5 z
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00723-01
D155AX-6
11
SEN00723-01
40 Troubleshooting
Failure code
E01
DXJAKY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal was output to blade quick drop EPC solenoid circuit, abnormal current flowed.
Turns signal to blade quick drop EPC solenoid circuit OFF.
Blade quick drop function does not operate.
Output to blade quick drop EPC solenoid can be checked with monitoring function.
(Code: 90900 Quick Drop Solenoid (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate blade control lever (Lower).
Cause
Defective blade quick drop
1 EPC solenoid (Internal short
circuit)
Possible causes
and standard
value in normal
state
Resistance
4.5 14.5 z
Min. 1 Mz
12
WEC3 (female)
Resistance
4.5 14.5 z
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00723-01
D155AX-6
13
SEN00723-01
40 Troubleshooting
Failure code
E02
DXJBKA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal is output to torque converter stator clutch ECMV solenoid circuit, no current flows.
Turns signal to torque converter stator clutch ECMV solenoid circuit OFF.
Sufficient torque may not be obtained during travel.
Output to torque converter stator clutch ECMV solenoid can be checked with monitoring function.
(Code: 90700 S/C ECMV (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate parking brake lever (Free).
Cause
a Prepare with starting switch OFF, then carry out troubleshootDefective stator clutch ECMV
ing without turning starting switch ON.
1 solenoid (Internal disconnecSSTC (male)
Resistance
tion)
Between (1) (2)
5 25 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC3 (female) (38)
2
or defective contact in con- SSTC (female) (1)
nector)
Wiring harness between STC3 (female) (13)
SSTC (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
14
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
STC3 (female)
Resistance
5 25 z
D155AX-6
40 Troubleshooting
SEN00723-01
D155AX-6
15
SEN00723-01
40 Troubleshooting
Failure code
E02
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
DXJBKB
Trouble
When signal was output to torque converter stator clutch ECMV solenoid circuit, abnormal current
flowed.
Turns signal to torque converter stator clutch ECMV solenoid circuit OFF.
Sufficient torque may not be obtained during travel.
Output to torque converter stator clutch ECMV solenoid can be checked with monitoring function.
(Code: 90700 S/C ECMV (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate parking brake lever (Free).
Cause
Defective stator clutch ECMV
1 solenoid (Internal short circuit)
Possible causes
and standard
value in normal
state
Resistance
5 25 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
2 ness (Contact with GND cirWiring harness between STC3 (female) (38)
Resiscuit)
Min. 1 Mz
SSTC (female) (1) and chassis ground
tance
Short circuit in wiring har3 ness (with another wiring
harness)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between STC3 (female) (38)
SSTC (female) (1) and between STC3
(female) (13) SSTC (female) (2)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4
16
STC3 (female)
Resistance
5 25 z
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00723-01
D155AX-6
17
SEN00723-01
40 Troubleshooting
Failure code
E02
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
DXJBKY
Trouble
When signal was output to torque converter stator clutch ECMV solenoid circuit, abnormal current
flowed.
Turns signal to torque converter stator clutch ECMV solenoid circuit OFF.
Sufficient torque may not be obtained during travel.
Output to torque converter stator clutch ECMV solenoid can be checked with monitoring function.
(Code: 90700 S/C ECMV (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate parking brake lever (Free).
Cause
Defective stator clutch ECMV
1 solenoid (Internal short circuit)
Possible causes
and standard
value in normal
state
Resistance
5 25 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between STC3 (female) (38)
SSTC (female) (1) and between STC3
(female) (13) SSTC (female) (2)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4
18
STC3 (female)
Resistance
5 25 z
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00723-01
D155AX-6
19
SEN00723-01
40 Troubleshooting
D155AX-6 Bulldozer
Form No. SEN00723-01
2006 KOMATSU
All Rights Reserved
Printed in Japan 05-06 (02)
20
D155AX-6
SEN00807-02
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
40 Troubleshooting
D155AX-6
SEN00807-02
40 Troubleshooting
D155AX-6
40 Troubleshooting
SEN00807-02
a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully.
Trouble
Related
information
Possible causes
and standard
value in normal
state
D155AX-6
SEN00807-02
40 Troubleshooting
E-1 When starting switch turned ON, machine monitor displays nothing 1
Trouble
Related
information
Min. 24 V
Min. 1.26
4
Possible causes
and standard
value in normal
state
Resistance
ON
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Disconnection in wiring harness (Disconnection in wiring Wiring harness between CB7 (2) CM01
5
or defective contact in con- (female) (1), (2)
nector)
Wiring harness between CM01 (female) (3),
(4) chassis ground (GND11)
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
D155AX-6
40 Troubleshooting
SEN00807-02
Cause
Possible causes
and standard
value in normal
state
Wiring harness between battery (+) terminal BRB CB30 (B30L) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then hold starting switch OFF
and ON and carry out troubleshooting in each case.
7 Defective machine monitor
CM01
Starting switch
Voltage
OFF
20 30 V
Between (14)
(3), (4)
ON
20 30 V
D155AX-6
SEN00807-02
40 Troubleshooting
When starting switch turned ON (before starting engine), basic check item lights up.
Basic check item is only lowering of radiator coolant level.
Cause
Lowering of radiator coolant
1 level (When system is normal)
WLV (male)
Resistance
Between FULL
LOW
Max. 1 z
Below LOW
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between CM02 (female) (3)
3
or defective contact in con- WLV (female) (1)
nector)
Wiring harness between CM01 (female) (7),
CM02 (female) (7) WLV (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
CM02
Between (3)
chassis ground
Voltage
Between FULL
LOW
Max. 1 V
Below LOW
20 30 V
D155AX-6
40 Troubleshooting
D155AX-6
SEN00807-02
SEN00807-02
40 Troubleshooting
Min. 24 V
Min. 1.26
Resistance
OFF
Min. 1 Mz
START
Max. 1 z
NSF
Voltage
Between B
chassis ground
20 30 V
Between ST (2)
chassis ground
Starting signal
20 30 V
Between ST (2)
chassis ground
Generation signal
Max. 1 V
Generation signal
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between terminal 280 NSF
or defective contact in con- (female) (3)
nector)
Wiring harness between NSF (female) (5)
PRE ST (female) (1)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between terminal 280 NSF
Ground fault in wiring har7 ness (Contact with GND cir- (female) (3) or circuit branch end and chassis ground
cuit)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Voltage
Max. 1 V
D155AX-6
40 Troubleshooting
SEN00807-02
D155AX-6
SEN00807-02
40 Troubleshooting
(1) When starting switch is turned to HEAT position, preheating monitor does not light up.
Preheater monitor lights up when starting switch is turned to HEAT.
If engine coolant temperature is below -5 C, automatic warm-up system operates and preheating
monitor lights up for up to 40 seconds.
Cause
Possible causes
and standard
value in normal
state
Resistance
OFF
Min. 1 Mz
HEAT
Max. 1 z
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
ness (Disconnection in wiring
2
or defective contact in con- Wiring harness between CM01 (female)
ResisMax. 1 z
nector)
(16) terminal 255
tance
a Prepare with starting switch OFF, then keep starting switch
OFF and turn it to HEAT and carry out troubleshooting in each
case.
3 Defective machine monitor
10
CM01
Starting switch
Voltage
Between (16)
chassis ground
OFF
Max. 1 V
HEAT
20 30 V
D155AX-6
40 Troubleshooting
SEN00807-02
Trouble
(2) When starting switch is turned to HEAT position, intake air heater mounting part does not become
warm.
Related
information
Check that engine can be turned with starting motor (If engine cannot be turned, carry out troubleshooting for E-3 Engine does not start (Engine does not turn)).
Cause
1
Heater relay
Between HT
chassis ground
Between HT/B
chassis ground
Starting switch
Voltage
20 30 V
HEAT
20 30 V
a Prepare with starting switch OFF (with wiring harness connected), then turn starting switch to HEAT and carry out troubleshooting in each case.
3
RH1
Starting switc
Voltage
Between terminal
chassis ground
HEAT
20 30 V
Possible causes
and standard
value in normal
state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring
4
or defective contact in connector)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between terminal 255 terminal HT or CM01 (female) (16) or circuit
branch end and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Ground fault in wiring har5 ness (Contact with GND cir- Wiring harness between terminal BRC
cuit)
CB105H (B105HS) and chassis ground
D155AX-6
11
SEN00807-02
40 Troubleshooting
12
D155AX-6
40 Troubleshooting
D155AX-6
SEN00807-02
13
SEN00807-02
40 Troubleshooting
Possible causes
and standard
value in normal
state
Engine speed
Voltage
Between R
chassis ground
Medium or higher
20 30 V
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
ness (Disconnection in wiring
2
or defective contact in con- Wiring harness between CM01 (female) (11)
ResisMax. 1 z
nector)
terminal R
tance
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring har3 ness (Contact with GND cir- Wiring harness between CM01 (female) (11)
cuit)
terminal R or circuit branch end and chassis ground
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then start engine and carry
out troubleshooting.
4 Defective machine monitor
14
CM01
Engine
Voltage
Between (11)
chassis ground
Medium or higher
20 30 V
D155AX-6
40 Troubleshooting
SEN00807-02
D155AX-6
15
SEN00807-02
40 Troubleshooting
Possible causes
and standard
value in normal
state
Trouble
Related
information
If cause 1 is not detected, engine coolant temperature sensor system may be defective. Carry out troubleshooting for failure codes
[CA144] and [CA145].
If causes 1 and 2 are not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried
out.)
Related
information
If causes 1 and 2 are not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried
out.)
Signals of torque converter oil temperature sensor are input to power train controller and then transmitted to machine monitor through communication system.
Power train oil temperature can be checked with monitoring function.
(Code: 30100 T/C Oil Temperature)
Standard value in normal state/Remarks on troubleshooting
If cause 1 is not detected, power train oil temperature sensor sysDefective power train oil temtem may be defective. Carry out troubleshooting for failure codes
perature sensor system
[DGT1KA] and [DGT1KX].
16
Cause
Possible causes
and standard
value in normal
state
Trouble
Cause
Possible causes
and standard
value in normal
state
If causes 1 and 2 are not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried
out.)
D155AX-6
40 Troubleshooting
Trouble
Related
information
SEN00807-02
Possible causes
and standard
value in normal
state
D155AX-6
17
SEN00807-02
40 Troubleshooting
Trouble
(1) While engine coolant temperature is rising normally, temperature gauge does not rise from white
range (C).
(2) While engine coolant temperature is stabilized normally, temperature gauge rises to red range (H).
Related
information
Signals of engine coolant temperature sensor are input to engine controller and then transmitted to
machine monitor through communication system.
Engine coolant temperature can be checked with monitoring function.
(Code: 04107 Coolant Temperature)
Possible causes
and standard
value in normal
state
Cause
1
Trouble
(3) Display of coolant temperature gauge is different from actual engine coolant temperature.
(4) Display of engine coolant temperature gauge is different from display of engine coolant temperature monitor.
Related
information
Signals of engine coolant temperature sensor are input to engine controller and then transmitted to
machine monitor through communication system.
Engine coolant temperature can be checked with monitoring function.
(Code: 04107 Coolant Temperature)
Cause
Possible causes
and standard
value in normal
state
105 C
102 C
100 C
85 C
60 C
30 C
Red
Blue
White
18
D155AX-6
40 Troubleshooting
SEN00807-02
(1) While fuel is added, fuel level gauge does not rise from red range (E).
(2) While fuel level is low, fuel level gauge does not lower from green range top (F)
Signal voltage of fuel level sensor can be checked with monitoring function.
(Code: 04200 Fuel Level Sensor Volt)
Cause
Defective fuel level sensor
1 (Internal disconnection or
short circuit)
Fuel level
Resistance
FULL
Approx. 4 z
EMPTY
Approx. 85 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between CM01 (female) (9)
2
or defective contact in con- FLV (female) (1)
nector)
Wiring harness between CM01 (female)
(12) FLV (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
3 ness (Contact with GND cirWiring
harness between CM01 (female) (9)
Resiscuit)
Min. 1 Mz
FLV (female) (1) and chassis ground
tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
Hot short (Short circuit with
4
24V circuit) in wiring harness Wiring harness between CM01 (female) (9)
Voltage Max. 1 V
FLV (female) (1) and chassis ground
5 Defective machine monitor
If causes 1 4 are not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried
out.)
D155AX-6
19
SEN00807-02
Trouble
Related
information
40 Troubleshooting
(3) Display of fuel level gauge is different from actual fuel level.
(4) Display of fuel level gauge is different from display of fuel level monitor.
Signal voltage of fuel level sensor can be checked with monitoring function.
(Code: 04200 Fuel Level Sensor Volt)
Cause
Possible causes
and standard
value in normal
state
Quantity of fuel
1 Defective machine monitor
565 l
425 l
310 l
220 l
150 l
75 l
Blue
Red
20
D155AX-6
40 Troubleshooting
SEN00807-02
E-9 Power train oil temperature gauge (multi-gauge) does not indicate
normally
1
Trouble
(1) While power train oil temperature is rising normally, temperature gauge does not rise from white
range (C).
(2) While power train oil temperature is stabilized normally, temperature gauge rises to red range (H).
Related
information
Signals of power train oil temperature sensor are input to power train controller and then transmitted
to machine monitor through communication system.
Power train oil temperature can be checked with monitoring function.
(Code: 30100 T/C Oil Temperature)
Cause
Possible causes
and standard
value in normal
state
Trouble
(3) Display of power train temperature gauge is different from actual power train oil temperature.
(4) Display of power train oil temperature gauge is different from display of power train oil temperature
monitor.
Related
information
Signals of power train oil temperature sensor are input to power train controller and then transmitted
to machine monitor through communication system.
Power train oil temperature can be checked with monitoring function.
(Code: 30100 T/C Oil Temperature)
Cause
Possible causes
and standard
value in normal
state
130 C
120 C
118 C
80 C
50 C
0 C
Red
Blue
White
Power train oil temperature gauge and power train oil temperature monitor
D155AX-6
21
SEN00807-02
40 Troubleshooting
(1) While hydraulic oil temperature is rising normally, temperature gauge does not rise from white
range (C).
(2) While hydraulic oil temperature is stabilized normally, temperature gauge rises to red range (H).
Hydraulic temperature can be checked with monitoring function.
(Code: 04401 Hyd Oil Temperature)
Cause
Defective hydraulic oil temperature sensor system
1
(Internal disconnection or
short circuit)
Possible causes
and standard
value in normal
state
Resistance
3.5 90 kz
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between CM01 (female) (8)
Resis2
Max. 1 z
or defective contact in con- HDT (female) (1)
tance
nector)
Wiring harness between CM01 (female)
ResisMax. 1 z
(12) HDT (female) (2)
tance
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
3 ness (Contact with GND cirWiring harness between CM01 (female) (8)
Resiscuit)
Min. 1 Mz
HDT (female) (1) and chassis ground
tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
Hot short (Short circuit with
4
24V circuit) in wiring harness Wiring harness between CM01 (female) (8)
Voltage Max. 1 V
HDT (female) (1) and chassis ground
5 Defective machine monitor
22
If causes 1 4 are not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried
out.)
D155AX-6
40 Troubleshooting
SEN00807-02
D155AX-6
23
SEN00807-02
Trouble
Related
information
40 Troubleshooting
(3) Display of hydraulic oil temperature gauge is different from actual hydraulic oil temperature.
(4) Display of hydraulic oil temperature gauge is different from display of hydraulic oil temperature
monitor.
Hydraulic oil temperature can be checked with monitoring function.
(Code: 04401 Hyd Oil Temperature)
Cause
Possible causes
and standard
value in normal
state
Reading of hydraulic
Color of monitor light
oil temperature
(a)
gauge
110 C
100 C
98 C
70 C
20 C
0 C
Red
Blue
White
24
D155AX-6
40 Troubleshooting
SEN00807-02
Related
information
Possible causes
and standard
value in normal
state
Cause
1 Defective machine monitor
Possible causes
and standard
value in normal
state
Related
information
Possible causes
and standard
value in normal
state
D155AX-6
Cause
1 Defective machine monitor
25
SEN00807-02
40 Troubleshooting
(1) When operation mode switch is operated, display of operation mode monitor does not change.
Related
information
Possible causes
and standard
value in normal
state
Trouble
Related
information
Possible causes
and standard
value in normal
state
Cause
1 Defective machine monitor
(1) When gearshift mode switch is operated, display of speed mode section does not change.
Related
information
Possible causes
and standard
value in normal
state
Trouble
Cause
1 Defective machine monitor
(2) When gearshift mode is changed, gearshift setting of power train is not changed.
Related
information
Possible causes
and standard
value in normal
state
26
Cause
1 Defective machine monitor
2
D155AX-6
40 Troubleshooting
SEN00807-02
Related
information
Possible causes
and standard
value in normal
state
Trouble
Cause
1 Defective machine monitor
(2) When setting is changed on customize screen, setting of machine is not changed.
Related
information
Cause
Possible causes
and standard
value in normal
state
(1) When customize memory switch is operated, customize memory screen is not displayed.
Related
information
Possible causes
and standard
value in normal
state
Trouble
Cause
1 Defective machine monitor
(2) When selection is changed on customize memory screen, setting of machine is not changed.
Related
information
Cause
Possible causes
and standard
value in normal
state
D155AX-6
27
SEN00807-02
40 Troubleshooting
(1) When float mode switch is operated, float mode monitor does not light up or go off.
Related
information
Possible causes
and standard
value in normal
state
Trouble
Cause
1 Defective machine monitor
Related
information
Possible causes
and standard
value in normal
state
Cause
Related
information
Possible causes
and standard
value in normal
state
28
Cause
1 Defective machine monitor
D155AX-6
40 Troubleshooting
SEN00807-02
(1) When air conditioner switch is operated, air conditioner control screen is not displayed.
Related
information
Possible causes
and standard
value in normal
state
Trouble
Cause
1 Defective machine monitor
(2) When air conditioner switch is operated, air conditioner does not operate at all.
Related
information
Cause
1
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between CB3 (2) fuse in
3
or defective contact in con- unit - ACW (wiring side) (6)
nector)
Wiring harness between ACW (wiring side)
(16) chassis ground (GND12)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring har4 ness (Contact with GND cir- Wiring harness between CB3 (2) fuse in
Resiscuit)
Min. 1 Mz
unit ACW (wiring side) (6) or circuit branch
tance
end and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
5
Voltage
20 30 V
D155AX-6
If causes 1 5 are not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried
out.)
29
SEN00807-02
Trouble
40 Troubleshooting
Related
information
Cause
AC03 (male)
Resistance
140 340 z
Voltage
Between (4)
chassis ground
20 30 V
MB (wiring side)
Voltage
20 30 V
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Disconnection in wiring harness (Disconnection in wiring Wiring harness between AC03 (female) (5)
4
or defective contact in con- MB (wiring side) (1)
nector)
Wiring harness between MB (wiring side) (2)
PTR (wiring side) (3)
30
D155AX-6
40 Troubleshooting
SEN00807-02
Cause
Possible causes
and standard
value in normal
state
D155AX-6
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
31
SEN00807-02
Trouble
40 Troubleshooting
Related
information
Cause
AC04 (male)
Resistance
140 340 z
Voltage
Between (2)
chassis ground
Cooling position
20 30 V
Defective high and low pres- High and low pressure switches may be defective. Carry out trousure switches
bleshooting for "Abnormality in refrigerant".
Possible causes
and standard
value in normal
state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between CB3 (2) fuse in
unit AC04 (female) (1)
Disconnection in wiring harness (Disconnection in wiring Wiring harness between AC04 (female) (3)
6
or defective contact in con- ACW (wiring side) (35)
nector)
Wiring harness between CB3 (2) AC04
(female) (4)
Wiring harness between AC04 (female) (2)
A/C (female) (1)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
32
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00807-02
Trouble
(5) Air conditioner fault history: Communication condition "CAN disconnection", Communication condition "Abnormal"
Related
information
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between AC02 (female) (1)
Resis1
Max. 1 z
or defective contact in con- CM02 (female) (8), (9)
tance
nector)
Wiring harness between AC02 (female) (2)
ResisMax. 1 z
CM02 (female) (10)
tance
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Max. 1 z
Resistance
Max. 1 z
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
CA1 (male)
Resistance
Approx. 120 z
D155AX-6
Resistance
If causes 1 4 are not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried
out.)
33
SEN00807-02
Trouble
Related
information
Possible causes
and standard
value in normal
state
Trouble
Related
information
40 Troubleshooting
Defective air conditioner con- Air conditioner controller may be defective. (Since trouble is in
troller
system, troubleshooting cannot be carried out.)
Resistance
300 z 430 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ACW (wiring side)
2
or defective contact in con- (11) THI (wiring side) (2)
nector)
Wiring harness between ACW (wiring side)
(27) THI (wiring side) (1)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ACW (wiring side)
(11) THI (wiring side) (2) and chassis
ground
Resistance
Min. 1 Mz
34
Voltage
Max. 1 V
D155AX-6
40 Troubleshooting
Trouble
Related
information
Possible causes
and standard
value in normal
state
Trouble
Related
information
SEN00807-02
Resistance
100 z 115 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ACW (wiring side)
2
or defective contact in con- (12) THF (wiring side) (2)
nector)
Wiring harness between ACW (wiring side)
(27) THF (wiring side) (1)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ACW (wiring side)
(12) THF (wiring side) (2) and chassis
ground
Resistance
Min. 1 Mz
D155AX-6
Voltage
Max. 1 V
35
SEN00807-02
Trouble
Related
information
40 Troubleshooting
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harResisness (Disconnection in wiring Wiring harness between ACW (wiring side)
Max. 1 z
2
or defective contact in con- (3) SLS (female) (1)
tance
nector)
Wiring harness between ACW (wiring side)
ResisMax. 1 z
(15) SLS (female) (2)
tance
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
36
Voltage
Max. 1 V
Voltage
Max. 1 V
D155AX-6
40 Troubleshooting
Trouble
Related
information
SEN00807-02
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between MV1 (wiring side)
(1) ACW (wiring side) (3) or circuit branch
end and chassis ground
Possible causes
and standard
value in normal
state
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Voltage
Max. 1 V
Voltage
Max. 1 V
Voltage
Max. 1 V
Voltage
Max. 1 V
D155AX-6
37
SEN00807-02
Trouble
Related
information
40 Troubleshooting
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between MAM(wiring side)
(3) ACW (wiring side) (3) or circuit branch
end and chassis ground
Possible causes
and standard
value in normal
state
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Voltage
Max. 1 V
Voltage
Max. 1 V
Voltage
Max. 1 V
Voltage
Max. 1 V
38
D155AX-6
40 Troubleshooting
Trouble
Related
information
SEN00807-02
Possible causes
and standard
value in normal
state
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harResisness (Disconnection in wiring Wiring harness between ACW (wiring side)
Max. 1 z
3
tance
or defective contact in con- (4) AC05 (female) (1)
nector)
Wiring harness between AC05 (female) (2)
ResisMax. 1 z
chassis ground (GND12)
tance
4
D155AX-6
39
SEN00807-02
40 Troubleshooting
40
D155AX-6
40 Troubleshooting
D155AX-6
SEN00807-02
41
SEN00807-02
40 Troubleshooting
Possible causes
and standard
value in normal
state
42
D155AX-6
40 Troubleshooting
D155AX-6
SEN00807-02
43
SEN00807-02
40 Troubleshooting
(1) When pin puller switch is pulled out, cylinder is not retracted.
(2) When pin puller switch is pushed in, cylinder is not extended.
Related
information
Cause
1 Defective fuse(FS2-3)
PLSW (male)
Between (1) (2)
Resistance
Pulled out
Max. 1 z
Pushed in
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3 Defective pin puller solenoid
PPL (male)
Resistance
10 80 z
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between FS22 (3) PLSW
5 ness (Contact with GND cir- (female) (1) or circuit branch end and chascuit)
sis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
44
Voltage
Max. 1 V
Voltage
Max. 1 V
D155AX-6
40 Troubleshooting
SEN00807-02
D155AX-6
45
SEN00807-02
40 Troubleshooting
Related
information
Cause
BKA
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring har3 ness (Contact with GND cir- Wiring harness between BKA (female) (5)
cuit)
BKAL (female) (1) or circuit branch end and
chassis ground
Resistance
Min. 1 Mz
46
Voltage
Max. 1 V
D155AX-6
40 Troubleshooting
SEN00807-02
D155AX-6
47
SEN00807-02
40 Troubleshooting
E-25 Headlamp, rear lamp, and ripper point lamp do not light up
Trouble
Related
information
Defective headlamp (Broken Headlamp bulb and ground wire may be defective. Check them
bulb, default grounding)
directly.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
FLSW (male)
Headlamp switch
Resistance
Moon mark
Max. 1 z
Neutral
Min. 1 Mz
Sun mark
Max. 1 z
LMFL
Possible causes
and standard
value in normal
state
LMFR
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
LMD1 (male), LMD2 (male)
Continuity
There is continuity
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
48
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
D155AX-6
40 Troubleshooting
SEN00807-02
Cause
Possible causes
and standard
value in normal
state
D155AX-6
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
49
SEN00807-02
Trouble
40 Troubleshooting
(2) Rear lamp and ripper point lamp do not light up.
Related
information
Cause
Defective rear lamp (Broken Rear lamp bulb and ground wire may be defective. Check them
bulb, default grounding)
directly.
RLSW (male)
Between (5) (6)
Possible causes
and standard
value in normal
state
Resistance
OFF
Min. 1 Mz
ON
Max. 1 z
LMRE
LMRP
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between terminal 270
RLSW (female) (5)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
50
D155AX-6
40 Troubleshooting
SEN00807-02
Cause
Possible causes
and standard
value in normal
state
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Ground fault in wiring har8 ness (Contact with GND cirWiring harness between CB5 (2) LMRE
cuit)
(female) (3), LMRP (female) (3) and chassis
ground
Circuit diagram related to headlamp, rear lamp, and ripper point lamp
D155AX-6
51
SEN00807-02
40 Troubleshooting
Related
information
Cause
1
Defective fuse
(FS1 4 or
-4)
If fuse is broken, circuit probably has ground fault (See cause 3).
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between FS12 (4) fuse
2
or defective contact in con- (B3)
nector)
Wiring harness between fuse
(4) CN11
(female) (5)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harWiring harness between FS12 (4) fuse
3 ness (Contact with GND cir(B3) and chassis ground
cuit)
Wiring harness between fuse
(4) CN11
(female) (5) and chassis ground
52
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
D155AX-6
40 Troubleshooting
Trouble
Related
information
SEN00807-02
(2) Front windshield wiper does not operate (Continuous operation is defective).
If fuse ( -5) is broken, operations of both front windshield wiper and rear windshield wiper become
defective.
If fuse ( -4) is broken, intermittent operation of all windshield wipers becomes defective.
Carry out troubleshooting with front wiper switch ON and intermittent switch OFF.
Cause
1 Defective fuse (
If fuse is broken, circuit probably has ground fault (See cause 7).
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
CN23
Voltage
ON
20 30 V
CN14 (male)
Between (2) (3)
Possible causes
and standard
value in normal
state
Resistance
OFF
Min. 1 Mz
ON
Max. 1 z
CN29
CN28
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between fuse
(5) CN14
(female) (3), (5), CN28 (female) (3), or
CN23 (female) (3)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
D155AX-6
53
SEN00807-02
40 Troubleshooting
Cause
Possible causes
and standard
value in normal
state
Trouble
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Ground fault in wiring har7 ness (Contact with GND cirWiring harness between CN14 (female) (2)
cuit)
CN29 (female) (3) and chassis ground
Related
information
If fuse ( -4) is broken, intermittent operation of all windshield wipers becomes defective.
Carry out troubleshooting with front wiper switch and intermittent switch ON.
During intermittent operation, wiper stops for 5 seconds after each cycle of operation.
Cause
CN11 (male)
Between (5) (6)
Possible causes
and standard
value in normal
state
Intermittent switch
Resistance
OFF
Min. 1 Mz
ON
Max. 1 z
CN29
CN28
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring
4
or defective contact in connector)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
54
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
D155AX-6
40 Troubleshooting
Trouble
Related information
SEN00807-02
(4) Rear windshield wiper does not operate (Continuous operation is defective).
If fuse ( -5) is broken, operations of both front windshield wiper and rear windshield wiper become
defective.
If fuse ( -4) is broken, intermittent operation of all windshield wipers becomes defective.
Carry out troubleshooting with rear wiper switch ON and intermittent switch OFF.
Cause
1 Defective fuse (
If fuse is broken, circuit probably has ground fault (See cause 7).
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
CN37
Voltage
ON
20 30 V
CN12 (male)
Between (2) (3)
Resistance
OFF
Min. 1 Mz
ON
Max. 1 z
Possible causes
and standard
value in normal
state
CN33
Defective rear wiper intermit- Replace rear wiper intermittent relay (Right
tent relay (Internal trouble)
No.) with another relay. If rear wiper
becomes normal at this time, intermittent
relay is defective.
CN32
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between fuse
(5) CN12
(female) (3), (5), CN32 (female) (3), or
CN37 (female) (6)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
D155AX-6
55
SEN00807-02
40 Troubleshooting
Cause
Possible causes
and standard
value in normal
state
Trouble
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Ground fault in wiring har7 ness (Contact with GND cirWiring harness between CN12 (female) (2)
cuit)
CN33 (female) (3) and chassis ground
Related
information
If fuse ( -4) is broken, intermittent operation of all windshield wipers becomes defective.
Carry out troubleshooting with rear wiper switch and intermittent switch ON.
During intermittent operation, wiper stops for 5 seconds after each cycle of operation.
Cause
CN11 (male)
Between (5) (6)
Intermittent switch
Resistance
OFF
Min. 1 Mz
ON
Max. 1 z
CN33
Defective rear wiper intermit- Replace rear wiper intermittent relay (Right
tent relay (Internal trouble)
No.) with another relay. If rear wiper
becomes normal at this time, intermittent
relay is defective.
CN32
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring
4
or defective contact in connector)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
56
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
D155AX-6
40 Troubleshooting
Trouble
Related
information
SEN00807-02
(6) Right door wiper does not operate (Continuous operation is defective).
If fuse (
-6) is broken, operations of both right door wiper and left door wiper become defective.
If fuse ( -4) is broken, intermittent operation of all windshield wipers becomes defective.
Carry out troubleshooting with right door wiper switch ON and intermittent switch OFF.
Cause
1 Defective fuse (
If fuse is broken, circuit probably has ground fault (See cause 7).
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
CN17
Voltage
ON
20 30 V
CN13 (male)
Resistance
OFF
Min. 1 Mz
ON
Max. 1 z
CN31
CN30
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
D155AX-6
Resistance
Max. 1 z
(6) CN30
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
57
SEN00807-02
40 Troubleshooting
Cause
Possible causes
and standard
value in normal
state
58
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
D155AX-6
40 Troubleshooting
Trouble
SEN00807-02
Related
information
If fuse ( -4) is broken, intermittent operation of all windshield wipers becomes defective.
Carry out troubleshooting with right door wiper switch and intermittent switch ON.
During intermittent operation, wiper stops for 5 seconds after each cycle of operation.
Cause
CN11 (male)
Between (5) (6)
Possible causes
and standard
value in normal
state
Intermittent switch
Resistance
OFF
Min. 1 Mz
ON
Max. 1 z
CN31
CN30
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring
4
or defective contact in connector)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
D155AX-6
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
59
SEN00807-02
Trouble
Related
information
40 Troubleshooting
(8) Left door wiper does not operate (Continuous operation is defective).
If fuse (
-6) is broken, operations of both right door wiper and left door wiper become defective.
If fuse ( -4) is broken, intermittent operation of all windshield wipers becomes defective.
Carry out troubleshooting with left door wiper switch ON and intermittent switch OFF.
Cause
1 Defective fuse (
If fuse is broken, circuit probably has ground fault (See cause 7).
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
CN24
Voltage
ON
20 30 V
CN15 (male)
Resistance
OFF
Min. 1 Mz
ON
Max. 1 z
CN27
CN26
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
(6) CN15
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
60
D155AX-6
40 Troubleshooting
SEN00807-02
Cause
Possible causes
and standard
value in normal
state
D155AX-6
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
61
SEN00807-02
Trouble
40 Troubleshooting
Related
information
If fuse ( -4) is broken, intermittent operation of all windshield wipers becomes defective.
Carry out troubleshooting with left door wiper switch and intermittent switch ON.
During intermittent operation, wiper stops for 5 seconds after each cycle of operation.
Cause
CN11 (male)
Between (5) (6)
Possible causes
and standard
value in normal
state
Intermittent switch
Resistance
OFF
Min. 1 Mz
ON
Max. 1 z
CN27
CN26
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring
4
or defective contact in connector)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
62
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
D155AX-6
40 Troubleshooting
Trouble
Related
information
SEN00807-02
(10) Water does not come out from front window washer.
Before carrying out troubleshooting, check that windshield wiper operates normally.
If fuse ( -5) is broken, operations of both front window washer and rear window washer become
defective.
Cause
1 Defective fuse (
If fuse is broken, circuit probably has ground fault (See cause 5).
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
WSH1
Voltage
ON
(Wash position)
20 30 V
Possible causes
and standard
value in normal
state
CN14 (male)
Between (5) (6)
Resistance
OFF
Min. 1 Mz
ON
(Wash position)
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring
4
or defective contact in connector)
(5) CN14
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
D155AX-6
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
63
SEN00807-02
Trouble
Related
information
40 Troubleshooting
(11) Water does not come out from rear window washer.
Before carrying out troubleshooting, check that windshield wiper operates normally.
If fuse ( -5) is broken, operations of both front window washer and rear window washer become
defective.
Cause
1 Defective fuse (
If fuse is broken, circuit probably has ground fault (See cause 5).
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
WSH2
Voltage
ON
(Wash position)
20 30 V
Possible causes
and standard
value in normal
state
CN12 (male)
Between (5) (6)
Resistance
OFF
Min. 1 Mz
ON
(Wash position)
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring
4
or defective contact in connector)
(5) CN12
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
64
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
D155AX-6
40 Troubleshooting
Trouble
Related
information
SEN00807-02
(12) Water does not come out from right door washer.
Before carrying out troubleshooting, check that windshield wiper operates normally.
If fuse (
tive.
-6) is broken, operations of both right door washer and left door washer become defec-
Cause
1 Defective fuse (
If fuse is broken, circuit probably has ground fault (See cause 5).
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
WSH2
Voltage
ON
(Wash position)
20 30 V
Possible causes
and standard
value in normal
state
CN13 (male)
Resistance
OFF
Min. 1 Mz
ON
(Wash position)
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring
4
or defective contact in connector)
(6) CN13
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
D155AX-6
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
65
SEN00807-02
Trouble
Related
information
40 Troubleshooting
(13) Water does not come out from left door washer.
Before carrying out troubleshooting, check that windshield wiper operates normally.
If fuse ( -6) is broken, operations of both right door washer and left door washer become defective.
Cause
1 Defective fuse (
If fuse is broken, circuit probably has ground fault (See cause 5).
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
WSH1
Voltage
ON
(Wash position)
20 30 V
Possible causes
and standard
value in normal
state
CN15 (male)
Resistance
OFF
Min. 1 Mz
ON
(Wash position)
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring
4
or defective contact in connector)
(6) CN15
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
66
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00807-02
D155AX-6
67
SEN00807-02
40 Troubleshooting
1 Defective transmission 1
Normal display
Completion
Positioning
E ###,##,##(Longitude)
N ###,##,##(Latitude)
2 Defective GPS
Possible causes
and standard
value in normal
state
Check item
In positioning
If latitude and longitude are not displayed in 5 minutes on open
ground, notify KOMTRAX service hot line.
a Turn starting switch ON and check "Condition of positioning
and communication" screen.
3
Defective communication
environment
Check item
Normal display
Communication
4 Defective transmission 2
Normal display
0 9 (Normally 0)
68
D155AX-6
40 Troubleshooting
D155AX-6
SEN00807-02
69
SEN00807-02
40 Troubleshooting
D155AX-6 Bulldozer
Form No. SEN00807-02
2008 KOMATSU
All Rights Reserved
Printed in Japan 10-08 (02)
70
D155AX-6
SEN00808-02
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
40 Troubleshooting
D155AX-6
SEN00808-02
H-13
H-14
H-15
H-16
H-17
H-18
H-19
H-20
H-21
H-22
H-23
40 Troubleshooting
D155AX-6
40 Troubleshooting
SEN00808-02
a The following information is summarized in the troubleshooting table. Before carrying out troubleshooting, understand that information fully.
Trouble
Related
information
Cause
Possible causes
and standard
value in normal
state
D155AX-6
SEN00808-02
40 Troubleshooting
Cause
1 Defective engine
PCCS lever
Engine speed
F3 stall
1,450 rpm
PCCS lever
Torque converter
inlet pressure
Torque converter
outlet pressure
Neutral
a Prepare with engine stopped, then run engine at high idle and
carry out troubleshooting.
PCCS lever
Neutral
Improper set pressure or
4 internal trouble of transmission main relief valve
Possible causes
and standard
value in normal
state
a Prepare with engine stopped, then run engine at low idle and
carry out troubleshooting.
Malfunction of transmission
clutch valve (ECMV)
PCCS lever
Transmission clutch
Clutch pressure
F3 stall
R3 stall
F1 stall
1ST
F2 stall
2ND
F3 stall
3RD
Prepare with engine stopped, then run engine at high idle and
carry out troubleshooting.
6 Defective brake valve
Steering brake
Free
RB
LB
2.16 MPa
{22.0 kg/cm2}
Defective adjustment of
If check result of cause 6 is abnormal, parking brake lever or brake
7 parking brake lever or brake
pedal linkage is adjusted defectively. Check them directly.
pedal linkage
8 Trouble in transmission
D155AX-6
40 Troubleshooting
SEN00808-02
H-2 Machine does not travel (at 2nd or 3rd gear speed)
Trouble
Related
information
PCCS lever
Torque converter
inlet pressure
Torque converter
outlet pressure
Neutral
a Prepare with engine stopped, then run engine at low idle and
carry out troubleshooting.
Possible causes
and standard
value in normal
state
Malfunction of transmission
clutch valve (ECMV)
PCCS lever
Transmission clutch
Clutch pressure
F2 stall
2ND
F3 stall
3RD
Trouble in transmission
clutch
Transmission clutch (2nd or 3rd gear speed) may have trouble in it.
Check it directly.
Malfunction of parking brake Parking brake may be malfunctioning (Dragging). Check linkage
(Dragging)
and valves.
a Move to level place, start engine, and check.
D155AX-6
Run engine at low idle and set transmission in F2. If machine does
not move at this time, brake is dragging. Carry out troubleshooting
for "H-8 Brake does not work".
6 Trouble in transmission
SEN00808-02
40 Troubleshooting
Cause
1 Defective power train pump
Possible causes
and standard
value in normal
state
Malfunction of transmission
clutch valve (ECMV)
Trouble in transmission
clutch
PCCS lever
Transmission clutch
Clutch pressure
F3 stall
R3 stall
F1 stall
1ST
F2 stall
2ND
F3 stall
3RD
5 Malfunction of brake
Released
Pressed
Steering brake
RB
LB
Brake pressure
2.16 MPa
{22.0 kg/cm2}
0 MPa
{0 kg/cm2}
D155AX-6
40 Troubleshooting
SEN00808-02
Cause
1 Defective power train pump
TM
Possible causes
and standard
value in normal
state
a Prepare with engine stopped, then run engine at low idle and
carry out troubleshooting (after checking transmission main
relief pressure is normal).
3
D155AX-6
Malfunction of transmission
clutch valve (ECMV)
PCCS lever
Transmission clutch
Clutch pressure
F3 stall
R3 stall
Defective transmission clutch If check result of cause 3 is abnormal, seal of transmission clutch
seal
(F or R) may be defective. Check it directly.
Trouble in transmission
clutch
SEN00808-02
40 Troubleshooting
H-5 When gear speed or travel direction is changed, time lag is large 1
Trouble
Related
information
Cause
1 Defective power train pump
Possible causes
and standard
value in normal
state
3
Malfunction of transmission
clutch valve (ECMV)
PCCS lever
Transmission clutch
Clutch pressure
F3 stall
R3 stall
F1 stall
1ST
F2 stall
2ND
F3 stall
3RD
Defective transmission clutch If check result of cause 3 is abnormal, seal of transmission clutch
seal
(F or R) may be defective. Check it directly.
Trouble in transmission
clutch
Run engine at low idle and set transmission in F2. If machine does
not move at this time, brake is dragging. Carry out troubleshooting
for "H-8 Brake does not work".
D155AX-6
40 Troubleshooting
SEN00808-02
H-6 Machine cannot be steered (Machine does not turn right or left)
Trouble
Related
information
Cause
Possible causes
and standard
value in normal
state
PCCS lever
Blade control lever
Ripper control lever
Neutral
Cause
Improper set pressure or
1 malfunction of HSS main
relief valve
Possible causes
and standard
value in normal
state
a Prepare with engine stopped, then run engine at high idle and
carry out troubleshooting.
Improper set pressure or
2 malfunction of self-acting
pressure reducing valve
D155AX-6
PCCS lever
Blade control lever
Ripper control lever
Neutral
SEN00808-02
40 Troubleshooting
Released
Possible causes
and standard
value in normal
state
Pressed
2
Defective adjustment of
brake pedal limit switch
10
Brake pedal
Steering brake
RB
LB
Brake pressure
2.16 MPa
{22.0 kg/cm2}
0 MPa
{0 kg/cm2}
D155AX-6
40 Troubleshooting
SEN00808-02
Related
information
Malfunction of transmission
clutch (Slip)
PCCS lever
Torque converter
inlet pressure
Torque converter
outlet pressure
Neutral
D155AX-6
11
SEN00808-02
40 Troubleshooting
H-10 Abnormal sound comes out from around HSS pump or HSS
motor
Trouble
Related
information
Abnormal sound comes out from around HSS pump or HSS motor.
Before carrying out troubleshooting, check that oil level in hydraulic tank is normal.
HSS pump is used for work equipment, too.
Cause
1 Use of improper oil
Possible causes
and standard
value in normal
state
12
D155AX-6
40 Troubleshooting
SEN00808-02
Cause
Defective PTO (work equip1 ment and HSS pump drive
section)
2
Defective work equipment or Work equipment or HSS pump may be defective. Check them
HSS pump
directly.
PCCS lever
Blade control lever
Ripper control lever
Unload pressure
Neutral
a Prepare with starting switch ON, then run engine at high idle
and carry out troubleshooting.
Blade control lever
Raise relief
a Prepare with engine stopped, then run engine at high idle and
carry out troubleshooting.
Improper set pressure or
6 malfunction of self-acting
pressure reducing valve
D155AX-6
PCCS lever
Blade control lever
Ripper control lever
Neutral
13
SEN00808-02
40 Troubleshooting
Cause
Defective PTO (work equip1 ment and HSS pump drive
section)
2
Defective work equipment or Work equipment or HSS pump may be defective. Check them
HSS pump
directly.
Possible causes
and standard
value in normal
state
PCCS lever
Blade control lever
Ripper control lever
Unload pressure
Neutral
a Prepare with starting switch ON, then run engine at high idle
and carry out troubleshooting.
Blade control lever
Raise relief
a Prepare with engine stopped, then run engine at high idle and
carry out troubleshooting.
Improper set pressure or
6 malfunction of self-acting
pressure reducing valve
PCCS lever
Blade control lever
Ripper control lever
Neutral
a Prepare with engine stopped, then run engine at high idle and
carry out troubleshooting.
7
14
Lock
0 MPa
{0 kg/cm2}
Free
D155AX-6
40 Troubleshooting
SEN00808-02
a Prepare with engine stopped, then run engine at high idle and
carry out troubleshooting.
Possible causes
and standard
value in normal
state
PCCS lever
Blade control lever
Ripper control lever
Neutral
Malfunction of blade lift con- Spool of blade lift control valve may be malfunctioning. Check it
trol valve (spool)
directly.
D155AX-6
Air may be in blade lift cylinder. Bleed air and then judge from
change of phenomenon.
15
SEN00808-02
40 Troubleshooting
Possible causes
and standard
value in normal
state
a Prepare with engine stopped, then run engine at high idle and
carry out troubleshooting.
Improper set pressure or
2 malfunction of self-acting
pressure reducing valve
PCCS lever
Blade control lever
Ripper control lever
Neutral
Malfunction of blade tilt con- Spool of blade tilt control valve may be malfunctioning. Check it
trol valve (spool)
directly.
16
Air may be in blade tilt cylinder. Bleed air and then judge from
change of phenomenon.
D155AX-6
40 Troubleshooting
SEN00808-02
a Prepare with engine stopped, then run engine at high idle and
carry out troubleshooting.
Possible causes
and standard
value in normal
state
PCCS lever
Blade control lever
Ripper control lever
Neutral
Malfunction of ripper lift con- Spool of ripper lift control valve may be malfunctioning. Check it
trol valve (spool)
directly.
D155AX-6
Air may be in ripper lift cylinder. Bleed air and then judge from
change of phenomenon.
17
SEN00808-02
40 Troubleshooting
a Prepare with engine stopped, then run engine at high idle and
carry out troubleshooting.
Possible causes
and standard
value in normal
state
PCCS lever
Blade control lever
Ripper control lever
Neutral
Malfunction of ripper tilt con- Spool of ripper tilt control valve may be malfunctioning. Check it
trol valve (spool)
directly.
Air may be in ripper tilt cylinder. Bleed air and then judge from
change of phenomenon.
Possible causes
and standard
value in normal
state
18
D155AX-6
40 Troubleshooting
SEN00808-02
Possible causes
and standard
value in normal
state
12 cc/min
Possible causes
and standard
value in normal
state
D155AX-6
Lower relief
11 cc/min
19
SEN00808-02
40 Troubleshooting
Cause
Possible causes
and standard
value in normal
state
Check point
Pushed in
Pulled out
Solenoid output
pressure
Min. 2.84 MPa
{Min. 29.0 kg/cm2}
2 Trouble in pin puller cylinder Pin puller cylinder has trouble in it. Check it directly.
Related
information
Possible causes
and standard
value in normal
state
20
Cause
D155AX-6
40 Troubleshooting
SEN00808-02
H-22 Abnormal sound comes out from around work equipment pump 1
Trouble
Related
information
Possible causes
and standard
value in normal
state
Cause
740 rpm
2100 rpm
4 Defective fan
D155AX-6
Engine speed
Fan speed
21
SEN00808-02
40 Troubleshooting
D155AX-6 Bulldozer
Form No. SEN00808-02
2010 KOMATSU
All Rights Reserved
Printed in Japan 11-10
22
D155AX-6
SEN00852-02
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
D155AX-6
Serial number
80001 and up
40 Troubleshooting
D155AX-6
SEN00852-02
40 Troubleshooting
D155AX-6
40 Troubleshooting
SEN00852-02
Questions
1
2
3
4
5
6
Check items
Troubleshooting
The troubleshooting chart consists of the "questions", "check items", "causes", and "troubleshooting" blocks.
The questions and check items are used to pinpoint
high probability causes by simple inspection or
from phenomena without using troubleshooting
tools.
Next, troubleshooting tools or direct inspection are
applied to check the narrowed causes in order from
the most probable one to make final confirmation
according to the troubleshooting procedure.
[Questions]
Items to be drawn from the user or operator.
They correspond to A and B in the chart on the
right. The items in A are basic ones. The
items in B can be drawn from the user or operator, depending on their level.
[Check items]
Simple check items used by the serviceman to
narrow the causes. They correspond to C in
the chart on the right.
[Causes]
Items to be narrowed from the questions and
check items. The serviceman narrows down
the probable causes from A, B, and C.
[Troubleshooting]
Items used to find out the true cause by verifying the narrowed causes finally in order from
the most probable one by applying troubleshooting tools or direct inspection.
8
9
10
11
a
b
c
d
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, and w.
E: Causes to be referred to for questions and check items
Q : Causes related to questions and check items
w : Causes highly probable among ones marked with Q
a When narrowing the "causes", apply the items marked with w before those marked with Q.
When narrowing the "causes", do not apply the items marked with E. (If no items have other marks and
the causes cannot be narrowed, however, you may apply them.)
D155AX-6
SEN00852-02
40 Troubleshooting
Correct
Adjust
Adjust
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Cause
Questions
Suddenly
Gradually
Check items
Troubleshooting
D155AX-6
40 Troubleshooting
SEN00852-02
There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 6 items in
the [Causes] section.
The method of pinpointing the [Causes] from the causal relationship and approaching the [troubleshooting]
is explained according to Step 1 - Step 3 shown below.
[Causes]: 6 items
Step 1
Clarify the relationship between the 3 items in the
[Questions] and [Check items] sections and the 6 items
in the [Causes] section.
Step 2
Count the and marks on the 3 items in the
[Questions] and [Check items] sections and the 6 items
in the [Causes] section.
(1) Clogged air cleaner element
:
(2) Clogged EGR gas pressure piping
:
(3) Defective contact of valve and valve seat :
(4) Leakage of air between turbocharger and
cylinder head
:
(5) Worn piston ring and cylinder liner
:
(6) Clogged or seized injector
:
Step 3
The result of Step 2 shows that the item having the
closest relationship with the trouble is "Clogged air
cleaner". If the "troubleshooting" items connected to it
and marked with are carried out, remedy of cleaning is
indicated. Accordingly, the exhaust gas color can be
changed to normal by cleaning.
D155AX-6
SEN00852-02
40 Troubleshooting
Defective injector
Causes
Questions
Starting performance
E E
E E
Q Q w w
Q Q
E
w
Filters have not been replaced according to Operation and Maintenance Manual
w w Q Q
w
w w
w
w Q Q
Check items
When air bleeding plug of fuel filter is removed, fuel does not
flow out
w w
w
w
Q Q
w
Q w Q Q
q
q q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
not change
When starting switch is turned to HEAT, intake air heater mount does not become
warm
Is voltage of 20 30 V generated between alternator terminals B and E
while engine is running at low idle?
Q Q Q Q
q
q
Yes
No
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Correct
Clean
Replace
Correct
Replace
Remedy
Clean
Replace
Degree of use of
machine
D155AX-6
40 Troubleshooting
SEN00852-02
D155AX-6
SEN00852-02
40 Troubleshooting
Causes
E E E
w
Q
When starting switch is turned to START, starting pinion does not move out
Q
Q
w
w
w
w
Q w
q
q
Replace
Replace
Replace
Correct
Replace
Replace
Replace
Remedy
Check items
When starting switch is turned ON, no operating sound comes out from battery relay
When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows out (*1).
Troubleshooting
Degree of use of
machine
Replace
Questions
D155AX-6
40 Troubleshooting
SEN00852-02
D155AX-6
SEN00852-02
40 Troubleshooting
Causes
E E E
w Q w w w
Q w
There are rust and water in fuel drained from fuel tank
w
Check items
Q Q Q
Q Q
w Q Q
While engine is
rotated with starting
When spill hose from injector is disconnected, little fuel
motor
spills
E E
Q
w Q
w w w w
q q
w w
q
q
q
q q
Replace
Correct
Replace
Replace
Replace
Clean
Replace
Replace
Correct
Correct
Add
Remedy
Replace
Replace
Degree of use of
machine
Replace
Questions
10
D155AX-6
40 Troubleshooting
SEN00852-02
Causes
E E
E
w
Q Q
w w
w
w
w
w w
There are rust and water in fuel drained from fuel tank
w Q Q
w
Check items
When engine is rotated, abnormal sound comes out from around cylinder head
While engine is rotated
with starting motor,
When air bleeding plug of fuel filter is removed, fuel does not
flow out
w w
q
q
q
Replace
Replace
Clean
Replace
Clean
Clean
Correct
Clean
Replace
Replace
Replace
Remedy
Clean
When starting switch is turned to HEAT, intake air heater mount does not become warm
Replace
Questions
D155AX-6
11
SEN00852-02
40 Troubleshooting
Causes
E E E
E E
Q Q
Q
w w w
w
w
w w
There are rust and water in fuel drained from fuel tank
Fuel is leaking from fuel piping
w Q Q
Q
Check items
Black
When engine is rotated, abnormal sound comes out from around cylinder head
When engine is rotated, interference sound comes out from around turbocharger
High idle speed under no load is normal, but speed suddenly drops when load is applied
w w
Q w
Carry out troubleshooting according to "EGR Valve Servo Error (*1)" indicated by code
w w
q
q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
change
Replace
Clean
Clean
Correct
Clean
Replace
Replace
Adjust
Replace
Replace
Clean
Remedy
q q
Correct
Degree of use of
machine
Replace
Questions
12
D155AX-6
40 Troubleshooting
SEN00852-02
Q w Q w
Causes
Questions
w Q
Stopped slowly
Q Q
w Q
Q Q Q
Q Q Q
w w
w
w
w Q Q
w w
Check items
There are rust and water in fuel drained from fuel tank
w w
Q Q
w w
w
w
q q
Replace
Replace
Clean
Clean
Correct
Clean
Add
Replace
Replace
Replace
Replace
Remedy
q
Replace
Troubleshooting
Degree of use of
machine
D155AX-6
13
SEN00852-02
40 Troubleshooting
Causes
E E
Q Q Q
At low idle
Engine hunts
E E
Q Q
Q Q Q Q Q Q Q
Q Q
Q Q
On slopes
Q Q
w w
Filters have not been replaced according to Operation and Maintenance Manual
w
Check items
Q Q
There are rust and water in fuel drained from fuel tank
Fuel is leaking from fuel piping
w Q Q
q
Carry out troubleshooting according to "EGR Valve Servo Error (*1)" indicated by code
Troubleshooting
Carry out troubleshooting according to "Bypass Valve Servo Error (*2)" indicated by
code
q
q
q q
Carry out troubleshooting according to "Eng Ne Speed Sensor Error (*3)" indicated by
code
Carry out troubleshooting according to "Eng Bkup Speed Sensor Error (*4)" indicated
by code
Correct
Correct
Replace
Replace
Replace
Correct
Clean
Add
Replace
Replace
Correct
Remedy
q
Correct
Questions
14
D155AX-6
40 Troubleshooting
SEN00852-02
D155AX-6
E E
Q Q
Q Q
Q Q Q
Q
Q
w
Q Q Q
w
w
w
w
w w
w
w
w
w
Q
w w Q
w
Q Q
Q Q Q Q
q
q
q
q q
q
q
Replace
Replace
Correct
Replace
Replace
Replace
Clean
Correct
q
Clean
Replace
Adjust
Replace
Replace
Correct
Remedy
E
Q
Replace
Causes
Clean
Troubleshooting
Check items
Questions
15
SEN00852-02
40 Troubleshooting
1
Defective coolant temperature sensor or wiring harness
Causes
E
E
w Q Q
w
w
Questions
E
Q
w
Q Q
E
Q Q
Q Q
Suddenly
Q
w
Gradually
Q Q
Q
Muffler is crushed
Q Q Q
Check items
Q w
When engine is rotated, abnormal sound comes out from around cylinder
head
Torque converter stall speed or pump relief speed is high (Fuel is injected
excessively)
Q Q
Q
Q Q
w
Q Q Q
Q
Q w
w
When spill hose from injector is disconnected, abnormally much fuel spills
q
q
Troubleshooting
q
q
When a cylinder is cut out for reduced cylinder mode operation, engine speed
does not change
q
q
q
16
Adjust
Adjust
Correct
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Replace
Replace
Replace
Replace
Clean
Remedy
q
Replace
D155AX-6
40 Troubleshooting
SEN00852-02
D155AX-6
17
SEN00852-02
40 Troubleshooting
1
Oil leakage from oil pan, cylinder head, etc.
Turbocharger
Worn seal at blower end
Causes
E E E E
E
w
Q
w
Q Q w
w w w w w
w
Q w
Excessive
w w
w
q q
q q
q q
q q q q
18
Replace
Replace
Correct
Replace
Replace
Clean
Replace
Replace
Replace
Correct
Remedy
Correct
Correct
Troubleshooting
None
Correct
w w
Correct
Check items
Correct
Questions
D155AX-6
40 Troubleshooting
SEN00852-02
E E E E
w
w Q
Q Q
w
w
Blow-by gas
Black
Q
Q w
Q
w
q q
See S-7
Exhaust gas is
D155AX-6
Replace
Replace
Clean
Clean
Replace
Replace
Replace
Remedy
Replace
Check items
Even when engine oil temperature rises, oil filter clogging monitor indicates clogging
(if monitor is installed)
Troubleshooting
Causes
Clean
Questions
19
SEN00852-02
40 Troubleshooting
Malfunction of injector
Causes
E E
Gradually increased
Q Q
Suddenly increased
Combustion is irregular
w
w
w
Q Q
Black
Q Q
White
Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by code
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change
Correct
Replace
Replace
Correct
Correct
Remedy
q
Replace
Correct
Check items
Troubleshooting
Q Q Q
Q
Correct
Fuel consumption
E
Q
Replace
Questions
20
D155AX-6
40 Troubleshooting
SEN00852-02
Causes
Q
Q
Q Q
There are excessive air bubbles in radiator and coolant spurts back
w
w
w
When hydraulic oil or power train oil is drained, water flows out
q q
D155AX-6
Replace
Replace
Replace
Remedy
Replace
Check items
Q Q
Gradually increased
Troubleshooting
Suddenly increased
Replace
Questions
21
SEN00852-02
40 Troubleshooting
Causes
E
Q w
Oil pressure monitor indicates low oil pressure (if monitor is installed)
Q
Q
w
Filters have not been replaced according to Operation and Maintenance Manual
w
Check items
w w w Q
Q Q
q q
Troubleshooting
q
q
q
q
Replace
Replace
Correct
Replace
Adjust
Replace
Clean
Clean
Add
Replace
Remedy
q
Replace
Questions
22
D155AX-6
40 Troubleshooting
D155AX-6
SEN00852-02
23
SEN00852-02
40 Troubleshooting
Q Q
Q Q
Q Q
Q Q
When radiator cap is removed and engine is run at low idle, abnormally many bubbles
come out or coolant spurts back
w
w
Q
Q
Q
w
When water pump drain hole (breather hole) is cleaned, coolant flows out
w
q
q
Troubleshooting
q q
q
Replace
Correct
Replace
Replace
Correct
Replace
Replace
Correct
Replace
Remedy
Replace
24
E E
Check items
Replace
Questions
Causes
D155AX-6
40 Troubleshooting
SEN00852-02
D155AX-6
25
SEN00852-02
40 Troubleshooting
1
Rise of power train oil temperature on applicable machine side
Malfunction of fan
Malfunction of thermostat
Causes
E E E
Q w
Q
Q w w
Rises quickly
w
w
w
w Q
E E
Occurred suddenly
Dirt and mud are accumulated in radiator shroud and undercover on applicable
machine side
26
Correct
Replace
Correct
Correct
Replace
Replace
Add
Replace
Replace
Replace
Remedy
Replace
Replace
Troubleshooting
Questions
D155AX-6
40 Troubleshooting
SEN00852-02
Causes
Gradually increased
Q
Q
When engine is rotated, interference sound comes out from around turbocharger
When engine is rotated, abnormal sound comes out from around EGR gas
piping
w
w
When engine is rotated, abnormal sound comes out from around cylinder head
Check items
Q Q Q
Suddenly increased
w
w
When engine is rotated, beat noise comes out from around muffler
Immediately after engine is started, temperature of exhaust manifold of a
cylinder is low
Exhaust gas is
w Q
w
Black
Q
w
Q Q
Q
w
q q
q q
q
D155AX-6
Correct
Replace
Correct
Replace
Replace
Replace
Adjust
Replace
Correct
Replace
Replace
Remedy
Replace
Correct
Questions
27
SEN00852-02
40 Troubleshooting
Causes
Suddenly increased
Gradually increased
Q Q Q Q
28
Replace
Adjust
Replace
Adjust
Replace
Replace
Replace
Remedy
Replace
Replace
Check items
Questions
D155AX-6
40 Troubleshooting
D155AX-6
SEN00852-02
29
SEN00852-02
40 Troubleshooting
D155AX-6 Bulldozer
Form No. SEN00852-02
2008 KOMATSU
All Rights Reserved
Printed in Japan 10-08 (02)
30
D155AX-6
SEN01204-04
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine Model
Serial Number
D155AX-6
80001 and up
D155AX-6
SEN01204-04
(Rev. 2009.01)
1
Removal
q
In "Removal" section, the work procedures,
precautions and know-how to do the work, and
the amount of oil and coolant to be drained are
described.
q
Common tools that are necessary for removal
are described as [1], [2] etc. and their part
numbers, part names and quantities are not
described.
q
Various symbols used in "Removal" section
are explained and listed below.
k
Installation
q
Unless otherwise instructed, installation of parts
is to be done in the reverse order to removal.
q
Instructions and precautions for parts installation is shown with the mark ([*1], [*2]...) which
corresponds to the mark in "Removal" section.
q
Common tools that are necessary for installation are described as [1], [2] etc. and their
part numbers, part names and quantities are not
described.
q
Marks shown in the "Installation" section stand
for the following.
k
: Tightening torque
D155AX-6
2.
SEN01204-04
Disassembly
q
In "Disassembly" section, the work procedures,
precautions and know-how to do the work, and
the amount of oil and coolant to be drained are
described.
q
Common tools that are necessary for disassembly are described as [1], [2] etc. and
their part numbers, part names and quantities
are not described.
q
The meanings of the symbols used in "Disassembly" section are as follows.
k
Assembly
q
In "Assembly" section, the work procedures,
precautions and know-how to do the work, and
the amount of oil and coolant to be replenished
are described.
q
Common tools that are necessary for assembly are described as [1], [2] etc. and their
part numbers, part names and quantities are
not described.
q
The meanings of the symbols used in "Assembly" section are as follows.
k
: Tightening torque
D155AX-6
SEN01204-04
(Rev. 2009.02)
1
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disassembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Category
Komatsu
code
Part number
Q'ty
Container
LT-1A
790-129-9030
150 g
Tube
Used to prevent rubber gaskets, rubber cushions, and cork plugs from coming out.
LT-1B
790-129-9050
20 g
(2 pcs.)
LT-2
09940-00030
50 g
Adhesive
LT-3
LT-4
790-129-9040
250 g
Holtz MH 705
790-129-9120
75 g
ThreeBond
1735
Gasket sealant
790-129-9140
Can
Polyethylene
Used to seal plugs.
container
Tube
50 g
Quick-setting adhesive.
Polyethylene Setting time: Within 5 sec. to 3 min.
container Used mainly to stick metals, rubbers, plastics,
and woods.
Quick-setting adhesive.
Quick-setting type.
Polyethylene
(max. strength is obtained after 30 minutes)
container
Used mainly to stick rubbers, plastics, and
metals.
Aron-alpha
201
790-129-9130
2g
Loctite
648-50
79A-129-9110
50 cc
1 kg
LG-5
790-129-9080
LG-6
790-129-9160
200 g
Tube
LG-7
790-129-9170
1 kg
Tube
Tube
Tube
LG-8
ThreeBond
1207B
LG-9
ThreeBond
1206D
790-129-9060
Adhesive: 1 kg
(Set of adhesive
Hardener: 500 g
and hardener)
419-15-18131
790-129-9310
100 g
200 g
D155AX-6
Gasket sealant
CateKomatsu code
gory
Part number
Q'ty
Container
LG-10
ThreeBond
1206E
790-129-9320
200 g
Tube
LG-11
ThreeBond
1121
790-129-9330
200 g
Tube
ThreeBond
1211
790-129-9090
100 g
Tube
Tube
Used to prevent scuffing and seizure of press-fitted portions, shrink-fitted portions, and threaded
portions.
Used to lubricate linkages, bearings, etc.
Can
Spray type
Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuffing each other.
Applicable for the propeller shaft splines, needle
bearings, pins and bolts of various links, etc.
Can
Feature: Seizure and scuffing prevention compound with metallic super-fine-grain, etc.
Used for the mounting bolt in the high temperature area of the exhaust manifold and the turbocharger, etc.
Various
Various
Seizure
prevention
compound
Molybdenum
disulfide
lubricant
LM-P
LC-G
NEVER-SEEZ
09940-00040
09995-00250
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI
SYG2-160LI
G0-LI
SYGA-160CNLI
*: For cold district
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
Molybdenum
SYG2-400M
disulfide grease SYG2-400M-A
LM-G (G2-M)
SYGA-16CNM
Grease
SEN01204-04
SYG2-400T-A
SYG2-16CNT
SYG0-400T-A (*)
*: For cold district SYG0-16CNT (*)
Hyper White
Grease G2-T,
G0-T (*)
SYG2-400B
Biogrease
G2-B, G2-BT (*) SYGA-16CNB
*: For use at high SYG2-400BT (*)
temperature and SYGA-16CNBT
under high load
(*)
G2-S
ThreeBond
1855
G2-U-S
ENS grease
D155AX-6
427-12-11871
200 g
190 g
400 g
16 kg
200 g
2 kg
Bellows-type
container
Can
Tube
Feature: Silicone grease with wide using temperature range, high resistance to thermal-oxidative degradation and performance to prevent
deterioration of rubber and plastic parts.
Used for oil seals of the transmission, etc.
Can
SEN01204-04
Part number
SUNSTAR
PAINT PRIMER
580 SUPER
SUNSTAR
PAINT PRIMER
435-95
Container
20 ml
Glass
container
20 ml
Glass
container
20 ml
Glass
container
417-926-3910
22M-54-27230
SUNSTAR
GLASS
PRIMER
435-41
22M-54-27240
150 ml
Can
SUNSTAR
SASH PRIMER
GP-402
22M-54-27250
20 ml
Glass
container
SUNSTAR
PENGUINE
SEAL 580
SUPER S or
W
417-926-3910
320 ml
Polyethylene
container
Sika Japan,
Sikaflex 256HV
20Y-54-39850
310 ml
Polyethylene
container
SUNSTAR
PENGUINE
SUPER 560
22M-54-27210
320 ml
Ecocart
(Special
container)
SUNSTAR
PENGUINE
SEAL No. 2505
417-926-3920
320 ml
Polyethylene
container
SEKISUI
SILICONE
SEALANT
20Y-54-55130
333 ml
Polyethylene
container
Cartridge
GE TOSHIBA
SILICONES
TOSSEAL 381
22M-54-27220
333 ml
Caulking material
Adhesive
Primer
SUNSTAR
GLASS
PRIMER 580
SUPER
Q'ty
CateKomatsu code
gory
D155AX-6
SEN01204-04
a Tools with part number 79*T-***-**** cannot be supplied (they must be locally manufactured).
a Necessity
: t . . . . . . Cannot be substituted, should always be installed (used)
: q . . . . . . Extremely useful if available, can be substituted with commercially available part
a New/Remodel: N. . . . . . Tools newly developed for this model and given new part Nos.
Work item
Symbol
Part No.
Part name
Standard puller
01010-81090
Bolt
01643-31032
Washer
790-331-1110
Wrench
Bolt
t 3
795-931-1100
Seal puller
t 1
Bolt
t 4
01643-31645
Washer
t 8
Bolt
t 4
01643-31645
Washer
t 4
Bolt
791-612-1100
Installer
t 1
790-101-4200
t 1
790-101-1102
Hydraulic pump
t 1
t 1
Bolt
D155AX-6
t 8
1
1
t 1
t 1 N Q
791T-615-1320 Plate
t 1 N Q
Bolt
791T-615-1330 Plate
01282-61230
Bolt
791T-615-1340 Plate
Wrench
01010-82040
t 1
01643-31645
799-301-1600
t 4
t 4
Bolt
791T-615-1310 Plate
t 1
01050-31645
t 1
01050-31640
t 1
01050-31645
t 1 R Q
t 3
q 1
Bolt
01050-31655
t 1
795-630-5500
Necessity
Q'ty
New/Remodel
Sketch
: R. . . . . . Tools remodeled from tools already available for other models and given
upgraded part Nos.
: Blank . . Tools already available for other models, usable without any modification
a Tools marked with Q in the sketch column are tools introduced in the sketches of the special tools (See
Sketches of special tools).
t 4
t 2 N Q
t 4
t 1 N Q
Work item
Symbol
Part No.
Part name
Necessity
Q'ty
New/Remodel
Sketch
SEN01204-04
791-662-1110
Bracket
t 1
01010-31685
Bolt
t 1
01017-31620
Bolt
t 1
790-302-1500
Spanner kit
t 1
09003-09200
Spanner
790-302-1500
Spanner kit
t 1
09003-08290
Spanner
790-337-1032
Lifting tool
t 1
791-627-1320
Shackle
t 2
791T-627-1910 Plate
t 1
01010-82080
Bolt
t 2
790-431-1031
Block
t 1
791-520-4140
Screw
t 2
790-101-2360
Plate
t 2
791-112-1180
Nut
t 2
790-101-2480
Adapter
t 2
791T-627-1920 Plate
t 1
790-101-2102
Puller
t 1
790-101-1102
Hydraulic pump
t 1
790-431-1031
Block
t 1
791-520-4140
Screw
t 1
791-112-1180
Nut
t 2
01643-32460
Washer
t 2
791T-627-1930 Plate
t 1
t 1
790-101-2102
Puller
t 1
790-101-1102
Hydraulic pump
t 1
791-627-1280
Installer
t 1
790-101-5401
t 1
790-101-5441
Plate
790-101-5421
Grip
01010-51240
Bolt
790-101-5401
790-101-5451
Plate
790-101-5421
Grip
01010-51240
Bolt
1
t 1
791T-627-1950 Plate
t 1
791T-627-1960 Plate
t 1
790-201-1500
t 1
790-201-1680
Plate
790-101-5021
Grip
01010-50816
Bolt
D155AX-6
Work item
Symbol
SEN01204-04
Part No.
Part name
791-520-4140
Screw
t 1
790-101-2420
Adapter
t 1
791-112-1180
Nut
t 1
01643-22460
Washer
t 1
792-785-1120
Plate
t 1
791-830-1410
Push tool
t 1
790-101-2102
Puller
t 1
790-101-1102
Hydraulic pump
t 1
791T-130-1010 Bracket
KK
Bolt
12
01643-33080
Washer
12
t 1
791-630-1220
Rod
t 2
790-101-2510
Block
t 1
790-101-2570
Washer
t 2
01580-01411
Nut
t 2
01643-31445
Washer
t 2
790-101-2102
t 1
790-101-1102
Hydraulic pump
t 1
796-670-1020
Installer
t 1
791-601-1000
Oil pump
t 1
14
22
L
23
15
16
D155AX-6
t 6 N Q
01010-63060
791T-130-1010 Bracket
791T-630-1230 Plate
Necessity
Q'ty
New/Remodel
Sketch
01010-63060
Bolt
t 2 N Q
t 4
01643-33080
Washer
t 4
790-401-1700
Lifting tool
t 1
790-401-1761
Adapter
t 1
791-630-1860
Bracket
t 1
791-630-1870
Bracket
t 1
790-101-2310
Block
t 1
790-101-2360
Plate
t 2
790-445-4130
Screw
t 2
791-112-1180
Nut
t 2
790-101-4000
t 1
790-101-1102
Pump
t 1
790-201-2760
Spacer
t 1
791-630-1370
Adapter
t 1
790-434-1060
Screw
t 2
01580-13024
Nut
t 2
01643-33080
Washer
t 1
790-101-4000
t 1
790-101-1102
Pump
t 1
Fixing of boggy
Work item
Symbol
Part No.
Part name
17
796-430-1110
Push tool
18
790-701-3000
Seal checker
19 791T-630-1390 Guide
791T-130-1010 Bracket
14
15
L
Removal and installation
of No. 2, No. 3 and No. 4
boggy assemblies
16
t 1
t 1
Bolt
t 4
01643-33080
Washer
t 4
791-630-1360
Spacer
t 1
790-101-2310
Block
t 1
790-101-2360
Plate
t 2
790-445-4130
Screw
t 2
791-112-1180
Nut
t 2
790-101-4000
t 1
790-101-1102
Pump
t 1
790-201-2760
Spacer
t 1
791-630-1370
Adapter
t 1
790-434-1060
Screw
t 2
01580-13024
Nut
t 2
01643-33080
Washer
t 2
t 1
790-101-1102
Pump
t 1
17
796-430-1110
Push tool
t 1
18
790-701-3000
Seal checker
21
1
Disassembly and assembly of track roller assem- N 2
bly
3
4
t 2 N Q
790-101-4000
20
t 1
01010-63060
19 791T-630-1390 Guide
10
Necessity
Q'ty
New/Remodel
Sketch
SEN01204-04
Fixing of boggy
t 1
t 1
790-101-2310
Block
t 1
790-445-4130
Screw
t 2
796T-470-1130 Plate
t 1
790-101-2360
Plate
t 2
790-112-1180
Nut
t 2
790-101-4000
t 1
790-101-1102
Pump
t 1
791-601-1000
Oil pump
t 1
791-685-8006
Compressor
t 1
791-635-3160
Extension
t 1
791T-630-2610 Spacer
t 1
790-101-1300
Cylinder
t 1
790-101-1102
Hydraulic pump
t 1
Compression of recoil
spring
791T-630-1290 Plate
t 1
Pulling out of shaft and pullQ ing out and press fitting of
seal guide
t 1
791-651-1510
Installer
t 2
791-601-1000
Oil pump
t 1
D155AX-6
Work item
Symbol
SEN01204-04
Part No.
Part name
Necessity
Q'ty
New/Remodel
Sketch
790-101-2310
Block
t 1
790-445-4130
Screw
t 2
796T-470-1130 Plate
t 1
790-101-2360
Plate
t 2
791-112-1180
Nut
t 2
790-101-4000
t 1
790-101-1102
Pump
t 1
21
791-601-1000
Oil pump
t 1
790-102-1891
Nut wrench
t 1
791-651-1510
Installer
t 1
791T-630-1350 Spacer
t 1
791-601-1000
Oil pump
t 1
791-675-9701
t 1
791-101-4300
791-101-4200
t 1
791-101-1102
Hydraulic pump
t 1
20
Disassembly and assemQ
bly of boggy assembly
Q
Pulling out and press fitting
of pin assembly and shaft
2
General disassembly and
general assembly of track S 3
shoe assembly
4
791-932-1110
t 1
791-660-7460
Pin brush
t 1
Cleaning of pin
791-432-1110
t 1
791-632-1052
Installer
t 1
790-701-3000
Seal checker
t 1
791-601-1000
Oil pump
t 1
791-675-9581
Adapter
t 1
791-675-9590
Guide
t 1
01010-52460
Bolt
t 2
01010-51440
Bolt
t 2
790-101-1102
Pump
t 1
790-101-4300
Cylinder
(1,470 kN {150 ton})
t 1
791-685-9510
Frame
t 1
791-685-9520
Frame
t 1
791-685-9530
Rod
t 1
791-685-9550
Nut
t 1
791-685-9560
Bolt
t 1
791-675-9570
Adapter
t 1
D155AX-6
04530-12030
Eyebolt
t 1
790-101-1102
Pump
t 1
790-101-4300
Cylinder
(1,470 kN {150 ton})
t 1
791-685-9540
Rod
t 1
791-685-9550
Nut
t 3
Disassembly of 1 link
Disassembly of 1 link
Disassembly of 1 link
11
Work item
Symbol
Part No.
Guide
t 1
791-675-5530
Pusher
t 1
01010-51030
Bolt
t 1
791-685-9620
Extension
t 1
790-101-1102
Pump
t 1
790-101-4200
t 1
791-675-5542
Adapter
t 1
791-675-5571
Adapter
t 1
790-101-1102
Pump
t 1
790-101-4300
Cylinder
(1,470 kN {150 ton})
t 1
791-675-5580
Guide
t 1
791-685-9510
Frame
t 1
791-685-9520
Frame
t 1
791-685-9530
Rod
t 1
791-685-9540
Rod
t 1
791-685-9550
Nut
t 3
791-685-9560
Bolt
t 4
791-126-0150
Adapter
t 1
01010-51030
Bolt
t 1
791-685-9620
Extension
t 1
791-675-5542
Adapter
t 1
791-675-5560
Guide
t 1
790-101-1102
Pump
t 1
790-101-4300
Cylinder
(1,470 kN {150 ton})
t 1
791-675-5560
Guide
t 1
791-675-5542
Adapter
t 1
790-101-1102
Pump
t 1
790-101-4200
t 1
791-670-3270
Guide
t 1
791-126-0150
Adapter
t 1
791-675-5560
Guide
t 1
791-675-9570
Adapter
t 1
01010-51030
Bolt
t 1
790-101-1102
Pump
t 1
790-101-4200
t 1
791-675-9701
t 1
790-101-1102
Pump
t 1
790-101-4200
t 1
790-101-4300
Cylinder
(1,470 kN {150 ton})
t 1
791-675-5520
5
T
9
10
11
12
13
1
Disassembly and assemU
bly of master link
12
Part name
Necessity
Q'ty
New/Remodel
Sketch
SEN01204-04
Disassembly of 1 link
Disassembly of 1 link
Assembly of 1 link
Assembly of 1 link
Assembly of 1 link
Assembly of 1 link
Assembly of 1 link
Assembly of 1 link
Assembly of 1 link
Assembly of 1 link
Expansion of link
D155AX-6
SEN01204-04
Necessity
Q'ty
New/Remodel
Sketch
791-432-1110
t 1
790-701-3000
Seal checker
t 1
791-932-1110
t 1
Work item
Symbol
X 1
1
2
3
Disassembly and assembly of hydraulic cylinder
Y
assembly
D155AX-6
Part No.
Part name
791T-650-2110 Sleeve
t 1
790-201-2770
t 1
Spacer
791T-650-2120 Plate
t 1
792-104-3940
Bolt
t 2
790-101-2510
Block
t 1
790-101-2570
Washer
t 2
01580-01613
Nut
t 1
790-105-2300
Jack assembly
(196 kN {20 ton})
t 1
790-101-1102
Hydraulic pump
t 1
Q
Q
791T-650-2130 Sleeve
t 1
790-101-2420
Adapter
t 1
791-502-4140
Screw
t 1
790-101-2540
Washer
t 2
790-112-1180
Nut
t 2
790-101-4000
t 1
790-101-1102
Hydraulic pump
t 1
793-498-1210
t 2
790-502-1003
t 1
790-101-1102
Hydraulic pump
t 1
790-102-3802
Multi-wrench
t 1
790-201-1702
t 1
790-201-1721
Push tool
790-201-1821
Push tool
Blade lift
790-201-1841
Push tool
Blade tilt
790-201-1851
Push tool
Ripper lift
790-201-1861
Push tool
Ripper tilt
790-101-5021
Grip
01010-50816
Bolt
790-201-1500
790-201-1630
Plate
Blade lift
790-201-1650
Plate
Blade tilt
790-201-1660
Plate
Ripper lift
790-201-1670
Plate
Ripper tilt
790-101-5021
Grip
01010-50816
Bolt
t 1
13
Work item
Symbol
14
Necessity
Q'ty
New/Remodel
Sketch
SEN01204-04
790-720-1000
Expander
t 1
796-720-1670
Ring
t 1
07281-01279
Clamp
t 1
796-720-1690
Ring
t 1
07281-01919
Clamp
t 1
796-720-1720
Ring
t 1
07281-02429
Clamp
t 1
790-102-4300
Wrench
t 1
790-102-4310
Pin
t 2
Part No.
Part name
Blade lift
Blade tilt
Ripper lift
Ripper tilt
Removal and installation of
screw-type piston
D155AX-6
SEN01204-04
1
Note) We will not be liable for any result of use of special tools
manufactured according to the following drawings.
D155AX-6
15
SEN01204-04
Note) We will not be liable for any result of use of special tools
manufactured according to the following drawings.
A5: Push tool
16
D155AX-6
SEN01204-04
Note) We will not be liable for any result of use of special tools
manufactured according to the following drawings.
A9: Push tool
G1: Plate
D155AX-6
17
SEN01204-04
Note) We will not be liable for any result of use of special tools
manufactured according to the following drawings.
G3: Push tool
G4: Plate
18
D155AX-6
SEN01204-04
Note) We will not be liable for any result of use of special tools
manufactured according to the following drawings.
G5: Plate
G6: Plate
D155AX-6
19
SEN01204-04
Note) We will not be liable for any result of use of special tools
manufactured according to the following drawings.
J: Plate
K1: Plate
20
D155AX-6
SEN01204-04
Note) We will not be liable for any result of use of special tools
manufactured according to the following drawings.
K2: Plate
D155AX-6
21
SEN01204-04
Note) We will not be liable for any result of use of special tools
manufactured according to the following drawings.
K5: Plate
K5: Plate
22
D155AX-6
SEN01204-04
Note) We will not be liable for any result of use of special tools
manufactured according to the following drawings.
KK, L14: Bracket
L1: Plate
D155AX-6
23
SEN01204-04
Note) We will not be liable for any result of use of special tools
manufactured according to the following drawings.
L19: Guide
24
D155AX-6
SEN01204-04
Note) We will not be liable for any result of use of special tools
manufactured according to the following drawings.
M2: Spacer
N1: Plate
D155AX-6
25
SEN01204-04
Note) We will not be liable for any result of use of special tools
manufactured according to the following drawings.
N2: Push tool
V: Sleeve
26
D155AX-6
SEN01204-04
Note) We will not be liable for any result of use of special tools
manufactured according to the following drawings.
V: Plate
W: Sleeve
D155AX-6
27
SEN01204-04
D155AX-6 Bulldozer
Form No. SEN01204-04
2009 KOMATSU
All Rights Reserved
Printed in Japan 06-09
28
D155AX-6
SEN01205-05
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine Model
Serial Number
D155AX-6
80001 and up
D155AX-6
SEN01205-05
3.
4.
5.
6.
7.
8.
9.
795-630-5500
A 1
Standard puller
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
t 1
01010-81090
Bolt
01643-31032
Washer
Removal
k
1.
2.
D155AX-6
SEN01205-05
13. Check that the mounting bolt hole (c) at the top
of cover align to the forcing tap of drive gear.
a If they are not aligned, rotate crankshaft
one more turn.
14. Remove nut (29). [*5]
a Take care not to drop into the case.
D155AX-6
SEN01205-05
15. Remove bracket (30), and loosen four mounting bolts (31).
16. Set tool A1 on drive gear (32), and tighten the
center bolt of tool A1 to remove drive gear (32)
from the shaft.
17. Remove mounting bolts (31) and remove fuel
supply pump assembly (33).
a Keep tool A1 set on drive gear (32) until
fuel supply pump assembly is installed, for
the drive gear falls off without the tools.
Installation
1.
2.
D155AX-6
3.
4.
5.
6.
7.
8.
9.
SEN01205-05
[*4]
a Install covers (21) and (22) with the notch in
the following direction.
q
Cover (21): Cylinder block side
q
Cover (22): Underside
[*5]
[*1]
[*2]
[*3]
3
3
D155AX-6
SEN01205-05
5.
6.
7.
8.
9.
Removal
a
This section explains the procedure for removing No.1 fuel injector assembly.
1.
Remove the engine hood referring to the section "Removal and installation of engine hood
assembly".
2.
3.
4.
D155AX-6
SEN01205-05
13. Loosen sleeve nut (26), and remove high pressure pipe (27) from injector.
14. Remove wiring harness clamping bolt (28) and
clip (29). [*6]
15. Remove two wiring harness capture nuts (30)
from fuel injector assembly. [*7]
a Tighten capture nuts alternately.
16. Remove holder mounting bolt (31).
D155AX-6
SEN01205-05
Installation
1.
6)
7)
3)
4)
5)
D155AX-6
2.
D155AX-6
SEN01205-05
3.
[*1]
[*2]
[*3]
[*4]
a Install with the notch downward.
[*5]
a When installing rocker arm and rocker shaft
assembly (22), check the ball portion of adjustment screw (25) to be inserted securely into
socket of push rod (23), and tighten mounting
bolts.
a As 3 mounting bolts are different each other,
install them referring to the followings.
q
Mounting bolt (19): Stem length 120mm
q
Mounting bolt (20): Stem length 90 mm
q
Mounting bolt (21): Stem length 75.2 mm
3 Mounting bolts (19), (20) and (21):
93 103 Nm {9.5 10.5 kgm}
a Adjust valve clearance referring to the section
of Testing and adjusting, "Adjusting valve
clearance".
SEN01205-05
[*6] [*7]
a Install wiring harness according to the following procedure.
1) Install clip (29).
2) Tighten two capture nuts (30).
a Tighten capture nuts alternately.
3 Capture nut:
2 0.2 Nm {0.2 0.02 kgm}
3) Tighten wiring harness clamping bolt (28).
10
D155AX-6
SEN01205-05
790-331-1110
Wrench
Sketch
A 6
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
q 1
Removal
1.
2.
Remove the engine hood referring to the section "Removal and installation of engine hood
assembly".
8.
9.
Remove two joint bolts (10), and remove corrosion resistor head assembly (11). [*2]
3.
Coolant: 82l
4.
5.
6.
Remove fuel tube (5), and remove fuel pre filter head assembly (6).
7.
D155AX-6
11
SEN01205-05
12
D155AX-6
SEN01205-05
26. Remove two, upper and lower side, wiring harness clamps (38) at the rear side of intake
manifold.
D155AX-6
13
SEN01205-05
14
Muffler: 55 kg
Intake manifold: 50 kg
D155AX-6
SEN01205-05
42. Remove oil tube (66) and water tube (67). [*13]
D155AX-6
15
SEN01205-05
16
D155AX-6
D155AX-6
SEN01205-05
5)
6)
17
SEN01205-05
Installation
1.
18
2)
3)
4)
D155AX-6
5)
Mounting bolt
1st time:
137 157 Nm {14 16 kgm}
2nd time:
284 294 Nm {29.0 30.0 kgm}
3rd time: Retighten 90 (+30/0) with
tool A6.
a When tool A6 is not available, put
marks (a) and (b) to bolt and cylinder
head, and retighten bolt 90 (+30/0).
Tighten mounting bolt (106) (tightening
order: 7th) with the following torque.
3 Mounting bolt:
66.6 7.4 Nm {6.8 0.8 kgm}
D155AX-6
SEN01205-05
2.
3.
19
SEN01205-05
4.
[*1] [*2]
3 Joint bolt: 24.5 34.3 Nm {2.5 3.5 kgm}
[*3]
3 Fuel tube sleeve nut:
43 47 Nm {4.4 4.8 kgm}
[*4] [*10]
a When loosened MIKALOR clamp, replace
clamp with new one.
a Install each MIKALOR clamp according to the
following procedure.
1) Set the hose to its original position.
2) Set the bridge (BR) under the bolt (BC)
and reduce lapping area (b) over the band
(BD) to Min. 5 mm.
3) Tighten bolt (BC).
a Do not use an impact wrench.
2 Threaded part of bolt: Lubricating
oil (THREEBOND, PANDO 18B)
q
When reusing the hose, install it to the
clamp mark on it.
3 Bolt (BC):
25 5 Nm {2.55 0.5 kgm}
q
When using a new hose, tighten until
dimension (BDG) is as follows.
a Dimension (BDG): 8 10 mm
[*11]
[*5]
a Adjust the tension of air compressor belt, referring Testing and adjusting section "Testing and
adjusting of air conditioner compressor belt
tension".
[*6]
3
3
20
[*12]
[*13]
D155AX-6
SEN01205-05
[*14]
a Tighten exhaust manifold mounting bolts in the
numerical order shown below.
2 Threads of mounting bolt:
Lubricant with molybdenum disulfide
(LM-P)
3 Mounting bolt: 58.8 73.5 Nm {6 7.5 kgm}
[*16]
[*17]
a Install cover with the notch downward.
[*19]
[*20]
[*21]
a When installing rocker arm and rocker shaft
assembly (87), check the ball portion of adjustment screw (90) to be inserted securely into
socket of push rod (88), and tighten mounting
bolts.
a As three mounting bolts are different each
other, install them referring the followings.
q
Mounting bolt (84): Stem length 120mm
q
Mounting bolt (85): Stem length 90mm
q
Mounting bolt (86): Stem length 75.2 mm
3 Mounting bolt:
93 103 Nm {9.5 10.5 kgm}
a Adjust valve clearance referring to the section
of Testing and adjusting, "Adjusting valve
clearance".
[*25] [*26]
a Install the fuel injector assembly referring to
the section, "Removal and installation of fuel
injector assembly".
q
D155AX-6
Coolant: 82 l
(For details, see "Table of fuel, coolant
and lubricants")
21
SEN01205-05
Removal
k
1.
2.
Coolant: 82l
Remove cover at the top of radiator, and disconnect connector LHD (1).
6.
3.
Cover: 50 kg
4.
5.
22
Radiator assembly: 25 kg
D155AX-6
SEN01205-05
Installation
q
[*1]
a Install hoses (5) and (7) with the red circle
paint upward.
2 Tube flange: gasket sealant
3 Hose clamp: 8.8 0.5 Nm {90 5 kgcm}
a Tighten two parallel clamps for hose (6) with its
bolt location rotated 180 each other.
2 Tube flange: gasket sealant
3 Hose clamp: 8.8 0.5 Nm {90 5 kgcm}
[*2]
a Install radiator mounting brackets (9) (11)
and cushion (19) according to the following
procedure.
1) Set plate (18), cushion (19) and brackets
(9) (11) on the mounting boss of radiator
(12). At this time, fit brackets (9) (11) to
the mounting seat of upper tank (17).
(You may tighten bracket mounting bolts
(22) temporarily.)
2) Install collar (20) upside down (with the
small diameter side up) and tighten
mounting bolt (21).
Compress cushion (19). (L1 o L2)
3) With mounting bolt (21) tightened, tighten
mounting bolts (22) of brackets (9) (11).
4) Once remove mounting bolt (21).
5) Install collar (20) again in the normal (with
the small diameter side down).
6) Tighten mounting bolt (21).
7) Check clearance (L3) (approx. 7 mm).
D155AX-6
23
SEN01205-05
[*3]
a Set radiator assembly according to the following procedure.
1) Set rubber (13) with its stepped portion (a)
downward.
a Apply appropriate amount of grease
to prevent drop down when lifted up.
2) Install O-ring (14).
2 O-ring periphery: Grease (G2-LI)
3)
4)
24
Coolant: 82 l
(For details, see "Table of fuel, coolant
and lubricants")
D155AX-6
SEN01205-05
3.
Open undercover.
4.
5.
6.
7.
Removal
k
1.
2.
Cover: 50 kg
D155AX-6
Aftercooler assembly: 35 kg
25
SEN01205-05
Installation
q
1.
2.
3.
4.
26
Assemble the duct and tube in 30 minutes after applying the gasket sealant.
5.
6.
D155AX-6
7.
SEN01205-05
[*1] [*2]
a When loosened MIKALOR clamp, replace
clamp with new one.
a Install each MIKALOR clamp according to the
following procedure.
1) Set the hose to its original position.
2) Set the bridge (BR) under the bolt (BC)
and reduce lapping area (b) over the band
(BD) to Min. 5 mm.
3) Tighten bolt (BC).
a Do not use an impact wrench.
2 Threaded part of bolt: Lubricating
oil (THREEBOND, PANDO 18B)
q
When reusing the hose, install it to the
clamp mark on it.
3 Bolt (BC):
25 5 Nm {2.55 0.5 kgm}
q
When using a new hose, tighten until
dimension (BDG) is as follows.
a Dimension (BDG): 8 10 mm
D155AX-6
27
SEN01205-05
7.
8.
Removal
1.
2.
Muffler: 50 kg
Coolant: 82l
3.
Remove the engine hood referring to the section "Removal and installation of engine hood
assembly".
4.
5.
6.
9.
Remove radiator assembly referring to the section, "Removal and installation of radiator
assembly".
28
D155AX-6
SEN01205-05
18. Disconnect two hoses each from air conditioner condenser (15) and oil cooler (16), and
remove frame (17).
D155AX-6
29
SEN01205-05
30
D155AX-6
SEN01205-05
Installation
q
[*1]
a When installing the hoses of the air conditioner
circuit, take care that dirt, dust, water, etc. will
not enter them.
a When installing each air conditioner hose,
check that O-ring (70) is fitted to it.
a Check O-ring (70) for a flaw and deterioration.
a When connecting each refrigerant pipe, apply
compressor oil for new refrigerant (R134a)
(DENSO: ND-OIL8 or ZEXEL ZXL100PT
(equivalent to PAG46) to O-ring (70)).
3 Apply engine oil (EO15W-40) to threaded
part and seat of mounting bolt.
3 Threaded part of hose (M16 x 1.5):
12 15 Nm {1.2 1.5 kgm}
3 Threaded part of hose (M22 x 1.5):
20 25 Nm {2.0 2.5 kgm}
3 Threaded part of hose (M24 x 1.5):
30 35 Nm {3.0 3.5 kgm}
[*2] [*3]
a When loosened MIKALOR clamp, replace
clamp with new one.
a Install each MIKALOR clamp according to the
following procedure.
1) Set the hose to its original position.
2) Set the bridge (BR) under the bolt (BC)
and reduce lapping area (b) over the band
(BD) to Min. 5 mm.
3) Tighten bolt (BC).
a Do not use an impact wrench.
2 Threaded part of bolt: Lubricating
oil (THREEBOND, PANDO 18B)
D155AX-6
31
SEN01205-05
[*4]
2
3
[*5]
[*6]
[*7]
32
Coolant: Approx. 82 l
(For details, see "Table of fuel, coolant
and lubricants")
D155AX-6
SEN01205-05
Removal
k
1.
2.
3.
4.
5.
6.
D155AX-6
33
SEN01205-05
7.
Installation
q
[*1]
[*2]
34
D155AX-6
SEN01205-05
a
a
Sketch
Push tool
t 1 R Q
2 01050-31655
Bolt
t 3
01050-31635
Bolt
t 3
Seal puller
t 1
795T-521-1150
Push tool
t 1
01050-31635
Bolt
t 4
795T-521-1111
Part name
New/Remodel
Part No.
Q'ty
Sym
bol
Necessity
Special tools
3 795-931-1100
8
Removal
1.
2.
a
a
3.
Tool A3
D155AX-6
35
SEN01205-05
Installation
a Check the seal by checking the wear of the
shaft and replace it with the "standard seal" or
"sleeved seal".
If the shaft is worn to the degree of luster (If
wear which you feel with your finger is less than
10 mmm) and does not have any flaw, install
"standard seal A". In other cases, install
"sleeved seal B".
a (7): Plastic inside cylinder which is also used as
installation guide.
a (6): Sleeve.
a Do not remove installation guide (7) from front
seal (3) before installing the front seal.
a Handle front seal (3) and sleeve (6) as an
assembly and never separate them from each
other.
Standard spare seal
Sleeved seal
36
D155AX-6
D155AX-6
SEN01205-05
37
SEN01205-05
3.
4.
38
D155AX-6
SEN01205-05
t 1
Push tool
t 1
Bolt
t 4
01643-31645
Washer
t 8
795T-421-1240
Push tool
t 1
Bolt
t 4
01643-31645
Washer
t 4
795T-421-1250
Push tool
t 1
Bolt
t 4
Wrench
t 8
795T-421-1270
4 01050-31645
5 01050-31645
9 01050-31645
01643-31645
Flywheel: 60 kg
Removal
1.
2.
D155AX-6
4.
Sketch
New/Remodel
Q'ty
Seal puller
3 795-931-1100
Part name
Necessity
Part No.
Special tools
Sym
bol
3.
5.
39
SEN01205-05
2)
Installation
a
a
a
a
a
a
a
a
40
D155AX-6
1.
SEN01205-05
2)
3)
D155AX-6
4)
2.
41
SEN01205-05
2)
3.
Flywheel
Using eyebolt [1] (12 mm, P = 1.75), sling flywheel (1), install it to the crankshaft, and
tighten the bolts.
a If there are 5 punch marks on a bolt, do
not use that bolt but replace it.
2 Threads and seat of bolt: Engine oil
(For details, see "Table of fuel, coolant
and lubricants" )
4
3)
4)
42
Flywheel: 65 kg
D155AX-6
D155AX-6
SEN01205-05
a
43
SEN01205-05
6.
7.
Removal
k
1.
2.
3.
4.
8.
5.
Installation
q
44
D155AX-6
SEN01205-05
4.
Removal
5.
6.
7.
1.
2.
3.
Installation
q
D155AX-6
45
SEN01205-05
Installation
q
Removal
1.
[*1]
Be sure to align the hole of lock plate (1) by turning
nut (2) in the tightening direction.
2.
[*2]
3.
4.
5.
46
D155AX-6
D155AX-6
SEN01205-05
47
SEN01205-05
D155AX-6 Bulldozer
Form No. SEN01205-05
2012 KOMATSU
All Rights Reserved
Printed in Japan 02-12
48
D155AX-6
SEN01206-03
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine Model
Serial Number
D155AX-6
80001 and up
D155AX-6
SEN01206-03
Removal
1.
2.
3.
4.
Remove the cooling fan pump assembly referring to the section, "Removal and installation of
cooling fan pump assembly".
5.
6.
7.
8.
9.
D155AX-6
SEN01206-03
Installation
q
[*1]
2
3
Damper assembly: 60 kg
[*2]
a Apply gasket sealant to damper cover, and
tighten mounting bolts 2 to 3 minutes after
application.
3 Damper cover mounting bolt:
98 123 Nm {10.0 12.5 kgm}
[*3]
a Install damper cover assembly according to
the following procedure.
1) Degrease the spline portion (a) of shaft (7),
apply dry lubricant (A), and leave it 2 to 3 minutes.
2) Fill (b) portion of inner body (8) with about 80 g
of lithium base extreme pressure grease with
molybdenum disulphide (B).
A
Kyodo yushi
Molylex No.2 or an
equivalent
Lithium base extreme
Showa Shell Sekiyu
B pressure grease with
Retinax AM or an equivmolybdenum disulphide
alent
Nippon Oil Corporation
Molytex or an equivalent
D155AX-6
SEN01206-03
3)
4)
[*4] [*5]
3 Damper mounting bolt:
98 123 Nm {10.0 12.5 kgm}
q
D155AX-6
SEN01206-03
t 1
791-612-1100
Installer
790-101-4200
Puller
t 1
(294 kN {30 ton})
790-101-1102
Hydraulic pump
D155AX-6
Sketch
Part name
New/Remodel
Part number
Q'ty
Symbol
Necessity
Special tools
t 1
SEN01206-03
Disassembly
2)
Coupling
Remove bolt (3) from cover (2), then remove
holder (4) and coupling (5).
3.
2.
Shaft
1) Set damper cover assembly (1) to block
[1], and remove shaft (6) by tapping it from
output side with plastic hammer, etc.
a Shaft (6) will be pulled out with inner
race (7-1) of bearing (7) and oil seal
(8).
2)
D155AX-6
SEN01206-03
3.
D155AX-6
SEN01206-03
Assembly
Assembly of damper assembly (10)
1.
D155AX-6
2.
SEN01206-03
3.
2.
4.
D155AX-6
SEN01206-03
3.
4.
5.
10
6.
D155AX-6
SEN01206-03
5.
6.
7.
8.
9.
Removal
k
k
1.
2.
3.
4.
D155AX-6
11
SEN01206-03
12
D155AX-6
SEN01206-03
D155AX-6
13
SEN01206-03
Installation
Carry out installation in the reverse order of
removal.
[*1]
[*2]
a Clamp seal of coupling securely at the bulge
portion, and assemble clamp threaded portion
parallel to the cap mounting seat surface.
[*3]
[*4]
[*5]
a When installing power train unit assembly,
install it carefully not to damage seal (28).
Refilling with oil
Fill the oil through oil filler port to the specified
level. Start the engine to circulate the oil
through the piping, and recheck the oil level.
14
D155AX-6
SEN01206-03
5.
6.
Disconnection
1.
2.
3.
4.
D155AX-6
8.
15
SEN01206-03
9.
lubrication
pump
16
D155AX-6
SEN01206-03
D155AX-6
17
SEN01206-03
18
PTOAss'y: 200 kg
D155AX-6
SEN01206-03
Connection
[*2]
[*1]
a Connect the pressure pick up hose to power
train unit referring to the table which indicates
the band color at the mouthpiece of pressure
pick up hose.
Symbol
Band color
Yellow red
Yellow blue
Red
Yellow
black
Red blue
White yellow
White blue
White
Yellow
D155AX-6
[*3]
[*4]
2
3
No color
19
SEN01206-03
D155AX-6 Bulldozer
Form No. SEN01206-03
2012 KOMATSU
All Rights Reserved
Printed in Japan 02-12
20
D155AX-6
SEN01207-03
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine Model
Serial Number
D155AX-6
80001 and up
D155AX-6
SEN01207-03
3)
4)
5)
Disassembly
1.
Lubrication tube
1) Remove shaft lubrication tube (1).
2)
2.
D155AX-6
3.
SEN01207-03
3)
Remove snap ring (14) and remove bearing (15) from cover (12).
6)
4.
4)
5)
D155AX-6
SEN01207-03
3)
Remove snap ring (20) and remove bearing (21) from the case.
1]
2]
5.
6.
2)
3)
D155AX-6
Assembly
a
a
a
1.
2.
SEN01207-03
1)
2)
3)
4)
D155AX-6
SEN01207-03
5)
6)
7)
3)
4.
3.
2)
D155AX-6
2)
3)
SEN01207-03
5)
5.
4)
2)
D155AX-6
SEN01207-03
6.
3)
4)
2)
Lubrication tube
1) Install lubrication tube (2).
3 Joint bolt:
34.3 44.2 Nm {3.5 4.5 kgm}
D155AX-6
SEN01207-03
3.
Disassembly
1.
Input shaft
1) Remove mounting bolts (18 pieces).
Using forcing screw [11], remove input
shaft (1).
2)
2.
2)
3)
D155AX-6
SEN01207-03
4)
4.
5.
10
6.
Turbine gear
Remove turbine gear (15).
Piston
1) Remove piston (10).
2) Remove 2 seal rings (11) from piston (10).
7.
2)
D155AX-6
3)
8.
Pump
1) Remove snap ring (22) and spacer (23).
2) Remove pump assembly (25) from stator
shaft and clutch assembly (24).
SEN01207-03
9.
2)
3)
4)
3)
4)
D155AX-6
11
SEN01207-03
5)
3]
4]
5]
6]
7]
12
D155AX-6
Assembly
a
a
a
1.
SEN01207-03
4)
5)
6)
2)
3)
D155AX-6
13
SEN01207-03
8)
9)
14
D155AX-6
SEN01207-03
2.
Pump
1) Press fit bearing (30) to retainer (27) and
install snap ring (29).
2) Install retainer (27) to pump (28).
2 Mounting bolt (26): Adhesive (LT-2)
3 Mounting bolt (26):
58.8 73.6 Nm {6.0 7.5 kgm}
3)
4)
3.
D155AX-6
Snap ring
Install snap ring (21) to the shaft.
15
SEN01207-03
4.
2)
5.
16
2)
3)
4)
D155AX-6
5)
6)
7)
D155AX-6
SEN01207-03
8)
9)
17
SEN01207-03
6.
Input shaft
1) Install bearing (3) and snap ring (2).
2)
18
D155AX-6
SEN01207-03
2)
Remove the nut of wiring harness connector (2A) and push in the connector.
3)
4)
01010-82040
Bolt
799-301-1600
791T-615-1330 Plate
01282-61230
Bolt
6 791T-615-1340 Plate
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
t 1
1
1
t 1
t 1 N Q
t 1 N Q
t 4
t 2 N Q
t 4
t 1 N Q
Disassembly
a
1.
2.
D155AX-6
19
SEN01207-03
3.
4.
Snap ring
Remove snap ring (123) from output shaft
(124).
a Remove the snap ring at this time.
Transmission case
1) Set the block with the torque converter
side up.
2) Remove sleeve (7).
5.
Tie bolts
Remove 4 remaining tie bolts (9).
6.
2)
3)
20
D155AX-6
3]
4]
5]
6]
7]
8]
D155AX-6
SEN01207-03
7.
8.
9.
Guide pin
Remove guide pins (35).
21
SEN01207-03
1]
2]
3]
3)
22
Disassemble No. 2 housing and No. 2 carrier assembly according to the following
procedure.
D155AX-6
5]
2)
SEN01207-03
4]
D155AX-6
23
SEN01207-03
2)
3)
24
D155AX-6
2]
SEN01207-03
D155AX-6
25
SEN01207-03
2)
3)
Assembly
q
a
a
a
a
1.
26
Output housing
1) Using the push tool, press fit bearing (121)
to spacer (122).
D155AX-6
2)
3)
2.
Cover assembly
1) Using the push tool, press fit bearing (119)
to cover (118).
2) Install seal rings (117) and (116) to cover
(118).
3)
4)
SEN01207-03
3.
No. 5 piston
Install No. 5 piston (112) to the output housing.
4.
5.
Guide pin
Install guide pin (93).
6.
Using the push tool, install cover assembly (114) to output housing assembly
(115).
a Press fit the inner race side of the
bearing to install.
Install snap ring (113).
D155AX-6
27
SEN01207-03
7.
8.
2]
3]
28
2)
9.
D155AX-6
SEN01207-03
8]
2)
Set the No. 3 ring gear to No. 4 carrier and install snap ring (77).
a Check that the snap ring is fitted
to the groove.
2]
3]
4]
5]
6]
7]
D155AX-6
29
SEN01207-03
2)
3]
30
D155AX-6
4]
5]
6]
7]
8]
9]
D155AX-6
SEN01207-03
2)
3)
4)
31
SEN01207-03
3]
Set No. 1 ring gear (23) to No. 1 carrier and install snap ring (22).
4]
5]
6]
7]
8]
32
D155AX-6
9]
2)
Sling input shaft and No. 1 carrier assembly (119) and install it, while meshing the
No. 2 sun gear with No. 2 planetary gear.
D155AX-6
SEN01207-03
2)
33
SEN01207-03
29. Sleeve
Install sleeve (7).
34
Piston
No. 1
7.2
No. 2
No. 3
No. 4
No. 5
D155AX-6
2)
3)
D155AX-6
SEN01207-03
35
SEN01207-03
1
H
2
3
791-662-1110
Bracket
t 1
01010-31685
Bolt
t 1
01017-31620
Bolt
t 1
790-302-1500
Spanner kit
t 1
09003-09200
Spanner
790-302-1500
Spanner kit
t 1
09003-08290
Spanner
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
2)
3)
Remove spacer (6), brake springs (7), piston (8) and cylinder (9).
Disassembly
1.
36
D155AX-6
4)
SEN01207-03
8)
9)
5)
6)
7)
D155AX-6
11) Remove snap ring (31) and remove stopper (32) from hub (18).
37
SEN01207-03
2.
2]
3]
6]
3.
Sun gear
Remove sun gear (45).
a Remove the sun gear on the opposite side
similarly.
4.
Gear
1) Remove snap ring (47) and spacer (48).
2)
4]
5]
38
D155AX-6
SEN01207-03
2)
3)
7.
5.
Valve seat
1) Pull out and remove 2 brake circuit tubes
(51) and 2 lubrication tubes (52).
2) Remove valve seat (53).
3)
6.
D155AX-6
39
SEN01207-03
4)
5)
3)
4)
9.
8.
2)
40
Intermediate gear
1) Remove shaft mounting bolts.
2) Using shock hammer [8], pull out shaft
(76) and remove gear (77) and bearing
(78).
D155AX-6
4)
SEN01207-03
2]
3]
4]
D155AX-6
41
SEN01207-03
5]
6]
Assembly
q
a
a
a
a
a
a
7]
1.
8]
42
D155AX-6
2]
3]
4]
5]
6]
D155AX-6
SEN01207-03
7]
8]
43
SEN01207-03
9]
Adjustment of shim
Tighten the 4 bolts lightly and measure dimensions [a] and [c] to obtain
dimension [b] and then select a shim
of dimension [b].
Shim thickness [b] =
([a] [c]) (0.1 0.2 mm)
10] Set selected shim (94) and tighten
bolts (95).
2)
3)
4)
44
D155AX-6
5)
SEN01207-03
3)
3.
2.
Intermediate gear
1) Install snap ring (83) and spacer (84) to
gear (77). Using the push tool, press fit
outer race (82).
2) Install lower bearing (78), spacer (81) and
upper bearing (78).
3)
D155AX-6
45
SEN01207-03
4.
46
4)
5)
3)
5.
2]
3]
D155AX-6
4]
5]
6.
6]
2)
SEN01207-03
D155AX-6
47
SEN01207-03
2)
2]
Adjustment
If the tooth contact pattern is not proper,
adjust the tooth contact according to the
following procedure.
1) If the bevel pinion is too far from the
center line of the bevel gear, the contact is at the small end of the bevel
gear tooth faces curved outward and
at the large end of the bevel gear
tooth faces curved inward.
q
In this case, adjust the tooth contact
according to the following procedure.
Adjust the thickness of the shims on
the bevel pinion side to move the
bevel pinion in direction (A). Move
the bevel gear in direction (B) and
then check the tooth contact pattern
and backlash again.
2)
48
D155AX-6
3)
SEN01207-03
4)
5)
8.
7.
Valve seat
1) Install lubrication tube (52).
2)
3)
3)
D155AX-6
49
SEN01207-03
9.
Gear
1) Install inside bearing (55), snap ring (54)
and outside bearing (55) to gear (49).
2) Install gear (49), while setting it to the
bevel gear shaft bearing.
3)
4)
Carrier assembly
1] Install bearing (26) to gear (25).
While fitting thrust washers (27) to
both sides of them, set them to the
carrier.
2] Fit ball (28) and install shaft (24).
3] Install snap ring (23).
4] Install sleeve (36) to carrier (35).
50
D155AX-6
5]
6]
7]
8]
5)
6)
D155AX-6
SEN01207-03
7)
8)
9)
Hub
1] Using the push tool, press fit bearing
(17) to hub (9).
51
SEN01207-03
3]
1)
2)
a
a
4]
5]
6]
52
D155AX-6
SEN01207-03
Installation
q
Removal
k
1.
2.
3.
4.
5.
Sling motor assembly (4), remove the 2 mounting bolts, and lift off the motor assembly.
4
D155AX-6
Motor assembly: 75 kg
53
SEN01207-03
D155AX-6 Bulldozer
Form No. SEN01207-03
2012 KOMATSU
All Rights Reserved
Printed in Japan 02-12
54
D155AX-6
SEN02707-01
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine Model
Serial Number
D155AX-6
80001 and up
D155AX-6
SEN02707-01
3.
Raising of machine
k 1)
Using a jack (686 kN {70 ton}) and
the ripper of the work equipment,
raise the machine and set right and
left support stands [1] under the
steering case.
2) Set right and left support stands [2]
under the main frame on the front
side of the machine.
a After setting support stands [1] and [2], set
the hydraulic jack and ripper as auxiliary
supports.
4.
790-337-1032
Lifting tool
t 1
791-627-1320
Shackle
t 2
791T-627-1910 Plate
01010-82080
Bolt
t 1
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
t 2
Removal
1.
2.
D155AX-6
5.
SEN02707-01
8.
9.
6.
Installation
q
[*1], [*2]
3 Final drive mounting bolt:
1,150 1,440 Nm {118 147 kgm}
7.
D155AX-6
SEN02707-01
Disassembly
1.
790-431-1031
Block
t 1
791-520-4140
Screw
t 2
790-101-2360
Plate
t 2
791-112-1180
Nut
t 2
790-101-2480
Adapter
t 2
791T-627-1920 Plate
t 1
790-101-2102
Puller
t 1
790-101-1102
Hydraulic pump
t 1
790-431-1031
Block
t 1
791-520-4140
Screw
t 1
791-112-1180
Nut
t 2
01643-32460
Washer
t 2
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
Draining oil
Remove the drain plug to drain the oil in the
final drive case.
Final drive case: Approx. 31 l
2.
Drive shaft
Remove drive shaft (1).
3.
Shaft
1) Set the final drive assembly to the block.
2) Remove mounting bolts (2).
791T-627-1930 Plate
t 1
t 1
790-101-2102
Puller
t 1
790-101-1102
Hydraulic pump
t 1
791-627-1280
Installer
t 1
790-101-5401
t 1
790-101-5441
Plate
790-101-5421
Grip
01010-51240
Bolt
1
t 1
790-101-5401
790-101-5451
Plate
790-101-5421
Grip
01010-51240
Bolt
791T-627-1950 Plate
t 1
791T-627-1960 Plate
t 1
790-201-1500
t 1
790-201-1680
Plate
790-101-5021
Grip
01010-50816
Bolt
791-520-4140
Screw
t 1
790-101-2420
Adapter
t 1
791-112-1180
Nut
t 1
01643-22460
Washer
t 1
792-785-1120
Plate
t 1
791-830-1410
Push tool
t 1
790-101-2102
Puller
t 1
790-101-1102
Hydraulic pump
t 1
D155AX-6
3)
4.
SEN02707-01
4)
5)
2)
3)
D155AX-6
5.
Wear guard
Remove wear guard (12).
SEN02707-01
6.
Cover assembly
1) Remove spacer (13).
2) Remove floating seal (14).
a Keep the floating seal in a safe place
so that it will not be damaged.
3) Remove mounting bolts (15).
6)
7)
7.
4)
Carrier assembly
1) Using 3 eyebolts [5], remove carrier
assembly (21).
2)
5)
D155AX-6
8.
3]
Remove planetary gear (25), bearings (26) and (27) and spacer (28)
from the carrier.
4]
SEN02707-01
9.
Holder
Remove mounting bolt (33) and holder (34).
10. Gear
1) Remove the gear according to the following procedure.
1] Sling case-hub-case assembly (35) a
little.
2] Push the shaft of case (36) to make a
clearance between bearing (37) and
case shaft.
a Take care not to damage the
bearing holding area on the pinion side.
Sun gear
Remove thrust washer (31) and sun gear (32).
3]
4]
D155AX-6
SEN02707-01
2)
3)
4)
5)
D155AX-6
2)
3)
SEN02707-01
D155AX-6
SEN02707-01
Assembly
a
a
1.
2.
Gear assembly
1) Using the push tool [11], press fit bearings
(52) and (53) to gear (54).
q
Bearing press fitting force:
6 17 kN {0.6 1.7 ton}
2) Install the drive shaft cover.
3) Install gear assembly (51).
3.
Cage assembly
1) Using tool K4, press fit oil seal (49) to
cage (47).
a When press fitting the oil seal, take
care of its direction.
a Apply gasket sealant thinly to the
inside wall of the housing and wipe off
projected part.
2 Oil seal lip: Grease (G2-LI)
2 Oil seal press fitting area:
Gasket sealant (LG-5)
2)
10
D155AX-6
2)
3)
4)
Adjustment of shim
q
Adjust the pinion bearing clearance
according to the following procedure.
1] Tighten mounting bolts (D), (E), (G)
and (H) of cage (40) evenly.
3 Mounting bolt: 20 Nm {2 kgm}
2] Using a thickness gauge, measure
clearances (a) and (b) between cage
(47) and case (36).
3] Referring to Table 1, determine quantity (c) of the shim from the total of
clearances (a) and (b).
D155AX-6
SEN02707-01
4]
11
SEN02707-01
Table 1
4.
Number of shims
to be used
a + b (mm)
Above
Below
t = 0.15
3.05
3.15
3.15
3.25
3.25
3.35
3.35
3.45
3.45
3.55
3.55
3.65
3.65
3.75
3.75
3.85
3.85
3.95
3.95
4.05
4.05
4.15
4.15
4.25
4.25
4.35
4.35
4.45
4.45
4.55
4.55
4.65
4.65
4.75
4.75
4.85
4.85
4.95
4.95
5.05
5.05
5.15
5.15
5.25
5.25
5.35
5.35
5.45
5.45
5.55
5.55
5.65
5.65
5.75
5.75
5.85
5.85
5.95
5.95
6.05
6.05
6.15
3.25
6.15
6.25
3.30
6.25
6.35
3.35
6.35
6.45
3.40
6.45
6.55
3.45
6.55
6.65
3.50
6.65
6.75
6.75
6.85
6.85
6.95
6.95
7.05
7.05
7.15
7.15
7.25
7.25
7.35
12
t = 0.5
t = 1.0
Total
shim
thickness
(mm)
1.75
1.80
1.85
1.90
1.95
2.00
2.05
2.10
2.15
2.20
2.25
2.30
2.35
1
1
1
2.40
2.45
2.50
2.55
2.60
2.65
2.70
2.75
2.80
2.85
2.90
2.95
3.00
3.05
3.10
3.15
3.20
1
1
1
3.55
3.60
3.65
3.70
3.75
3.80
3.85
2)
3)
D155AX-6
5.
SEN02707-01
4)
2)
5)
3)
Gear
1) Using eyebolts [6], sling gear (39). While
slanting the hub, set the gear to the hub.
D155AX-6
6.
Holder
Install holder (34) and tighten mounting bolt
(33).
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
230 289 Nm {23.5 29.5 kgm}
13
SEN02707-01
7.
Sun gear
Install sun gear (32) and thrust washer (31).
8.
Carrier assembly
a Since each planetary gear bearing is an
assembly, assemble it from the inner race,
outer race and spacer of the same identification mark.
1) Using tool K6, press fit bearing outer
races (29) and (30) to the planetary gear.
q
Bearing press fitting force:
10 35 kN {1.0 3.6 ton}
2)
14
3)
4)
5)
D155AX-6
9.
Cover assembly
1) Install ring gear (20) and 6 lock plates (19)
and tighten the mounting bolts.
2 Mounting bolt: Adhesive (LT-2)
2)
3)
4)
SEN02707-01
5)
6)
D155AX-6
15
SEN02707-01
2)
16
3)
4)
D155AX-6
5)
SEN02707-01
2)
a
12. Shaft
1) Fit the O-ring to the sprocket hub assembly. Using eyebolts [1], install shaft (3).
5
3
3
D155AX-6
17
SEN02707-01
D155AX-6 Bulldozer
Form No. SEN02707-01
2007 KOMATSU
All Rights Reserved
Printed in Japan 10-07 (02)
18
D155AX-6
SEN01208-02
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine Model
Serial Number
D155AX-6
80001 and up
D155AX-6
SEN01208-02
D155AX-6
SEN01208-02
2)
791T-130-1010 Bracket
KK
3)
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
t 6 N Q
01010-63060
Bolt
t 12
01643-33080
Washer
t 12
Removal
1.
2.
3.
4.
D155AX-6
5.
6.
7.
8.
SEN01208-02
9.
Guard (6): 25 kg
11. Disconnect hoses (8), (9), (10) and (11) connected in cover (7) pulled out and then remove
cover (7).
D155AX-6
Installation
q
[*1]
SEN01208-02
[*4]
a Install seal (17) according to the following procedure.
1) Reverse seal (17) so that the molded letter (c) face will be on the inside.
2) With the seal reversed, insert seal (17) in
pivot shaft (18).
3) Apply engine oil (For details, see "Table of
fuel, coolant and lubricants") to face (d) of
track frame assembly (16).
4) Install track frame assembly (16) to the
pivot shaft (18).
[*3]
a When inserting the track frame assembly, take
care extremely not to damage the seal surface.
D155AX-6
SEN01208-02
7.
Removal
1.
2.
3.
Installation
q
[*1]
a Set the idler assembly to the center of the track
frame and adjust clearance (a) between the
track frame and guide plate with the shims.
q
Standard clearance (a): 0.5 1.0 mm
q
Standard shim thickness: 6 mm
4.
5.
6.
D155AX-6
SEN01208-02
791T-630-1230 Plate
t 1
791-630-1220
Rod
t 2
790-101-2510
Block
t 1
790-101-2570
Washer
t 2
01580-01411
Nut
t 2
01643-31445
Washer
t 2
790-101-2102
Puller
t 1
(294 kN {30 ton})
790-101-1102
Hydraulic pump
t 1
796-670-1020
Installer
t 1
791-601-1000
Oil pump
t 1
1
L
7.
8.
9.
Sketch
New/Remodel
Q'ty
Part name
Necessity
Part No.
Special tools
Symbol
6.
Disassembly
1.
2.
3.
4.
5.
D155AX-6
SEN01208-02
Assembly
a
1.
2.
Using tool L2, install floating seal (12) to retainers (5) and (9).
a Dimension (b) of projection of the seal
shown in the figure (A) must be 7 11
mm.
a After inserting the seal, check that its tilt is
1 mm or less.
a Before inserting the seal, thoroughly
clean, degrease and dry the parts indicated with the thick lines in figure (B) (the
O-ring and the O-ring contact surface).
3.
D155AX-6
4.
5.
SEN01208-02
6.
7.
8.
9.
D155AX-6
SEN01208-02
11. Using the push tool, press fit ring (6) to dimension (d).
a Ring press fitting dimension (d):
80 0.2 mm
a Before installing the ring, apply engine oil
(For details, see "Table of fuel, coolant
and lubricants") thinly to the mating face of
the floating seal.
13. Using tool L3, add oil to the specified level and
tighten the plug.
5
3
10
D155AX-6
SEN01208-02
Installation
q
Removal
1.
2.
D155AX-6
11
SEN01208-02
3)
791-685-8006
Compressor
791-635-3160
Extension
M 2 791T-630-2610 Spacer
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
t 1
t 1
t 1
790-101-1300
Cylinder
t 1
790-101-1102
Hydraulic pump
t 1
Disassembly
1.
2.
12
3.
D155AX-6
4.
5.
Disassembly of holder
1) Remove cover (15) from holder (14).
2) Remove seal (16) and bushing (17) from
holder (14).
SEN01208-02
7.
8.
9.
6.
D155AX-6
13
SEN01208-02
1)
2)
3)
4)
14
Assembly
1.
2.
3.
Temporarily install recoil spring (20) and cylinder (10) to recoil spring case (12) and set them
to tool M2.
2 Inside of case and parts in case:
Grease (Apply G2-LI to minimum
thickness of 3 mm)
k Set the spring securely since its installed
load is heavy and dangerous.
a Installed load of spring:
314 kN {32,000 kg}
a When compressing the spring, align it by
using lever block [2] etc. so that the
threaded part will not be damaged.
a Installed length of spring: 656 mm
D155AX-6
4.
5.
SEN01208-02
6.
7.
Assembly of holder
1) Using the push tool, press fit bushing (17)
to holder (14) and install seal (16).
2 Bushing and oil seal:
Grease (G2-LI)
2) Install cover (15) to holder (14).
8.
D155AX-6
15
SEN01208-02
9.
2)
3)
16
D155AX-6
SEN01208-02
791T-130-1010 Bracket
KK
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
t 6 N Q
01010-63060
Bolt
t 12
01643-33080
Washer
t 12
Removal
1.
2.
3.
4.
5.
6.
Track roller
assembly to be
removed
Related bogie
No. 1 roller
Note 1
No. 2 bogie
No. 2 roller
No. 2 bogie
No. 1 bogie
No. 3 roller
No. 2 bogie
No. 3 bogie
No. 4 roller
No. 3 bogie
No. 2 bogie
No. 5 roller
No. 3 bogie
No. 4 bogie
No. 6 roller
No. 4 bogie
No. 3 bogie
No. 7 roller
No. 4 bogie
D155AX-6
17
SEN01208-02
7.
Installation
q
[*1], [*2]
Install the track roller assembly according to the following procedure.
1. Set the track roller assembly on the track shoe.
a Direct the oil filler of the track roller
assembly out of the machine.
8.
2.
3.
[*3]
Installation composition of track roller assembly
S: Track roller assembly (single flange)
D: Track roller assembly (double flange)
a Install the track roller assembly with the oil filler
plug directed out.
18
D155AX-6
SEN01208-02
7.
8.
9.
Sketch
New/Remodel
Q'ty
Part name
Necessity
Part No.
Special tools
Symbol
6.
1 791T-630-1290 Plate
t 1
t 1
791-651-1510
Installer
t 2
791-601-1000
Oil pump
t 1
Disassembly
1.
2.
3.
4.
5.
D155AX-6
19
SEN01208-02
Assembly
a
1.
2.
3.
4.
20
5.
6.
D155AX-6
7.
8.
9.
SEN01208-02
D155AX-6
21
SEN01208-02
791T-130-1010 Bracket
14
22
23
t 2 N Q
01010-63060
Bolt
t 4
01643-33080
Washer
t 4
790-401-1700
Lifting tool
t 1
790-401-1761
Adapter
t 1
791-630-1860
Bracket
t 1
791-630-1870
Bracket
t 1
790-101-2310
Block
t 1
790-101-2360
Plate
t 2
Screw
t 2
Nut
t 2
790-445-4130
15 791-112-1180
790-101-4000
Puller
t 1
(490 kN {50 ton})
790-101-1102
Pump
t 1
790-201-2760
Spacer
t 1
791-630-1370
Adapter
t 1
790-434-1060
Screw
t 2
01580-13024
Nut
t 2
01643-33080
Washer
t 1
790-101-4000
Puller
t 1
(490 kN {50 ton})
790-101-1102
Pump
t 1
17 796-430-1110
Push tool
t 1
18 790-701-3000
Seal checker
t 1
16
19 791T-630-1390 Guide
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
t 1
4.
5.
6.
Removal
1.
2.
3.
22
D155AX-6
7.
8.
SEN01208-02
3)
9.
D155AX-6
23
SEN01208-02
4)
5)
6)
7)
Installation
1.
2)
24
Bogie assembly: 60 kg
D155AX-6
SEN01208-02
6)
3)
4)
5)
2.
3.
D155AX-6
25
SEN01208-02
4.
5.
6.
7.
8.
26
D155AX-6
9.
SEN01208-02
10. Align the dowel pin hole and tighten bolts (16).
2 Roller cap mounting bolt:
Adhesive (LT-2)
3 Roller cap mounting bolt:
662 829 Nm {67.5 84.5 kgm}
D155AX-6
27
SEN01208-02
2.
791T-130-1010 Bracket
Bolt
t 4
01643-33080
Washer
t 4
791-630-1360
Spacer
t 1
790-101-2310
Block
t 1
790-101-2360
Plate
t 2
790-445-4130
Screw
t 2
791-112-1180
Nut
t 2
790-101-4000
Puller
t 1
(490 kN {50 ton})
790-101-1102
Pump
t 1
790-201-2760
Spacer
t 1
791-630-1370
Adapter
t 1
790-434-1060
Screw
t 2
01580-13024
Nut
t 2
01643-33080
Washer
t 1
790-101-4000
Puller
t 1
(490 kN {50 ton})
790-101-1102
Pump
t 1
17 796-430-1110
Push tool
t 1
18 790-701-3000
Seal checker
t 1
15
t 2 N Q
01010-63060
14
16
19 791T-630-1390 Guide
20
t 1
790-101-2310
Block
t 1
790-445-4130
Screw
t 2
796T-470-1130 Plate
t 1
790-101-2360
Plate
t 2
790-112-1180
Nut
t 2
790-101-4000
Puller
t 1
(490 kN {50 ton})
790-101-1102
Pump
t 1
Oil pump
t 1
21 791-601-1000
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
3.
4.
5.
6.
7.
Removal
1.
28
D155AX-6
8.
SEN01208-02
3)
4)
5)
6)
7)
9.
D155AX-6
29
SEN01208-02
Installation
1.
2)
30
D155AX-6
3)
4)
D155AX-6
SEN01208-02
5)
2.
3.
4.
31
SEN01208-02
5.
6.
4)
5)
2)
3)
32
7.
8.
D155AX-6
SEN01208-02
9.
D155AX-6
33
SEN01208-02
20
790-101-2310
Block
790-445-4130
Screw
790-101-2360
Plate
t 2
791-112-1180
Nut
t 2
790-101-4000
Puller
t 1
(490 kN {50 ton})
790-101-1102
Pump
t 1
Oil pump
t 1
34
4.
Bogies
Disconnect inner bogie (5) and outer bogie (6).
Sketch
Q
t 2
t 1
Disassembly
1.
3.
t 1
796T-470-1130 Plate
21 791-601-1000
New/Remodel
Q'ty
Part name
Necessity
Part No.
Cover
Remove cover (3).
Special tools
Symbol
2.
D155AX-6
Assembly
1.
SEN01208-02
4.
2.
Bogies
Set outer bogie (6) and inner bogie (5).
3.
2)
D155AX-6
5.
6.
Cover
Install covers (3).
a Install the covers to 2 places of inside and
outside.
35
SEN01208-02
7.
2)
36
D155AX-6
SEN01208-02
4.
Removal
1.
Carrier roller: 45 kg
Installation
q
2.
3.
[*1]
When installing the carrier roller to the support,
make clearance (a) shown in the figure.
q
Clearance (a): 1.2 mm
2 Support mounting bolt: Adhesive (LT-2)
q
D155AX-6
37
SEN01208-02
5.
6.
7.
8.
9.
790-102-1891
Nut wrench
791-651-1510
Installer
t 1
t 1
3 791T-630-1350 Spacer
t 1
t 1
791-601-1000
Oil pump
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
Disassembly
1.
2.
3.
4.
38
D155AX-6
D155AX-6
SEN01208-02
Assembly
a
1.
2.
3.
4.
39
SEN01208-02
5.
6.
9.
10. Fit the O-ring and install ring (8) while setting it
to the dowel pin.
a
8.
40
Before installing the floating seal, thoroughly clean, degrease and dry the O-ring
and O-ring contact surface (hatched
areas).
After inserting the floating seal, check that
its tilt is 1 mm or less and projection (a) of
the seal is 7 11 mm.
Coat the sliding surfaces of the floating
seal and take care that dirt will not stick to
them.
D155AX-6
SEN01208-02
D155AX-6
41
SEN01208-02
791T-650-2110 Sleeve
Spacer
t 1
Sketch
New/Remodel
Q'ty
Part name
Necessity
Part No.
790-201-2770
Special tools
Symbol
3.
t 1
791T-650-2120 Plate
t 1
792-104-3940
Bolt
t 2
790-101-2510
Block
t 1
790-101-2570
Washer
t 2
01580-01613
Nut
t 1
790-105-2300
Jack assembly
t 1
(196 kN {20 ton})
790-101-1102
Hydraulic pump
t 1
Removal
1.
2.
42
D155AX-6
SEN01208-02
Installation
q
[*1]
a Install seal (1) according to the following procedure.
1) Reverse seal (1) so that the molded letter
(a) face will be on the inside.
2) With seal (1) reversed, insert it in pivot
shaft (3).
[*2]
D155AX-6
43
SEN01208-02
1.
1.
2.
2.
3.
44
D155AX-6
3.
4.
D155AX-6
SEN01208-02
1.
2.
3.
4.
5.
45
SEN01208-02
Installation
q
[*1]
a Adjust the track shoe tension. For details, see
Testing and adjusting, "Testing and adjusting
track shoe tension".
[*2]
a Tighten the shoe mounting bolts for the master
link in the following order.
2 Shoe mounting bolt:
Molybdenum disulfide grease (LM-P)
3 Shoe mounting bolt:
1st time: 590 60 Nm {60 6 kgm}
2nd time: Retighten by 180 10
a Tighten all the 4 bolts with fingers until the
master link mating faces are fitted.
a If the bolts are tightened forcibly before the
master link mating faces are fitted, their
threads and master link may be damaged.
46
D155AX-6
SEN01208-02
a
Remover and
installer
791-101-4300
Cylinder
t 1
(196 kN {20 ton})
791-101-4200
Puller
t 1
(294 kN {30 ton})
791-101-1102
Hydraulic pump
t 1
791-932-1110
t 1
791-660-7460
Pin brush
t 1
Sketch
New/Remodel
Part name
791-675-9701
Part No.
Q'ty
Symbol
Necessity
Special tools
t 1
791-432-1110
t 1
791-632-1052
Installer
t 1
790-701-3000
Seal checker
t 1
791-601-1000
Oil pump
t 1
General disassembly
1.
Removal of shoe
Sling the shoe assembly and set it with the
shoe up on the floor and remove the shoe by
using a shoe bolt impact wrench.
a If a shoe bolt is not loosened after it is
unscrewed by 1 turn (If its torque is not
reduced to 0), loosen the other bolts first,
and it will be removed smoothly.
a If a shoe bolt is turned forcibly while its
torque is not 0, it and link will adhere to
each other and they will need to be
repaired.
a When moving the shoe assembly, take
care not to damage the master link.
D155AX-6
2.
Disassembly of link
1) Set the link assembly on a link press and
hit it with a hammer so that the bushing
will be fitted to the jaw.
a If the link tread, outside of the bushing, etc. are worn, adjust the height of
jaw [1] or guide plate and align disassembly jigs [2] and [3] with the pin
and bushing so that the link hole will
not be damaged during disassembly
work.
a If the disassembly jigs are not aligned
well, the link hole may be damaged
and the pin and bushing may be broken during disassembly work.
47
SEN01208-02
a
2)
3)
48
4)
3.
Inspection
Check the parts for the following items to see if
they can be used for an oil lubricated track or a
grease lubricated track, then examine them
generally and determine to use them for an oil
lubricated track or a grease lubricated track.
a For judgment of reuse of the parts, see
"Parts judgment guide, Undercarriage, Oil
lubricated track".
1) Check the parts visually for damage. If a
part seems to be damaged, check it by
dye penetrant test or magnaflux inspection. If it has any crack, it cannot be used
again. Discard it.
D155AX-6
2)
D155AX-6
SEN01208-02
General assembly
a
2)
When reusing the pin, chamfer its end corners smoothly with a grinder. Remove the
nodules sticking to the press fitting parts
with the grinder, too.
a If the ends are worn and sharpened,
they may scuff the press fitting parts
and cause oil leakage.
49
SEN01208-02
3)
4)
1]
2]
3]
50
Insert plug (3) through the plug insertion window into the guide hole.
Push the bar with the hand and insert
the plug until it stops.
Push the plug with the bar to press
the guide against pin (4).
a Driving distance (a) from pin end:
10 1 mm
a If the chamfered part of the pin
hole has been worn, chamfer it
with a small-sized grinder (grindstone tip angle: 45 60) so that
the plug will not be damaged.
a Coat the plug with oil (GO90) and
drive it with the small diameter
end ahead.
5)
6)
D155AX-6
7)
2.
SEN01208-02
Assembly of link
1) Apply oil (GO90) to the mating surfaces of
the pin and bushing with a clean brush
and assemble them, and then set them
before the jaw of the link press.
a When reusing (reversing) the bushing, set the worn outside surface of
the bushing on the shoe fitting side of
the link (set the bushing with the worn
outside surface up on the link press).
3)
4)
5)
2)
D155AX-6
51
SEN01208-02
6)
9)
7)
8)
52
D155AX-6
D155AX-6
SEN01208-02
13) Using a shoe bolt hole pitch gauge, measure the distance between the shoe bolt
holes and check that the result is within
the standard range.
a If the distance between the shoe bolt
holes is longer than the standard
range, disassemble and check for
abnormality, then press fit again.
a If the distance between the shoe bolt
holes is shorter than the standard
range and the shoe cannot be
installed, the spacer or bushing end
may be worn more than repair limit.
In this case, disassemble and replace
the parts.
53
SEN01208-02
54
3.
Installation of shoe
1) Set the link assembly on the bed and
install the shoe with a shoe bolt impact
wrench and a torque wrench.
a When reusing (reversing) the bushing, set the worn outside face of the
bushing to the shoe mounting side of
the link (set the bushing with the worn
outside surface up on the link press).
2 Shoe bolt:
Molybdenum disulfide grease
(LM-P)
3 Shoe bolt (Regular link)
Initial torque:
590 60 Nm {60 6 kgm}
Retightening angle: 120 10
D155AX-6
2)
3)
4)
5)
SEN01208-02
2)
D155AX-6
When reusing the pin, chamfer its end corners carefully with a grinder so that it will
be press fitted smoothly.
55
SEN01208-02
3)
4)
5)
56
6)
7)
D155AX-6
2.
Assembly of link
1) Apply lithium grease (G2-LI) to the mating
surfaces of the pin and bushing and
assemble them, then set them before the
jaw of the link press.
a When reusing (reversing) the bushing, set the worn outside surface of
the bushing on the shoe fitting side of
the link (set the bushing with the worn
outside surface up on the link press).
SEN01208-02
3)
4)
5)
2)
D155AX-6
57
SEN01208-02
6)
3.
7)
58
8)
Using a shoe bolt hole pitch gauge, measure the distance between the shoe bolt
holes. When the distance is in the standard range, stop press fitting.
9)
Installation of shoe
1) Set the link assembly on the bed and
install the shoe with a impact wrench and
a torque wrench.
a When reusing (reversing) the bushing, set the worn outside surface of
the bushing on the shoe fitting side of
the link (set the bushing with the worn
outside surface up on the link press).
2 Shoe bolt:
Molybdenum disulfide grease
(LM-P)
3 Shoe bolt (Regular link):
Initial torque:
590 60 Nm {60 6 kgm}
Retightening angle: 120 10
D155AX-6
2)
3)
4)
5)
SEN01208-02
D155AX-6
59
SEN01208-02
Adjustment
Adjust the dimensions of the press fitting jig of the
link press to keep the projection of the pin and
bushing constant and keep the installed dimensions of the seal within the standard range.
a If the pin end (part P) or the sides of the link
(parts Q and R) are worn, add the dimensions
of the worn parts when adjusting the standard
dimensions so that the projections of the pins
and bushings on the right and left sides will be
even.
Unit: mm
Precaution
1. The link receiving faces of jaw (5) must be vertical.
2. Wear plate (6) should be replaceable.
Dimensions of jig
60
4.5
3.25
50.6
D155AX-6
SEN01208-02
791-675-5580
Guide
t 1
t 1
791-685-9510
Frame
t 1
t 2
791-685-9520
Frame
t 1
Bolt
t 2
791-685-9530
Rod
t 1
790-101-1102
Pump
t 1
791-685-9540
Rod
t 1
790-101-4300
Cylinder
t 1
(1,470 kN {150 ton})
791-685-9550
Nut
t 3
Bolt
t 4
791-685-9510
Frame
t 1
791-685-9560
Adapter
t 1
Frame
t 1
791-126-0150
791-685-9520
Bolt
t 1
Rod
t 1
01010-51030
791-685-9530
Extension
t 1
Nut
t 1
791-685-9620
791-685-9550
Adapter
t 1
791-685-9560
Bolt
t 1
791-675-5542
Guide
t 1
Adapter
t 1
791-675-5560
791-675-9570
Pump
t 1
Eyebolt
t 1
790-101-1102
04530-12030
790-101-1102
Pump
t 1
790-101-4300
Cylinder
t 1
(1,470 kN {150 ton})
790-101-4300
Cylinder
t 1
(1,470 kN {150 ton})
791-675-5560
Guide
t 1
791-675-5542
Adapter
Rod
t 1
t 1
791-685-9540
790-101-1102
Pump
Nut
t 3
t 1
791-685-9550
791-675-5520
Guide
t 1
790-101-4200
Puller
(294 kN {30 ton})
t 1
791-675-5530
Pusher
t 1
12 791-670-3270
Guide
t 1
791-675-9581
Adapter
t 1
791-675-9590
Guide
01010-52460
Bolt
01010-51440
10
11
01010-51030
Bolt
t 1
791-126-0150
Adapter
t 1
791-685-9620
Extension
t 1
791-675-5560
Guide
t 1
790-101-1102
Pump
t 1
791-675-9570
Adapter
t 1
790-101-4200
Puller
(294 kN {30 ton})
t 1
01010-51030
Bolt
t 1
791-675-5542
Adapter
t 1
791-675-5571
Adapter
t 1
790-101-1102
Pump
t 1
790-101-4300
Cylinder
t 1
(1,470 kN {150 ton})
D155AX-6
13
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
61
SEN01208-02
2.
62
3.
4.
5.
D155AX-6
2)
2.
SEN01208-02
3.
4.
5.
D155AX-6
63
SEN01208-02
6.
7.
64
D155AX-6
SEN01208-02
2.
790-101-1102
Pump
t 1
790-101-4200
Puller
(294 kN {30 ton})
t 1
791-675-9701
Remover and
installer
t 1
790-101-1102
Pump
t 1
790-101-4200
Puller
(294 kN {30 ton})
t 1
790-101-4300
Cylinder
t 1
(1,470 kN {150 ton})
791-432-1110
t 1
790-701-3000
Seal checker
t 1
791-932-1110
t 1
U 2
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
Disassembly
a
1.
D155AX-6
2)
65
SEN01208-02
Assembly
a
1.
2.
66
2)
3)
4)
169 0.7
L2
219.8 0.7
D1
27 drill hole
D2
24 x 2.0
D155AX-6
5)
6)
SEN01208-02
2)
3)
4.
3.
D155AX-6
67
SEN01208-02
791T-650-2130 Sleeve
t 1
790-101-2420
Adapter
t 1
791-502-4140
Screw
t 1
790-101-2540
Washer
t 2
790-112-1180
Nut
t 2
790-101-4000
Puller
t 1
(294 kN {50 ton})
790-101-1102
Hydraulic pump
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
t 1
5.
7.
Removal
1.
2.
3.
4.
68
D155AX-6
8.
SEN01208-02
Installation
q
[*1]
2
3
[*2]
9.
Do not lower the machine after removing the equalizer bar assembly.
D155AX-6
69
SEN01208-02
Assembly
1.
Center bushing
Using the press, press fit center bushing (5) to
equalizer bar (4).
a Press fitting force for center bushing:
47.1 131.4 kN {4.8 13.4 ton}
2 Periphery of spherical bushing:
Molybdenum disulfide grease (LM-P)
2.
Side bushing
1) Install ring (2) to one side of equalizer bar
(4).
2) Using the press, press fit spherical bushing (3) to equalizer bar (4).
a Press fitting force for spherical bushing: 27.4 64.7 kN {2.8 6.6 ton}
2 Periphery of spherical bushing:
Molybdenum disulfide grease
(LM-P)
Disassembly
1.
2.
Side bushing
1) Remove seal (1).
2) Remove ring (2).
3)
3.
70
Center bushing
Remove center bushing (5) from equalizer bar
(4).
D155AX-6
3)
4)
SEN01208-02
D155AX-6
71
SEN01208-02
Installation
Removal
1.
Stop the machine in a position where the segment teeth can be removed easily (between
the shoe and track frame).
2.
72
[*1]
a When installing, press segment teeth (1)
toward the center of sprocket hub (2) and
tighten the nuts in the order of [1] o [2] o [3].
2 Threaded part of segment teeth mounting
nut: Adhesive (LT-2)
3 Segment teeth mounting nut:
1,176 98 Nm {120 10 kgm}
D155AX-6
D155AX-6
SEN01208-02
73
SEN01208-02
D155AX-6 Bulldozer
Form No. SEN01208-02
2009 KOMATSU
All Rights Reserved
Printed in Japan 06-09
74
D155AX-6
SEN01209-02
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine Model
Serial Number
D155AX-6
80001 and up
D155AX-6
SEN01209-02
Removal
k
1.
3.
4.
6.
7.
8.
9.
2.
5.
D155AX-6
SEN01209-02
Installation
q
Hydraulic oil (For details of specification, see "Table of fuel, coolant and
lubricants"): Approx. 91.5 l
Bleeding air
Bleed air from each part. For details, see Testing and adjusting, "Bleeding air from each
part".
D155AX-6
SEN01209-02
3)
4)
5)
6)
7)
Removal
k
1.
2.
8)
D155AX-6
9)
SEN01209-02
D155AX-6
SEN01209-02
3)
4)
5)
Installation
q
q
q
Bleeding air
Bleed air from each part. For details, see Testing and adjusting, "Bleeding air from each
part".
D155AX-6
SEN01209-02
Disassembly
1.
2.
1
2
Y
4
790-502-1003
Cylinder repair
stand
t 1
790-101-1102
Hydraulic pump
t 1
790-102-3802
Multi-wrench
t 1
790-201-1702
t 1
790-201-1721
Push tool
790-201-1821
Push tool
790-201-1841
Push tool
790-201-1851
Push tool
790-201-1861
Push tool
790-101-5021
Grip
01010-50816
Bolt
790-201-1500
790-201-1630
Plate
790-201-1650
Plate
790-201-1660
Plate
790-201-1670
Plate
790-101-5021
Grip
01010-50816
Bolt
790-720-1000
Expander
t 1
796-720-1670
Ring
t 1
t 1
07281-01279
Clamp
t 1
796-720-1690
Ring
t 1
07281-01919
Clamp
t 1
796-720-1720
Ring
t 1
07281-02429
Clamp
t 1
790-102-4300
Wrench
t 1
790-102-4310
Pin
t 2
D155AX-6
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
SEN01209-02
3.
Piston assembly
q
Blade lift cylinder
1) Remove the mounting bolts and
spacer (6) and pull out valve (7).
2) Pull out piston assembly (8).
3) Remove backup rings (9) and O-ring
(10).
4) Remove retainer (11).
4)
5)
D155AX-6
2)
SEN01209-02
4.
a
Head assembly
1) Remove head assembly (2) or (4).
2)
3)
Using tool Y6, remove piston assembly (17) from piston rod (23).
4)
D155AX-6
SEN01209-02
Assembly
a
1.
Head assembly
1) Assembly of head assembly
1]
3]
4]
5]
6]
7]
8]
2]
10
D155AX-6
2)
2.
SEN01209-02
2)
3)
Piston assembly
q
Ripper lift cylinder and ripper tilt cylinder
1) Assembly of piston assembly
1] Using tool Y5, expand piston ring
(26).
a Set the piston ring to tool Y5
and turn the handle of the
tool by 8 10 turns to
expand the piston ring.
2] Remove piston ring (26) from
tool Y5 and install it to the piston.
3] Using tool Y5, compress piston
ring (26).
4]
5]
D155AX-6
11
SEN01209-02
2]
4]
4)
12
D155AX-6
2)
3)
SEN01209-02
5)
3.
2)
3)
4)
D155AX-6
13
SEN01209-02
14
D155AX-6
D155AX-6
SEN01209-02
15
SEN01209-02
D155AX-6 Bulldozer
Form No. SEN01209-02
2012 KOMATSU
All Rights Reserved
Printed in Japan 02-12
16
D155AX-6
SEN01210-01
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine Model
Serial Number
D155AX-6
80001 and up
D155AX-6
SEN01210-01
1.
2.
3.
4.
5.
6.
D155AX-6
SEN01210-01
Installation
q
[*1]
a Adjust clearance (a) at the cap mating surfaces to the following range with the shim and
check that the cylinder turns smoothly.
q
Standard clearance (a): 0.2 0.5 mm
q
Standard shim thickness: 4 mm
a After installing the blade, adjust the blade tilting
distance. For details, see Testing and adjusting, "Adjusting blade".
q
[*2]
a Adjust height (b) and width (c) of the right and
left straight frames to the following values with
blocks [1] etc.
q
Height (b) of trunnion: Approx. 636 mm
q
Width (c) of frame: Approx. 3,053 mm
D155AX-6
SEN01210-01
Disassembly
a
1.
Run the engine and set the ripper in the maximum raising and maximum tilt-in position.
2.
3.
4.
Shank: 270 kg
5.
6.
D155AX-6
7.
8.
SEN01210-01
Assembly
1.
Arm: 650 kg
Set block [2] under the arm.
2.
9.
Beam: 1,250 kg
Set support stands [1] under the beam.
Beam: 1,250 kg
10. Sling arm (12), remove the lock plates, pull out
right and left pins (13), and lift off arm (12).
4
D155AX-6
Arm: 650 kg
SEN01210-01
3.
7.
8.
Run the engine and set the ripper in the maximum raising and maximum tilt-in position.
9.
a
4.
5.
6.
Shank: 270 kg
D155AX-6
SEN01210-01
10. Greasing
After assembling, supply sufficient amount of
grease to each pin.
2 Pin: Grease (G2-LI)
q
D155AX-6
SEN01210-01
D155AX-6 Bulldozer
Form No. SEN01210-01
2007 KOMATSU
All Rights Reserved
Printed in Japan 10-07 (02)
D155AX-6
SEN01211-02
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine Model
Serial Number
D155AX-6
80001 and up
D155AX-6
SEN01211-02
6.
7.
8.
Removal
k
1.
Remove cigarette lighter cover (1) and disconnect wiring harness connector ACC.
2.
3.
4.
5.
D155AX-6
9.
SEN01211-02
Installation
q
[*1]
a Connect the window washer hoses according
to their band colors.
Window washer hoses
Red ................... Right door
Blue................... Left door
Black ................. Rear window
No color band ... Front window
[*2]
a Before installing, check that seal rubber parts
(brown, 2 pieces) are installed to the connector
and they are not broken.
3 Connector mounting bolt:
2.83 0.28 Nm {0.288 0.028 kgm}
[*3], [*4]
1) Tighten bolts (1) (23) in the numeric order
shown in the attached drawing.
2)
D155AX-6
SEN01211-02
Among the panes of window glass of the operator's cab, the 3 panes of (1) and (3) on both
sides are stuck. In this section, the procedure
for replacing the stuck glass is explained.
D155AX-6
SEN01211-02
793-498-1210
Lifter
(Suction cup)
X 1
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
t 2
Removal
*
1.
a
a
D155AX-6
2.
SEN01211-02
Installation
1.
2.
3.
D155AX-6
4.
Install each trim seal (4) so that its finishing end and starting end will be jointed at
position (c) and dimension (b) between
the corner and position (c) will be 90 mm.
D155AX-6
SEN01211-02
5.
3)
SEN01211-02
6.
1)
2)
3)
Apply adhesive.
2
a
a
a
a
a
Adhesive:Sikaflex 256HV
manufactured by Sika Japan
Do not use primer.
The using limit of the adhesive is 6 months
after the date of manufacture. Do not use
the adhesive after this limit.
Keep the adhesive in a dark place where
the temperature is below 25C.
Never heat the adhesive higher than
30C.
When reusing the adhesive, remove the
all hardened part from the nozzle tip.
D155AX-6
4)
SEN01211-02
a
a
a
5)
Apply adhesive (13) to the outside of bothsided adhesive tape (3) of the operator's
cab.
7.
D155AX-6
SEN01211-02
3)
4)
Mask front window glass (1) and operator's cab (7) with masking tapes [8].
Fill the clearance between front window
glass (1) and operator's cab (7) with caulking material (14) all around the window.
2 Caulking material:
SEKISUI SILICONE SEALANT
a The usable period of the following
caulking material is 6 months after the
date of manufacture. Do not use the
caulking material after its usable
period.
8.
5)
10
D155AX-6
SEN01211-02
9.
3)
Fill the clearance between each door window glass and trim in the range of dimension (k).
i) Mask the range of dimension (k) of
each door window glass.
ii) Fill clearance (m) between each door
window glass (2) and trim seal (4)
with caulking material.
a The usable period of the following
caulking material is 6 months after the
date of manufacture. Do not use the
caulking material after its usable
period.
a Apply the caulking material to joint (c)
of the trim seal, too.
2 Caulking material:
SEKISUI SILICONE SEALANT
D155AX-6
11
SEN01211-02
2)
Immediately after sticking both door window glasses, install door handles (5), and
lock the doors to fix the glasses.
12
D155AX-6
SEN01211-02
5.
6.
7.
8.
Removal
k
k
a
a
k
1.
2.
3.
4.
D155AX-6
Cover: 75 kg
13
SEN01211-02
9.
17. Sling pin (20), tighten the bolt to pull out pin
(21), and lift off pin (20).
18. Remove the pin on the other side at the rear
and the 2 pins at the front according to steps
16 and 17.
14
D155AX-6
SEN01211-02
Installation
q
[*1], [*3]
a When installing the hoses of the air conditioner
circuit, take care that dirt, dust, water, etc. will
not enter them.
a When installing each air conditioner hose,
check that O-ring (70) is fitted to it.
a Check O-ring (70) for a flaw and deterioration.
a When connecting each refrigerant pipe, apply
compressor oil for new refrigerant (R134a)
(DENSO: ND-OIL8 or ZEXEL ZXL100PT
(equivalent to PAG46) to O-ring (70)).
3 Apply engine oil (EO15W-40) to threaded
part and seat of mounting bolt.
3 Threaded part of hose (M16 x 1.5):
12 15 Nm {1.2 1.5 kgm}
3 Threaded part of hose (M22 x 1.5):
20 25 Nm {2.0 2.5 kgm}
3 Threaded part of hose (M24 x 1.5):
30 35 Nm {3.0 3.5 kgm}
[*2], [*4]
a Before installing, check that seal rubber parts
(brown, 2 pieces) are installed to the connector
and they are not broken.
3 Connector mounting bolt:
2.83 0.28 Nm {0.288 0.028 kgm}
[*5], [*6]
3 Floor frame mounting bolts (19) and (20):
824 1,030 Nm {84 105 kgm}
D155AX-6
15
SEN01211-02
5.
6.
7.
8.
Remove the 4 mounting bolts of work equipment controller assembly (7) and disconnect
the assembly.
Removal
1.
2.
3.
4.
16
D155AX-6
9.
SEN01211-02
Installation
q
[*1], [*2]
a When installing the hoses of the air conditioner
circuit, take care that dirt, dust, water, etc. will
not enter them.
a When installing each air conditioner hose,
check that O-ring (70) is fitted to it.
a Check O-ring (70) for a flaw and deterioration.
a When connecting each refrigerant pipe, apply
compressor oil for new refrigerant (R134a)
(DENSO: ND-OIL8 or ZEXEL ZXL100PT
(equivalent to PAG46) to O-ring (70)).
3 Apply engine oil (EO15W-40) to threaded
part and seat of mounting bolt.
3 Threaded part of hose (M16 x 1.5):
12 15 Nm {1.2 1.5 kgm}
3 Threaded part of hose (M22 x 1.5):
20 25 Nm {2.0 2.5 kgm}
3 Threaded part of hose (M24 x 1.5):
30 35 Nm {3.0 3.5 kgm}
D155AX-6
17
SEN01211-02
D155AX-6 Bulldozer
Form No. SEN01211-02
2009 KOMATSU
All Rights Reserved
Printed in Japan 06-09
18
D155AX-6
SEN02708-01
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine Model
Serial Number
D155AX-6
80001 and up
D155AX-6
SEN02708-01
Installation
Removal
k
1.
2.
3.
4.
[*1]
D155AX-6
SEN02708-01
Removal
Removal
1.
1.
2.
2.
3.
3.
Remove 4 mounting bolts (4) and work equipment controller assembly (5).
Installation
q
[*1]
Installation
q
[*1]
D155AX-6
SEN02708-01
D155AX-6 Bulldozer
Form No. SEN02708-01
2007 KOMATSU
All Rights Reserved
Printed in Japan 10-07 (02)
D155AX-6
SEN04683-01
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine Model
Serial Number
D155AX-6
80001 and up
80 Air conditioner
D155AX-6
SEN04683-01
80 Air conditioner
D155AX-6
80 Air conditioner
SEN04683-01
1.
2.
3.
4.
5.
6.
7.
8.
9.
Condenser
Hot water return piping
Hot water piping
Front window defroster
Side window defroster
Air outlet for face
Air outlet for center
Air outlet for rear
Air conditioner unit
10.
11.
12.
13.
14.
15.
16.
A.
B.
Specifications
D155AX-6
Refrigerant
R134a
1200 50
SEN04683-01
80 Air conditioner
Component
Compressor
Condenser
Expansion valve
Evaporator
Engine compartment
Front of radiator
In operators cab
(In air conditioner unit)
In operators cab
(In air conditioner unit)
Item
Location
Function
Circulates refrigerant
gas and increases its
temperature and
pressure so that it can
be liquefied easily in
condenser.
Gas o Gas
Adiabatic compression
Gas o Liquid
Constant pressure
change
Evaporates refrigerant
to absorb heat from (or
cool) air around
evaporator.
(Evaporation of refrigerant)
Liquid and gas o Gas
Constant pressure
change
D155AX-6
80 Air conditioner
SEN04683-01
3.
Receiver drier
The refrigerant liquefied in the condenser is
reserved in the receiver drier temporarily so
that it can be supplied to the evaporator
according to the cooling load. A strainer and a
drying agent are sealed in the receiver drier to
remove dirt and water in the refrigerating
cycle.
If any water is in the refrigerating cycle, it is frozen in the small hole of the expansion valve
and retards the flow of the refrigerant.
It can cause a cooling trouble.
4.
2.
Compression (Compressor)
The refrigerant gas is compressed by the compressor to the state where it can be liquefied
easily at the normal temperature (ambient temperature).
The refrigerant evaporated in the evaporator is
sucked into the compressor.
This action is performed to keep the refrigerant
pressure in the evaporator low so that the
refrigerant liquid can continue evaporation
actively even if the ambient temperature is
close to 0C.
The refrigerant gas sucked into the compressor is compressed in the cylinder and its pressure and temperature are so changed that is
can be liquefied easily when it is cooled with
the external air at the normal temperature.
Condensation (Condenser)
The refrigerant gas in the condenser is cooled
to be liquefied with the external air.
The refrigerant gas of high temperature and
high pressure discharged from the compressor
is cooled to be liquefied with the external air
and then stored in the receiver drier.
The heat discharged from the refrigerant of
high temperature and high pressure discharged from the compressor is called the condensation heat, which is the total of the heat
that the refrigerant absorbed from the
operators cab through the evaporator (vaporization heat) and the work performed to compress the refrigerant (the value converted into
heat).
During condensation, the refrigerant gas and
refrigerant liquid are mixed together in the condenser. While the refrigerant gas changes to
the refrigerant liquid, the relationship between
the pressure (condensation pressure) and
temperature (condensation temperature) is
kept constant.
Reference: The pressure varies with the type
of refrigerant and the condensation temperature.
D155AX-6
SEN04683-01
5.
80 Air conditioner
Evaporation (Evaporator)
The refrigerant changes from liquid to gas
(superheated vapor) in the evaporator.
The refrigerant mist in the evaporator evaporates actively.
At this time, the refrigerant evaporates quickly,
absorbing heat necessary for evaporation
(latent heat of vaporization) from the air around
the cooling fins (air in the operators cab). The
cooled air is spread in the operators cab by
the fan to lower the tem per atur e in t he
operators cab.
The refrigerant mist sent through the expansion
valve and the evaporated refrigerant are mixed
together in the evaporator. While the refrigerant
liquid changes to the refrigerant gas, the relationship between the pressure (evaporation
pressure) and temperature (evaporation temperature) is kept constant. If the pressure is set,
the temperature is decided automatically.
That is, the relationship between the above
pressure and temperature is equal to the relationship between saturation pressure and saturation temperature.
To evaporate the refrigerant at lower temperature, the pressure in the evaporator must be
kept lower.
Accordingly, the evaporated refrigerant is
sucked into the compressor.
The refrigerant circulates in the refrigerating
cycle, repeating the above four actions, to
move the heat from the operators cab where
the temperature is low to the outside where the
temperature is high.
If the amount of the refrigerant is insufficient,
all of the refrigerant is evaporated while it is
passing through the evaporator and the evaporator capacity decreases. It can cause a cooling trouble.
To the contrary, if the amount of the refrigerant
is too much, a part of it is not evaporated in the
evaporator and is absorbed in the compressor.
As a result, the compressor compresses the
liquid and may be broken.
D155AX-6
80 Air conditioner
D155AX-6
SEN04683-01
SEN04683-01
80 Air conditioner
Outline
q
The air conditioner unit consists of the evaporator, heater core and fan (blower) and generates cool air and hot air.
q
Temperature control
The machine monitor sends temperature setting data to the control amplifier (See Control
plate) according to the temperature control
switch operation.
The control amplifier controls the air mix servomotor to adjust the angle of the cool door, hot
door and sub hot door for temperature control.
D155AX-6
80 Air conditioner
Evaporator
Evaporator fins are cooled by low-pressure,
low-temperature refrigerant gas being sent
from the expansion valve. Air from the blower
motor is cooled and dehumidified when passing through the fins.
Heater core
Fins of the heater core are heated by the hot
water (cooling water) being sent from the
engine. Air from the blower motor is heated as
it passes through the fins.
Expansion valve
This valve converts high-pressure, high-temperature liquid refrigerant coming from the
receiver to low-pressure, low-temperature
misty refrigerant through the throttling function.
It controls the flow rate of the refrigerant by
changing the level of throttling depending on
the thermal load (temperature) in the operator's cab. As a result, temperature of the air
blown out of the grill is adjusted depending on
the volume of refrigerant circulated in evaporator.
1) Structure
The box-type expansion valve consists of
the diaphragm, thermosensing rod, needle
valve (ball), spring, etc. The outside of diaphragm (hatched part) is pre-enclosed
with refrigerant gas.
The spring is installed on the needle valve
(ball) side of the thermosensing rod. The
needle valve opening ratio is decided
when the constant force of the spring to
push the ball to the right is balanced with
the force (Fg) of the refrigerant gas to
push the thermosensing rod to the left
through the diaphragm. As a result, the
refrigerant flow rate to the evaporator is
decided and the temperature is controlled.
D155AX-6
SEN04683-01
2)
Operation
The thermosensing rod senses the temperature of the refrigerant which passed
the evaporator. The temperature at this
time is conducted through the thermosensing rod to the refrigerant gas in the
diaphragm chamber (hatched part). As the
pre-enclosed refrigerant gas temperature
changes, the gas pressure changes and
pressing force (Fg) also changes. The
thermosensing rod attached directly to the
diaphragm so moves that the constant
force of the spring to push the ball will be
balanced with variable force (Fg) to adjust
the needle valve opening ratio.
A: When the evaporator outlet temperature is high (at start of cooling (air is
not cooled yet))
The gas pressure in the diaphragm
chamber increases and the gas volume increases.
Pushing force (Fg) of the refrigerant
gas increases and the thermosensing
rod (ball) moves to the left and the
needle valve op ens wide . Mu ch
refrigerant is supplied to the evaporator and the cooling capacity
increases.
B.
SEN04683-01
Servomotor
This servomotor is used for temperature control (AIR MIX) and blowing out (MODE).
1.
10
80 Air conditioner
2.
3.
D155AX-6
80 Air conditioner
Control plate
1.
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D155AX-6
11
SEN04683-01
80 Air conditioner
Symbol
Symbol
17
CAN (+)
CAN communication +
Input/
Output
CAN communication
Input/
Output
Signal name
A/M P
POT 5V
18
CAN ()
PRESS
SW
19
R/F A
Output
+24 V
Input
20
R/F B
Output
Input
21
A/M A
Output
Output
22
A/M B
8
9
Power supply
10
11
THI
12
THEVA
13
14
15
SS
16
GND
Input
and
output
Pin
No.
Input
and
output
Input
Input
Input
Output
24
Output
25
Input
26
Input
27
GND S
28
29
Sunlight sensor
Input
30
GND
Input
31
Sensor GND
Input
32
33
34
35
CCRL
12
Output
23
Output
Output
D155AX-6
80 Air conditioner
SEN04683-01
Compressor
Function
q
Other than circulating the refrigerant, compressor compresses the refrigerant gas from the
evaporator to a high-pressure, high-temperature misty refrigerant so that it may be easily
regenerated (liquefied) at normal temperature.
q
The magnetic clutch in the compressor is
engaged depending on the evaporator temperature and refrigerant pressure.
If the magnetic clutch is engaged, the shaft in
the compressor rotates to operate the compressor.
Specifications
D155AX-6
157.3
6,000
Denso: ND-OIL8
(For R134a)
180
13
SEN04683-01
80 Air conditioner
Condenser
1.
Condenser
Specifications
Fin pitch (mm)
4.0
357 540 16
3.6 {36}
14
D155AX-6
80 Air conditioner
SEN04683-01
Receiver drier
1.
2.
Receiver drier
(Dual) pressure switch
A:
B:
Specifications
Weight of desiccating agent (g)
D155AX-6
370
15
SEN04683-01
16
80 Air conditioner
D155AX-6
80 Air conditioner
SEN04683-01
a
a
k
D155AX-6
17
SEN04683-01
80 Air conditioner
The air conditioner has a self-diagnosis function for inspecting the main component parts. With this function,
you can inspect the operation of sensors and servomotors in the system.
If a troubled section is detected, every part of that section must be inspected.
Troubleshooting procedure
1.
2.
3.
After basic check, find the troubled section according to the detected trouble of the air conditioner.
Find the troubled section with the self-diagnosis function (See Inspection with self-diagnosis).
If the air conditioner unit does not operate at all, check that the power supplied to the control amplifier is
normal and that CAN communication between machine monitor and the control amplifier is normal.
If any part of the air conditioner unit operates, the power supply and CAN communication do not need to
be checked.
After finding out the troubled section, inspect the component parts in that section and repair the troubled
part.
Basic check
operate?
Troubleshooting with
troubleshooting chart 1
Inspection with
troubleshooting chart 2
*1: By error display or abnormal display on Abnormality Record screen on machine monitor.
*2: If refrigerant leaks, recirculating compressor oil in the air conditioner circuit always leaks, too.
*3: Start engine and then air conditioner switch ON.
18
D155AX-6
80 Air conditioner
Block diagram
a
SEN04683-01
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19
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20
80 Air conditioner
D155AX-6
80 Air conditioner
a
a
SEN04683-01
INSIDE TEMP. SENSOR means Inner sensor on Abnormality Record screen: 03 Air-conditioning
System.
BLOWING OUT (MODE) SERVOMOTOR means BLOWING OUT (MODE) CHANGEOVER SERVOMOTOR.
D155AX-6
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80 Air conditioner
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80 Air conditioner
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23
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1.
2.
24
80 Air conditioner
3.
4.
There are a circuit breaker and a fuse. The circuit breaker is in the battery cover on the left
side of the machine and the fuse is wound onto
the wiring harness between the air conditioner
unit and control amplifier.
The air conditioner unit is at the rear of the
operator seat.
Open the battery cover on the left side of the
machine. (See the fuse locations in Troubleshooting Volume.)
q
Circuit breaker CB3 (5th from left) (20 A):
For power supply for air conditioner compressor and air conditioner unit (for all
devices related to air conditioner)
a If the reset button (RB) of the circuit
breaker is projected, the circuit is turned
OFF. In this case, push in the reset button
(RB). If it is kept pushed in, the circuit is
normal. If it is soon projected again, the
circuit may have a ground fault etc. (See
E-1.)
D155AX-6
80 Air conditioner
SEN04683-01
5.
6.
7.
D155AX-6
25
SEN04683-01
q
q
q
q
q
q
q
26
80 Air conditioner
D155AX-6
80 Air conditioner
8.
9.
SEN04683-01
q
q
q
Pressure switch
Open engine left cover (6) and remove covers
(7) (9).
D155AX-6
27
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80 Air conditioner
28
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3)
4)
D155AX-6
SEN04683-01
5)
6)
29
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7)
2)
3)
30
80 Air conditioner
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80 Air conditioner
2.
SEN04683-01
3.
4.
5.
D155AX-6
31
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6.
32
80 Air conditioner
For air leakage through the defroster blowingout route of C2 and C3, check each duct joint
for air leakage in the defroster mode at the
maximum air flow.
a When air does not come out of only C2
(Air comes out of C1 and C3)
1) Remove duct (6).
2) Check to see if air comes out of (P) in
the defroster mode at the maximum
air flow.
3) If no air comes out of (P), inspect duct
(7).
4) If air comes out of (P), remove dashboard (8), referring to Part and connector locations, Item 11.
5) Inspect duct (9).
D155AX-6
80 Air conditioner
SEN04683-01
Outline
On the air conditioner operation screen of the
machine monitor, the system performs self-diagnosis for the communication with the air conditioner
unit, temperature control, vent (mode) changeover
and refrigerant pressure with the pressure switch. If
any of these items has trouble, A/C Controller
error is displayed red to notify the trouble.
a A/C Controller error display for the refrigerant pressure switch is turned OFF will be
abolished in the future.
1.
2.
3.
Press [F6] (
) to confirm.
D155AX-6
33
SEN04683-01
80 Air conditioner
4.
5.
Press [F6] (
34
) to confirm.
Caution
Inner Sensor means inside temperature sensor on
block diagram or circuit diagram.
Ventilating Sensor is abnormal means that evaporator temperature sensor is short circuit or disconnected.
Sunlight Sensor is abnormal means that Sunlight
Sensor is short circuit only.
Ventilation is abnormal means servomotor for
blowing out changeover (mode) damper does not
rotate judging from the servomotor potentiometer
voltage.
a Damper is the same as door.
Air Mix is abnormal means servomotor
for Air Mix (temperature adjustment)
damper does not rotate judging from the
servomotor potentiometer voltage.
Refrigerant means refrigerant pressure
from (dual) pressure switch. Namely,
refrigerant is abnormal means that
(dual) pressure switch of refrigerant is
OFF.
1.
2.
Setting abnormal
The software of the air conditioner amplifier
does not match that of the monitor. Check the
part numbers of those components.
D155AX-6
80 Air conditioner
3.
4.
5.
SEN04683-01
6.
Ventilation is abnormal
Servomotor for blowing out changeover
(mode) damper does not rotate judging from
the servomotor potentiometer voltage.
a Damper is the same as door.
a Trouble: Blowing out is not changed.
a Action of control amplifier:
The control amplifier stops outputting to
the servomotor for blowing out changeover (mode).
a Even if the link is disconnected and the
damper does not rotate, the self-diagnosis
system judges the damper normal since
the servomotor potentiometer voltage
changes normally.
(For mechanical troubles, see Testing
vent (mode) changeover.
7.
8.
Refrigerant is abnormal
(Dual) pressure switch signal for refrigerant is
abnormal. Namely pressure switch for refrigerant is OFF.
a Trouble: The air conditioner does not
work.
a Action of control amplifier:
The control amplifier stops outputting to
the compressor.
k
D155AX-6
35
SEN04683-01
80 Air conditioner
2.
3.
4.
Outline
q
Temperature is controlled by mixing ratio of the
hot air from the heater and cooled air from the
evaporator by changing the angles of the four
doors (dampers) in the air mix section. The
angle of each door (damper) is set changed by
the air mix servomotor through plate (P1),
lever 1 (L1) lever 6 (L6) and rod (RODAM).
Only rod (RODAM), lever 5 (L5) and lever 6
(L6) are seen from outside. (For the figure, see
item 5.)
a
1.
36
D155AX-6
80 Air conditioner
5.
6.
7.
3)
SEN04683-01
a
D155AX-6
37
SEN04683-01
38
80 Air conditioner
5)
6)
7)
a
8)
9)
D155AX-6
80 Air conditioner
SEN04683-01
2.
3.
4.
5.
Press the vent selector switch on the air conditioner screen of the monitor and check visually
that lever 7 (L7) and lever 8 (L8) move
smoothly between the foot mode and defroster
mode shown in the figure.
6.
7.
8.
D155AX-6
39
SEN04683-01
80 Air conditioner
9.
10. Press the vent selector switch on the air conditioner screen of the monitor and check the
opening and closing operations of the front
face door and rear face door (damper).
3)
4)
40
D155AX-6
80 Air conditioner
5)
D155AX-6
SEN04683-01
a
41
SEN04683-01
80 Air conditioner
Testing Recirc/Fresh
changeover
Outline
Recirculated air or fresh air is selected by changing
the door (damper) angle in the air conditioner unit
with the servomotor. Check the opening and closing operations of the door (damper) visually.
a The system does not have self-diagnosis function for the Recirc/Fresh changeover servomotor.
1.
2.
3.
4.
42
80 Air conditioner
Reference
q
How to remove fresh air duct.
1. Remove duct (4).
D155AX-6
SEN04683-01
43
SEN04683-01
80 Air conditioner
8.
Inner Sensor is the same as inside temperature sensor on block diagram or circuit
diagram.
If Inner Sensor abnormal is displayed by the
self-diagnosis (Abnormality Record screen
on machine monitor: 03 Air-conditioning
System), test the inner sensor.
To reset the self-diagnosis system (detection of
abnormality), the starting switch must be
turned OFF.
Check that the resistance between female connector [8] (2) (PB) (on the wiring harness side)
and connector [1] (11) (PB) (on the wiring harness side) is 1 z or below. (If not, the wiring
harness is defective.)
9.
Check that the resistance between female connector [8] (1) (BrR) (on the wiring harness side)
and connector [2] (27) (BrR) (on the wiring harness side) is 1 z or below. (If not, the wiring
harness is defective.)
1.
2.
3.
4.
5.
6.
7.
44
D155AX-6
80 Air conditioner
SEN04683-01
6.
7.
1.
2.
3.
4.
8.
5.
D155AX-6
45
SEN04683-01
a
If the evaporator temperature sensor is defective, replace it according to the following procedure.
1.
2.
3.
4.
5.
6.
46
80 Air conditioner
D155AX-6
80 Air conditioner
7.
8.
SEN04683-01
Installation
1.
2.
D155AX-6
47
SEN04683-01
1.
2.
48
80 Air conditioner
3.
4.
5.
6.
Check that the resistance between female connector SLS (2) (L) (on the wiring harness side)
and connector [1] (3) (YW) (on the wiring harness side) is 1 z or below. (If not, the wiring
harness is defective.)
a If the result of item 6 or item 7 is abnormal,
check the contact of connector CN-AC01.
(See Part and connector locations.)
7.
Check that the resistance between female connector SLS (1) (O) (on the wiring harness side)
and connector [1] (15) (RB) (on the wiring harness side) is 1 z or below. (If not, the wiring
harness is defective.)
8.
9.
Turn the starting switch ON and carry out selfdiagnosis (on the air conditioner fault history
screen of the machine monitor). If Sunlight
Sensor abnormal is still displayed, replace the
control amplifier.
Disconnect SLS connector and measure voltage between male terminals on sunlight sensor (S) at voltage range of tester because the
sensor (S) may be broken by measurement of
resistance at resistance range of tester.
q
Approximate voltage of sunlight sensor
unit
0.55 (V): direct sunlight
0.45 (V): cloudy
0.4 (V): in room
D155AX-6
80 Air conditioner
1.
SEN04683-01
3.
2.
D155AX-6
49
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50
80 Air conditioner
3)
4)
5)
6)
D155AX-6
80 Air conditioner
SEN04683-01
1.
2.
3.
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D155AX-6
80 Air conditioner
Troubleshooting chart 1
SEN04683-01
a
a
1.
The numbers in the boxes are the item numbers in the troubleshooting table.
E-2, E-3 means Troubleshooting for electrical system (E mode).
Cooling trouble
2.
Heating trouble
D155AX-6
53
SEN04683-01
80 Air conditioner
Troubleshooting chart 2
1.
Blower fan motor does not revolve or its speed is different from set value.
a See troubleshooting "E-3 Blower motor system (No air comes out or air flow is abnormal)" for troubleshooting for the electrical system.
Possible cause
Check method
Remedy
Replace
Disconnection of wire or defective Check connector of blower fan motor for disconnec- Repair broken parts and conconnection
nect correctly
tion. See E-3 and Part and connector locations
Defective blower motor
Replace
2.
Replace
Check method
Remedy
Repair
Air leakage
Repair or replace
Repair or replace
(Evaporator temperature sensor and expansion valve are in
air conditioner unit)
Check method
Remedy
3.
Low/high pressure
Possible cause
Insufficient refrigerant
54
D155AX-6
80 Air conditioner
4.
SEN04683-01
Troubled part
Possible cause
Magnet clutch
Check method
Remedy
Repair or replace
Slip of clutch
Charge battery
Replace
Disconnection in wiring or defective Check ground wire and connecconnection of ground wire
tions
Repair
Relay
Replace
Refrigerant
pressure
Low/high pressure
(Operation of pressure switch)
Replace
Diode
Replace
5.
Check method
Remedy
Repair
Check duct joints for defective duct seal and disconnection of duct
Repair
Repair
6.
Check method
Remedy
Add coolant
7.
Repair
D155AX-6
Check method
See "Checking and adjusting air conditioner compressor belt tension" in chapter 30 "Testing and
adjusting" of shop manual.
Remedy
Repair
55
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8.
80 Air conditioner
Other items
Possible cause
Check method
See "Testing temperature control" and "Troubleshooting for electrical system, E-4"
See "Testing vent (mode) changeover" and "Troubleshooting for electrical system, E-5"
See "Testing Recirc/Fresh changeover" and "Troubleshooting for electrical system, E-6"
Remark
Cooling only
56
D155AX-6
80 Air conditioner
SEN04683-01
The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before troubleshooting, understand the information fully.
Trouble
Related
information
Causes
Possible causes
and standard
value in normal
state
<Described contents>
Standard (value) required for judgement (Normal state value)
1 Assumed causes for trouble Remarks required for judgement
(The order number indicates
a serial number, not a priority <Notes on troubleshooting>
sequence. Perform trouble- (1) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus () leads
shooting according to these
as shown below unless otherwise specified.
2 numbers, however.)
Connect the plus (+) lead to pin or harness indicated in the
front.
Connect the minus () lead to a pin or harness indicated in
the rear.
(2) Example of troubleshooting by inspection of multiple items
3 - defective
a Normal in 1 but abnormal in 2
At this time - defective shown at left is applied
D155AX-6
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80 Air conditioner
Air conditioner does not operate due to power supply system failure.
A/C Controller Error is displayed red on air conditioner screen of machine monitor.
No air blows out (Blower motor does not rotate).
If failure code [DAFRMC] is displayed on machine monitor, see Chapter 40 Troubleshooting first and
repair so that [DAFRMC] will not be displayed.
a CAN communication is connected to machine monitor, engine controller, pump controller and air
conditioner controller.
Related
information
A/C Controller Error is displayed on air conditioner operation screen of machine monitor in following cases. In E-1, 1), 2) and 3) of following cases are explained.
1) Power is not supplied to control amplifier.
2) Control amplifier is broken.
3) Control amplifier (CNTAMP) cannot communicate with machine monitor.
4) Blowing out door (damper) servomotor does not rotate.
5) Temperature control (AIRMIX) door (damper) servomotor does not rotate.
6) Refrigerant pressure is abnormal.
Referring to Testing with self-diagnosis function, display Abnormality Record screen on
machine monitor: 03 Air-conditioning System and check to see if CAN Status is abnormal.
Abnormality of CAN Status indicates that control amplifier at rear of air conditioner unit cannot
communicate with machine monitor.
CAN Status is indicated as abnormal in any case of 1), 2) and 3) above.
Referring to Part and connector locations, ensure the following.
1) Circuit breaker CB3 is not OFF (Its reset button is not projected). (It is ON, if normal.)
2) Fuse Fu5A is not broken.
Ground cable of air conditioner is grounded together with that of machine wiring harness for electrical equipment of machine.
For each connector and relay, see Part and connector locations.
If fuse is broken when A/C switch is pressed, see E-2.
T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220
a T-adapter is not prepared for other connectors.
Causes
Possible causes
and standard
value in normal
state
58
Resistance
Max. 1 z
D155AX-6
80 Air conditioner
SEN04683-01
Causes
Possible causes
and standard
value in normal
state
D155AX-6
Disconnection in wiring
harness
Voltage
20 30 V
a If fuse is broken again in test A above, perform following procedure. (Replace broken fuse.)
1) Turn starting switch OFF.
2) Disconnect battery ground cable.
3) Disconnect control amplifier connector [1] and carry out
troubleshooting without turning starting switch ON.
a If fuse is broken again in test A above and results B and C below
are normal, blower motor circuit may be cause of trouble. See E3.
Between (6) (red) (16) (black)
wiring harness side of connector
[1]
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
59
SEN04683-01
80 Air conditioner
Causes
Possible causes
and standard
value in normal
state
Disconnection in CAN
communication circuit
6 (Communication between
control panel and control
amplifier is defective)
Approx.
60 z
60
Resistance
Resistance
Approx.
60 z
When test results for causes 1, 2, result A for cause 3 and result H
for cause 6 are normal, replace control amplifier.
D155AX-6
80 Air conditioner
SEN04683-01
D155AX-6
61
SEN04683-01
80 Air conditioner
Indication of
problem on
machine
When engine is started and A/C switch is pressed on air conditioner screen of machine monitor, air is
not cooled as displayed on screen.
Air conditioner compressor does not operate.
A/C Controller Error may be displayed red on air conditioner screen of machine monitor. Causes of
this phenomenon are 1) 6). For 1) 5), see Related information in E-1.
Related
information
Possible causes
and standard
value in normal
state
2
Resistance
Max. 1 z
Resistance
Approx.
15 z
62
There is no continuity
There is continuity
There is no continuity
There is continuity
D155AX-6
80 Air conditioner
SEN04683-01
Causes
Disconnection in wiring
harness
Resistance
Max. 1 z
Resistance
Approx.
15 z
Resistance
Max. 1 z
Click is
heard.
Possible causes
and standard
value in normal
state
Air is
cooled.
Resistance
Approx.
140
340 z
Resistance
Approx.
15 z
Disconnection in wiring
harness
10
D155AX-6
Voltage
Max. 1 V
A/C ON is
displayed.
63
SEN04683-01
80 Air conditioner
64
D155AX-6
80 Air conditioner
SEN04683-01
E-3 Blower motor system (No air comes out or air flow is abnormal)
Problem
No air comes out or air flow is abnormal due to blower motor system failure.
Indication of
problem on
machine
LCD of machine monitor on air conditioner operation screen lights normally but air does not come
out.
Air flow does not match fan switch setting on air conditioner operation screen.
Related
information
Possible causes
and standard
value in normal
state
2 Defective power transistor
D155AX-6
Approx. 11 kz
Approx. 2.2 kz
There is continuity
* Diode range
There is no continuity
* Diode range
65
SEN04683-01
80 Air conditioner
Causes
Click is
heard.
Air comes
out.
a If air does not come out even when blower is turned ON forcibly
without using relay, cause is part other than relay.
1) Turn starting switch OFF.
2) Disconnect connector AC03 and carry out troubleshooting
without turning starting switch ON.
Between (1) (2) of AC03 (relay
side) (coil resistance)
4 Defective Diode
Possible causes
and standard
value in normal
state
5
Resistance
Approx.
140
340 z
There is no continuity
There is continuity
Resistance
Max. 1 z
Approx.
24 V
Voltage
Voltage
Max. 2 V
Voltage
Approx.
24 V
*1
66
D155AX-6
80 Air conditioner
SEN04683-01
Causes
Possible causes
and standard
value in normal
state
Control amplifier
1) Turn starting switch OFF.
2) Disconnect connectors [1] and [2] and insert T-adapter.
3) Turn starting switch ON.
4) Press fan switch on air conditioner operation screen.
(Air flow may be set to any position.)
a If F below is abnormal, go to causes 7-J and 9.
a If G below is abnormal, go to causes (9) and (10).
Between (36) (16) of connector
[2]
Voltage
Max. 1 V
Voltage
Max. 2 V
When test results D for cause 6 are normal (voltage is normal but
motor does not rotate), blower (fan) motor is defective.
1) Turn starting switch OFF.
2) Disconnect connectors AC03 and [1] and carry out
troubleshooting without turning starting switch ON.
10
Disconnection in wiring
harness
D155AX-6
Resistance
Resistance
Min. 1 Mz
Min. 1 Mz
Resistance
Min. 1 Mz
67
SEN04683-01
80 Air conditioner
68
D155AX-6
80 Air conditioner
D155AX-6
SEN04683-01
69
SEN04683-01
80 Air conditioner
Indication of
problem on
machine
A/C Controller Error may be displayed red on air conditioner screen of machine monitor. (See E-1.)
While air conditioner operation screen of machine monitor is displayed, temperature does not
change even if temperature control switch is operated.
Related
information
a Temperature control means Air Mix of cooled air and hot air.
Referring to Testing with self-diagnosis function, display Abnormality Record screen on
machine monitor: 03 Air-conditioning System and check to see if Air Mix is abnormal and
Inner sensor is abnormal.
See Testing inner sensor when Inner sensor is abnormal.
Even if rod etc. is disconnected (See Testing temperature control), if current is supplied to air mix
servomotor by operating switches and potentiometer in servomotor reaches normal voltage, selfdiagnosis function judges system normal.
Referring to Testing temperature control, check that there is not contact of connector [6] or
mechanical trouble (removal or interference of link, etc.)
Air mix servomotor and air blowing out (mode) servomotor are same part number. Operating angle of
temperature control (air mix) is less, however. Accordingly, do not test servomotor to see if it rotates
by connecting connector [5] to connector [6]. It is allowed, however, to exchange air mix servomotor
and blowing out (mode) servomotor to see if they are normal.
Air mix servomotor can be checked for trouble by connecting new servomotor to connector [6] and
see if it operates normally.
For each connector, see Part and connector locations.
T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220
a Since T-adapter is not prepared for other connectors, check signals with control amplifier during
operation.
Causes
Possible causes
and standard
value in normal
state
70
Resistance
400
3000 z
Resistance
4 k 8 kz
Resistance
4 k 8 kz
Voltage
5V
Voltage
Approx.
24 V
Voltage
Change
below 5 V
D155AX-6
80 Air conditioner
SEN04683-01
Causes
3
Possible causes
and standard
value in normal
state
D155AX-6
71
SEN04683-01
80 Air conditioner
Related
information
Referring to Testing vent (mode) changeover, check that there is not contact of connector [5] or
mechanical trouble (removal or interference of link, etc.)
Air mix servomotor and blowing out (mode) servomotor are same. Operating angle of temperature
control (air mix) is less, however. Accordingly, do not test servomotor to see if it rotates by connecting connector [5] to connector [6]. It is allowed, however, to exchange air mix servomotor and blowing out (mode) servomotor to see if they are normal.
Blowing out servomotor can be checked for trouble by connecting new servomotor to connector [5]
and see if it operates normally.
For each connector, see Part and connector locations.
T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220
a Since T-adapter is not prepared for other connectors, check signals with control amplifier during
operation.
Causes
72
Resistance
400
3000 z
Resistance
4 k 8 kz
Resistance
4 k 8 kz
Voltage
5V
Voltage
Approx.
24 V
Voltage
Changes
below 5 V
D155AX-6
80 Air conditioner
SEN04683-01
Causes
3
Possible causes
and standard
value in normal
state
D155AX-6
73
SEN04683-01
80 Air conditioner
Indication of
problem on
machine
When Recirc/Fresh selector switch of machine monitor is operated, recirculated or fresh air does not
changeover (Recirc/Fresh changeover door (damper) does not rotate).
Related
information
Defective Recirc/Fresh
changeover servomotor
1
(Unit test) or defective air
conditioner wiring harness
Resistance
400
3000 z
Resistance
400
3000 z
Possible causes
and standard
value in normal
state
Defective control amplifier or Between connector [1] (6) (+) and connector
Approx.
Voltage
3 defective Recirc/Fresh
24 V
[2] (20) ()
changeover servomotor
See 1) 3) above.
4) Set Recirc/Fresh selector switch on air conditioner operation
screen to Fresh.
5) Set Recirc/Fresh selector switch on air conditioner operation
screen to Recirc.
a Voltage appears across connector [1] (6) and connector [2] (19)
for about 3 seconds (only while door moves to Recirc position).
Between connector [1] (6) (+) and connector
[2] (19) ()
Defective Recirc/Fresh
4
changeover servomotor
74
Voltage
Approx.
24 V
a When test result for cause 1 is abnormal and that for cause 2 is
normal, Recirc/Fresh changeover servomotor is defective.
(If all test results for causes 1, 2 and 3 are normal, cause may be
mechanical trouble such as hitch.)
D155AX-6
80 Air conditioner
SEN04683-01
Causes
Possible causes
and standard
value in normal
state
Display of Recirc/
Fresh changes.
D155AX-6
75
SEN04683-01
80 Air conditioner
20 50?
Engine speed
Low idle
ON
Fan switch
Hl
Set temperature
Full cool
q
q
q
q
Item
Pressure is normal
Cause
Check method
Remedy
(*2)
Clean or replace
(*2)
Replace
Evaporator is frozen
Air flow is down by freezing
(At cool max. and HI speed
of fan, later it becomes not to
cold.)
Repair or replace
Replace receiver drier
Collect refrigerant, then fill
up with proper quantity of
refrigerant again
(*2)
76
Condition value
(*2)
Clean or replace
(*2)
D155AX-6
80 Air conditioner
SEN04683-01
Cause
Check method
Remedy
Collect refrigerant, then fill
up with proper quantity of
refrigerant again
(*2)
Defective adjustment of
expansion valve (Valve is
opened too wide)
Air in cycle
Replace
(*2)
Evacuate and then fill up
with proper quantity of refrigerant again
(*2)
(*2)
If refrigerant leaks, internal oil always leaks, too. So perform the check mainly on pipe joints and parts which are
stained with oil. Increase tightening of the joints or replace parts.
*2.
k When replacing a cooling cycle part, see Caution about refrigerant and collect refrigerant. After replacing it,
fill up the air conditioner system with refrigerant again.
D155AX-6
77
SEN04683-01
80 Air conditioner
Part No.
799-703-1200
Part name
Service tool kit
78
Connect the gauge manifold, hoses and other service tools according to the following procedure.
1.
2.
3.
4.
Close the high-pressure valve (HI) and lowpressure valve (LO) of gauge manifold (1).
Connect red charging hose (2) to the (HI) side
and blue charging hose (3) to the (LO) side.
Connect quick joints (4) and (5) to each hose.
Connect the quick joints to the service valves
of the high and low-pressure pipings.
D155AX-6
80 Air conditioner
SEN04683-01
D155AX-6
Tightening torque
M6 1.0
8 12 {0.8 1.2}
M16 1.5
12 15 {1.2 1.5}
M24 1.5
30 35 {3.1 3.6}
79
SEN04683-01
80 Air conditioner
Contents
Insufficiency of oil
Excess of oil
2.
80
Quantity to be added
(cm3)
Approx. 40
Condenser
Approx. 40
Receiver drier
Approx. 20
Hose (Compressor
Condenser)
Approx. 10
Hose (Condenser
Receiver)
Approx. 20
Approx. 15
Approx. 10
D155AX-6
80 Air conditioner
3.
Compressor replacement
q
3)
D155AX-6
SEN04683-01
4.
81
SEN04683-01
80 Air conditioner
D155AX-6 Bulldozer
Form No. SEN04683-01
2009 KOMATSU
All Rights Reserved
Printed in Japan 06-09
82
D155AX-6
SEN00616-03
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
D155AX-6
SEN00616-03
D155AX-6
D155AX-6
SEN00616-03
D155AX-6
SEN00616-03
D155AX-6
SEN00616-03
D155AX-6
SEN00616-03
D155AX-6
SEN00616-03
11
D155AX-6
SEN00616-03
13
SEN00616-03
D155AX-6 Bulldozer
Form No. SEN00616-03
2008 KOMATSU
All Rights Reserved
Printed in Japan 07-08 (02)
14
D155AX-6
SEN00617-05
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
D155AX-6
SEN00617-05
D155AX-6
SEN00617-05
D155AX-6
SEN00617-05
D155AX-6
SEN00617-05
D155AX-6
SEN00617-05
D155AX-6
SEN00617-05
D155AX-6
11
SEN00617-05
D155AX-6
13
SEN00617-05
D155AX-6
15
SEN00617-05
D155AX-6
17
SEN00617-05
D155AX-6
19
SEN00617-05
D155AX-6
21
SEN00617-05
D155AX-6
23
SEN00617-05
D155AX-6
25
D155AX-6
SEN00617-05
27
Type of
Number
Location
connector
of pin
Terminal
1
Starting switch (Terminal B)
Terminal
1
Starting switch (Terminal R1)
Terminal
1
Starting switch (Terminal R2)
Terminal
1
Starting switch (Terminal BR)
Terminal
1
Starting switch (Terminal ACC)
Terminal
1
Starting switch (Terminal C)
DT
2
Air conditioner compressor
DT
2
Intermediate conncector
YAZAKI
8
Intermediate conncector
SUMITOMO4
4
Intermediate conncector
Relay
5
Air conditioner blower relay
Relay
4
Air conditioner compressor relay
S090
2
Air conditioner gas pressure sensor
040
36
Air conditioner controller
DT
2
Diode
DT
2
Diode
DT
2
Diode
Relay
5
Engine ACC signal cut relay
DT
2
Air cleaner clogging switch (If equipped)
Terminal
1
Alternator terminal B
Terminal
1
Alternator terminal R
DT
2
Service connector (for air suspension seat)
1
Machine monitor
1
GPS antenna
1
KOMTRAX communication module
1
ORBCOMM antenna
1
Terminal
1
Circuit breaker (30A)
Terminal
1
Circuit breaker (30A)
Terminal
1
Circuit breaker (105A)
Terminal
1
Circuit breaker (105A)
Terminal
1
Circuit breaker (105A)
Terminal
1
Circuit breaker (105A)
Relay
5
Backup alarm relay
DT
2
Backup alarm
DT
3
Brake pedal switch
3
Blade float switch
3
Blade pitch switch
DT
6
Blade control lever (knob switch)
DT
2
Bypass valve solenoid
Terminal
1
Battery relay (Contact input terminal)
Terminal
3
Battery relay (Contact output terminal)
Terminal
1
Battery relay (Coil ground terminal)
DT
3
Brake pedal potentiometer
DT
2
Transmission bevel speed sensor
DT
3
CAN terminal resistance
1
Circuit breaker (20A)
1
Circuit breaker (20A)
1
Circuit breaker (20A)
1
Circuit breaker (20A)
1
Circuit breaker (20A)
1
Circuit breaker (20A)
1
Circuit breaker (20A)
1
Circuit breaker (20A)
1
Circuit breaker (20A)
2
Circuit breaker (30A)
2
Circuit breaker (105A)
2
Circuit breaker (105A)
DTP
4
Intermediate connector
070
14
070
10
070
18
Machine monitor
070
12
Machine monitor
070
18
Machine monitor
070
12
Machine monitor
070
8
Machine monitor
DT
2
Injecter #1
DT
2
Injecter #2
DT
2
Injecter #3
DT
2
Injecter #4
DT
2
Injecter #5
DT
2
Injecter #6
DT
3
Decelerator pedal potentiometer
M
3
Fuel control dial
DRC-70A
70
Intermediate connector
DT
6
Intermediate connector
DTP
2
Intermediate connector
DT-B
12
Intermediate connector
DRC-60
60
Engine controller
DRC-50
50
Engine controller
DTP
4
Engine controller
DTP
2
Intermediate connector
DT
2
EGR valve solenoid
5
Engine hold relay
DT
3
Service connector (for engine option)
DTHD
1
Intermediate connector
DT
2
Transmission 1st clutch ECMV (Fill switch)
DT
2
Transmission 2nd clutch ECMV (Fill switch)
DT
2
Transmission 3rd clutch ECMV (Fill switch)
DTHD
1
Intermediate connector
DT
2
Fan pump control valve
DT
2
Fan reverse solenoid valve
DT
2
Left brake ECMV (Fill switch)
DT
2
Right brake ECMV (Fill switch)
24-31
31
Intermediate connector
DT-C
12
Intermediate connector
DT
6
Intermediate connector
24-31
31
Intermediate connector
DT
2
Transmission F clutch ECMV (Fill switch)
SWP
6
Headlamp switch
DT
2
Torque converter lockup clutch ECMV (Fill switch)
DT
2
Fuel level sensor
DT
2
Transmission R clutch ECMV (Fill switch)
5
Fuse box
5
Fuse box
5
Fuse box
5
Fuse box
24-21
21
Intermediate connector
DT
2
Torque converter stator clutch ECMV (Fill switch)
DT
12
Intermediate connector
SUMITOMO
3
Engine Bkup speed sensor
Terminal
1
Ground (ROPS)
Terminal
6
Ground (ROPS)
Terminal
4
Ground (Fender)
Terminal
1
Ground (Bulkhead)
Terminal
4
Ground (Guard) [Additional headlamp specification]
Terminal
1
Ground (Engine)
Terminal
6
Ground (Floor)
Terminal
6
Ground (Floor)
Terminal
2
Ground (Engine)
DT
2
Hydraulic oil temperature sensor
AC-4
AC-5
AD-7
AE-7
AE-7
AH-7
P-6
AB-8
P-2, V-1
AG-2
H-1, AH-5
H-1, AH-5
AH-4
AH-4
AG-3
L-3
AC-5
D-9
U-2
K-2
AL-9
AK-8
AK-8
L-3
AI-3
C-1
AL-7
AM-7
K-2, AB-4
L-3
M-3
J-2, AB-3
AM-9
P-5
AJ-1
M-4
AL-9
A-8
A-8
A-7
A-7
B-9, AB-4
AK-1
M-7
AD-2
M-3
M-5
J-1
G-1
AE-2
AB-6
AB-6
AF-2
AI-2
Connector
Type of
Number
Location
No.
connector
of pin
HHP
DT
3
Work equipment and HSS pump pressure sensor
HNSW
DT
2
Horn switch
HRN
1
Horn
HSL
DT
2
HSS left EPC valve
HSR
DT
2
HSS right EPC valve
HSS
DT
6
Intermediate connector
HT
Terminal
2
Heater relay (Terminal C)
HT/A
Terminal
1
Heater relay (Terminal A)
HT/B
Terminal
1
Heater relay (Terminal B)
HTD
DT
2
Diode
J1939
DT
3
Service connector
JM01
6
Junction wiring harness
JM02
7
Junction wiring harness
JM03
4
Junction wiring harness
JM04
3
Junction wiring harness
JM05
3
Junction wiring harness
JM06
3
Junction wiring harness
JM07
5
Junction wiring harness
JM08
7
Junction wiring harness
KEY
DT
6
Starting switch
LHD
DT
2
Intermediate connector
LHDL
DT
2
Left headlamp
LHDL1
DT
2
Additional left headlamp [Additional headlamp specification]
LHDL2
DT
2
Additional left headlamp [Additional headlamp specification]
LHDR
DT
2
Right headlamp
LHDR1
DT
2
Additional right headlamp [Additional headlamp specification]
LHDR2
DT
2
Additional right headlamp [Additional headlamp specification]
LMD1
DT
2
Diode
LMD2
DT
2
Diode
LMFL
Relay
5
Left headlamp relay
LMFR
Relay
5
Right headlamp relay
LMRE
Relay
5
Rear lamp relay
LMRP
Relay
5
Ripper lamp relay
LREL
DT
2
Left rear lamp
LRER
DT
2
Right rear lamp
LRP1
DT
2
Ripper lamp
LRP2
DT
3
Intermediate connector
NE
FRAMATONE
3
Engine Ne speed sensor
NSF
Relay
5
Neutral safety relay
OPPW
DT
2
Intermediate connector
PAMB
FRAMATONE
4
Ambient pressure sensor
PBD
DT
2
Diode
PBS
DT
2
Pedal brake solenoid
PCV1
SUMITOMO
2
Supply pump #1
PCV2
SUMITOMO
2
Supply pump #2
PEVA
CANNON
4
EGR inlet pressure sensor
PFUEL
AMP
3
Common rail pressure sensor
PHR
Relay
5
Preheat relay
PIM
CANNON
4
Charge pressure sensor
PKD
DT
2
Diode
PKS
DT
2
Parking brake solenoid
PKSW
DT
3
Parking brake lever switch
PL1
DRC-70A
70
Intermediate connector
PLSW
DT
2
Pin puller switch
POIL
CANNON
4
Engine oil pressure sensor
PPL
DT
2
Pin puller solenoid valve
PRE
DT
2
Pre-lubrication connector
PRT
DT-A
12
Intermediate connector
PT1
DT
3
Pitch angle sensor
PUMP
DT-A
12
Intermediate connector
QDP
DT
2
Blade quick drop solenoid valve
RDG
DT-A
12
Intermediate connector
RES
DT
2
Service connector
RHT
Terminal
1
Intake air heater (Electrical intake air heater)
RLSW
SWP
6
Rear lamp switch
RSD
DT
2
Diode
S1T
DT
2
Transmission 1st clutch ECMV (Solenoid)
S2T
DT
2
Transmission 2nd clutch ECMV (Solenoid)
S3T
DT
2
Transmission 3rd clutch ECMV (Solenoid)
SBP
DT
4
Bypass valve lift sensor
SBRL
DT
2
Left brake ECMV (Solenoid)
SBRR
DT
2
Right brake ECMV (Solenoid)
SEGR
DT
4
EGR valve lift sensor
SFT
DT
2
Transmission F clutch ECMV (Solenoid)
SFTD
3
Shift-down switch
SFTU
3
Shift-up switch
SLS
050
2
Daylight sensor
SLUC
DT
2
Torque converter lockup clutch ECMV (Solenoid)
SRT
DT
2
Transmission R clutch ECMV (Solenoid)
SRV
DT-A
12
Service connector (for CAN communication)
SSP
DT
2
Sudden stop prevent valve
SSTC
DT
2
Torque converter stator clutch ECMV (Solenoid)
ST
DT
2
Starting motor (Terminal R, S)
ST/B
Terminal
1
Starting motor (Terminal B)
STC1
DRC26-24
24
Power train controller
STC2
DRC26-40A
40
Power train controller
STC3
DRC26-40B
40
Power train controller
SW
Terminal
1
Battery relay (Coil signal terminal)
TCT
DT
2
Torque converter oil temperature sensor
TFUEL
PACKARD
2
Fuel temperature sensor
TIM
PACKARD
2
Charge temperature sensor
TIP
DT
3
Torque converter inlet pressure sensor
TLV1
DT-B
8
Steering/directional/gearshift lever (Potentiometer)
TLV2
DT
6
Steering/directional/gearshift lever (Shift switch)
TMV
24-23
23
Intermediate connector
TOP
DT
3
Torque converter outlet pressure sensor
TVC
DT
2
Work equipment and HSS pump TVC valve
TWTR
PACKARD
2
Engine coolant temperature sensor
WEC1
DRC26-24
24
Work equipment controller
WEC2
DRC26-40A
40
Work equipment controller
WEC3
DRC26-40B
40
Work equipment controller
WELK
DT
3
Work equipment lock lever switch
WEP1
DT
2
Blade lift raise EPC valve
WEP2
DT
2
Blade lift lower EPC valve
WEP3
DT
2
Blade left tilt head EPC valve
WEP4
DT
2
Blade left tilt bottom EPC valve
WEP5
DT
2
Blade right tilt head EPC valve
WEP6
DT
2
Blade right tilt bottom EPC valve
WEP7
DT
2
Ripper lift raise EPC valve
WEP8
DT
2
Ripper lift lower EPC valve
WEP9
DT
2
Ripper tilt in EPC valve
WEPA
DT
2
Ripper tilt back EPC valve
WEPW
DT
2
Service connector (Power supply for driving work equipment in emergency)
WESL
DRC-40A
40
Intermediate connector
WLK
DT
2
Work equipment lock solenoid valve
WLV
DT
2
Radiator coolant level sensor
WLV1
DT-B
8
Blade control lever (Potentiometer)
WLV2
DT-B
8
Ripper control lever
WSH
DT
4
Intermediate connector
WSH1
DT
6
Window washer tank (Front, left)
WSH2
DT
6
Window washer tank (Rear, right)
Address
AI-4
V-9
C-2
T-8
U-9
U-9, AJ-8
A-5
B-5
A-4
H-1
AF-8
AH-4
AH-3
AH-3
AG-2
AH-5
AH-5
AF-8
AG-8
R-6
C-3
C-3
C-4
Q-8
Q-8
C-9
C-9
A-9
D-7
M-7
I-9
M-6
M-4
AH-4
C-9
V-1
AH-3
AB-6
AL-7
AD-2
AD-2
AC-6
AF-2
B-9
AH-6
AB-6
AL-7
L-8, AB-5
AB-4, AN-6
W-9
AG-2
M-4
W-1
E-7
D-6
T-7, AI-8
C-2
C-5
AG-7
AC-6
P-4
AA-1
AK-9
AK-8
AK-8
AD-6
AM-7
AM-7
AC-3
AL-7
X-1
Y-1
P-7
AK-1
AK-8
V-1
AN-2
AK-1
AC-3
AD-7
Z-1
Z-1
AA-1
N-1
AM-2
AH-7
AH-6
AM-2
Y-1
Y-1
AN-3
AM-2
AI-3
AF-8
T-2
T-3
T-5
W-9
T-9
T-9
T-9
T-9
U-9
T-8
U-9
T-8
U-9
T-8
T-8
T-6
AJ-6
C-2
T-6
V-9
X-9
J-2
I-1
SEN00617-05
D155AX-6
29
D155AX-6
SEN00617-05
31
SEN00617-05
D155AX-6 Bulldozer
Form No. SEN00617-05
2010 KOMATSU
All Rights Reserved
Printed in Japan 08-10
32
D155AX-6