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BULLDOZER
D155AX -6
SERIAL NUMBERS 80001 and up
SEN00598-05
D155AX-6
D155AX-6 1
SEN00598-05 00 Index and foreword
01 Specification SEN00600-01
Specification and technical data SEN00601-01
40 Troubleshooting SEN00613-01
General information on troubleshooting SEN00851-00
Troubleshooting by failure and error codes, Part 1 SEN00716-01
Troubleshooting by failure and error codes, Part 2 SEN00717-01
Troubleshooting by failure and error codes, Part 3 SEN00718-01
Troubleshooting by failure and error codes, Part 4 SEN00719-01
Troubleshooting by failure and error codes, Part 5 SEN00720-01
Troubleshooting by failure and error codes, Part 6 SEN00721-01
2 D155AX-6
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D155AX-6 3
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Table of contents 1
00 Index and foreword
Index SEN00598-05
Composition of shop manual....................................................................................................... 2
Table of contents ......................................................................................................................... 4
01 Specification
Specification and technical data SEN00601-01
Specification dimension drawings ............................................................................................... 2
Specifications .............................................................................................................................. 3
Weight table ................................................................................................................................ 9
Table of fuel, coolant and lubricants ............................................................................................ 12
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D155AX-6 5
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40 Troubleshooting
General information on troubleshooting SEN00851-00
General information on troubleshooting ...................................................................................... 2
Points to remember when troubleshooting .............................................................................. 2
Sequence of events in troubleshooting.................................................................................... 3
Check before troubleshooting.................................................................................................. 4
Classification and procedures for troubleshooting................................................................... 5
Connector pin Nos. and connection table................................................................................ 8
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D155AX-6 Bulldozer
Form No. SEN00598-05
2007 KOMATSU
All Rights Reserved
Printed in Japan 10-07 (02)
16 D155AX-6
SEN00599-01
D155AX-6
D155AX-6 1
SEN00599-01 00 Index and foreword
2 D155AX-6
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3) When disassembling or assembling, sup- 8) When removing piping, stop the fuel or oil
port the machine with blocks, jacks, or from spilling out. If any fuel or oil drips
stands before starting work. onto the floor, wipe it up immediately. Fuel
4) Remove all mud and oil from the steps or or oil on the floor can cause you to slip
other places used to get on and off the and can even start fires.
machine. Always use the handrails, lad- 9) As a general rule, do not use gasoline to
ders or steps when getting on or off the wash parts. Do not use it to clean electri-
m a c h i n e . N e v e r j u m p o n o r o ff t h e cal parts, in particular.
machine. If it is impossible to use the 10) Be sure to assemble all parts again in their
handrails, ladders or steps, use a stand to original places. Replace any damaged
provide safe footing. parts and parts which must not be reused
with new parts. When installing hoses and
3. Precautions during work wires, be sure that they will not be dam-
1) Before disconnecting or removing compo- aged by contact with other parts when the
nents of the oil, water, or air circuits, first machine is operated.
release the pressure completely from the 11) When installing high pressure hoses,
circuit. When removing the oil filler cap, a make sure that they are not twisted. Dam-
drain plug, or an oil pressure pickup plug, aged tubes are dangerous, so be
loosen it slowly to prevent the oil from extremely careful when installing tubes for
spurting out. high pressure circuits. In addition, check
2) The coolant and oil in the circuits are hot t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
when the engine is stopped, so be careful installed.
not to get scalded. Wait for the oil and 12) When assembling or installing parts,
coolant to cool before carrying out any always tighten them to the specified
work on the oil or water circuits. torques. When installing protective parts
3) Before starting work, stop the engine. such as guards, or parts which vibrate vio-
When working on or around a rotating lently or rotate at high speed, be particu-
part, in particular, stop the engine. When l a r ly c a r e fu l t o c he c k t h a t t h e y ar e
checking the machine without stopping installed correctly.
the engine (measuring oil pressure, 13) When aligning 2 holes, never insert your
revolving speed, temperature, etc.), take fingers or hand. Be careful not to get your
extreme care not to get rolled or caught in fingers caught in a hole.
rotating parts or moving parts. 14) When measuring hydraulic pressure,
4) Before starting work, remove the leads check that the measuring tools are cor-
from the battery. Always remove the lead rectly assembled.
from the negative () terminal first. 15) Take care when removing or installing the
5) When raising a heavy component (heavier tracks of track-type machines. When
than 25 kg), use a hoist or crane. Before removing the track, the track separates
starting work, check that the slings (wire suddenly, so never let anyone stand at
ropes, chains, and hooks) are free from either end of the track.
damage. Always use slings which have 16) If the engine is operated for a long time in
ample capacity and install them to proper a place which is not ventilated well, you
places. Operate the hoist or crane slowly may suffer from gas poisoning. Accord-
to prevent the component from hitting any ingly, open the windows and doors to ven-
other part. Do not work with any part still tilate well.
raised by the hoist or crane.
6) When removing a cover which is under
internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
7) When removing components, be careful
not to break or damage the electrical wir-
ing. Damaged wiring may cause electrical
fires.
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q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard Z twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over
16 22.6 2.3
wind stop device, electric shock preven-
18 28.6 2.9
tion earth leakage breaker, crane collision
20 35.3 3.6
prevention device, and power application
warning lamp, and check safety. 25 55.3 5.6
2) Observe the signs for sling work. 30 79.6 8.1
3) Operate the hoist at a safe place. 40 141.6 14.4
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
D155AX-6 5
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2) Connection
1] When installing the air conditioner cir-
cuit 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 dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
ZEXEL: ZXL100PG (equivalent to
PAG46)) to its O-rings.
6 D155AX-6
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q 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.
q Materials and specifications are subject to change without notice.
q 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.
01. Specification
This section explains the specifications of the machine.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The S mode of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
D155AX-6 7
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3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
8 D155AX-6
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Example:
Standard size Tolerance
0.022
120
0.126
Example:
Tolerance
Standard size
Shaft Hole
0.030 +0.046
60
0.076 +0
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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 sol-
dering may be damaged, or the wiring
may be broken.
12 D155AX-6
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D155AX-6 13
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2) 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 dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
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 break-
age, 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 stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected 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.
14 D155AX-6
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3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
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4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol 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 control-
ler.
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 con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
D155AX-6 17
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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.
18 D155AX-6
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6. Flushing operations
After disassembling and assembling the equip-
ment, 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 cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
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q 114 engine
q 107 engine
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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.
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In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. 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 nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- 30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
D155AX-6 23
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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
Cov-
AV Standard 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 3.8 4.6
24 D155AX-6
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(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW 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.
(Table 4)
Type of wire AVS or AV AEX
Charge R WG R
Ground B B
Start R R
Light RW RB RY RG RL D
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB L
Type of
Br BrW BrR BrY BrB
circuit
Lg LgR LgY LgB LgW
O
Others Gr
P
Sb
Dg
Ch
D155AX-6 25
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3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
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a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
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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.
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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 hexag-
onal 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 discon-
nect 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 hexag-
onal portion at the male end. (Fig. 9)
30 D155AX-6
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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 hexag-
onal 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 por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect 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 hexag-
onal portion at the male end. (Fig. 13)
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a Fig. A a Fig. B
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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.
6. 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
Thread size
Bolts and nuts
mm Nm kgm
6 10 2 1.02 0.20
8 24 4 2.45 0.41
10 43 6 4.38 0.61
12 77 12 7.85 1.22
14
7. 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.
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8. 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.
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Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
36 D155AX-6
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Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
D155AX-6 37
SEN00599-01 00 Index and foreword
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
38 D155AX-6
00 Index and foreword SEN00599-01
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
D155AX-6 39
SEN00599-01 00 Index and foreword
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade 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 Fahren-
heit 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 Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1C = 33.8F
C F C F C F C F
40.4 40 40.0 11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
37.2 35 31.0 11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
34.4 30 22.0 10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
31.7 25 13.0 10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
28.9 20 4.0 9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
40 D155AX-6
00 Index and foreword SEN00599-01
D155AX-6 41
SEN00599-01 00 Index and foreword
D155AX-6 Bulldozer
Form No. SEN00599-01
2007 KOMATSU
All Rights Reserved
Printed in Japan 03-07 (02)
42 D155AX-6
SEN00601-01
D155AX-6
01 Specification 1
Specification and technical data
Specification dimension drawings ................................................................................................................... 2
Specifications .................................................................................................................................................. 3
Weight table .................................................................................................................................................... 9
Table of fuel, coolant and lubricants.............................................................................................................. 12
D155AX-6 1
SEN00601-01 01 Specification
2 D155AX-6
01 Specification SEN00601-01
Specifications
Machine model D155AX-6
Forward
2nd 5.6
km/h
3rd (low speed) 7.5
3rd 11.6
1st 4.6
Reverse
2nd 6.8
km/h
3rd (low speed) 9.2
3rd 14.0
Bare tractor 79.85 {0.81}
Ground pressure
mm
With Sigma-tilt dozer + variable multi-shank
8,285
ripper
Bare tractor 2,765
With semi U-dozer + tractor mm 4,125
With Sigma-tilt dozer + variable multi-shank
ripper 4,125
D155AX-6 3
SEN00601-01 01 Specification
4 D155AX-6
01 Specification SEN00601-01
D155AX-6 5
SEN00601-01 01 Specification
6 D155AX-6
01 Specification SEN00601-01
Performance
D155AX-6 7
SEN00601-01 01 Specification
Shank positions 2
8 D155AX-6
01 Specification SEN00601-01
Weight table
k This weight table is for reference in handling or transporting components.
D155AX-6 9
SEN00601-01 01 Specification
10 D155AX-6
01 Specification SEN00601-01
D155AX-6 11
SEN00601-01 01 Specification
12 D155AX-6
01 Specification SEN00601-01
Unit: l
D155AX-6
Refilling points
Specified capacity Refill capacity
Engine oil pan 45 37
Damper case 1.5 1.5
Power train case 130 90
Fainal drive case (each) 31 31
Hydraulic system
240 85
(with blade, without ripper)
Cooling system
82
(including reservoir tank)
Fuel tank 625
D155AX-6 13
SEN00601-01 01 Specification
D155AX-6 Bulldozer
Form No. SEN00601-01
2007 KOMATSU
All Rights Reserved
Printed in Japan 03-07 (02)
14 D155AX-6
SEN00603-00
D155AX-6
D155AX-6 1
SEN00603-00 10 Structure, function and maintenance standard
2 D155AX-6
10 Structure, function and maintenance standard SEN00603-00
1. Overflow hose
2. Air bleed hose
3. Inlet hose
4. Coolant filler cap
5. Radiator core assembly
6. Reservoir tank
7. Inlet hose (for circulating at low coolant
temperature)
8. Outlet hose
9. Lower tank (power train oil cooler built-in)
10. Fan
11. Drain plug
12. Cushion
13. Breather cap
14. Pressure valve
a: Aftercooler
b: Aftercooler outlet hose
c: Aftercooler inlet hose
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
Core type
wave fin
Fin pitch (mm) 4.0
Heat dissipation area (m )
2 41.99 x 2
Relief
(MPa {kg/cm2}) 0.09 {0.9}
Pressure pressure
valve Vacuum
(MPa {kg/cm2}) 0.005 {0.05}
pressure
Specification
Aftercooler: Rectangle wave fin 8.0/2P
D155AX-6 3
SEN00603-00 10 Structure, function and maintenance standard
Oil cooler
Outline
q The power train oil cooler is built in the lower
tank of the radiator.
4 D155AX-6
10 Structure, function and maintenance standard SEN00603-00
Engine mount 1
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between bracket size Shaft Hole clearance limit
1
and cushion
0.1 +0.046 0.1
60 Replace
0.3 +0.046 0.346
Standard clearance Clearance limit
2 Free height of mount rubber
86 84
D155AX-6 5
SEN00603-00 10 Structure, function and maintenance standard
1. Servo valve
2. Air bleeder
6 D155AX-6
10 Structure, function and maintenance standard SEN00603-00
1. Shaft
2. Oil seal
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Spring
10. Servo piston
D155AX-6 7
SEN00603-00 10 Structure, function and maintenance standard
8 D155AX-6
10 Structure, function and maintenance standard SEN00603-00
D155AX-6 9
SEN00603-00 10 Structure, function and maintenance standard
10 D155AX-6
10 Structure, function and maintenance standard SEN00603-00
Servo valve
D155AX-6 11
SEN00603-00 10 Structure, function and maintenance standard
12 D155AX-6
SEN00603-00 10 Structure, function and maintenance standard
14 D155AX-6
10 Structure, function and maintenance standard SEN00603-00
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x Installation Installation Free Installation
13 Spool return spring outer diameter length load length load Replace spring
146 N 117 N if damaged or
62.66 x 19.8 53.5
{14.9 kg} {11.9 kg} deformed.
13.7 N 11.0 N
14 Check valve spring 16.4 x 8.9 11.5
{1.4 kg} {1.12 kg}
D155AX-6 15
SEN00603-00 10 Structure, function and maintenance standard
1. Hydraulic motor
Function
q This hydraulic motor is called a swash plate-
type 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 gener-
ates 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 trans-
mit the torque.
16 D155AX-6
10 Structure, function and maintenance standard SEN00603-00
2. Suction valve
D155AX-6 17
SEN00603-00 10 Structure, function and maintenance standard
1) When the ON-OFF solenoid is de-energized. 2) When the ON-OFF solenoid is energized.
q If ON-OFF solenoid (1) is de-energized, the q If ON-OFF solenoid (1) is energized, ON-
pressurized oil from the pump is blocked by OFF selector valve (2) changes to let the pres-
ON-OFF selector valve (2), and port (C) opens surized oil from the pump flow through port (C)
for the tank circuit. into spool chamber (D).
q Spool (3) is pushed to the right by spring (4). q The pressurized oil in chamber (D) pushes
q Motor port (MA) opens and pressurized oil valve spool (3) to the left against spring (4).
flows in to revolve the motor in forward (clock- q Motor port (MB) opens and pressurized oil
wise). flows in to revolve the motor in reverse (coun-
terclockwise).
18 D155AX-6
10 Structure, function and maintenance standard 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 pres-
surized oil into port (T).
q By this operation, generation of abnormal pres-
sure in port (P) is prevented.
D155AX-6 19
SEN00603-00 10 Structure, function and maintenance standard
D155AX-6 Bulldozer
Form No. SEN00603-00
2005 KOMATSU
All Rights Reserved
Printed in Japan 12-05 (02)
20 D155AX-6
SEN00604-01
D155AX-6
D155AX-6 1
SEN00604-01 10 Structure, function and maintenance standard
Outline
q The power generated by engine (1) has its tor- q The power transmitted to the bevel gear shaft
sional vibration dampened by damper (2), and is transmitted to HSS (Hydrostatic Steering
then passes through universal joint (3), and is System) (11). Hydraulic, HSS pump (5) is
transmitted to torque converter (8). driven by PTO (6), and output oil of the
q The power from the engine is transmitted Hydraulic, HSS pump drives HSS motor (12).
through the oil by torque converter (8) to the The rotation of the pair of the HSS gears on
transmission input shaft (turbine shaft) in the right and left is controlled by HSS motor
accordance with the change in load. (with L/U) (12). The steering is carried out by generating
q Transmission (9) uses a combination of a plan- a difference in speed on the right and left. It is
etary gear system and hydraulic clutches to also possible to use the HSS mechanism to
reduce the speed and shift the gears (3 for- rotate the right and left sides in opposite direc-
ward gears and 3 reverse gears). It connects tions to carry out pivot turns.
2 sets of clutches selected according to the q Brake (13) of the HSS is used for braking the
change in load, and transmits the power to machine. Brake (13) is a wet, multiple disc
bevel gear (10) from the bevel pinion at the clutch, spring boosted type. The power sent
rear end of the transmission. from brake (13) is transmitted to final drive
(14).
q Final drive (14) consists of a single-stage spur
gear and a single-stage planetary gear system.
It reduces the speed and rotates sprocket (15)
to drive track shoe (16) and move the machine.
It also rotates cooling fan motor (18) with the
oil discharged from cooling fan pump (17)
driven with PTO (6).
2 D155AX-6
10 Structure, function and maintenance standard SEN00604-01
D155AX-6 3
SEN00604-01 10 Structure, function and maintenance standard
4 D155AX-6
10 Structure, function and maintenance standard SEN00604-01
D155AX-6 5
SEN00604-01 10 Structure, function and maintenance standard
6 D155AX-6
10 Structure, function and maintenance standard SEN00604-01
D155AX-6 7
SEN00604-01 10 Structure, function and maintenance standard
8 D155AX-6
10 Structure, function and maintenance standard SEN00604-01
1. Breather
2. Dipstick
3. Drain plug
4. Output shaft
5. Flywheel
6. Outer body
7. Coupling
8. Universal joint
9. Cover
10. Rubber coupling
11. Inner body
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between flywheel size Shaft Hole clearance limit
12
housing and cover
0.022 +0.070 0.022
511.18 0.2
0.092 +0.070 0.162
Clearance between flywheel 0.020 +0.063 0.020 Replace
13 466.72 0.2
and damper 0.083 +0.070 0.146
Standard size Tolerance Repair limit
Outside diameter of coupling
14 0.087
oil seal contact surface 90 89.8
0.087
Outline
q The damper, dampens the torsional vibration
caused by the change in engine torque and
the impact torque generated when accelerat-
ing 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 trans-
mitted to inner body (11). It passes through uni-
versal joint (8), and is then transmitted to the
torque converter and transmission.
D155AX-6 9
SEN00604-01 10 Structure, function and maintenance standard
10 D155AX-6
10 Structure, function and maintenance standard SEN00604-01
D155AX-6 11
SEN00604-01 10 Structure, function and maintenance standard
12 D155AX-6
10 Structure, function and maintenance standard SEN00604-01
Outline Structure
q The torque converter is a 3-element, 1-stage, q Pump (15) is integrated with coupling (6), input
and 2-phase type, which is integral with the shaft (7), lockup clutch housing (10), and drive
transmission. case (12), and rotated by the engine power.
q The torque converter is equipped with a wet q Turbine (11) is integrated with turbine boss
double disc clutch type torque converter lockup (29) and transmission input shaft (25), and
device and a stator clutch in order to reduce rotated by the oil from pump (15).
fuel consumption, to increase the operability, q Stator (14) is integrated with stator shaft (20)
and to reduce the horsepower consumption by and stator clutch hub (21), and fixed to torque
the engine. converter case (5) through the stator clutch
q For higher efficiency of continuous light dozing unit.
and leveling operation, the torque converter is q The lockup clutch unit consists of clutch plate
locked up and the engine power is transferred (26) meshed with drive case (12), clutch disc
directly to the transmissions input shaft. (27) meshed with turbine boss (29), and clutch
q When the torque converter is locked up (the piston (28) which slides inside clutch housing
pump and turbine is integrated into 1 unit), the (10) integrated with drive case (12).
oil is still supplied to the torque converter. q The stator clutch unit consists of clutch hub
Accordingly, the oil flowing from the pump (21) attached to stator shaft (20) with spline,
through the turbine to the stator is obstructed clutch disc (23) meshed with clutch hub (21),
by the stator blades and cannot flow in any clutch plate (22) supported by the pins on
direction. As a result, this oil resists the rotation clutch front housing (17) and clutch rear hous-
of the pump and turbine (it is agitated). ing (19), and clutch piston (24) which slides
q To reduce the rotating resistance of the pump inside clutch front housing (17).
and turbine, the stator clutch is disengaged Clutch front housing (17) is fixed to sleeve (35)
simultaneously with lockup of the torque con- with torque converter case (5).
verter so that the stator can rotate freely. q The PTO unit consists of input shaft (7), PTO
As the stator is dragged and turned by the idler gear (8), PTO gear A(30), PTO gear B(31)
pump and turbine, the oil returns from the tur- and scavenging pump drive gear (32).
bine to the pump smoothly against less resis-
tance.
D155AX-6 13
SEN00604-01 10 Structure, function and maintenance standard
14 D155AX-6
10 Structure, function and maintenance standard SEN00604-01
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
Outer diameter of oil seal
1 contact surface of the coupling -0.054
100 99.8 Repair by hard
-0.054 chrome plating
Inner diameter of the seal or replace
+0.025
ring contact surface of the input 35 +0.025 35.1
shaft
2 -0.01
Wear of the trans- Width 2.56 -0.03 2.3
mission input shaft Replace
seal ring Thickness 1.7 0.1 1.55
Repair by hard
Inner diameter of the seal ring 90 +0.035 90.1 chrome plating
contact surface of the sleeve +0.025 or replace
4 Width 3 -0.01 2.7
Wear of the stator -0.03
Replace
shaft seal ring
Thickness 3.7 0.12 3.55
D155AX-6 15
SEN00604-01 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
size Shaft Hole clearance limit
Fitting tolerance
of the PTO idler Outer -0.025 -0.008 -0.033
12 gear 140
diameter -0.018 -0.033 0.010
and bearing
Inner 0.025 0 -0.015
diameter 80 -0.019 -0.015 0.019
Outside
diameter 180 -0.025 +0.026 -0.014
(cover side) -0.025 -0.014 0.051
Fitting tolerance of
HSS, work equip- Outside
diameter 120 -0.025 +0.022 -0.013
ment, -0.015 -0.013 0.037
power train, (case side)
13 steering
Inner
lubrication pump diameter 100 +0.035 -0.025 -0.055
drive gear (cover side) +0.013 -0.020 -0.013
bearing
Inner
diameter 65 +0.030 -0.025 -0.045
(case side) +0.011 -0.015 -0.011
Outside
diameter 120 -0.025 +0.022 -0.013
-0.015 -0.013 0.037 Replace
(cover side)
Outside
-0.025 +0.022 -0.013
Fitting tolerance of diameter 120
-0.015 -0.013 0.037
fan pump (case side)
14 drive gear Inner
bearing diameter 55 +0.030 -0.025 -0.045
(cover side) +0.011 -0.015 -0.011
Inner
diameter 65 +0.030 -0.025 -0.045
(case side) +0.011 -0.015 -0.011
16 D155AX-6
10 Structure, function and maintenance standard SEN00604-01
When lockup clutch isdisengagedand stator When lockup clutch isengagedand stator
clutch is engaged clutch is disengaged
Drive case (4) is disconnected from turbine boss (8) Drive case (4) is connected to boss (8) and turbine
and turbine (7) and lockup torque converter works (7) and lockup torque converter is locked up.
as an ordinary torque converter.
The power from engine
The power from engine O
O Damper
Damper O
O Universal joint
Universal joint O
O Coupling (1)
Coupling (1) O
O Input shaft (2)
Input shaft (2) O
O Clutch housing (3), drive case (4) and pump (5)
Clutch housing (3), drive case (4) and pump (5) rotate together
rotate together O
O Lockup clutch (6)
Oil is used as medium O
O Turbine boss (8)
Turbine (7) and turbine boss (8) O
O Transmission input shaft (9)
Transmission input shaft (9)
q If stator clutch (10) is disengaged at this time,
q If stator clutch (10) is "engaged" at this time, torque converter case (11) and stator shaft (12)
torque converter case (11) and stator shaft (12) are disconnected from each other, and stator
are connected to each other to fix stator (13). (13) is dragged and turned by pump (5) and
turbine (7).
D155AX-6 17
SEN00604-01 10 Structure, function and maintenance standard
Oil flow
18 D155AX-6
10 Structure, function and maintenance standard SEN00604-01
D155AX-6 19
SEN00604-01 10 Structure, function and maintenance standard
A: To clutch *1:
P: From pump
Operated clutches Stamp of the nameplates
T: Drain
DR: Drain Lockup E*******
P1: Clutch oil pressure pickup port Stator A*******
P2: Pilot oil pressure pickup port
20 D155AX-6
10 Structure, function and maintenance standard SEN00604-01
At gear shift (in direct travel) q When traveling in torque converter range, cur-
rent 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).
D155AX-6 21
SEN00604-01 10 Structure, function and maintenance standard
q When traveling in direct (lockup) range, current q If current flows in proportional solenoid (1), the
is supplied to proportional solenoid (1), the oil solenoid generates thrust in proportion to the
pressure force balanced with the solenoid current. This thrust of the solenoid is balanced
force is applied to chamber (B) and pushes with the sum of the thrust generated by the oil
pressure control valve (3) to the left.As a pressure in clutch port and the tension of pres-
result, pump port (P) and clutch port (A) are sure control valve spring (2), and then the
opened and oil starts filling the clutch. If the pressure is settled.
clutch is filled with oil, fill switch (5) is turned q While shifting gears, the lockup clutch oil pres-
on. sure is reduced temporarily to reduce the
shock when shifting gear.
Oil pressure at this time is controlled so that
the lockup piston pushing force balances with
the inside pressure of torque converter.
22 D155AX-6
10 Structure, function and maintenance standard SEN00604-01
D155AX-6 23
SEN00604-01 10 Structure, function and maintenance standard
q When traveling in torque converter range cur- q If current flows in proportional solenoid (1), the
rent is supplied to proportional solenoid (1), the solenoid generates thrust in proportion to the
oil pressure force balanced with the solenoid current. This thrust of the solenoid is balanced
force is applied to chamber (B) and pushes with the sum of the thrust generated by the oil
pressure control valve (3) to the left.As a pressure in clutch port and the tension of pres-
result, pump port (P) and clutch port (A) are sure control valve spring (2), and then the
opened and oil starts filling the clutch. If the pressure is settled.
clutch is filled with oil, fill switch (5) is turned
on.
24 D155AX-6
10 Structure, function and maintenance standard SEN00604-01
D155AX-6 25
SEN00604-01 10 Structure, function and maintenance standard
Transmission control 1
a For steering operation of the Palm Command Steering Control lever (PCCS lever), see Steering, brake
control.
a PCCS: Abbreviation for Palm Command Control System
26 D155AX-6
10 Structure, function and maintenance standard 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 10 Structure, function and maintenance standard
Transmission 1
28 D155AX-6
10 Structure, function and maintenance standard SEN00604-01
D155AX-6 29
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30 D155AX-6
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D155AX-6 31
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32 D155AX-6
10 Structure, function and maintenance standard SEN00604-01
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Installation Installation Installation
Free length Free length
1 R clutch spring (12 pcs.) length load load
59.8 N 51.0 N
81.7 72.4 76.8
{6.1 kg} {5.2 kg}
34.3 N 29.4 N
2 F clutch spring (12 pcs.) 81.7 76.4 76.8
{3.5 kg} {3.0 kg}
97.1 N 82.4 N
3 3rd clutch spring (12 pcs.) 70.0 50.2 65.8
{9.9 kg} {8.4 kg}
90.2 N 76.5 N
4 2nd clutch spring (12 pcs.) 70.0 51.6 65.8
{9.2 kg} {7.8 kg}
66.7 N 56.9 N
5 1st clutch spring (12 pcs.) 66.0 51.8 62.0
{6.8 kg} {5.8 kg}
Total thickness of R clutch Standard size Tolerance Repair limit
6 assembly consisting of 6 discs
and 6 plates 51.6 0.35 48.4
-0.01
Width 2.56 2.30
Wear of the input -0.03
13
shaft seal ring (small)
Thickness 1.7 0.1 1.55
-0.01
Width 3.0 2.70
Wear of the input -0.03
14
shaft seal ring (large)
Thickness 2.7 0.1 2.55
-0.01
Width 4.0 3.60
Wear of the 2nd car- -0.04
16
rier seal ring (large)
Thickness 4.0 0.15 3.85
-0.01
Width 4.0 3.60
Wear of the 2nd car- -0.04
17
rier seal ring (small)
Thickness 4.0 0.15 3.85
D155AX-6 33
SEN00604-01 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
-0.01
Wear of the 1st car- Width 4.0 3.60
18 -0.04
rier seal ring (large)
Thickness 4.0 0.15 3.85
-0.01
Width 4.0 3.60
Wear of the 1st car- -0.04
19
rier seal ring (small)
Thickness 5.0 0.15 4.85
R, F, Replace
Backlash between 0.14 - 0.35
3rd, 1st
20 sun gear and
planetary pinion 2nd 0.13 - 0.32
R 0.15 - 0.39
Backlash between
F, 2nd,
21 planetary pinion and 0.15 - 0.38
1st
ring gear
3rd 0.16 - 0.42
Disc clutch
Operation
Structure When clutch is engaged (fixed)
q The disc clutch consists of piston (2), plates q The oil from ECMV is sent with pressure to the
(3), discs (4), pin (5), return spring (6) etc. to fix rear side of piston (2) through oil the passage
ring gear (1). of housing (7) and pushes piston (2) leftward.
q Inside teeth of disc (4) are engaged with out- q Piston (2) contacts plate (3) closely against
side teeth of ring gear (1). disc (4) to stop rotation of disc (4) by use of the
q Plate (3) is assembled to clutch housing (7) friction force generated between them.
with pin (5). q Since inside teeth of disc (4) are engaged with
outside teeth of ring gear (1), move of ring gear
(1) is stopped.
34 D155AX-6
10 Structure, function and maintenance standard SEN00604-01
D155AX-6 35
SEN00604-01 10 Structure, function and maintenance standard
36 D155AX-6
10 Structure, function and maintenance standard SEN00604-01
F ring gear (4) of F clutch and 1st ring gear (19) of 1st clutch are fixed hydraulically.
D155AX-6 37
SEN00604-01 10 Structure, function and maintenance standard
38 D155AX-6
10 Structure, function and maintenance standard SEN00604-01
F ring gear (4) of F clutch and 2nd ring gear (16) of 2nd clutch are fixed hydraulically.
D155AX-6 39
SEN00604-01 10 Structure, function and maintenance standard
40 D155AX-6
10 Structure, function and maintenance standard SEN00604-01
F ring gear (4) of F clutch and 3rd ring gear (13) of 3rd clutch are fixed hydraulically.
D155AX-6 41
SEN00604-01 10 Structure, function and maintenance standard
42 D155AX-6
10 Structure, function and maintenance standard SEN00604-01
R ring gear (7) of R clutch and 1st ring gear (19) of 1st clutch are fixed hydraulically.
D155AX-6 43
SEN00604-01 10 Structure, function and maintenance standard
Transmission ECMV 1
a ECMV: Abbreviation for Electronic Control Modulation Valve
a Don't try to disassemble it since adjustment for maintaining the performance will be needed.
44 D155AX-6
10 Structure, function and maintenance standard SEN00604-01
1. 3rd clutch proportional solenoid a When the directional lever is in (neutral) posi-
2. 1st clutch proportional solenoid tion, the speed clutch of the speed selected by
3. R clutch proportional solenoid gear shift lever activates.
4. F clutch proportional solenoid
5. 2nd clutch proportional solenoid
6. 3rd clutch fill switch
7. 2nd clutch fill switch
8. 1st clutch fill switch
9. R clutch fill switch
10. F clutch fill switch
11. Transmission oil filter
12. Connector for 1st clutch proportional solenoid
13. Connector for 3rd clutch fill switch
14. Connector for 3rd clutch proportional solenoid
15. Connector for R clutch proportional solenoid
16. Connector for 2nd clutch fill switch
17. Connector for 2nd clutch proportional solenoid
18. Connector for F clutch proportional solenoid
19. Connector for 1st clutch fill switch
20. Connector for R clutch fill switch
21. Connector for F clutch fill switch
D155AX-6 45
SEN00604-01 10 Structure, function and maintenance standard
1. Fill switch
2. Pressure control valve
3. Body (upper)
4. Body (lower)
5. Proportional solenoid
6. Filter
7. Pressure detection valve
8. Sleeve
46 D155AX-6
10 Structure, function and maintenance standard SEN00604-01
D155AX-6 47
SEN00604-01 10 Structure, function and maintenance standard
48 D155AX-6
10 Structure, function and maintenance standard SEN00604-01
q If current is supplied to proportional solenoid q If current flows in proportional solenoid (1), the
(1) with no oil in the clutch, the oil pressure solenoid generates thrust in proportion to the
force balanced with the solenoid force is current. This thrust of the solenoid is balanced
applied to chamber (B) and pushes pressure with the sum of the thrust generated by the oil
control valve (3) to the right. As a result, pump pressure in clutch port and the tension of pres-
port (P) and clutch port (A) are opened and oil sure control valve spring (2), and then the
starts filling the clutch. If the clutch is filled with pressure is settled.
oil, fill switch (5) is turned on.
D155AX-6 49
SEN00604-01 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between main relief size Shaft Hole clearance limit
1
valve and body
-0.035 +0.013 0.035
28 0.078
-0.045 +0.013 0.058
Clearance between the torque con- -0.035 +0.013 0.035
2 22 0.078
verter relief valve and the body -0.045 +0.013 0.058
Standard size Repair limit
Replace
Installation Installation Installation
Main relief valve spring Free length Free length
3 length load load
(outside)
481 N 457 N
122 78.0 118.3
{49 kg} {46.6 kg}
Main relief valve spring 368 N 349 N
4 108 78.0 104.8
(inside) {37.5 kg} {35.6 kg}
Torque converter relief valve 182 N 174 N
5 50 40.5 48.5
spring {18.6 kg} {17.7 kg}
6. Body A: Drain (Torque converter relief)
7. Piston B: Drain
8. Torque converter relief valve C: From pump
9. Piston D: Drain
10. Main relief valve E: To torque converter
P1: Main relief oil pressure pickup port
P8a: Torque converter relief oil pressure pickup port
P8b: Torque converter inlet oil pressure pickup port
50 D155AX-6
10 Structure, function and maintenance standard SEN00604-01
Operation
D155AX-6 51
SEN00604-01 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Installation Installation Installation
Free length Free length
1 Lubrication relief valve spring length load load Replace
12.5 N 11.9 N
26 23.6 25.2
{1.27 kg} {1.21 kg}
52 D155AX-6
10 Structure, function and maintenance standard SEN00604-01
Scavenging pump 1
Type: SAR(4)140
Unit: mm
No. Check item Criteria Remedy
Standard clearance Clearance limit
1 Side clearance
0.11 0.16 0.19
Clearance between plain bear-
2 ing inner diameter and gear 0.06 0.14 0.20
shaft outer diameter Replace
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
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54 D155AX-6
10 Structure, function and maintenance standard SEN00604-01
Unit: mm
No. Check item Criteria Remedy
Type Standard clearance Clearance limit
3 Side clearance SAR(3)100
0.10 - 0.15 0.19
SAR(3)40
Clearance between plain bear- SAR(3)100
4 ing inner diameter 0.06 - 0.15 0.20 Replace
and gear shaft outer diameter SAR(3)40
Type Standard size Tolerance Repair limit
5 Pin driving depth SAR(3)100 -0.5
14
SAR(3)40 -0.5
6 Rotating torque of spline shaft 13.7 - 23.5 Nm {1.4 - 2.4 kgm}
Delivery
Rotation Standard Delivery
pressure
Type speed delivery limit
Delivery amount (MPa{kg/
(rpm) (l/min) (l/min)
Oil: SAE10WCD cm2})
Oil temperature: 45 55C
SAR(3)100 2,500 2.94{30} 241 96
SAR(3)40 2,500 2.94{30} 239 85
D155AX-6 55
SEN00604-01 10 Structure, function and maintenance standard
D155AX-6 Bulldozer
Form No. SEN00604-01
2007 KOMATSU
All Rights Reserved
Printed in Japan 03-07 (02)
56 D155AX-6
SEN00605-01
D155AX-6
D155AX-6 1
SEN00605-01 10 Structure, function and maintenance standard
HSS system 1
2 D155AX-6
10 Structure, function and maintenance standard SEN00605-01
D155AX-6 3
SEN00605-01 10 Structure, function and maintenance standard
HSS motor 1
Type: KMF140
Outline Specifications
q This motor is composed of the fixed capacity Type: KMF140
bent axis type piston motor, the counterbal- Theoretical delivery: 141.1 cm3/rev
ance valve, the check valve and relief valve. Rated output pressure: 41.2 MPa {420 kg/cm2}
Rated rpm: 2,205 rpm
4 D155AX-6
10 Structure, function and maintenance standard SEN00605-01
D155AX-6 5
SEN00605-01 10 Structure, function and maintenance standard
6 D155AX-6
10 Structure, function and maintenance standard SEN00605-01
1. Drive shaft
2. Motor case
3. Piston
4. Cylinder block
5. Valve plate
6. Housing
7. Cover
8. Counterbalance valve spool
9. Check valve
10. Spool
11. Safety valve
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x Installation Installation Free Installation
outer diameter length load length load
12 Check valve spring
3.04 N 1.96 N Replace spring
62.5 x 20 39
{0.31 kg} {0.25 kg} if damaged or
Spool return spring 241 N 155 N deformed.
13 43.4 x 35 41
(Large) {24.6 kg} {19.7 kg}
Spool return spring 96.1 N 76.9 N
14 40.44 x 21.9 38
(Small) {9.8 kg} {7.84 kg}
D155AX-6 7
SEN00605-01 10 Structure, function and maintenance standard
Principle Operation
q Supposed that the axis of the disc is supported q The pressurized oil sent from the main piston
and the disc can rotate freely.If force (F) is pump enters from the piston motor inlet port,
applied to the disc diagonally, force (F) is and the oil pressure is applied to the back of
divided into vertical force to the disc (F1) and piston (3), and drive shaft (1) rotates by the
circumferential force (F2). (F1) pushes the inclination (Q) of piston (3) and cylinder block
disc to axis direction, and (F2) rotates the disc (4).
clockwise.
q Instead, if force (F'), not force (F) is applied to
the disc, the force is also divided into (F1') and
(F2'), and the disc rotates counterclockwise by
force (F2').
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).
8 D155AX-6
10 Structure, function and maintenance standard SEN00605-01
Brake valve
q The brake valve consists of check valve (9), Operation when pressurized oil is supplied
counterbalance valve (8), and safety valve q If steering lever is operated, the pressurized oil
(11). from the control valve is supplied to port (PA).
q Functions and operations of respective compo- q It pushes open check valve (9A), and flows
nents shall conform to the following. from motor inlet port (MA) to motor outlet port
(MB).
1) Counterbalance valve and check valve q The outlet port side of the motor is closed by
check valve (9B) and spool (8), so the pres-
Function sure at the side where the oil is being supplied
q When the steering is operated on a downhill rises.
slope, the gravity force tends to make the cur-
rent 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.
D155AX-6 9
SEN00605-01 10 Structure, function and maintenance standard
q The pressurized oil at the side where the oil is Brake operation when traveling downhill
being supplied flows from orifice (E1) of spool q When steering is operated on a downhill slopes,
(8) into chamber (S1). if the machine attempts to run away, the motor
q When the pressure in chamber (S1) becomes will rotate under no load, and the oil pressure at
higher than the spool switching pressure, spool the inlet port of motor will drop.
(8) is pushed to the right. q Through orifice (E1), the pressure in chamber
q Port (MB) and port (PB) are connected, open- (S1) drops.
ing the motor outlet port side and starting the q If the pressure in chamber (S1) drops below
motor rotating. the spool switching pressure, spool (8) is
pushed to the left by spring (13), (14), and out-
let port (MB) is throttled.
q The pressure at the outlet port side rises, gen-
erating rotation resistance on the motor to pre-
vents the machine from running away.
q Spool (8) moves to a position where it bal-
ances the pressure at outlet port (MB) with the
force resulting from the weight of the machine
and the pressure at the inlet port.
q In this way, it throttles the outlet port circuit and
possible to steer to a speed that matches the
amount of oil discharged from the pump.
10 D155AX-6
10 Structure, function and maintenance standard SEN00605-01
2) Safety valve
(Both operated safety valve.)
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
SEN00605-01 10 Structure, function and maintenance standard
(2) When pressure in chamber (MA) has become q As the pressure goes above the set pressure,
high (when rotating counterclockwise) [Difference in areas of circles (D1) and (D3) x
q When the operation of the steering is finished, Pressure] compresses spring (2).
the check valve of the counterbalance valve q Poppet (1) is moved leftward and the pressur-
closes the circuit at outlet ports (MA) of the ized oil flows into chamber (MB) of the oppo-
motor. site circuit.
q The motor tries to continue rotation resorting to
inertial force, thus pressure on the outlet port
(MA) is increased.
12 D155AX-6
10 Structure, function and maintenance standard SEN00605-01
D155AX-6 13
SEN00605-01 10 Structure, function and maintenance standard
14 D155AX-6
10 Structure, function and maintenance standard SEN00605-01
Outline
q This pump consists of a variable displacement
swash plate type piston pump, PC valve, and
EPC valve.
1. Front pump
2. LS valve
3. PC valve
4. PC-EPC valve
D155AX-6 15
SEN00605-01 10 Structure, function and maintenance standard
1. Shaft
2. Cradle
3. Case
4. Rocker cam
5. Shoe
6. Piston
7 Cylinder block
8. Valve plate
9. End cap
10. Servo piston
11. PC valve
16 D155AX-6
10 Structure, function and maintenance standard SEN00605-01
D155AX-6 17
SEN00605-01 10 Structure, function and maintenance standard
Operation of pump
q Cylinder block (7) rotates together with shaft q As center line (X) of rocker cam (4) matches
(1), and shoe (5) slides on flat surface (A). the axial direction of cylinder block (7) (swash
q When this happens, rocker cam (4) moves plate angle (a) = 0), the difference between
along cylindrical surface (B), so angle (a) volumes (E) and (F) inside cylinder block (7)
between center line (X) of rocker cam (4) and becomes 0.
the ax ial di rec tio n of cy li nder b loc k (7) q Suction and discharge of pressurized oil is not
changes. carried out in this state. Namely pumping
q Angle (a) is called the swash plate angle. action is not performed. (Actually, however, the
swash plate angle is not set to 0)
18 D155AX-6
10 Structure, function and maintenance standard SEN00605-01
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 accord-
ing 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 con-
trolled 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
SEN00605-01 10 Structure, function and maintenance standard
1. LS valve
Function
q The LS (load sensing) valve detects the load
and controls the delivery.
q This valve controls pump delivery (Q) accord-
ing 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 pres-
sure ( 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
10 Structure, function and maintenance standard SEN00605-01
Operation
q The LS valve is a three-way selector valve, q The same pump discharge pressure (PP)
with pressure (PLS) (LS pressure) from the enters the small diameter end of piston port
inlet port of the control valve brought to spring (J).
chamber (B), and pump discharge pressure q Because of the difference in area of servo pis-
(PP) brought to port (H) of sleeve (8). ton (10), it moves in the direction to make the
q Magnitude of the force resulting from this LS swash plate angle smaller.
pressure (PLS), force of spring (4) and the
pump delivery pressure (self pressure) (PP)
determine the position of spool (6).
q Before the engine is started, servo piston (10)
is pushed to the right.(See right drawing)
q If the control lever is at the neutral position
when the engine is started, LS pressure (PLS)
will be set to 0 MPa {0 kg/cm2}. (It is intercon-
nected to the drain circuit through the control
valve spool)
q Spool (6) is pushed to the right, and port (C)
and port (D) will be connected.
q Pump discharge pressure (PP) enters the
large diameter end of piston from port (K).
D155AX-6 21
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22 D155AX-6
10 Structure, function and maintenance standard SEN00605-01
D155AX-6 23
SEN00605-01 10 Structure, function and maintenance standard
q Let us take the area receiving the pressure at q The position where spool (6) is balanced and
the large diameter end of the piston as (A1), stopped is the standard center, and the force of
the area receiving the pressure at the small spring (4) is adjusted so that it is determined
diameter end as (A0), and the pressure flowing when (PP) (PLS) = 1.96 MPa {20kg/cm2}.
into the large diameter end of the piston as
(PEN).
q If pump discharge pressure (PP) of the LS
valve and the combined force of spring (4) and
LS pressure (PLS) are balanced, and the rela-
tionship becomes (A0) x (PP) = (A1) x (PEN),
servo piston (10) stops at that position.
q And the swash plate of the pump will be held in
an intermediate position. [Spool (6) will be
stopped at a position where the distance of the
opening from port (D) to port (E) and the dis-
tance from port (C) to port (D) is almost the
same.]
q The relationship between the area receiving
the pressure at both ends of servo piston (10)
is (A0):(A1) = 3:5, so the pressure applied to
both ends of the piston when it is balanced
becomes (PP):(PEN) C 5 : 3.
24 D155AX-6
10 Structure, function and maintenance standard SEN00605-01
2. PC valve
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 accor-
dance 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 dis-
charge pressure (PP) and pump delivery (Q)
with the electric current value (X) given to PC-
EPC valve solenoid as the parameter is shown
in the diagram.
D155AX-6 25
SEN00605-01 10 Structure, function and maintenance standard
Operation
(1) When the load on the actuator is small and pump discharge pressure (PP) is low
26 D155AX-6
10 Structure, function and maintenance standard SEN00605-01
D155AX-6 27
SEN00605-01 10 Structure, function and maintenance standard
Action of spring
q The load of spring (4) at the PC valve is deter-
mined 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 push-
ing piston (2).
q The load of spring (4) also changes according
to the PC-EPC valve solenoid command cur-
rent (X).
28 D155AX-6
10 Structure, function and maintenance standard SEN00605-01
D155AX-6 29
SEN00605-01 10 Structure, function and maintenance standard
(2) When the load on the actuator is large and pump discharge pressure (PP) is high
Outline Operation
q When the load is large and pump discharge q When port (E) and port (G) of the LS valve are
pressure (PP) is high, the force pushing spool connected, this pressure from port (J) enters
(3) to the right becomes larger and spool (3) the large diameter end of servo piston (9),
moves to the position shown in the diagram stopping servo piston (9).
above. q If pump discharge pressure (PP) increases fur-
q As shown in the diagram above, part of the ther and spool (3) moves further to the right,
pressurized oil from port (B) flows out to port pump discharge pressure (PP) flows to port
(D) from port (C) through the LS valve, and the (C) and acts to make the delivery the mini-
pressure oil flowing from port (C) to the LS mum.
valve becomes approximately half of pump dis- q If servo piston (9) moves to the right, spring (4)
charge pressure (PP). 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.
30 D155AX-6
10 Structure, function and maintenance standard SEN00605-01
D155AX-6 31
SEN00605-01 10 Structure, function and maintenance standard
2) As the emergency pump drive switch is turned on due to failure on the pump controller
q If there is a failure in the pump controller, the q Since the pressure on the small diameter end
emergency pump drive switch is turned ON to of the piston large, servo piston (9) moves in
hand the control to the resistor side. the direction to make the delivery larger.
q In this case, the power is directly supplied from
the battery. The current, however, is too large
as is, so the resistor is set in between to con-
trol the current flowing to PC-EPC valve sole-
noid (1).
q The current becomes constant, so the force
pushing piston (2) is also constant.
q When pump discharge pressure (PP) is low,
spool (3) is balanced at left position, since the
combined force of PC-EPC valve solenoid (1)
and pump discharge pressure (PP) is smaller
than the spring set force.
q At this point, port (C) is connected to the drain
pressure of port (D), and the large diameter
end of the piston of servo piston (9) also
becomes the drain pressure (PT) through the
LS valve.
32 D155AX-6
10 Structure, function and maintenance standard SEN00605-01
q If the emergency pump drive switch is turned q The curve resulting when the emergency pump
on In the same way as in above, the command drive switch is ON is situated further to the left
current (X) sent to PC-EPC valve solenoid (1) (B) than when the pump controller is normal
becomes constant. (A).
q For this reason, the force of piston (2) pushing
spool (3) is constant.
q If pump discharge pressure (PP) increases,
spool (3) moves to the right from the position
where the load of the pump is smaller, and bal-
anced at the above diagram position.
q In this case, the pressure from port (B) flows to
port (C), so servo piston (9) moves to the right
(smaller pump delivery) and stops at a position
to the further to the right then when the load on
the pump is light.
q The curb of pump discharge pressure (PP) and
pump delivery (Q) is shown in the diagram. It
is determined corresponding to the electric cur-
rent value sent from the PC-EPC valve sole-
noid through the resistor even when the
emergency pump driving switch turns ON.
D155AX-6 33
SEN00605-01 10 Structure, function and maintenance standard
3. PC-EPC valve
C: To PC valve
P: From self pressure reducing valve
T: To tank
1. Connector
2. Coil
3. Body
4. Spring
5. Spool
6. Rod
7. Plunger
34 D155AX-6
10 Structure, function and maintenance standard SEN00605-01
Function Operation
q The EPC valve consists of the proportional
solenoid portion and the hydraulic valve por- 1) When signal current is 0 (Coil is de-ener-
tion. gized)
q On receiving signal current (i) from the control- q When there is no signal current flowing from
ler, the EPC valve generates EPC output pres- the controller to coil (2), coil (2) is de-ener-
sure in proportion to the signal current and gized.
outputs it to the PC valve. q Spool (5) is pushed to the left by spring (4).
q Since port (P) is closed, the pressurized oil
from self pressure reducing valve does not
flow to the PC valve.
q The oil from the PC valve is drained through
ports (C) and (T) to the tank.
D155AX-6 35
SEN00605-01 10 Structure, function and maintenance standard
2) When signal current is very small (coil is 3) When signal current is maximum (coil is
energized) energized)
q When a very small signal current flows to coil q As the signal current flows to coil (2), coil (2) is
(2), coil (2) is energized, and a propulsion force energized.
is generated on the right side of plunger (7). q When this happens, the signal current is at its
q Rod (6) pushes spool (5) to the right, and pres- maximum, so the propulsion force of plunger
surized oil flows from port (P) to port (C). (7) is also at its maximum.
q Pressures on port (C) increases and the force q Spool (5) is pushed toward the right side by rod
to act on spool (5) surface and the spring load (6).
on spring (4) become larger than the propul- q Hydraulic oil from port (P) flows to port (C) with
sion force of plunger (7). maximum flow rate. As the result, the circuit
q Spool (5) is pushed to the left, and port (P) is pressure between the EPC and PC valves
shut off from port (C). becomes maximum.
q Port (C) and port (T) are connected. q Since port (T) is closed, pressurized oil does
q Spool (5) moves up and down so that the pro- not flow to the tank.
pulsion force of plunger (7) may be in balance
with pressure of port (C) + spring load of spring
(4).
q Circuit pressure between the EPC valve and
PC valve is controlled in proportion to the size
of the signal current.
36 D155AX-6
10 Structure, function and maintenance standard SEN00605-01
1. Body Outline
2. Valve q This valve is installed in the oil cooler inlet cir-
3. Spring cuit. If any abnormal pressure is generated in
the oil flowing to the oil cooler, this valve acts
A: Hydraulic oil cooler inlet to return the oil directly to the hydraulic tank.
B: To hydraulic tank
Set pressure
Cracking pressure ( MPa {kg/cm })
2 0.5 {5.1}
D155AX-6 37
SEN00605-01 10 Structure, function and maintenance standard
38 D155AX-6
10 Structure, function and maintenance standard SEN00605-01
1. Potentiometer Outline
2. Lock lever q PCCS lever (3) sends electric signals to power
3. PCCS lever (Steering) train controller (5). Upon receiving those sig-
4. Limit switch nals, power train controller (5) sends signals to
5. Power train controller the EPC valve of the control valve to change
6. Rod (From brake pedal) the delivery of the pump and operate the steer-
7. Brake pedal ing motor.
q Brake pedal (7) receives signals from potenti-
Positions of levers and pedals ometer (1) through rod (6). Then, power train
A: Neutral controller (5) sends signals to the brake valve
B: Forward straight to operate the brake.
C: Reverse straight q Lock lever (2) is connected to limit switch (4)
D: Left turn and used as the parking brake lever, too.
E: Right turn When it is in lock position "J", power train con-
F: Brake OFF troller (5) does not send turning signals to the
G: Brake ON EPC valve of the control valve.
H: Free
J: Lock
D155AX-6 39
SEN00605-01 10 Structure, function and maintenance standard
Steering unit 1
(Bevel gear shaft, HSS and brake)
a HSS: Abbreviation for Hydrostatic Steering System
40 D155AX-6
10 Structure, function and maintenance standard SEN00605-01
A: To transmission case
B: From scavenging pump, steering lubrication pump
C: R.H. brake oil pressure pickup port (RB)
D: L.H. brake oil pressure pickup port (LB)
E: From the pin puller solenoid valve (Drain)
D155AX-6 41
SEN00605-01 10 Structure, function and maintenance standard
42 D155AX-6
10 Structure, function and maintenance standard SEN00605-01
D155AX-6 43
SEN00605-01 10 Structure, function and maintenance standard
44 D155AX-6
10 Structure, function and maintenance standard SEN00605-01
Outline
D155AX-6 45
SEN00605-01 10 Structure, function and maintenance standard
46 D155AX-6
10 Structure, function and maintenance standard SEN00605-01
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
Replace
1 Brake disc Thickness 4.5 0.1 4.0
Repair or
Strain 0.05 0.14
replace
Large
+0.081
Inner diameter of the diameter 280
+0.081
280.1
seal ring parts
5
contact surface Small
of the brake piston +0.072
diameter 220 220.1
+0.081
parts
Standard size Repair limit
Installation Installation Installation Replace
Brake spring Free length Free length
6 length load load
(2 pieces for 1 set)
35.7 kN 33.9 kN
33 19.6 32.0
{3,640 kg} {3,460 kg}
Standard Tolerance Standard Clearance
Clearance between bevel gear size Shaft Hole clearance limit
7
and reamer bolt
+0.019 +0.027 -0.019-
16 0.026
+0.001 +0.027 0.026
Backlash between the brake
8 0.23 0.42
hub and the disc
Backlash between the brake
9 0.23 0.42
drum and the plate
Backlash between sun gear and
10 0.17 0.52
planetary pinion
Backlash between planetary
11 0.17 0.54
pinion and ring gear
Standard shim thickness of the
12 2.0
retainer
Adjust the shim
Standard shim thickness for
13 0.7
plate
Preload of bevel gear shaft
14 Starting torque for no-loading: 2.94 Nm {0.3 kgm} Adjust
bearing A
D155AX-6 47
SEN00605-01 10 Structure, function and maintenance standard
48 D155AX-6
10 Structure, function and maintenance standard SEN00605-01
Unit: mm
No. Check item Criteria Remedy
Backlash between bevel gear Adjust or
1 0.25 0.33
and bevel pinion replace
Backlash between drive gear
2 0.19 0.62
and gear D
Backlash between gear D and
3 0.18 0.58
gear C
Replace
Backlash between gear B and
4 0.19 0.61
gear A
Backlash between gear D and
5 0.20 0.67
gear A
Standard shim thickness for
6 2.0 Adjust the shim
cage
D155AX-6 49
SEN00605-01 10 Structure, function and maintenance standard
50 D155AX-6
10 Structure, function and maintenance standard SEN00605-01
When steering operation of PCCS lever is at "neutral", HSS motor (7) is stopped.
D155AX-6 51
SEN00605-01 10 Structure, function and maintenance standard
52 D155AX-6
10 Structure, function and maintenance standard SEN00605-01
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 The power from HSS motor (7)
(Forward) (Counterclockwise, viewing from
the left side of the machine body.)
O
Bevel pinion (1) Drive gear (8)
O O
Bevel gear (2) Gear D (9) Gear C (10)
O O
Bevel gear shaft (3) Shaft (11)
O O
Hub (4) Gear B (12)
O O
Ring gear (5) L.H. gear A (13) R.H. gear A (13)
(Counterclockwise, viewing from (Clockwise, viewing from the left
the left side of the machine body.) side of the machine body.)
O O
L.H. sun gear (14) R.H. sun gear (14)
D155AX-6 53
SEN00605-01 10 Structure, function and maintenance standard
54 D155AX-6
10 Structure, function and maintenance standard SEN00605-01
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 The power from HSS motor (7)
(Reverse) (Clockwise, viewing from the left
side of the machine body.)
O
Bevel pinion (1) Drive gear (8)
O O
Bevel gear (2) Gear D (9) Gear C (10)
O O
Bevel gear shaft (3) Shaft (11)
O O
Hub (4) Gear B (12)
O O
Ring gear (5) L.H. gear A (13) R.H. gear A (13)
(Clockwise, viewing from the left (Counteclockwise, viewing from
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 55
SEN00605-01 10 Structure, function and maintenance standard
56 D155AX-6
10 Structure, function and maintenance standard SEN00605-01
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 The power from HSS motor (7)
(Forward) (Clockwise, viewing from the left
side of the machine body.)
O
Bevel pinion (1) Drive gear (8)
O O
Bevel gear (2) Gear D (9) Gear C (10)
O O
Bevel gear shaft (3) Shaft (11)
O O
Hub (4) Gear B (12)
O O
Ring gear (5) 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
SEN00605-01 10 Structure, function and maintenance standard
58 D155AX-6
10 Structure, function and maintenance standard SEN00605-01
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 The power from HSS motor (7)
(Reverse) (Counterclockwise, viewing from
the left side of the machine body.)
O
Bevel pinion (1) Drive gear (8)
O O
Bevel gear (2) Gear D (9) Gear C (10)
O O
Bevel gear shaft (3) Shaft (11)
O O
Hub (4) Gear B (12)
O O
Ring gear (5) L.H. gear A (13) R.H. gear A (13)
(Counterclockwise, viewing from (Clockwise, viewing from the left
the left side of the machine body.) side of the machine body.)
O O
L.H. sun gear (14) R.H. sun gear (14)
D155AX-6 59
SEN00605-01 10 Structure, function and maintenance standard
Brake operation
q When the PCCS lever is in the neutral posi- q If the brake pedal is depressed, the brake
tion and the brake pedal is released, the maxi- pressure applied to the back of brake piston (1)
mum brake pressure is applied to the back of starts to lower by the brake control valve.
brake piston (1) by the brake control valve. q At this time, brake piston (1) is pushed back to
q As the oil pressure rises, brake piston (1) com- the right by the tension of the brake spring (2)
presses brake spring (2) and moves to the left to press discs (3) and plates (4) against brake
to eliminate the pressing force between discs drum (5).Brake drum (5) is fixed to the steering
(3) and plates (4). case.
q The power transmitted from bevel gear shaft q Power towards brake hub (6) or output shaft
through HSS to brake hub (6) is transmitted to (7) is controlled by compressing disc (3) and
output shaft (7), then to the final drive. plate (4).
q The brake force can be adjusted by controlling
the oil pressure applied to the back side of
brake piston (1) according to the stroke of the
brake pedal.
60 D155AX-6
10 Structure, function and maintenance standard SEN00605-01
D155AX-6 61
SEN00605-01 10 Structure, function and maintenance standard
62 D155AX-6
10 Structure, function and maintenance standard SEN00605-01
D155AX-6 63
SEN00605-01 10 Structure, function and maintenance standard
Brake ECMV 1
a ECMV: Abbreviation for Electronic Control Modulation Valve
a Don't try to disassemble it since adjustment for maintaining the performance will be needed.
A: To brake
*1:
P: From pump
S: To parking brake solenoid valve Operated clutches Stamp of the nameplates
T: Drain Brake R*******
DR: Drain
P1: Brake oil pressure pickup port
Outline
1. Fill switch connector
q The brake ECMV keeps the brake oil pressure
2. Proportional solenoid connector
to the set pressure and furthermore changes
3. Pressure detection valve
the circuit to the piston chamber of brake.
4. Fill switch
5. Proportional solenoid
6. Pressure control valve
7. Nameplate (*1)
64 D155AX-6
10 Structure, function and maintenance standard SEN00605-01
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 finish-
ing 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.
Operation of ECMV
q The ECMV is controlled by the command
current from the controller to the propor-
tional solenoid and the fill switch output
signal.
D155AX-6 65
SEN00605-01 10 Structure, function and maintenance standard
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
10 Structure, function and maintenance standard SEN00605-01
When the PCCS lever is operated to the left halfway, brake pedal is released, and parking brake
lever is in free position: Gradual left turn
(L.H. brake is half released, R.H. brake is released, parking brake is released)
q When the PCCS lever is in operated to the left q Accordingly, if the stroke of the PCCS lever is
halfway position and the brake pedal is short, the oil pressure after port (A) is set high
released, proportional solenoid (1) of the and the brake is turned from released to half
brake ECMV is energized and pushes ball (2) released. If the stroke of the PCCS lever is
to the left and closes the sealing part. long, the oil pressure after port (A) is set low
q The oil in port (P) of the brake ECMV flows in and the brake is turned from half released to
chamber (B) and pushes valve (3) to the left.As applied.
for the oil pressure after port (A), the controller q When the parking brake lever is set in the
outputs the command current to proportional free position, the pilot pressure of brake
solenoid (1) according to the stroke of the ECMV port (S) remains, because the parking
PCCS lever. brake solenoid valve is de-energized.
q Proportional solenoid (1) generates the propul-
sion force in proportion to the command cur-
rent. 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.
D155AX-6 67
SEN00605-01 10 Structure, function and maintenance standard
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)
68 D155AX-6
10 Structure, function and maintenance standard SEN00605-01
Solenoid valve
5. Coil (ON-OFF type)
6. Push pin
7. Spring
8. Spool
9. Body
D155AX-6 69
SEN00605-01 10 Structure, function and maintenance standard
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)
q When the parking brake lever is in the lock q When the parking brake lever is in the free
position, the parking brake lever switch is position, the parking brake lever switch is
turned ON and coil (1) of the parking brake OFF and coil (1) of the parking brake sole-
solenoid valve is energized. noid valve is de-energized.
q Spool (3) is pushed to the right direction by q Spool (3) is returned to the left, and close port
push pin (2), then port (P) and (T) are opened (P) and (T) to remain the pilot pressure of the
to drain the pilot pressure of the L.H. and R.H. L.H. and R.H. brake ECMV.
brake ECMV. q The oil pressure from the brake ECMV is
q The oil which had flown into the brake piston applied to the back pressure port of the brake
back pressure port is drained through the piston, and brake is released.
brake ECMV.
q The oil pressure in the back pressure port of
the brake piston continues to decrease, then
the brake is fully applied and that situation is
kept.
q When the engine is started again, as port (P)
and (T) are still opened, the brake is continu-
ously applied.
70 D155AX-6
10 Structure, function and maintenance standard SEN00605-01
EPC valve
2. Coil (proportional type)
3. Push pin
4. Valve
5. Ball
6. Spool
7. Body
D155AX-6 71
SEN00605-01 10 Structure, function and maintenance standard
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 con-
sequently 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 pre-
vention valve (1) is de-energized. Then, the oil
of port (DR) is drained through orifice (a) so
that the brake is applied gradually.
72 D155AX-6
10 Structure, function and maintenance standard SEN00605-01
Final drive 1
Outline
q The final drive is a single stage spur gear, sin-
gle 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 slid-
ing portion of the sprocket to prevent the entry
of dirt or sand and to prevent leakage of lubri-
cating oil.
D155AX-6 73
SEN00605-01 10 Structure, function and maintenance standard
74 D155AX-6
10 Structure, function and maintenance standard SEN00605-01
Unit: mm
No. Check item Criteria Remedy
Backlash between No.1 pinion Standard clearance Clearance limit
18
and No.1 gear 0.25 0.77 0.77
Backlash between sun gear Replace
19 0.20 0.55 0.55
and planetary gear
Backlash between planetary
20 0.22 0.71 0.71
gear and ring gear
Standard size Tolerance Repair limit
Outside diameter of No.1 pin- Repair or
21 0.087
ion oil seal contact surface 95 94.913 replace
0.087
Thickness of thrust collar of
22 23 22.95
inner body roller bearing
Standard Tolerance Standard Clearance
Clearance between outer size clearance limit
Shaft Hole
diameter of planet gear shaft
23
and inner diameter of carrier (Max.
0.015 0.009 - 0.024 Replace
hole. (Small diameter) 68.262 clearance)
0.034 0.039 + 0.025
+ 0.025
Clearance between outer
diameter of planet gear shaft 0.036 0.066 - 0.065
24 90 0.008
and inner diameter of carrier 0.058 0.101 - 0.008
hole.(Large diameter)
Standard shim thickness for
25 2 Adjust
No.1 pinion bearing cage
Standard size Repair limit Repair or
26 Wear of wear guard
67 21 replace
D155AX-6 75
SEN00605-01 10 Structure, function and maintenance standard
q The power from the bevel gear shaft and steer- Then, the rotating force of sun gear (2) forms
ing clutch is transmitted to 1st pinion (10) to the rotating force of carrier (3), which supports
rotate 1st gear (13) meshed with the 1st pinion the planetary gear (7), via shaft (15), and is
and sun gear (2) meshed with the 1st gear. transmitted to sprocket boss (4).
The rotation of sun gear (2) is transmitted to The rotating direction of carrier (3) is the same
planetary gear (7). Since ring gear (8) meshed with sun gear (2).
with the planetary gear is fixed to cover (6), the The rotational force transmitted to sprocket
planetary gear (7) rotates along the ring gear boss (4) is further transmitted to sprocket teeth
(8) and revolves around the sun gear (2). (5).
76 D155AX-6
10 Structure, function and maintenance standard SEN00605-01
D155AX-6 77
SEN00605-01 10 Structure, function and maintenance standard
Sprocket 1
Unit: mm
No. Check item Criteria Remedy
Standard clearance Repair limit
1 Wear of sprocket tooth tip
351 339
2 Wear of sprocket tooth root 23.7 17.5
Rebuid or
Wear of width of sprocket replace
3 83 75
tooth tip
Wear of width of sprocket
4 103 95
tooth root
78 D155AX-6
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D155AX-6 79
SEN00605-01 10 Structure, function and maintenance standard
D155AX-6 Bulldozer
Form No. SEN00605-01
2007 KOMATSU
All Rights Reserved
Printed in Japan 03-07 (02)
80 D155AX-6
SEN00606-01
D155AX-6
D155AX-6 1
SEN00606-01 10 Structure, function and maintenance standard
Track frame 1
2 D155AX-6
10 Structure, function and maintenance standard SEN00606-01
Unit: mm
No. Check item Criteria Remedy
Item Repair limit
Curvature 7 (over length of 3,000) Correct or
4 Deformation of track frame
Twisting 3 (over length of 300) replace
Dents (pipe portion) 12
D155AX-6 3
SEN00606-01 10 Structure, function and maintenance standard
Recoil spring 1
1. Yoke Outline
2. Dust seal q Recoil spring (4) is used to adjust the track ten-
3. Rod sion by pumping in or releasing grease from
4. Recoil spring lubricator (6) to move rod (3) forward or back-
5. Wear ring ward. The recoil spring also acts to dampen
any sudden shock brought to bear on the idler.
6. Lubricator
7. Nut
8. Housing
9. Cylinder
10. Holder
11. Bushing
4 D155AX-6
10 Structure, function and maintenance standard SEN00606-01
Unit: mm
No. Check item Criteria Remedy
Press-fitting force for
1 392 kN {40 ton} Adjust
idler yoke
Standard Tolerance Standard Clearance
Clearance between rod size Shaft Hole clearance limit
11
and bushing
0.036 +0.277 0.098
120 1.0
0.090 +0.062 0.367
Standard size Repair limit Replace
Installed Installed Installed
Free length Free length
4 Recoil spring length load load
314 kN 288 kN
859 656 804
{32,000 kg} {29,400 kg}
D155AX-6 5
SEN00606-01 10 Structure, function and maintenance standard
Idler 1
6 D155AX-6
10 Structure, function and maintenance standard SEN00606-01
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Outer diameter of protrusion
792
2 Outer diameter of tread 750 725
Rebuild or
3 Depth of tread 21 33.5
replace
4 Thickness of tread 24 11.5
5 Width of tread 58.5
6 Overall width 240
Standard Tolerance Standard Clearance
Clearance between shaft size Shaft Hole clearance limit
7
and bushing
0.350 +0.265 0.353
140
0.413 +0.003 0.678 Replace
Tolerance bushing
Standard Standard Interference
Interference between shaft size Shaft Hole interference limit
8
and ring
+0.046 +0.13 0.130
75
+0.046 0.18 0.226
Standard size Repair limit Rebuild or
9 Play of shaft in axial direction
0.4 0.9 replace
D155AX-6 7
SEN00606-01 10 Structure, function and maintenance standard
Track roller 1
8 D155AX-6
10 Structure, function and maintenance standard SEN00606-01
Unit: mm
No. Check item Criteria Remedy
Outer diameter of flange Standard size Repair limit
1
(outside flange) 285
Outer diameter of flange
2 275
(inside flange)
3 Outer diameter of tread 250 210
4 Thickness of tread 57.5 37.5
5 Overall width 295
Rebuild or
Width of tread
6 61 replace
(single flange)
Width of tread
7 61
(double flange)
Flange width
8 25
(outside of double flange)
Flange width
9 22
(inside of double flange)
10 Shaft flange width 246
Tolerance Standard
Standard size
Clearance between shaft Shaft Hole clearance
11
and bushing
0.350 +0.260
125 0.360 0.673
0.413 +0.010
Replace
Tolerance Standard
Standard size
Interference between shaft Shaft Hole interference
12
and ring
+0.046 0.15
65 0.150 0.246
+0.000 0.20
Standard size Clearance limit Adjust or
13 End play
0.44 0.91 replace
D155AX-6 9
SEN00606-01 10 Structure, function and maintenance standard
Carrier roller 1
10 D155AX-6
10 Structure, function and maintenance standard SEN00606-01
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Outer diameter of flange
220
2 Outer diameter of tread 190 167 Rebuild or
3 Width of tread 63 replace
4 Thickness of tread 37.5 26
5 Width of flange 21
Tolerance Standard
Standard size
Interference between Shaft Hole interference
6
shaft and ring
+0.166 +0.030
70 0.090 0.166
+0.120 +0.030
Tolerance Standard
Standard size Replace
Clearance between Shaft Hole clearance
7
shaft and support
0.2 +0.300
68 0 0.5
0.2 +0.030
Standard clearance
8 Play of roller in axial direction
0.010 0.230
D155AX-6 11
SEN00606-01 10 Structure, function and maintenance standard
Track shoe 1
Dry type
12 D155AX-6
10 Structure, function and maintenance standard SEN00606-01
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Link pitch 231.85 (Heavy-duty areas)
228.85
233.85 (Standard areas)
When turned Reverse or
Standard size replace
2 Bushing outside diameter Normal load Impact load
81 75.0 77.0
3 Thickness of bushing metal 15.8 9.8 11.8
Standard size Repair limit
4 Link height
144 128 Repair or
replace
Thickness of link metal
5 45.5 29.5
(bushing press-fitting portion)
Tightening torque Additional tightening
6 Shoe bolt (Nm {kgm}) angle (deg.) Retighten
588.4 58.8 {60 6} 120 10
Tolerance Standard
Standard size
Interference between Shaft Hole interference
7
bushing and link
+0.404 +0.074
77.0 0.230 0.404
+0.304 +0.074
Interference between +0.484 0.038
8a 48.5 0.372 0.584 Adjust or
regular pin and link +0.334 0.100
replace
Interference between +0.230 0.038
8b 48.5 0.238 0.330
master pin and link +0.200 0.100
Standard clearance
9 Clearance between links One side Both side
1.4 2.8
D155AX-6 13
SEN00606-01 10 Structure, function and maintenance standard
14 D155AX-6
10 Structure, function and maintenance standard SEN00606-01
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Link pitch
228.85 231.85
When turned Reverse or
Standard size
2 Bushing outside diameter Normal load Impact load replace
81 72.5 75.0
3 Thickness of bushing metal 15.8 7.3 9.8
Standard size Repair limit
4 Link height
144 128 Repair or
replace
Thickness of link metal
5 45.5 29.5
(bushing press-fitting portion)
Tightening torque Additional tightening
a. Regular link (Nm {kgm}) angle (deg.)
6 Shoe bolt Retighten
588.4 58.8 {60 6} 120 10
b. Master link 588.4 58.8 {60 6} 180 10
Standard Tolerance Standard
Interference between size Shaft Hole interference
7
bushing and link
+0.404 +0.074
77.0 0.230 0.404
+0.304 +0.074
Adjust or
Interference between +0.484 0.038
8 48.5 0.372 0.584 replace
regular pin and link +0.334 0.100
Standard clearance
9 Clearance between links One side Both side
1.4 2.8
D155AX-6 15
SEN00606-01 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Height of
1 single 80 30
grouser
Repair or
heavy duty 80 30
replace
Overall height single 97 47
2
of shoe heavy duty 99 49
16 D155AX-6
10 Structure, function and maintenance standard SEN00606-01
D155AX-6 17
SEN00606-01 10 Structure, function and maintenance standard
Main frame 1
18 D155AX-6
10 Structure, function and maintenance standard SEN00606-01
1. Main frame
2. Cage
3. Clamp
4. Cover
5. Seal
6. Coupling
7. Cap
8. Plate
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between size clearance limit
Shaft Hole
9 equalizer bar shaft Replace
and bushing 0.036 +0.213 0.165
95 1.0
0.090 +0.129 0.303
Press-fitting force for
10 equalizer bar shaft 29.42 68.65 kN {3 7 ton} Adjust
mounting bushing
D155AX-6 19
SEN00606-01 10 Structure, function and maintenance standard
Suspension 1
20 D155AX-6
10 Structure, function and maintenance standard SEN00606-01
Unit: mm
No. Check item Criteria Remedy
Press-fitting force for side
9 pin bushing 27.46 64.7 kN {2.8 6.6 ton}
Press-fitting force for center
12 pin bushing 47.07 131.41 kN {4.8 13.4 ton}
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 10 Structure, function and maintenance standard
D155AX-6 Bulldozer
Form No. SEN00606-01
2007 KOMATSU
All Rights Reserved
Printed in Japan 03-07 (02)
22 D155AX-6
SEN00607-01
D155AX-6
D155AX-6 1
SEN00607-01 10 Structure, function and maintenance standard
2 D155AX-6
10 Structure, function and maintenance standard SEN00607-01
Multi-shank ripper
1. Control valve
2. Divider block
3. Ripper lift cylinder
4. Ripper tilt cylinder
D155AX-6 3
SEN00607-01 10 Structure, function and maintenance standard
Giant ripper
1. Control valve
2. Divider block
3. Ripper lift cylinder
4. Pin puller cylinder
5. Ripper tilt cylinder
6. Pin puller solenoid valve
4 D155AX-6
10 Structure, function and maintenance standard SEN00607-01
D155AX-6 5
SEN00607-01 10 Structure, function and maintenance standard
6 D155AX-6
10 Structure, function and maintenance standard SEN00607-01
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 7
SEN00607-01 10 Structure, function and maintenance standard
8 D155AX-6
10 Structure, function and maintenance standard SEN00607-01
Specified
value
Tank capacity (l) 125
Hydraulic Hi (l) 95
Level
tank inside Center (l) 85
tank
Low (l) 75
Cracking pressure 16.76.9
Breather (kPa {kg/cm2}) {0.170.07}
cap Vacuum valve actuating 0 0.49
pressure (kPa {kg/cm2}) {0 0.005}
Cracking pressure 14729.4
(kPa {kg/cm2}) {1.50.31}
Hydraulic Mesh size ( m) 20/10/3
filter
Filtering area (cm2) 13,600
Filtering oil flow (l/min) 550
Mesh size ( m) 105
Strainer
Filtering area (cm2) 1,850
D155AX-6 9
SEN00607-01 10 Structure, function and maintenance standard
Accumulator 1 Function
q The accumulator is installed between the
For EPC valve redusing valve and the EPC valve. Even if the
engine is started with the work equipment still
raised, the pressure of the nitrogen gas com-
pressed 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
q After the engine is stopped, when the EPC
valve is at neutral, chamber (A) inside the blad-
der is compressed by the oil pressure in cham-
ber (B).
q When the EPC valve is operated, the oil pres-
sure 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.
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. 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}
10 D155AX-6
10 Structure, function and maintenance standard SEN00607-01
PCCS lever 1
(For blade, ripper)
a Do not disassemble.
Otherwise, adjustments will be required for the characteristics of voltage output and operating efforts.
1. Boot
2. Nut
3. Connector
D155AX-6 11
SEN00607-01 10 Structure, function and maintenance standard
(For steering)
a Do not disassemble.
Otherwise, adjustments will be required for the characteristics of voltage output and operating efforts.
1. Boot 5. Screw
2. Bracket 6. Lever
3. Plate 7. Connector
4. Bolt
12 D155AX-6
10 Structure, function and maintenance standard SEN00607-01
Function
(For steering)
1) Operation for forward and reverse travel
q The control lever is held at 3 positions:
forward, neutral and reverse.
D155AX-6 13
SEN00607-01 10 Structure, function and maintenance standard
14 D155AX-6
10 Structure, function and maintenance standard SEN00607-01
1. Solenoid
2. Body
3. 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 equip-
ment.
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 pres-
sure valve and port (B) connected to the con-
trol valve is opened.
D155AX-6 15
SEN00607-01 10 Structure, function and maintenance standard
Control valve 1
Outline
q This manual explains the 5-spool valve (single
tilt specification) and 6-spool valve (dual tilt
specification).
1. EPC valve
16 D155AX-6
10 Structure, function and maintenance standard SEN00607-01
Outside view
5-spool valve (single tilt specification)
D155AX-6 17
SEN00607-01 10 Structure, function and maintenance standard
1. EPC valve
18 D155AX-6
10 Structure, function and maintenance standard SEN00607-01
D155AX-6 19
SEN00607-01 10 Structure, function and maintenance standard
Sectional view
(1/8)
5-spool valve
20 D155AX-6
10 Structure, function and maintenance standard SEN00607-01
(2/8)
6-spool valve
D155AX-6 21
SEN00607-01 10 Structure, function and maintenance standard
1. Steering spool
2. Blade tilt spool
3. Blade lift spool
4. Blade tilt (pitch) spool (only for 6-spool valve)
5. Ripper lift spool
6. Ripper tilt spool
7. Valve block
8. Valve block
9. Valve block (only for 6-spool valve)
10. Valve body
11. Steering priority valve
12. Load check valve
13. Pressure compensation valve
14. Filter
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installation Installation Free Installation
x outer
length load length load
15 Spool return spring diameter
140 N 112 N
51.7 x 31.3 50
{14.3 kg} {11.4 kg}
224 N 179 N
16 Spool return spring 76.3 x 30 68.5
{22.8 kg} {18.2 kg}
217 N 173 N
17 Spool return spring 54.7 x 36.5 33.5
{22.1 kg} {17.7 kg}
Load check valve 12.7 N 10.2 N Replace spring
18 20.8 x 12.2 13.5 if damaged or
spring {1.3 kg} {1.04 kg}
deformed.
Pressure compensation 468 N 374 N
19 67.04 x 26.5 62.5
valve spring {47.7 kg} {38.2 kg}
Pressure compensation 562 N 450 N
20 108.3 x 29.5 81
valve spring {57.3 kg} {45.8 kg}
Pressure compensation 453 N 362 N
21 97.7 x 29.5 81
valve spring {46.2 kg} {37 kg}
Pressure compensation 563 N 450 N
22 109.4 x 29.5 81
valve spring {57.4 kg} {45.9 kg}
192 N 154 N
23 Unload valve spring 86.7 x 30 66
{19.6 kg} {15.7 kg}
22 D155AX-6
10 Structure, function and maintenance standard SEN00607-01
(3/8)
5-spool valve
D155AX-6 23
SEN00607-01 10 Structure, function and maintenance standard
(4/8)
6-spool valve
24 D155AX-6
10 Structure, function and maintenance standard SEN00607-01
(5/8)
D155AX-6 25
SEN00607-01 10 Structure, function and maintenance standard
(6/8)
1. EPC valve
2. Suction valve
26 D155AX-6
10 Structure, function and maintenance standard SEN00607-01
(7/8)
D155AX-6 27
SEN00607-01 10 Structure, function and maintenance standard
1. EPC valve
2. Suction valve
3. LS bypass valve
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installation Installation Free Installation
x outer Replace spring if
length load length load
4 Suction valve spring diameter damaged or
5.49 N 4.41 N deformed.
46.8 x 7.5 40.6
{0.56 kg} {0.45 kg}
28 D155AX-6
10 Structure, function and maintenance standard SEN00607-01
(8/8)
1. EPC valve
2. Suction valve
D155AX-6 29
SEN00607-01 10 Structure, function and maintenance standard
30 D155AX-6
10 Structure, function and maintenance standard SEN00607-01
1. Steering valve
1) At hold
D155AX-6 31
SEN00607-01 10 Structure, function and maintenance standard
PLS = Differential pressure between ports (K) q Chamber (C) and chamber (D) are connected,
and (J) = 2.0 MPa {20 kg/cm2} and the oil from the pump flows through ports
PLS' = Differential pressure between ports I (A), (B), (C) and (D) to HSS motor (6).
and D q At the same time, the load pressure in cham-
PLS C PLS' ber (D) passes through LS orifice (5) and
chamber (H), and is sent to chamber (G). It is
Operation also sent from LS circuit (O) to pump LS valve.
q The condition of the pressure of pressure com-
q When the PCCS lever is operated to turn the
pensation valve spool (3) is chamber (B) pres-
machine to the left, pilot pressure (PI) acts
sure C chamber (C) pressure, and chamber (G)
on the right end of steering spool (1) through
pressure C chamber (D) pressure, so pressure
the EPC valve.
compensation spool (3) is controlled by the dif-
q When the pressure becomes greater than the
ferential pressure of steering spool (1) (cham-
set load of spring (2), the steering spool (1)
ber (C) pressure - chamber (D) pressure), and
moves to the left. It becomes balanced at a
balances with spring (4).
position that matches pilot pressure (PI).
32 D155AX-6
10 Structure, function and maintenance standard SEN00607-01
D155AX-6 33
SEN00607-01 10 Structure, function and maintenance standard
34 D155AX-6
10 Structure, function and maintenance standard SEN00607-01
Operation
q When blade lift spool (1) is at the hold posi-
tion, 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 com-
pensation 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 35
SEN00607-01 10 Structure, function and maintenance standard
3. Meter-out control when blade moves down under its own weight
36 D155AX-6
10 Structure, function and maintenance standard SEN00607-01
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
q 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.
D155AX-6 37
SEN00607-01 10 Structure, function and maintenance standard
4. Meter-out control when blade moves down under its own weight
(work equipment lever at float)
38 D155AX-6
10 Structure, function and maintenance standard SEN00607-01
Function
q When the blade lift valve is at float, the cylin-
der 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 condi-
tion, the pump passage and cylinder ports (A3)
and (B3) are separated so that the other con-
trol valves can be operated.
Operation
q 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/cm 2 or more
and blade lift spool (1) is moved to the maxi-
mum 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.
D155AX-6 39
SEN00607-01 10 Structure, function and maintenance standard
At relief
1. Steering valve
a The diagram shows the condition at relief for steering LS relief valve (5).
40 D155AX-6
10 Structure, function and maintenance standard SEN00607-01
Function
q It sets the maximum pressure when HSS
motor (7) is operated.
Operation
q 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 cham-
bers (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 + leak-
age 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 41
SEN00607-01 10 Structure, function and maintenance standard
42 D155AX-6
10 Structure, function and maintenance standard SEN00607-01
Operation
q If blade tilt spool (1) is moved and the pres-
sure 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 cham-
bers (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 differen-
tial 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 + leak-
age 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 43
SEN00607-01 10 Structure, function and maintenance standard
44 D155AX-6
10 Structure, function and maintenance standard SEN00607-01
= 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 pres-
sure 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 pres-
sure (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 compen-
sation 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 mini-
mum 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 equip-
ment LS relief valve (5).
D155AX-6 45
SEN00607-01 10 Structure, function and maintenance standard
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.
46 D155AX-6
10 Structure, function and maintenance standard SEN00607-01
D155AX-6 47
SEN00607-01 10 Structure, function and maintenance standard
48 D155AX-6
10 Structure, function and maintenance standard SEN00607-01
Function
q It consists of a parallel circuit, so when com-
pound operations are carried out, the oil flow is
divided according to the size of each spool
opening.
Operation
q 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 pres-
sure.
D155AX-6 49
SEN00607-01 10 Structure, function and maintenance standard
50 D155AX-6
10 Structure, function and maintenance standard SEN00607-01
Function
q This improves the response of the system
including the pump swash plate and pressure
compensation valve by sending the pilot pres-
sure (basic pressure of EPC valve) to the LS
circuit, and compensating the rise of the LS cir-
cuit pressure.
Operation
q 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 compensa-
tion valve. This pressure is called preset pres-
sure (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 cham-
bers (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 sup-
plied 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.
D155AX-6 51
SEN00607-01 10 Structure, function and maintenance standard
Ripper cylinder
a The piping of the lift cylinder and tilt cylinder of the variable multi-shank ripper is different from the
above.
52 D155AX-6
10 Structure, function and maintenance standard SEN00607-01
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
size Shaft Hole clearance limit
Blade -0.030 +0.279 0.095
75 0.666
LIFT -0.076 +0.065 0.355
Clearance between
1 piston rod and bush- Blade 90
-0.036 +0.270 0.097
0.695
ing TILT -0.090 +0.061 0.330
Ripper -0.036 +0.257 0.105
100 0.675
LIFT -0.090 +0.047 0.375
Ripper -0.036 +0.261 0.105
110 0.675
TILT -0.090 +0.047 0.375
Clearance between
piston rod support Blade +0.3
2 85 1.0
shaft and blade LIFT +0.3
ball portion
Clearance between Replace
Blade -0.100 0.100
3 cylinder support 85 0.5
LIFT -0.174 0.228
shaft and bushing
Clearance between
Blade -0.200
4 piston rod spherical 115
TILT -0.300
surface and cap
Blade -0.030 +0.174 0.130
60 1.0
TILT -0.050 +0.100 0.224
Clearance between
cylinder bottom sup- Ripper -0.036 +0.207 0.156
5 90 1.0
port shaft and bush- LIFT -0.090 +0.120 0.297
ing
Ripper -0.036 +0.201 0.156
100 1.0
TILT -0.090 +0.119 0.291
Clearance between Ripper -0.036 +0.207 0.156
90 1.0
cylinder rod sup- LIFT -0.090 +0.120 0.297
6
port shaft and bush- Ripper -0.036 +0.201 0.156
ing 100 1.0
TILT -0.090 +0.119 0.291
D155AX-6 53
SEN00607-01 10 Structure, function and maintenance standard
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 cylin-
der to rise and moving piston (2) in the direc-
tion of the arrow.
54 D155AX-6
10 Structure, function and maintenance standard SEN00607-01
D155AX-6 55
SEN00607-01 10 Structure, function and maintenance standard
56 D155AX-6
10 Structure, function and maintenance standard SEN00607-01
1. Body
2. Main spool
3. Plate
4. Body
5. Selector valve spool
6. EPC valve
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between main size Shaft Hole clearance limit
7
spool and valve body
-0.002 +0.010 0.008
36 0.015 Replace
-0.007 +0.010 0.010
Clearance between selec-
-0.010 +0.018 0.010
8 tor valve spool and valve 6 0.02
-0.022 +0.010 0.015
body
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installation Installation Installation
x outer Free length
Main spool return length load load Replace
9 diameter
spring spring if dam-
449 N 359 N aged or
76.4 x 27 69.5
{45.8 kg} {36.6 kg} deformed.
Selector valve spool return 97 N 77.6 N
10 20.9 x 13.8 12.5
spring {9.89 kg} {7.91 kg}
D155AX-6 57
SEN00607-01 10 Structure, function and maintenance standard
1. No circulating condition
q Fine control of lowering blade (Stroke of lever is less than 70%.)
q QDV mode: OFF
58 D155AX-6
10 Structure, function and maintenance standard SEN00607-01
2. Circulating condition
q Lowering blade (Stroke of lever is more than 70%.)
q QDV mode: ON
D155AX-6 59
SEN00607-01 10 Structure, function and maintenance standard
3. From the circulating condition of lowering blade to the blade tensed condition
q Lowering blade (Stroke of lever is more than 70%.)
q QDV mode: ON
60 D155AX-6
10 Structure, function and maintenance standard SEN00607-01
T: To tank
P1: From pump
P2: To fan motor
PR: Supply to PPC valve and EPC valve
D155AX-6 61
SEN00607-01 10 Structure, function and maintenance standard
62 D155AX-6
10 Structure, function and maintenance standard SEN00607-01
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installation Installation Free Installation
Spring (pressure reducing x outer
11 length load length load
valve main) diameter
19.6 N 17.7 N
19.2 x 7.20 16.1
{2.0 kg} {1.80 kg} Replace spring
Spring if damaged or
28 N 25.6 N deformed.
12 (pressure reduction valve 17.8 x 7.20 12.7
{2.90 kg} {2.60 kg}
pilot)
200 N 186 N
13 Spring 71.0 x 18.0 59.0
{20.4 kg} {19.0 kg}
61.7 N 58.8 N
14 Spring (safety valve) 16.1 x 7.80 13.4
{6.30 kg} {6.0 kg}
Function
q The self pressure reducing valves reduce the
discharge pressure of the fan pump and sup-
plies it to the PPC valve, the EPC valve, etc. as
the control pressure.
D155AX-6 63
SEN00607-01 10 Structure, function and maintenance standard
Operation
At engine stop (total low pressure)
64 D155AX-6
10 Structure, function and maintenance standard SEN00607-01
When load pressure (P2) is lower than output pressure (PR) of the self pressure reducing valve.
D155AX-6 65
SEN00607-01 10 Structure, function and maintenance standard
66 D155AX-6
10 Structure, function and maintenance standard SEN00607-01
D155AX-6 67
SEN00607-01 10 Structure, function and maintenance standard
D155AX-6 Bulldozer
Form No. SEN00607-01
2007 KOMATSU
All Rights Reserved
Printed in Japan 03-07 (02)
68 D155AX-6
SEN00608-01
D155AX-6
D155AX-6 1
SEN00608-01 10 Structure, function and maintenance standard
Cylinder stay 1
1. Yoke
2. Dust seal
3. Bushing
4. Bushing
5. Grease nipple
2 D155AX-6
10 Structure, function and maintenance standard SEN00608-01
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between cylinder size Shaft Hole clearance limit
6
yoke and bushing
0.172 +0.063 0.172
125
0.235 +0.046 0.298
Replace
Clearance between cylinder 0.170 +0.054 0.170
7 100
yoke and bushing 0.224 +0.046 0.278
Clearance between bushing
0.172 +0.054 0
8 of cylinder support shaft and 110 0.5
0.035 +0.046 0.089
yoke
D155AX-6 3
SEN00608-01 10 Structure, function and maintenance standard
Blade 1
Sigma-tilt dozer
4 D155AX-6
10 Structure, function and maintenance standard SEN00608-01
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between brace size Shaft Hole clearance limit
1 Replace
and pin
0.3 +0.174 0.4
60 2
0.5 +0.100 0.674
Clearance between brace 0.3 +0.5 Adjust shims
2 60 0.5 1.0 2
pin and bracket 0.5 +0.2 or replace
Clearance between brace 0.2 +0.3
3 115 0.2 0.6 1
spherical surface and cap 0.3 +0.6
Clearance between 0.3 +0.3
4 90 0.4 0.8 2
brace pin and bracket 0.5 +0.1
Clearance between brace 0.3 +0.5
5 90 0.6 1.0 2
pin and brace 0.5 +0.3
Clearance between joint 0.2 +0.5
6 140 0.5 1.2 2 Replace
and blade bracket 0.7 +0.3
Clearance between frame 0.5 +0.3
7 70 0.5 0.9 3
pin and joint 0.6 +0.6
Clearance between bracket 0.5 +0.3
8 70 0.5 0.9 3
pin and blade bracket 0.6 +0.6
Clearance between blade 0.5 +0.3
9 70 0.5 0.9 3
bracket pin and joint 0.6 +0.6
Clearance between center
0.2 +0.3 Adjust shims
10 brace spherical surface 165 0.2 0.6 1 or replace
0.3 +0.6
and cap
Clearance between trunnion 0.5 +0.5
11 160 0.5 1.5 8
spherical surface and cap 1.0 +0.0
Replace
Clearance between trunnion 0.5 +0.5
12 195 0.5 1.5 8
spherical surface and cap 1.0 +0.0
D155AX-6 5
SEN00608-01 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit Turn
1 Height of cutting edge
330 260 (215 to turning) or replace
2 Height of outside of end bit 300 235
3 Height of inside of end bit 330 260 Replace
4 Width of end bit 640 500
6 D155AX-6
10 Structure, function and maintenance standard SEN00608-01
D155AX-6 7
SEN00608-01 10 Structure, function and maintenance standard
Ripper 1
Variable multi-shank ripper
8 D155AX-6
10 Structure, function and maintenance standard SEN00608-01
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between arm size clearance limit
Shaft Hole
1,7 mounting pin and mounting
bracket or beam bracket 0.036 +0.207 0.156
110 1.5
0.090 +0.120 0.297
Clearance between arm 0.036 +0.459 0.405
2,8 110 1.5
mounting pin and bushing 0.090 +0.369 0.549
Clearance between tilt cylin-
0.036 +0.207 0.156
3,9 der mounting pin and mount- 100 1.5
0.090 +0.120 0.297
ing bracket or beam bracket
Clearance between tilt cylin- 0.036 +0.457 0.406
4,10 100 1.5
der mounting pin and bushing 0.090 +0.370 0.547
Clearance between lift cylinder
0.036 +0.207 0.156
5,11 mounting pin and mounting 90 1.5 Replace
0.090 +0.120 0.297
bracket or beam bracket
Clearance between lift cylinder
0.036 +0.207 0.156
6,12 mounting pin and shank bush- 90 1.5
0.090 +0.120 0.297
ing
Clearance between shank
Shaft 75 +0.300 +0.300 1.400
13 mounting pin and shank 10.0
Hole 77 0.300 0.300 2.600
holder
Clearance between shank Shaft 75 +0.300 +1.000 3.700
14 15.0
mounting pin and shank hole Hole 80 0.300 1.000 6.300
Standard size Repair limit
15 Wear of point
335 225
16 Wear of protector 115 90
D155AX-6 9
SEN00608-01 10 Structure, function and maintenance standard
10 D155AX-6
10 Structure, function and maintenance standard SEN00608-01
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between arm size clearance limit
Shaft Hole
1,7 mounting pin and mounting
bracket or beam bracket 0.036 +0.207 0.156
110 1.5
0.090 +0.120 0.297
Clearance between arm 0.036 +0.459 0.405
2,8 110 1.5
mounting pin and bushing 0.090 +0.369 0.549
Clearance between tilt cylin-
0.036 +0.207 0.156
3,9 der mounting pin and mount- 100 1.5
0.090 +0.120 0.297
ing bracket or beam bracket
Clearance between tilt cylin- 0.036 +0.457 0.406
4,10 100 1.5
der mounting pin and bushing 0.090 +0.370 0.547
Clearance between lift cylinder
0.036 +0.207 0.156
5,11 mounting pin and mounting 90 1.5 Replace
0.090 +0.120 0.297
bracket or beam bracket
Clearance between lift cylinder
0.036 +0.207 0.156
6,12 mounting pin and shank bush- 90 1.5
0.090 +0.120 0.297
ing
Clearance between shank
Shaft 75 +0.300 +0.300 1.400
13 mounting pin and shank 10.0
Hole 77 0.300 0.300 2.600
holder
Clearance between shank Shaft 75 +0.300 +1.000 3.700
14 15.0
mounting pin and shank hole Hole 80 0.300 1.000 6.300
Standard size Repair limit
15 Wear of point
335 225
16 Wear of protector 115 90
D155AX-6 11
SEN00608-01 10 Structure, function and maintenance standard
D155AX-6 Bulldozer
Form No. SEN00608-01
2007 KOMATSU
All Rights Reserved
Printed in Japan 03-07 (02)
12 D155AX-6
SEN00609-01
D155AX-6
D155AX-6 1
SEN00609-01 10 Structure, function and maintenance standard
1. Support Outline
2. Damper mount (front) q Viscous mounts are installed at two places at
3. Damper mount (rear) the front and two places at the rear to secure
4. ROPS pin (front) the floor frame and cab.
5. ROPS pin (rear) 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.
2 D155AX-6
10 Structure, function and maintenance standard SEN00609-01
ROPS cab 1
Cab assembly
1. Front wiper
2. Front glass
3. Rear wiper
4. Door
5. ROPS sub (built in CAB)
D155AX-6 3
SEN00609-01 10 Structure, function and maintenance standard
Air conditioner 1
Air conditioner piping
4 D155AX-6
10 Structure, function and maintenance standard SEN00609-01
D155AX-6 5
SEN00609-01 10 Structure, function and maintenance standard
D155AX-6 Bulldozer
Form No. SEN00609-01
2007 KOMATSU
All Rights Reserved
Printed in Japan 03-07 (02)
6 D155AX-6
SEN00610-01
D155AX-6
D155AX-6 1
SEN00610-01 10 Structure, function and maintenance standard
Engine control 1
2 D155AX-6
10 Structure, function and maintenance standard SEN00610-01
D155AX-6 3
SEN00610-01 10 Structure, function and maintenance standard
Deceleration potentiometer 1
1. Connector Outline
2. Lever q The deceleration potentiometer is installed to
3. Body the inside of the dashboard and connected to
4. Potentiometer the decelerator pedal by linkage.
5. Cuppling q If the decelerator pedal is pressed, it rotates
6. Shaft the throttle potentiometer shaft through the
7. Stopper linkage and the potentiometer resistance
changes.
Constant voltage is applied between pins (A)
and (C) of the potentiometer and a voltage sig-
nal is sent through pin (B) to the engine con-
troller according to the position of the
decelerator pedal.
4 D155AX-6
10 Structure, function and maintenance standard SEN00610-01
D155AX-6 5
SEN00610-01 10 Structure, function and maintenance standard
Monitor system 1
q The monitor system monitors the machine con- q The CPU (Central Processing Unit) in the mon-
dition with the sensors installed to various itor panel displays and outputs various infor-
parts of the machine and processes and dis- mation items processed by the power train
plays the obtained information on the panel controller. The display unit is LCD (Liquid Crys-
quickly to notify the operator of the machine tal Display)
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,
6 D155AX-6
10 Structure, function and maintenance standard SEN00610-01
Other items
Contents and conditions of processing Method Flow of signals
01 Monitoring
02 Trouble history
03 Maintenance history
04 Maintenance mode change
05 Telephone number set
06 Default
07 Adjustment
08 PM clinic
09 Reduced cylinders mode operation
10 No injection cranking
11 Fuel consumption display
12
13 Service message display
88 Screen adjustment a
89
a See testing and adjusting, special functions of machine monitor.
D155AX-6 7
SEN00610-01 10 Structure, function and maintenance standard
Machine monitor
8 D155AX-6
10 Structure, function and maintenance standard SEN00610-01
CN-CM02 CN-CM04
Input/ Input/
Pin No. Signal name output Pin No. Signal name output
1 NC(*) 1 NC(*)
2 NC(*) 2 NC(*)
3 Coolant level sensor Input 3 NC(*)
4 NC(*) 4 NC(*)
5 NC(*) 5 NC(*)
6 NC(*) 6 NC(*)
7 Chassis signal GND 7 NC(*)
8 CAN terminating resistance 8 NC(*)
9 CAN_H Input/ 9 NC(*)
Output
10 NC(*)
10 CAN_L Input/
Output 11 NC(*)
11 NC(*) 12 NC(*)
12 NC(*) *: Never connect to NC or malfunctions or failures will
occur.
*: Never connect to NC or malfunctions or failures will
occur.
CN-CM05
Input/
Pin No. Signal name
output
1 Electric power supply for camera Output
2 Camera NTSC signal input 1 Input
3 Camera NTSC signal input 2 Input
4 Camera NTSC signal input 3 Input
5 Electric power supply GND for camera
6 Camera signal GND1
7 Camera signal GND2
8 Camera signal GND3
D155AX-6 9
SEN00610-01 10 Structure, function and maintenance standard
10 D155AX-6
10 Structure, function and maintenance standard SEN00610-01
D155AX-6 11
SEN00610-01 10 Structure, function and maintenance standard
Below 49.0kPa
Engine oil pressure
{0.5kg/cm2}
Above 105C:
Symbol ON + buzzer Display when normal: OFF
When at highest level on Display when abnormal: ON
engine coolant Alarm buzzer sounds
temperature gauge
Torque converter oil tem-
Above 120C:
perature
Symbol ON
Above 130C:
Symbol ON + buzzer
Above 100C:
Symbol ON
Hydraulic oil temperature
Above 110C:
Symbol ON + buzzer
12 D155AX-6
10 Structure, function and maintenance standard SEN00610-01
Display
Symbol Display item Display range Display method
category
Engine coolant
temperature
Service meter
From 0 to 99999 Actuated when the engine is rotating
(Hours meter)
D155AX-6 13
SEN00610-01 10 Structure, function and maintenance standard
Gauge
The gauge pointer disappears when information on coolant temperature or hydraulic oil temperature cannot
be obtained due to disconnection of CAN.
Temperature or vol-
Gauge Range ume Indicator Buzzer sound
A1 105 Red Q
A2 102 Red
Engine coolant A3 100 Off
temperature
(C) A4 85 Off
A5 60 Off
A6 30 White
B1 130 Red Q
B2 120 Red
Power train oil B3 118 Off
temperature
(C) B4 90 Off
B5 50 Off
B6 0 White
C1 110 Red Q
C2 100 Red
Hydraulic oil C3 98 Off
temperature
(C) C4 70 Off
C5 20 Off
C6 0 White
D1 565 Off
D2 425 Off
D3 310 Off
Fuel level (l)
D4 220 Off
D5 150 Off
D6 75 Red
14 D155AX-6
10 Structure, function and maintenance standard SEN00610-01
1. 0 km/h 3. 10 km/h 1. 0 V 4. 25 V
2. 5 km/h 4. 15 km/h 2. 17 V 5. 30 V
3. 20 V 6. 31 V
D155AX-6 15
SEN00610-01 10 Structure, function and maintenance standard
Selects item on left side (Selects right end item after left
F3 Select item
end item).
Selects item on right side (Selects left end item after right
F4 Select item
end item).
16 D155AX-6
10 Structure, function and maintenance standard SEN00610-01
D155AX-6 17
SEN00610-01 10 Structure, function and maintenance standard
Maintenance function
q Pressing F5 on the normal screen switches to
the maintenance screen.
Replacement interval
No. Item
(Hours)
01 Engine oil 500
02 Engine oil filter 500
03 Fuel main filter 1000
F1 : Displays the next page. 41 Fuel pre filter 500
Displays the top page when the last page is 04 Hydraulic filter 2000
displayed.
06 Corrosion resistor 1000(*)
F2 : Displays the previous page.
07 Damper case oil 2000
Displays the last page when the top page is
08 Final drive case oil 1000
displayed.
10 Hydraulic oil 2000
F3 : Selects (highlights) an item one down.
19 P/L oil 1000
F4 : Selects (highlights) an item one up.
F5 : Returns to the normal screen. 20 P/L oil filter 500
F6 : Switches to the maintenance time reset screen. *: If equipped (To be determined)
P/L: Power train
No operation at least 30 sec. : Returns to the nor-
mal screen.
q The content of the caution display differs
according to the remaining time. The relation-
q If the remaining time on the maintenance table
ship is as shown in the table below.
screen is less than 30 hours, the relevant items
are highlighted in yellow, and if 0 hours, they Display Condition
are done in red. Remaining time for mainte-
q On the maintenance time reset screen, reset None nance for all items is more
the remaining time for the selected item to than 30 hours.
return to the default. There is one or more items
Notice display (black sym-
with less than 30-hour
bol displayed on yellow
remaining time for mainte-
background)
nance.
There is one or more items
Warning display (white
with less than 0-hour
symbol displayed on red
remaining time for mainte-
background)
nance.
18 D155AX-6
10 Structure, function and maintenance standard SEN00610-01
D155AX-6 19
SEN00610-01 10 Structure, function and maintenance standard
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 q The following items can be selected.
range.
No. Selected item Remarks
q The graph on the screen is updated and
scrolled to the left at intervals of several sec- 1 Power train oil Temperature With caution
onds. 2 HYD oil temperature With caution
3 Vehicle Speed
4 HYD Pressure
5 ENG Oil Pressure With caution
6 Battery Voltage
7 Engine Speed
8 Traction Force
9 Clock
10 ENG coolant temperature For Utility Screen Select
11 Fuel For Utility Screen Select
20 D155AX-6
10 Structure, function and maintenance standard SEN00610-01
1) Time setting
Set the clock time. If the time setting item
is not highlighted, press F6 to highlight it.
D155AX-6 21
SEN00610-01 10 Structure, function and maintenance standard
Language setting
q Selecting the Language from the user menu
screen and pressing F6 switches to the lan-
guage setting screen.
q From this menu, you can change the language
to be displayed on the monitor. Available lan-
guages are as follows.
English, Japanese, Chinese, French, Spanish,
Portuguese, Italian, German, Russian, and
Turkish
22 D155AX-6
10 Structure, function and maintenance standard SEN00610-01
q Press F6 to enter user mode and select Mes- Fan reverse mode
sage display and you can view (open) the q In this mode, the fan is driven in reverse to
messages. clean the radiator core.
q While the starting switch is OFF, select an item
with switch F3 or F4 and confirm that item with
switch F6.
q While screen (A) is displayed, press switch F6,
and the fan is ready to run in reverse.
q While screen (B) is displayed, start the engine.
D155AX-6 23
SEN00610-01 10 Structure, function and maintenance standard
24 D155AX-6
10 Structure, function and maintenance standard SEN00610-01
Sensors 1
Type of sensor Sensor method When normal When abnormal
Engine oil pressure Contact OFF ON
Engine coolant temperature Resistance
Torque converter oil temperature Resistance
Hydraulic oil temperature Resistance
Coolant level Contact ON OFF
Fuel level Resistance
Engine speed sensor Resistance
Bevel gear speed sensor Resistance
Pitch angle sensor Resistance
1. Plug 4. Diaphragm
2. Contact ring 5. Spring
3. Contact 6. Terminal
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
D155AX-6 25
SEN00610-01 10 Structure, function and maintenance standard
1. Float 4. Wire
2. Sensor 5. Connector
3. Tube
1. Connector Function
2. Float q The fuel sensor is installed to the side face of
3. Arm the fuel tank. The float moves up and down
4. Body according go the fuel level. This movement of
5. Spring the float is transmitted by the arm and actuates
6. Contact a variable resistance. This sends a signal to
7. Spacer the monitor panel to indicate the remaining fuel
level.
26 D155AX-6
10 Structure, function and maintenance standard SEN00610-01
1. Magnet 4. Boots
2. Terminal 5. Connector
3. Case
1. Body 3. Wire
2. Tube 4. Connector
D155AX-6 27
SEN00610-01 10 Structure, function and maintenance standard
28 D155AX-6
10 Structure, function and maintenance standard SEN00610-01
Display of screen
The gearshift mode is displayed in the gearshift
mode display section of the monitor panel as
shown below.
A: Auto gearshift mode
1. Gear speed used currently
2. Preset (gear speed at start) and maximum
gear speed during travel
3. Mark of AUTO (which indicates auto gear-
shift mode)
4. Mark of Dozing (which indicates auto
gearshift mode)
B: Manual gearshift mode
5. Gear speed used currently
6. Preset (gear speed at start)
7. Mark of Ripping (which indicates manual
gearshift mode)
D155AX-6 29
SEN00610-01 10 Structure, function and maintenance standard
Setting preset with shift switches in neutral Changing gear speed with gearshift switches
q Set the preset (gear speed at start) and the during travel
maximum gear speed during travel (for only q The maximum gear speed during travel (in the
the auto gearshift mode) with the gearshift auto gearshift mode) or the gear speed used
switches in neutral. during travel (in the manual gearshift mode)
A: Auto gearshift mode can be changed with the gearshift switches
2. Setting preset (gear speed at start) and while the machine is traveling.
maximum gear speed during travel) A: Auto gearshift mode
2. Changing maximum speed during travel
During forward travel: The maximum gear
speed can be set to F1 F3.
During reverse travel: The maximum gear
speed can be set to R1 R3.
30 D155AX-6
10 Structure, function and maintenance standard SEN00610-01
KOMTRAX system 1
D155AX-6 31
SEN00610-01 10 Structure, function and maintenance standard
Connector B
Input/
Pin No. Signal name
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)
*1: Never connect to NC or malfunctions or failures
will occur.
32 D155AX-6
10 Structure, function and maintenance standard SEN00610-01
D155AX-6 33
SEN00610-01 10 Structure, function and maintenance standard
D155AX-6 Bulldozer
Form No. SEN00610-01
2007 KOMATSU
All Rights Reserved
Printed in Japan 03-07 (02)
34 D155AX-6
SEN00678-01
D155AX-6
D155AX-6 1
SEN00678-01 20 Standard value table
Engine SAA6D140E-5
Oil temperature Whole speed range (In oil pan) C 90 110 120
2 D155AX-6
20 Standard value table SEN00678-01
Hydraulic oil
temperature: Within
operating range
Max. speed rpm 1,250 50 1,250 50
Fan: Set in 100%
mode
Engine: High idle
Hydraulic oil temperature: Within
Fan pump circuit operating range MPa
pressure Fan: Set in 100% mode {kg/cm2}
Engine: High idle
No
mm 30 5 30 5
Forward/ Forward
Reverse travel No
PCCS lever
Stroke of control lever/pedal
mm 30 5 30 5
Stop engine Reverse
Center of lever grip
N o Left mm 40 5 40 5
Steering
N o Right mm 40 5 40 5
Stop engine
Decelerator pedal mm 50 10 50 10
Center of pedal
All stroke mm 79 10 79 10
Engine: Low idle
Brake pedal
Center of pedal Stroke to 0 of
mm 54 4 54 4
oil pressure
D155AX-6 3
SEN00678-01 20 Standard value table
N o Raise mm 72 10 72 10
N o Lower mm 72 10 72 10
Stop engine
Stroke of control lever/pedal
No
mm 53 10 53 10
Right tilt
N o Raise mm 75 10 75 10
N o Lower mm 75 10 75 10
Stop engine
Ripper control lever
Center of lever knob
N o In mm 80 10 80 10
N o Out mm 80 10 80 10
4 D155AX-6
20 Standard value table SEN00678-01
D155AX-6 5
SEN00678-01 20 Standard value table
operating range
Power train oil F3L km/h 7.5 0.4 7.5 0.4
temperature: Within
operating range F3 km/h 11.6 0.6 11.6 0.6
Travel speed Select manual
gearshift mode R1 km/h 4.6 0.2 4.6 0.2
Engine: High idle
Approach run: R2 km/h 6.8 0.4 6.8 0.4
10 30 m
Measuring distance: R3L km/h 9.2 0.5 9.2 0.5
20 m
(Converted into km/h) R3 km/h 14.0 0.7 14.0 0.7
Hydraulic oil tempera- MPa
Low idle
ture: Within operating {kg/cm2}
Unload pressure range
MPa 2.45 (+1.37/0) 2.45 (+1.37/0)
All levers: High idle
Set in neutral {kg/cm2} {25 (+14/0)} {25 (+14/0)}
Blade lift relief MPa 27.5 1.5 27.5 1.5
pressure {kg/cm2} {280 15} {280 15}
Blade tilt relief MPa 27.5 1.5 27.5 1.5
pressure Hydraulic oil temperature: Within {kg/cm2} {280 15} {280 15}
Work equipment/HSS oil pressure
operating range
Ripper lift relief MPa 27.5 1.5 27.5 1.5
Engine: High idle
pressure {kg/cm2} {280 15} {280 15}
Cylinder of measured circuit:
Ripper tilt relief Stroke end MPa 27.5 1.5 27.5 1.5
pressure {kg/cm2} {280 15} {280 15}
Work equipment LS MPa 25.0 0.98 25.0 0.98
relief pressure {kg/cm2} {255 10} {255 10}
Hydraulic oil temperature: Within MPa 38.2 41.7 38.2 41.7
HSS relief pressure operating range {kg/cm2} {390 425} {390 425}
Engine: High idle
HSS LS relief Steering of measured circuit: MPa 36.2 38.1 36.2 38.1
pressure Press brake pedal {kg/cm2} {369 389} {369 389}
Hydraulic oil temperature: Within
Control circuit basic operating range MPa 3.97 (+0.49/0) 3.78 4.46
pressure Engine: High idle {kg/cm2} {40.5 (+5/0)} {38.5 45.5}
All levers: Set in neutral
Hydraulic oil temperature: Within
Control valve EPC
operating range
valve output MPa 3.82 4.12 3.53
Engine: High idle
pressure {kg/cm2} {39 42} {36}
Lever of measured circuit: Stroke
(Reference)
end
Hydraulic oil tempera-
ture: Within operating
Work equipment speed
6 D155AX-6
20 Standard value table SEN00678-01
operating range
Engine: High idle Raise sec 2.0 3.0 4.0
Select P mode
Apply no load to ripper
Ripper lift (Shank hole: Lowest)
Measure time required
to move ripper from
ground level to raise Lower sec 1.5 2.5 3.5
end
For measuring posture,
see Fig. 3
Work equipment
D155AX-6 7
SEN00678-01 20 Standard value table
Hydraulic drift
Stop engine
of machine mm Max. 50/5 minutes 70/5 minutes
Measure reduction of idler center
tilted by blade
height h in 5 minutes
For measuring posture, see Fig. 7
Hydraulic oil temperature: Within
operating range
Hydraulic drift
Stop engine
of machine mm Max. 50/5 minutes 70/5 minutes
Measure reduction of sprocket center
lifted by ripper
height h in 5 minutes
For measuring posture, see Fig. 8
Leakage from cylinder
Blade lift
cc/min Max. 3.0 12
cylinder
Hydraulic oil temperature: Within
operating range
Ripper lift
Engine: High idle cc/min Max. 2.7 11
cylinder
Measure leakage from relieved
cylinder in 1 minute
Ripper tilt
cc/min Max. 2.7 11
cylinder
8 D155AX-6
20 Standard value table SEN00678-01
Fig. 3: Ripper lift speed Fig. 6: Hydraulic drift of machine lifted by blade
D155AX-6 9
SEN00678-01 20 Standard value table
10 D155AX-6
SEN00678-01 20 Standard value table
D155AX-6 Bulldozer
Form No. SEN00678-01
2006 KOMATSU
All Rights Reserved
Printed in Japan 05-06 (02)
12 D155AX-6
SEN00679-01
D155AX-6
D155AX-6 1
SEN00679-01 30 Testing and adjusting
2 D155AX-6
30 Testing and adjusting SEN00679-01
Q'ty
Testing and adjusting item Part No. Part name Remarks
bol
101 200 kPa
Measuring intake air pres- 799-201-2202 Boost gauge kit 1
A { 760 1,500 mmHg}
sure (boost pressure)
799-401-2220 Hose 1 Straight type quick coupler
Measuring exhaust
B 799-101-1502 Digital thermometer 1 99.9 1,299C
temperature
1 799-201-9001 Handy smoke checker 1
Measuring exhaust gas
C Commercially Bosch index: 0 9
color 2 Smoke meter 1
available
Commercially Air intake: 0.35 mm,
Adjusting valve clearance D Thickness gauge 1
available Exhaust: 0.57 mm
1 795-502-1590 Compression gauge 1 0 6.9 MPa {0 70 kg/cm2}
Measuring compression
E 795-471-1330 Adapter 1
pressure 2 For 140E-5 engine
6261-71-6150 Gasket 1
Measuring blow-by
F 799-201-1504 Blow-by checker 1 0 5 kPa {0 500 mmH2O}
pressure
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 5.9, 39.2, 58.8 MPa
1 {25, 60, 400, 600 kg/cm2}
Measuring engine oil Pressure gauge: 58.8 MPa
G
pressure 790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
Pressure gauge: 0.98 MPa
2 799-401-2320 Hydraulic tester 1
{10 kg/cm2}
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 5.9, 39.2, 58.8 MPa
1 {25, 60, 400, 600 kg/cm2}
Pressure gauge: 58.8 MPa
790-261-1204 Digital hydraulic tester 1
Measuring fuel pressure H {600 kg/cm2}
Pressure gauge: 0.98 MPa
2 799-401-2320 Hydraulic tester 1
{10 kg/cm2}
795-471-1450 Adapter 1
3 8 1.25 mm o R1/8
07005-00812 Gasket 1
1 6151-51-8490 Spacer 1 Inside diameter: 14 mm
2 6206-71-1770 Joint 1 Inside diameter of joint: 10 mm
Commercially
3 Hose 1 5 mm 2 3 m
available
Measuring fuel return rate Commercially
J 4 Hose 1 15 mm 2 3 m
and fuel leakage available
Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
Measuring fan speed K 795-205-1100 Tachometer kit 1 6.0 99999.9 rpm
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 5.9, 39.2, 58.8 MPa
1 {25, 60, 400, 600 kg/cm2}
Measuring fan circuit Pressure gauge: 58.8 MPa
L 790-261-1204 Digital hydraulic tester 1
pressure {600 kg/cm2}
2 799-401-3400 Adapter 1 Size: 05
799-101-5220 Nipple
3 1 Size: 10 1.25 mm
07002-11023 O-ring
D155AX-6 3
SEN00679-01 30 Testing and adjusting
Sym-
Q'ty
Testing and adjusting item Part No. Part name Remarks
bol
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 5.9, 39.2, 58.8 MPa
Measuring power train oil {25, 60, 400, 600 kg/cm2}
M
pressure
Pressure gauge: 58.8 MPa
790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
Adjusting brake pedal N 79A-264-0091 Push-pull scale 1 0 490 N {0 50 kg}
Emergency escape 19M-06-32820 Switch assembly 1
1
method when power train P 17A-06-41410 Wiring harness 1
has trouble 2 790-190-1601 Pump assembly 1
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 5.9, 39.2, 58.8 MPa
1 {25, 60, 400, 600 kg/cm2}
Measuring and adjusting
work equipment and HSS Q Pressure gauge: 58.8 MPa
790-261-1204 Digital hydraulic tester 1
oil pressure {600 kg/cm2}
799-101-5220 Nipple 2
2 Size: 10 1.25 mm
07002-11023 O-ring 2
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 5.9, 39.2, 58.8 MPa
Measuring control circuit 1 {25, 60, 400, 600 kg/cm2}
R
basic pressure Pressure gauge: 58.8 MPa
790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
2 799-401-3200 Adapter 1 Size: 03
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 5.9, 39.2, 58.8 MPa
Testing work equipment 1 {25, 60, 400, 600 kg/cm2}
lock solenoid valve output S
Pressure gauge: 58.8 MPa
pressure 790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
2 799-401-3200 Adapter 1 Size: 03
Emergency operation
when work equipment has T 17A-06-41421 Wiring harness 1
trouble
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 5.9, 39.2, 58.8 MPa
Measuring ripper pin puller 1 {25, 60, 400, 600 kg/cm2}
solenoid valve output U
Pressure gauge: 58.8 MPa
pressure 790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
2 799-401-3200 Adapter 1 Size: 03
Measuring internal leak-
Commercially
age of work equipment V Measuring cylinder 1
available
cylinder
Measuring coolant
temperature and oil 799-101-1502 Digital thermometer 1 99.9 1,299C
temperature
Testing operating effort 79A-264-0021 Push-pull scale 1 0 294 N {0 30 kg}
and pressing force 79A-264-0091 Push-pull scale 1 0 490 N {0 50 kg}
Measuring stroke and Commercially
Ruler 1
hydraulic drift available
Measuring work equip- Commercially
Stopwatch 1
ment speed available
Measuring voltage and Commercially
Circuit tester 1
resistance available
a 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 Trou-
bleshooting (Information related to troubleshooting), List of T-boxes and T-adapters.
4 D155AX-6
30 Testing and adjusting SEN00679-01
D155AX-6 5
SEN00679-01 30 Testing and adjusting
a The parking brake lever and work a The preset mode display section (at
equipment lock lever may be kept in the right bottom of the screen) can be
the LOCK position. set to [F3-R3] only while the Adjust-
ment function is selected.
6. Measuring torque converter stall speed 3) Set the work equipment lock lever in the
1) Start the engine and set the fuel control free position and operate the ripper control
dial in the low idle (MIN) position. lever to set the ripper lift cylinder to the
2) Operate the shiftup (UP) switch of the raise stroke end.
PCCS lever and set the preset mode dis- 4) While pressing the brake pedal securely,
play section to [F3-R3]. set the parking brake lever in the free
a The preset mode display section (at position and set the direction of PCCS
the right bottom of the screen) can be lever in the forward position.
set to [F3-R3] only while the Adjust- a Before going to the next step, check
ment function is selected. that [F3] is displayed in the gear
3) While pressing the brake pedal securely, speed display section (at the right
set the parking brake lever in the free bottom of the screen).
position and set the direction of PCCS a Keep the steering system in neutral.
lever in the forward position. 5) Press the decelerator pedal and set the
a Before going to the next step, check fuel control dial in the high idle (MAX)
that [F3] is displayed in the gear position.
speed display section (at the right 6) Return the decelerator pedal slowly to stall
bottom of the screen). the torque converter with the engine at
a Keep the steering system in neutral. high idle.
4) Press the decelerator pedal and set the k Keep pressing the brake pedal se-
fuel control dial in the high idle (MAX) curely and keep your right foot on the
position. decelerator pedal for safety until the
5) Return the decelerator pedal slowly to stall work is finished.
the torque converter with the engine at 7) Just after the power train oil temperature
high idle. gauge (T/C TEMPERATURE) indicates
k Keep pressing the brake pedal se- 118 120 C, return the direction of PCCS
curely and keep your right foot on the lever to neutral.
decelerator pedal for safety until the a The top of the green range of the
work is finished. power train oil temperature gauge
6) Just after the power train oil temperature indicates about 118 120 C.
gauge (T/C TEMPERATURE) indicates 8) Repeat above steps 4) 7) 3 times.
118 120 C, return the direction of PCCS 9) Perform steps 4) 6) again, operate the
lever to neutral. ripper control lever to relieve the ripper
a The top of the green range of the raise system, and measure the engine
power train oil temperature gauge speed about 5 seconds after the power
indicates about 118 120 C. train oil temperature gauge (T/C TEM-
7) Repeat above steps 3) 6) 3 times. PERATURE) indicates 118 120 C.
8) Perform steps 3) 5) again and measure a Immediately after finishing measure-
the engine speed about 5 seconds after ment, return the direction of PCCS
the power train oil temperature gauge (T/C lever to neutral and lower the power
TEMPERATURE) indicates 118 120 C. train oil temperature with the engine
a Immediately after finishing measure- at high idle.
ment, return the direction of PCCS
lever to neutral and lower the power
train oil temperature with the engine
at high idle.
6 D155AX-6
30 Testing and adjusting SEN00679-01
Measuring intake air pressure 4. Run the engine at a medium or higher speed
(boost pressure) 1 and drain the oil from the test hose.
a Insert the connecting parts of the gauge
a Measuring instruments for intake air pressure and hose about a half and open the self-
(boost pressure) seal on the hose side repeatedly, and the
Symbol Part No. Part name oil will be drained.
a If Pm kit (A) is available, you may drain
799-201-2202 Boost gauge kit
A the oil by using the oil draining coupling
799-401-2220 Hose
(790-261-1130) in that kit.
k Stop the machine on level ground, lower a If oil is left in the hose, the gauge does not
the work equipment to the ground, stop the work. Accordingly, be sure to drain the oil.
engine, and set the parking brake lever and
5. Turn the starting switch ON and set the
work equipment lock lever in the lock posi-
machine monitor to Adjustment function of the
tion.
service mode.
k Be careful not to touch any hot part of the
q Adjustment code: 0530 (Stall mode)
engine when removing or installing the
a For the operating method, see Special
measuring tools.
functions of machine monitor (EMMS).
a Measure the intake air pressure (boost pres-
sure) under the following conditions.
q Engine coolant temperature: Within oper-
ating range
q Power train oil temperature: Within operat-
ing range
q Hydraulic oil temperature: Within operat-
ing range
1. Open the engine left side cover.
2. Remove intake air pressure pickup plug (1)
from the rear of the air intake connector.
D155AX-6 7
SEN00679-01 30 Testing and adjusting
8 D155AX-6
30 Testing and adjusting SEN00679-01
2) Start the engine and set the fuel control 8) Under the condition of step 7), stop reliev-
dial in the low idle (MIN) position. ing the ripper raise system and lower the
3) Operate the shiftup (UP) switch of the exhaust temperature by only stalling the
PCCS lever and set the preset mode dis- torque converter (Condition (b) in the fig-
play section to [F3-R3]. ure).
a The preset mode display section (at a If the exhaust temperature does not
the right bottom of the screen) can be lower but rises, set the temperature
set to [F3-R3] only while the Adjust- high in step 7).
ment function is selected. 9) After the exhaust temperature is lowered
4) Set the work equipment lock lever in the and stabilized, measure the exhaust tem-
free position and operate the ripper control perature (Condition (c) in the figure).
lever to set the ripper lift cylinder to the k Just after the power train oil tem-
raise stroke end. perature (T/C TEMPERAT URE)
5) While pressing the brake pedal securely, reaches about 120 C, return the
set the parking brake lever in the free direction of PCCS lever to neutral
position and set the direction of PCCS and lower the power train oil tem-
lever in the forward position. perature with the engine at high
a Before going to the next step, check idle.
that [F3] is displayed in the gear a The border between the green range
speed display section (at the right and red range of the power train oil
bottom of the screen). temperature gauge indicates about
a Keep the steering system in neutral. 120 C.
6) Press the decelerator pedal and set the
fuel control dial in the high idle (MAX)
position.
7) Return the decelerator pedal slowly to stall
the torque converter and relieve the ripper
raise system to raise the exhaust temper-
ature to about 650 C (Condition (a) in the
figure) with the engine at high idle.
k Keep pressing the brake pedal
securely and keep your right foot
on the decelerator pedal for safety
until the work is finished.
D155AX-6 9
SEN00679-01 30 Testing and adjusting
10 D155AX-6
30 Testing and adjusting SEN00679-01
D155AX-6 11
SEN00679-01 30 Testing and adjusting
1. Remove the engine hood assembly and air 5. Install adapter E2 to the mounting hole on the
cleaner together. injector and connect compression gauge E1.
4 Engine hood assembly: 170 kg a Be sure to fit the gasket to the injector
end.
2. Remove cylinder head cover (1) of the cylinder a Fix the adapter with the injector holder.
to measure the compression pressure. 3 Holder mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
a Apply a little amount of engine oil to the
connecting parts of the adapter and gauge
so that air will not leak easily.
12 D155AX-6
30 Testing and adjusting SEN00679-01
7. Disconnect power supply connector EGC3 (6) a Install the injector and fuel high-pressure
of the engine controller. tube according to the following procedure.
k If this connector is not disconnected, a Before installing the injector, replace the
the engine will start during measure- copper gasket and O-ring with new ones.
ment and will be dangerous. Accord- 1) Push in injector (11) with the hand to
i n g l y, b e s u r e t o d i s c o n n e c t t h i s assemble holder (12) temporarily.
connector. 2) Tighten bolt (13) and washer (14) tempo-
k Cover the controller side and wiring rarily.
harness side with vinyl sheets, etc. to 2 Spherical part of washer:
measure the compression pressure. 29.4 34.3 kgm {3.0 3.5 kgm}
a Read the pressure gauge pointer when it
is stabilized.
a When measuring the compression pres-
sure, check that the engine speed is in the
range of the measurement condition.
D155AX-6 13
SEN00679-01 30 Testing and adjusting
14 D155AX-6
30 Testing and adjusting SEN00679-01
Measuring engine oil pressure 1 4. Run the engine at low idle and high idle and
measure the engine oil pressure.
a Measuring instruments for engine oil pressure
Symbol Part No. Part name
799-101-5002 Hydraulic tester
1
G 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester
D155AX-6 15
SEN00679-01 30 Testing and adjusting
16 D155AX-6
30 Testing and adjusting SEN00679-01
Measuring fuel pressure 1 3. Run the engine at high idle and measure the
fuel pressure.
a Measuring instruments for fuel pressure a If the fuel pressure is in the following
Symbol Part No. Part name range, it is normal.
799-101-5002 Hydraulic tester Engine speed Fuel pressure
1
790-261-1204 Digital hydraulic tester 0.15 0.3 MPa
High idle
H 2 799-401-2320 Hydraulic tester {1.5 3 kg/cm}
795-471-1450 Adapter
3
07005-00812 Gasket
D155AX-6 17
SEN00679-01 30 Testing and adjusting
18 D155AX-6
30 Testing and adjusting SEN00679-01
D155AX-6 19
SEN00679-01 30 Testing and adjusting
3) Run the engine at high idle and stall the 2) Lay test hose J4 so that it will not slacken
torque converter. After the engine speed and put its end in the oil pan.
is stabilized, measure the leakage in 1
minute with measuring cylinder J5.
a For the procedure for stalling the
torque converter, see Measuring
torque converter stall speed.
a You may measure the leakage for 20
seconds and judge by multiplying the
result by 3.
a If the leakage from the pressure lim-
iter is in the following range, it is nor-
mal.
Leakage
Engine speed
(cc/min)
Torque converter 3) Turn the starting switch ON set the
Max. 10
stall machine monitor to Adjusting function of
the service mode.
q Adjustment code: 0530 (Stall mode)
a For the operating method, see "Spe-
cial functions of machine monitor
(EMMS)".
20 D155AX-6
30 Testing and adjusting SEN00679-01
D155AX-6 21
SEN00679-01 30 Testing and adjusting
22 D155AX-6
30 Testing and adjusting SEN00679-01
D155AX-6 23
SEN00679-01 30 Testing and adjusting
Measuring fuel circuit for leakage1 9. Check the fuel piping and devices for fuel leak-
age.
k Very high pressure is generated in the high- a Check mainly around the high-pressure
pressure circuit of the fuel system. If fuel circuit parts coated with the color checker
leaks while the engine is running, it is dan- for fuel leakage.
gerous since it can catch fire. a If any fuel leakage is detected, repair it
a After testing the fuel system or removing and and inspect again from step 1.
installing its parts, test it for fuel leakage a If no fuel leakage is detected, inspection is
according to the following procedure. completed.
a Clean and degrease the engine and the parts
around it in advance so that you can test it eas-
ily for fuel leakage.
24 D155AX-6
30 Testing and adjusting SEN00679-01
Testing and adjusting alternator 6. Install belt cover (1) with the 2 mounting bolts.
belt tension 1 a Check for breakage of the pulleys, wear of
the V-grooves, contact of the belts and V-
k Stop the machine on level ground, lower grooves, and contact of the belt covers
the work equipment to the ground, stop the and rotating parts.
engine, and set the parking brake lever and a If the belt is lengthened to the adjustment
work equipment lock lever in the lock posi- limit, cut, or cracked, replace it with new
tion. one.
a If the V-belt is replaced, adjust its tension
Testing again after 1 operating hour.
1. Open the engine right side cover and remove a After tightening the bolts, check that the
the inspection plate on the right of the radiator belt tension is normal according to the
guard. above procedure.
Adjusting
a If the deflection is out of the standard range,
adjust it according to the following procedure.
D155AX-6 25
SEN00679-01 30 Testing and adjusting
Testing and adjusting air a After tightening the bolts, check that the
conditioner compressor belt belt tension is normal according to the
above procedure.
tension 1
k 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 posi-
tion.
Testing
1. Open the engine left side cover and left mud-
guard.
Adjusting
a If the deflection is out of the standard range,
adjust it according to the following procedure.
26 D155AX-6
30 Testing and adjusting SEN00679-01
D155AX-6 27
SEN00679-01 30 Testing and adjusting
k Stop the machine on level ground, lower 5. Close the radiator mask.
the work equipment to the ground, stop the k Before starting the engine, be sure to
engine, and set the parking brake lever and close the radiator mask. Do not start
work equipment lock lever in the lock posi- the engine while the radiator mask is
tion. open.
a Measure the fan circuit oil pressure under the
following condition. 6. Start the engine and set the machine monitor
q Hydraulic oil temperature: Within operat- to Adjusting function of the service mode.
ing range a Adjustment code: 1005 (Fan 100% mode)
a For the operating method, see "Special
1. Open the radiator mask and remove the fan functions of machine monitor (EMMS)".
net. a If this adjustment code is displayed, the
fan speed is kept at 100% speed in accor-
2. Disconnect supply hose (1) of the fan motor. dance with the engine speed, regardless
of the state of the machine.
28 D155AX-6
30 Testing and adjusting SEN00679-01
7. While running the engine at high idle, measure Bleeding air from fan pump 1
the fan circuit oil pressure.
a If the fan pump is removed and installed or its
piping is disconnected and connected, bleed
air from the fan pump case according to the
following procedure.
a Before starting the following work, check that
the hydraulic oil level is normal.
D155AX-6 29
SEN00679-01 30 Testing and adjusting
30 D155AX-6
30 Testing and adjusting SEN00679-01
D155AX-6 31
SEN00679-01 30 Testing and adjusting
D155AX-6 Bulldozer
Form No. SEN00679-01
2006 KOMATSU
All Rights Reserved
Printed in Japan 05-06 (02)
32 D155AX-6
SEN00680-01
D155AX-6
D155AX-6 1
SEN00680-01 30 Testing and adjusting
2 D155AX-6
30 Testing and adjusting SEN00680-01
D155AX-6 3
SEN00680-01 30 Testing and adjusting
1. Measuring transmission main relief pres- 2. Measuring torque converter lockup clutch
sure (TM) pressure (LU)
1) Connect oil pressure gauge [1] of hydrau- 1) Connect oil pressure gauge [1] of hydrau-
lic tester M to oil pressure pickup plug (1). lic tester M to oil pressure pickup plug (2).
a When using an analog oil pressure a When using an analog oil pressure
gauge, use one of 5.9 MPa {60 kg/ gauge, use one of 2.5 MPa {25 kg/
cm}. cm}.
2) Start the engine and set the PCCS lever in 2) Start the engine and raise the machine
the fully neutral position. with the blade and ripper to a height where
a The parking brake lever may be set in you can run the track shoe idle.
the LOCK position. k After raising the machine, set the
3) While running the engine at low idle and work equipment lock lever in the
high idle, measure the main relief pres- LOCK position.
sure.
4 D155AX-6
30 Testing and adjusting SEN00680-01
D155AX-6 5
SEN00680-01 30 Testing and adjusting
6 D155AX-6
30 Testing and adjusting SEN00680-01
D155AX-6 7
SEN00680-01 30 Testing and adjusting
8 D155AX-6
30 Testing and adjusting SEN00680-01
9. Measuring steering right brake pressure 10. Measuring steering left brake pressure (LB)
(RB) 1) Connect oil pressure gauge [1] of hydrau-
1) Connect oil pressure gauge [1] of hydrau- lic tester M to oil pressure pickup plug
lic tester M to oil pressure pickup plug (9). (10).
a When using an analog oil pressure a When using an analog oil pressure
gauge, use one of 5.9 MPa {60 kg/ gauge, use one of 5.9 MPa {60 kg/
cm}. cm}.
2) Start the engine and set the parking brake 2) Start the engine and set the parking brake
lever in the FREE position. lever in the FREE position.
3) While running the engine at low idle and 3) While running the engine at low idle and
high idle, measure the right brake pres- high idle, measure the left brake pressure.
sure. a During measurement, check that the
a During measurement, check that the oil pressure lowers to 0 when the
oil pressure lowers to 0 when the brake pedal is pressed or the parking
brake pedal is pressed or the parking brake lever is set in the LOCK posi-
brake lever is set in the LOCK posi- tion.
tion.
D155AX-6 9
SEN00680-01 30 Testing and adjusting
10 D155AX-6
30 Testing and adjusting SEN00680-01
k Stop the machine on level ground, lower 6. Start the engine, set the machine monitor to
the work equipment to the ground, stop the Monitoring function of the service mode, and
engine, and set the parking brake lever and check that the transmission speed is indicated
work equipment lock lever in the LOCK normally.
position. a Monitoring code: 31400 T/M Out Speed
a For the operating method, see Special
1. Remove the fuel tank and transmission output functions of machine monitor (EMMS).
shaft speed sensor (1). a To rotate the transmission output shaft,
4 Fuel tank: 950 kg (when full) drive the machine actually or run the track
idle.
a Before adjusting the transmission output
shaft speed sensor, remove it and check
that its tip is free from steel chips and
flaws, and then reinstall it.
D155AX-6 11
SEN00680-01 30 Testing and adjusting
Simple test procedure for brake 6. Return the decelerator pedal slowly and check
performance 1 that the machine does not start when the
engine speed reaches the high idle speed.
k
k
Stop the machine on level ground, lower Since the torque converter is stalled,
the work equipment to the ground, stop the keep pressing the brake pedal securely
engine, and set the parking brake lever and
and keep your right foot on the deceler-
work equipment lock lever in the LOCK
ator pedal for safety until the work is
position.
finished.
a Carry out the simple performance test of the
brake under the following condition.
q Power train oil temperature:
Within operating range
12 D155AX-6
30 Testing and adjusting SEN00680-01
D155AX-6 13
SEN00680-01 30 Testing and adjusting
14 D155AX-6
30 Testing and adjusting SEN00680-01
k Stop the machine on level ground, lower q Brake oil pressure (At high idle)
the work equipment to the ground, stop the
Parking brake lever Oil pressure
engine, and set the parking brake lever and
work equipment lock lever in the LOCK 2.75 0.29 MPa
FREE position
position. {28.0 3.0 kg/cm}
a Tighten the locknut of the rod securely and LOCK position 0 MPa {0 kg/cm}
bend the cotter pin securely.
a When adjusting the parking brake lever,
remove the battery cover.
4 Battery cover: 65 kg
1. Assembly and installation of lever assem-
bly
1) Assemble lever assembly (1) and adjust
the operation of limit switch (2).
q Lever raising position: OFF, lowering
position: ON
q Limit switch operation stroke: 2.8 mm
2) Install lever assembly (1).
D155AX-6 15
SEN00680-01 30 Testing and adjusting
16 D155AX-6
30 Testing and adjusting SEN00680-01
D155AX-6 17
SEN00680-01 30 Testing and adjusting
4) Start the engine and set the parking brake 2) Install volume pump [3] of pump assembly
lever in the FREE position. P2 to the outside of the operator's cab.
5) Operate switch assembly [1] and move
the machine to a safe place.
a The gear speed switch is so made
that the switch on the lower gear
speed will be operated first.
18 D155AX-6
30 Testing and adjusting SEN00680-01
D155AX-6 19
SEN00680-01 30 Testing and adjusting
a If the idler runs out or tilts because of wear of 2. Adjusting in vertical direction
the right and left side guide plates or upper and 1) Measure clearance (b) between guide
lower guide plates, and guide plate, adjust plates (5) and (6) at 2 places.
according to the following procedure. 2) The idler cannot be adjusted vertically. If
k Stop the machine on level ground, lower clearance (b) is more than 8 mm, replace
the work equipment to the ground, stop the the upper and lower guide plates (5), (6),
engine, and set the parking brake lever and (7) and (8) with new ones.
work equipment lock lever in the LOCK a Guide plates (5), (7) and (8) are
position. welded.
3) After finishing measurement, return the
1. Adjusting in lateral direction removed parts.
1) Drive the machine for 1 2 m on a level
place, then remove 2 covers (1).
2) Measure clearance (a) between the track
frame and right and left guide plates (2) at
2 places.
3) If clearance (a) is more than 4 mm,
remove bolt (3) and reduce shims (4).
q Standard clearance (a) on each side:
0.5 1.0 mm
a Do not loosen the bolt more than 3
turns.
a This part can be adjusted to 6 mm on
each side.
4) After finishing measurement, return the
removed parts.
20 D155AX-6
30 Testing and adjusting SEN00680-01
Testing
1. Drive the machine slowly on a level place, then
stop it.
a Do not apply the brake when stopping.
2. Place straight steel bar (1) between the idler 4. After finishing adjustment, return the removed
and front carrier roller and measure maximum parts.
clearance (a) between the bottom of the steel
bar and shoe grouser.
a For the above measurement, use an L-
shaped steel which will be deflected less.
q Standard max. clearance (a): 20 30 mm
Adjusting
a If the track shoe tension is abnormal, adjust it
according to the following procedure.
D155AX-6 21
SEN00680-01 30 Testing and adjusting
22 D155AX-6
30 Testing and adjusting SEN00680-01
2) Install nipples Q2 and connect them to oil 3. Measuring HSS oil pressure
pressure gauges [1] of hydraulic tester 1) Install the measuring instruments to the
Q1. control valve.
a When using analog oil pressure a Measuring points of the HSS oil pres-
gauges, use ones of 39.2 MPa {400 sure are the same as those of the
kg/cm}. work equipment oil pressure.
a When using analog oil pressure
gauges, use ones of 58.8 MPa {600
kg/cm}.
D155AX-6 23
SEN00680-01 30 Testing and adjusting
24 D155AX-6
30 Testing and adjusting SEN00680-01
D155AX-6 25
SEN00680-01 30 Testing and adjusting
26 D155AX-6
30 Testing and adjusting SEN00680-01
D155AX-6 27
SEN00680-01 30 Testing and adjusting
28 D155AX-6
30 Testing and adjusting SEN00680-01
6. Disconnect EPC solenoid connectors EWP1 7. Start the engine and operate switch [1] of wir-
WEPA above the control valve and connect ing harness T to move the work equipment.
connectors WEPX and WEPY of wiring har- k Before starting the engine, check that
ness T to the male side. the switch is in neutral.
a Disconnect only the pair (2 pieces) of the k Since the work equipment cannot be
connector of the control valve spool (cylin- controlled finely with the switch, keep
der) to be moved and connect the connec- the engine speed as low as possible.
tors on the wiring harness T side to them
respectively.
a When connecting the connectors, check
the operating direction of the switch and
the connector numbers again.
k Do not connect wiring harness T to the
HSS connectors (HSL and HSR).
D155AX-6 29
SEN00680-01 30 Testing and adjusting
30 D155AX-6
30 Testing and adjusting SEN00680-01
[Reference]
Reason why the lowering speed is increased when
the cylinder packing is the cause of the hydraulic
2) Blade tilt cylinder drift:
Extract the tilt cylinder to the stroke end 1. If the machine is set in the above position
and brace the blade to push up the left (where the holding pressure is applied to the
side of the machine body. 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
3) Ripper lift cylinder the drain circuit. As a result, the pressure is
Brace the ripper to push up the rear side unbalanced and the lowering speed is
of the machine body. increased.
D155AX-6 31
SEN00680-01 30 Testing and adjusting
32 D155AX-6
30 Testing and adjusting SEN00680-01
D155AX-6 33
SEN00680-01 30 Testing and adjusting
k Stop the machine on level ground, lower a Monitoring code: 70300 Blade Sw Input
the work equipment to the ground, stop the a For the operating method, see Special
engine, and set the parking brake lever and functions of machine monitor (EMMS).
work equipment lock lever in the LOCK
position.
a Tighten the locknut of the rod securely and
bend the cotter pin securely.
a When adjusting the work equipment lock lever,
remove the control valve cover.
4 Control valve cover: 25 kg
34 D155AX-6
30 Testing and adjusting SEN00680-01
Adjusting blade 1
D155AX-6 35
SEN00680-01 30 Testing and adjusting
2) Adjust the shim of center section (2) (2 2. Adjusting blade tilt distance (Single tilt
places). specification)
a After reassembling the center section, 1) Adjust installed dimension (d) of brace (4)
supply grease to it. with the handle.
2 Center section: Grease (G2-LI)
Dimen-
blade Semi-U blade Full-U blade
Adjusted Adjusted Standard Standard shim sion
point clearance clearance thickness d 1,292 mm 1,372 mm 1,372 mm
2 b See note. 4 mm
2) Measure right and left tilt distances (e1)
a Adjust the shim so that the play of the and (e2).
ball in the axial direction will be less
Dimen-
than 1 mm and the ball can rotate blade Semi-U blade Full-U blade
sion
smoothly.
e1 565 mm 570 mm 583 mm
e2 565 mm 570 mm 583 mm
36 D155AX-6
30 Testing and adjusting SEN00680-01
D155AX-6 37
SEN00680-01 30 Testing and adjusting
4) Check around the dashboard carefully for 4) Loosen the mounting bolts of damper rub-
water leakage. ber (6).
a If water leaks, caulk the leaking part a You can remove and install the shims
and check again. without removing the mounting bolts.
5) Increase or decrease shims (7) under
damper rubber (6) to adjust the height of
damper rubber (6) properly.
38 D155AX-6
30 Testing and adjusting SEN00680-01
5) Open and close door (5) and check that it 2) Check that striker (10) is not leaning
is locked and unlocked smoothly. against or from center (g) of latch (11).
a If the door is not locked or unlocked 3) Check that striker (10) is aligned with cen-
smoothly (the operating effort of the ter (h) of latch (11).
knob is large), repeat adjustment q Normal: Quantity of misalignment is
from the first. 0.5 mm or less.
a Operating effort of door knob:
49 19.6 N {5 2 kg}
6) Apply grease to latch (8).
a If the latch dries up, the operating
e ff o r t o f t h e k n ob i s i n c r ea s e d .
Accordingly, apply sufficient grease to
the latch.
2 Latch: Grease (G2-LI)
D155AX-6 39
SEN00680-01 30 Testing and adjusting
40 D155AX-6
SEN00680-01 30 Testing and adjusting
D155AX-6 Bulldozer
Form No. SEN00680-01
2006 KOMATSU
All Rights Reserved
Printed in Japan 05-06 (02)
42 D155AX-6
SEN00681-01
D155AX-6
D155AX-6 1
SEN00681-01 30 Testing and adjusting
2 D155AX-6
30 Testing and adjusting SEN00681-01
D155AX-6 3
SEN00681-01 30 Testing and adjusting
4 D155AX-6
30 Testing and adjusting SEN00681-01
D155AX-6 5
SEN00681-01 30 Testing and adjusting
Display of screen to input password Display of warning after check before starting
After the KOMATSU logo is displayed, the screen If any abnormality is detected by the check before
to input the engine start lock password is displayed. starting, the warning monitor is displayed on the
a This screen is displayed only when the engine screen.
start lock function is set effective. a The following figure shows that the radiator
a If the password is input normally, the screen coolant level monitor (a) is warning of low radi-
changes to "Display of check before starting". ator coolant level.
a The machine monitor has some password
functions other than the engine start lock.
Those functions are independent from one
another.
6 D155AX-6
30 Testing and adjusting SEN00681-01
D155AX-6 7
SEN00681-01 30 Testing and adjusting
8 D155AX-6
30 Testing and adjusting SEN00681-01
a Heater specification
D155AX-6 9
SEN00681-01 30 Testing and adjusting
Operation to display camera mode (if camera is Operation to display clock and service meter
installed) While the ordinary screen is displayed, press [F4],
When a camera is installed, if [F3] is pressed, the and section (a) changes to the service meter and
multi-display changes to the camera image. clock alternately.
a Set the connection of the camera in the service a When the clock is selected, adjust the time, set
mode. 12-hour or 24-hour display, and set the sum-
mer time with the user mode function.
a Display of service meter
10 D155AX-6
30 Testing and adjusting SEN00681-01
a To reset the time left after finishing mainte- a There are following items in the user menu.
nance, more operations are necessary.
Utility Screen Select
Multi Gage Select
Screen Adjustment
Clock Adjustment
Language
Message display
Hydraulic fan reversing
[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
SEN00681-01 30 Testing and adjusting
12 D155AX-6
30 Testing and adjusting SEN00681-01
a Remedies given by displayed action codes to operator to take (The following table is an excerpt from the
Operation and Maintenance Manual)
Action
Method of indicating trouble Examples of trouble Remedy given to operator to take
code
Although all or a part of automatic
function stops, machine can be
Action code and failure code are Backup alarm does not sound.
E01 operated.
displayed. Fan speed is kept at maximum.
Ask your Komatsu distributor for
repair.
If operator stops and restarts
Gear is not shifted up or down. engine, machine can be operated
Action code and failure code are Engine boost pressure is abnor- without limiting any function.
E02 displayed. mal. Operator must take care, how-
Alarm buzzer sounds. Exhaust gas color is bad when ever.
temperature is low. Ask your Komatsu distributor for
repair.
Engine coolant temperature sen-
sor is abnormal.
Action code and failure code are
Usable gear speeds are limited.
displayed. Move machine to safe place.
Engine speed does not rise to
E03 Telephone No. is displayed (if Ask your Komatsu distributor for
maximum.
set). repair.
Gearshift shock is increased.
Alarm buzzer sounds.
Steering performance lowers.
Braking shock is increased.
Action code and failure code are
displayed. Engine cannot be controlled. Stop machine immediately.
E04 Telephone No. is displayed (if Machine cannot travel. Ask your Komatsu distributor for
set). Machine stops. repair.
Alarm buzzer sounds.
D155AX-6 13
SEN00681-01 30 Testing and adjusting
14 D155AX-6
30 Testing and adjusting SEN00681-01
D155AX-6 15
SEN00681-01 30 Testing and adjusting
16 D155AX-6
30 Testing and adjusting SEN00681-01
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.
D155AX-6 17
SEN00681-01 30 Testing and adjusting
18 D155AX-6
30 Testing and adjusting SEN00681-01
D155AX-6 19
SEN00681-01 30 Testing and adjusting
20 D155AX-6
30 Testing and adjusting SEN00681-01
D155AX-6 21
SEN00681-01 30 Testing and adjusting
22 D155AX-6
30 Testing and adjusting SEN00681-01
D155AX-6 23
SEN00681-01 30 Testing and adjusting
24 D155AX-6
30 Testing and adjusting SEN00681-01
D155AX-6 25
SEN00681-01 30 Testing and adjusting
26 D155AX-6
30 Testing and adjusting SEN00681-01
E03 15SEL1 Speed 1st clutch: Fill high q P/T Electrical system
E03 15SELH Speed 1st clutch: Fill Low q P/T Electrical system
E03 15SFL1 Speed 2nd clutch: Fill high q P/T Electrical system
E03 15SFLH Speed 2nd clutch: Fill Low q P/T Electrical system
E03 15SGL1 Speed 3rd clutch: Fill high q P/T Electrical system
E03 15SGLH Speed 3rd clutch: Fill Low q P/T Electrical system
E04 CA115 Eng Ne and Bkup Speed Sens Error q ENG Electrical system
E03 CA122 Chg Air Press Sensor High Error q ENG Electrical system
E03 CA123 Chg Air Press Sensor Low Error q ENG Electrical system
E02 CA135 Eng Oil Press Sensor High Error q ENG Electrical system
E02 CA141 Eng Oil Press Sensor Low Error q ENG Electrical system
E02 CA144 Coolant Temp Sens High Error q ENG Electrical system
E02 CA145 Coolant Temp Sens Low Error q ENG Electrical system
E01 CA153 Chg Air Temp Sensor High Error ENG Electrical system
D155AX-6 27
SEN00681-01 30 Testing and adjusting
E01 CA154 Chg Air Temp Sensor Low Error ENG Electrical system
E03 CA187 Sens Supply 2 Volt Low Error q ENG Electrical system
E03 CA221 Ambient Press Sens High Error q ENG Electrical system
E03 CA222 Ambient Press Sens Low Error q ENG Electrical system
E03 CA227 Sens Supply 2 Volt High Error q ENG Electrical system
E03 CA238 Ne Speed Sens Supply Volt Error q ENG Electrical system
E01 CA263 Fuel Temp Sensor High Error ENG Electrical system
E01 CA265 Fuel Temp Sensor Low Error ENG Electrical system
E03 CA352 Sens Supply 1 Volt Low Error q ENG Electrical system
E03 CA386 Sens Supply 1 Volt High Error q ENG Electrical system
E03 CA449 Rail Press Very High Error q ENG Electrical system
E03 CA451 Rail Press Sensor High Error q ENG Electrical system
E03 CA452 Rail Press Sensor Low Error q ENG Electrical system
E03 CA731 Eng Bkup Speed Sens Phase Error q ENG Electrical system
E04 CA757 All Continuous Data Lost Error q ENG Electrical system
E03 CA778 Eng Bkup Speed Sensor Error q ENG Electrical system
28 D155AX-6
30 Testing and adjusting SEN00681-01
E03 CA1626 BP Valve Sol Current High Error q ENG Electrical system
E03 CA1627 BP Valve Sol Current Low Error q ENG Electrical system
E03 CA1631 BP Valve Pos Sens High Error q ENG Electrical system
E03 CA1632 BP Valve Pos Sens Low Error q ENG Electrical system
E01 CA1642 EGR Inlet Press Sens Low Error ENG Electrical system
E01 CA1653 EGR Inlet Press Sens High Error ENG Electrical system
E03 CA2185 Throt Sens Sup Volt High Error q ENG Electrical system
E03 CA2186 Throt Sens Sup Volt Low Error q ENG Electrical system
E03 CA2249 Rail Press Very Low Error q ENG Electrical system
E03 CA2271 EGR Valve Pos Sens High Error q ENG Electrical system
E03 C2272 EGR Valve Pos Sens Low Error q ENG Electrical system
E03 CA2351 EGR Valve Sol Current High Error q ENG Electrical system
E03 CA2352 EGR Valve Sol Current Low Error q ENG Electrical system
E01 CA2555 Grid Htr Relay Volt Low Error ENG Electrical system
E01 CA2256 Grid Htr Relay Volt High Error ENG Electrical system
E01 D161KB Back-up alarm relay: Short circuit P/T Electrical system
E03 D5ZKKX Throttle Dial: Out of normal range q P/T Electrical system
D155AX-6 29
SEN00681-01 30 Testing and adjusting
E02 DD13KB Shift down Sw: Short circuit q P/T Electrical system
E03 DD14KB Parking lever Sw: Short circuit q P/T Electrical system
E02 DDDDKB Back up brake Sw: Short circuit q P/T Electrical system
E02 DDDDKX Back up brake Sw: Signal mismatch q P/T Electrical system
E02 DDN7KB WEQ Knob Sw(down): Short circuit q W/E Electrical system
E01 DDN9KB WEQ Knob Sw(up): Short circuit W/E Electrical system
E03 DDNLKB Weq lock Sw: Short circuit q W/E Electrical system
30 D155AX-6
30 Testing and adjusting SEN00681-01
E01 DGT1KX T/C oil temp sensor abnormal P/T Electrical system
E02 DHT5KB T/C in-pressure sensor: Short circuit q P/T Electrical system
E02 DHT7KB T/C out-pressure sensor: Short circuit q P/T Electrical system
E03 DK10KX Fuel control Dial: Out of normal range q P/T Electrical system
D155AX-6 31
SEN00681-01 30 Testing and adjusting
E03 DKH1KB Pitch angle sensor: Short circuit q P/T Electrical system
E01 DW7BKB Fan rev EPC: Short circuit P/T Electrical system
E01 DWN5KB Fan pump solenoid: Short circuit W/E Electrical system
E03 DXH4KB 1st clutch ECMV: Short circuit q P/T Electrical system
E03 DXH4KY 1st clutch ECMV: Short circuit q P/T Electrical system
E03 DXH5KB 2nd clutch ECMV: Short circuit q P/T Electrical system
E03 DXH5KY 2nd clutch ECMV: Short circuit q P/T Electrical system
E03 DXH6KA 3rd clutch ECMV: Disconnection q P/T Electrical system
E03 DXH6KB 3rd clutch ECMV: Short circuit q P/T Electrical system
E03 DXH6KY 3rd clutch ECMV: Short circuit q P/T Electrical system
32 D155AX-6
30 Testing and adjusting SEN00681-01
E04 DXHBKB Right brake ECMV: Short circuit q P/T Electrical system
E04 DXHBKY Right brake ECMV: Short circuit q P/T Electrical system
E04 DXHCKB Left brake ECMV: Short circuit q P/T Electrical system
E04 DXHCKY Left brake ECMV: Short circuit q P/T Electrical system
E03 DXHSKB Blade down EPC: Short circuit q W/E Electrical system
E03 DXHSKY Blade down EPC: Short circuit q W/E Electrical system
E03 DXHTKB Blade left 1 EPC: Short circuit q W/E Electrical system
E03 DXHTKY Blade left 1 EPC: Short circuit q W/E Electrical system
E03 DXHUKB Blade right 1 EPC: Short circuit q W/E Electrical system
E03 DXHUKY Blade right 1 EPC: Short circuit q W/E Electrical system
E03 DXHXKB Ripper down EPC: Short circuit q W/E Electrical system
E03 DXHXKY Ripper down EPC: Short circuit q W/E Electrical system
E03 DXHYKB Ripper Tilt In EPC: Short circuit q W/E Electrical system
E03 DXHYKY Ripper Tilt In EPC: Short circuit q W/E Electrical system
E03 DXHZKA Ripper Tilt Back EPC: Disconnection q W/E Electrical system
E03 DXHZKB Ripper Tilt Back EPC: Short circuit q W/E Electrical system
E03 DXHZKY Ripper Tilt Back EPC: Short circuit q W/E Electrical system
E03 DXJ4KB WEQ lock Sol.: Short circuit q W/E Electrical system
E03 DXJ8KB Blade left 2 EPC: Short circuit q W/E Electrical system
E03 DXJ8KY Blade left 2 EPC: Short circuit q W/E Electrical system
D155AX-6 33
SEN00681-01 30 Testing and adjusting
E03 DXJ9KB Blade right 2 EPC: Short circuit q W/E Electrical system
E03 DXJ9KY Blade right 2 EPC: Short circuit q W/E Electrical system
34 D155AX-6
30 Testing and adjusting SEN00681-01
D155AX-6 35
SEN00681-01 30 Testing and adjusting
36 D155AX-6
30 Testing and adjusting SEN00681-01
D155AX-6 37
SEN00681-01 30 Testing and adjusting
38 D155AX-6
30 Testing and adjusting SEN00681-01
1. Selecting menu
Select "05 Phone Number Entry" on the "Ser-
vice Menu" screen.
D155AX-6 39
SEN00681-01 30 Testing and adjusting
40 D155AX-6
30 Testing and adjusting SEN00681-01
1. Selecting menu
Select "06 Default" on the "Service Menu"
screen.
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
SEN00681-01 30 Testing and adjusting
Default setting (Setting of maintenance pass- q [F6]: Confirm selection and return to default
word) screen
Check or change various settings related to the
machine monitor and machine by default setting.
The function of setting maintenance password is
used to set the display of the password screen
when the functions related to the maintenance are
used in the operator mode.
1. Selecting menu
Select "06 Default" on the "Service Menu"
screen.
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 Initial-
ization screen
42 D155AX-6
30 Testing and adjusting SEN00681-01
D155AX-6 43
SEN00681-01 30 Testing and adjusting
Default setting (Setting of ECO display) a If ECO display is turned ON, ECO is dis-
Check or change various settings related to the played when the screen changes to the
machine monitor and machine by initialization. ordinary screen.
The ECO display setting function is used to set the
display of the ECO gauge.
1. Selecting menu
Select "06 Default" on the "Service Menu"
screen.
44 D155AX-6
30 Testing and adjusting SEN00681-01
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.
D155AX-6 45
SEN00681-01 30 Testing and adjusting
46 D155AX-6
30 Testing and adjusting SEN00681-01
Adjustment ID: 0002 (Power train controller initial- Adjustment ID: 0004 (Work equipment specifica-
ization) tion setting)
q This adjustment code is used to initialize the q This adjustment code is used to make the work
specification code recognized by the power equipment controller recognize the type of the
train controller and the set values of the mem- work equipment.
ory in the controller. a After the work equipment controller is re-
a After the power train controller is replaced, be placed, be sure to carry out this adjustment
sure to carry out this adjustment once. once.
D155AX-6 47
SEN00681-01 30 Testing and adjusting
q This adjustment code is used to make the q This adjustment code is used to stop the auto-
power train controller recognize the zero point deceleration function of the engine and check
of the brake pedal potentiometer. the high idle speed of the engine unit.
a After the power train controller or brake pedal a The engine can be driven and tested with the
potentiometer is replaced or the brake pedal auto-deceleration reset only while this adjust-
linkage is disconnected and connected, be ment code is selected.
sure to carry out this adjustment once. a Use this adjustment code for testing, adjusting,
or troubleshooting when necessary.
q Functions of function switches
[F3]: Unused q Functions of function switches
[F4]: Unused [F3]: Unused
[F5]: Return to adjustment item selecting [F4]: Unused
screen (ID inputting screen) [F5]: Return to adjustment item selecting
[F6]: Save corrected value screen (ID inputting screen)
[F6]: Unused
q Operating method:
1) Check that the brake pedal is in the neu- q Operating method:
tral position (it is not pressed at all) and When this adjustment code is displayed, its
keep it in that position. function is effective and the auto-deceleration
2) Press [F6] and check that the alarm buzz- function is stopped.
er sounds. a After this adjustment code is turned OFF,
a Even if the adjustment is carried out, the its function is ineffective.
displayed value does not change.
a Even if this adjustment code is turned off,
the correction is effective.
a This adjustment code is used to make the
controller recognize the zero point of the
potentiometer. It is not used to adjust the
braking force.
48 D155AX-6
30 Testing and adjusting SEN00681-01
Adjustment ID: 0009 (Pitch angle sensor initial cor- Adjustment ID: 0010
rection) (Fan 70% mode)
q This adjustment code is used to make the q This adjustment code is used to set the cooling
power train controller recognize the zero point fan speed to about 70% forcibly.
of the pitch angle sensor and to correct the a Use this adjustment code for testing, adjusting,
installation error. or troubleshooting when necessary.
a After the power train controller is replaced or
the pitch angle sensor is removed and installed q Functions of function switches
or replaced, be sure to carry out this adjust- [F3]: Increase adjustment value [FAN 70%
ment once. SPEED MODE]
[F4]: Decrease adjustment value [FAN 70%
q Functions of function switches SPEED MODE]
[F3]: Unused [F5]: Return to adjustment item selecting
[F4]: Unused screen (ID inputting screen)
[F5]: Return to adjustment item selecting [F6]: Unused
screen (ID inputting screen)
[F6]: Save corrected value q Operating method:
When this adjustment code is displayed, its
q Operating method: function is effective and the cooling fan speed
1) Check that the machine is level. is controlled to about 70% of the maximum
2) Press [F6] and check that the alarm buzz- speed.
er sounds. a After this adjustment code is turned OFF,
a If adjustment is carried out, displayed item its function is ineffective.
[BODY PITCH ANGLE] changes to [0.0 ]
(The other displayed items do not
change).
a Even if this adjustment code is turned off,
the correction is effective.
D155AX-6 49
SEN00681-01 30 Testing and adjusting
q This adjustment code is used to initialize the q This adjustment code is used to set the fan
specification code recognized by the work speed in the 100% mode automatically and
equipment controller and the set values of the make it possible to set the preset (gear speed
memory in the controller. at start) to [F3-R3] to stall the torque converter.
a After the work equipment controller is re- a The preset (gear speed at start) can be
placed, be sure to carry out this adjustment set to [F3-R3] only while this adjustment
once. code is selected.
a Use this adjustment code for testing,
q Functions of function switches adjusting, or troubleshooting when neces-
[F3]: Unused sary.
[F4]: Unused
[F5]: Return to adjustment item selecting q Functions of function switches
screen (ID inputting screen) [F3]: Unused
[F6]: Save setting [F4]: Unused
[F5]: Return to adjustment item selecting
q Operating method: screen (ID inputting screen)
1) Press [F6] and check that the alarm buzz- [F6]: Unused
er sounds.
2) Check that the displayed specification q Mode setting information within screen
code [CODE] has changed from [6x6] to [P-AUTO SFT MODE]:
[666]. Automatic gearshift in P mode
a If specification code [666] is not displayed, [E-AUTO SFT MODE]:
the controller wiring harness or the con- Automatic gearshift in E mode
troller unit may be defective. [P-MANUAL SFT MODE]:
a Even if this adjustment code is turned off, Manual gearshift in P mode
the setting is effective. [E-MANUAL SFT MODE]:
Manual gearshift in E mode
q 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 This adjustment code does not stall the
t o r q u e c o n v e r t e r a u t o m a t i c a l l y.
Accordingly, operate the levers and
pedals securely when stalling the
torque converter (For the procedure for
stalling the torque converter, see Mea-
suring engine speed).
a After this adjustment code is turned OFF,
its function is ineffective.
50 D155AX-6
30 Testing and adjusting SEN00681-01
Adjustment ID: 0910 (Load record check mode) Adjustment ID: 1005 (Fan 100% mode)
q This adjustment code is used to check the load q This adjustment code is used to set the cooling
on the machine, odometer, and reverse odom- fan speed to about 100% forcibly. It is also
eter. used to set the adjustment value of the maxi-
a Use this adjustment code for testing, adjusting, mum speed.
or troubleshooting when necessary. a Use this adjustment code for testing, adjusting,
or troubleshooting when necessary.
q Functions of function switches
[F3]: Unused q Functions of function switches
[F4]: Unused [F3]: Increase adjustment value [FAN 100%
[F5]: Return to adjustment item selecting SPEED MODE]
screen (ID inputting screen) [F4]: Decrease adjustment value [FAN 100%
[F6]: Unused SPEED MODE]
[F5]: Return to adjustment item selecting
q Mode setting information within screen screen (ID inputting screen)
[1000 rpm SMR]: Time displayed by service [F6]: Save adjustment value
meter in which engine speed
was above 1,000 rpm q Operating method:
[ODO METER FORWARD]: a When this adjustment code is displayed,
Total forward travel distance its function is effective and the cooling fan
[ODO METER REVERSE]: speed is controlled to about 100% of the
Total reverse travel distance maximum speed.
1) Increase or decrease the adjustment
q Operating method: value by pressing [F3] or [F4].
When this adjustment code is displayed, its 2) When confirming the adjustment value,
function is effective and the load on the press [F6] and check that the alarm
machine, odometer, and reverse odometer are buzzer sounds.
displayed simultaneously. a After this adjustment code is turned OFF,
a The data cannot be reset. its function is ineffective but the set adjust-
a After this adjustment code is turned OFF, ment value is effective.
its function is ineffective.
D155AX-6 51
SEN00681-01 30 Testing and adjusting
Adjustment ID: 1012 (Steering lever neutral posi- Adjustment ID: 1013 (Steering lever leftmost posi-
tion adjustment) tion adjustment)
q This adjustment code is used to make the q This adjustment code is used to make the
power train controller recognize the neutral power train controller recognize the leftmost
position of the steering potentiometer of the position of the steering potentiometer of the
PCCS lever. PCCS lever.
a After the power train controller or PCCS lever a After the power train controller or PCCS lever
is replaced, be sure to carry out this adjust- is replaced, be sure to carry out this adjust-
ment once. ment once.
52 D155AX-6
30 Testing and adjusting SEN00681-01
Adjustment ID: 1014 (Steering lever rightmost posi- Adjustment ID: 1015 (Right brake oil pressure off-
tion adjustment) set)
q This adjustment code is used to make the q This adjustment code is used to adjust the right
power train controller recognize the rightmost brake oil pressure manually.
position of the steering potentiometer of the a Use this adjustment code for work when nec-
PCCS lever. essary.
a After the power train controller or PCCS lever
is replaced, be sure to carry out this adjust- q Functions of function switches
ment once. [F3]: Increase adjustment value
[F4]: Decrease adjustment value
q Functions of function switches [F5]: Return to adjustment item selecting
[F3]: Unused screen (ID inputting screen)
[F4]: Unused [F6]: Save adjustment value
[F5]: Return to adjustment item selecting
screen (ID inputting screen) q Information displayed on screen
[F6]: Save adjustment value The offset oil pressure is displayed and the
adjustment value is increased or decreased by
q Operating method: 0.1 kg/cm (The value displayed on the screen
1) Operate the PCCS lever to the right stroke is multiplied by 100).
end of the steering direction and keep it in a The default adjustment value is 0 kg/cm.
that position. a The adjustment range is -3 3 kg/cm.
2) Press [F6] and check that the alarm
buzzer sounds. q Operating method:
a Even if the adjustment is carried out, the 1) Increase or decrease the adjustment val-
displayed value does not change. ue by pressing [F3] or [F4].
a Even if this adjustment code is turned off, 2) Press [F6] and check that the alarm buzz-
the adjustment is effective. er sounds.
a This adjustment code is used to make the a If the oil pressure has been adjusted, it is
controller recognize the rightmost position displayed. It can be adjusted again within
of the potentiometer. It is not used to the adjustment range, however.
adjust the steering force. a It is not necessary to operate the brake
during adjustment. After finishing adjust-
ment, 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.
D155AX-6 53
SEN00681-01 30 Testing and adjusting
Adjustment ID: 1016 Adjustment ID: 2021 (Power train controller voltage
(Left brake oil pressure offset) check mode)
q This adjustment code is used to adjust the left q This adjustment code is used to check the con-
brake oil pressure manually. stant power supply voltage and switch power
a Use this adjustment code for work when nec- supply voltage applied to the power train con-
essary. troller.
a Use this adjustment code for testing, adjusting,
q Functions of function switches or troubleshooting when necessary.
[F3]: Increase adjustment value
[F4]: Decrease adjustment value q Functions of function switches
[F5]: Return to adjustment item selecting [F3]: Unused
screen (ID inputting screen) [F4]: Unused
[F6]: Save adjustment value [F5]: Return to adjustment item selecting
screen (ID inputting screen)
q Information displayed on screen [F6]: Unused
The offset oil pressure is displayed and the
adjustment value is increased or decreased by q Information displayed on screen
0.1 kg/cm (The value displayed on the screen [PT CONTROLLER UNSWITCH POWER]:
is multiplied by 100). Constant power supply voltage
a The default adjustment value is 0 kg/cm. [PT CONTROLLER ACC POWER]:
a The adjustment range is -3 3 kg/cm. Switch power supply voltage
54 D155AX-6
30 Testing and adjusting SEN00681-01
Adjustment ID: 2022 (Work equipment controller Adjustment ID: 2222 (HSS min. current setting
voltage check mode) mode)
q This adjustment code is used to check the con- q This adjustment code is used to adjust the
stant power supply voltage and switch power turning radius to start steering the machine
supply voltage applied to the work equipment when the steering feel is different by the steer-
controller. ing direction.
a Use this adjustment code for testing, adjusting, a Use this adjustment code for work when nec-
or troubleshooting when necessary. essary.
D155AX-6 55
SEN00681-01 30 Testing and adjusting
q Operating method
1) Increase or decrease the adjustment val-
ue by pressing [F3] or [F4].
2) Press [F6] and check that the alarm buzz-
er 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 adjust-
ment, 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.
56 D155AX-6
30 Testing and adjusting SEN00681-01
Adjustment ID: 6002 (R2 reverse slow set speed) Adjustment ID: 6003 (R3 reverse slow set speed)
q This adjustment code is used to adjust the q This adjustment code is used to adjust the
engine speed applied to travel at gear speed engine speed applied to travel at gear speed
R2 with the reverse slow mode ON. R3 with the reverse slow mode ON.
a Use this adjustment code for work when nec- a Use this adjustment code for work when nec-
essary. essary.
D155AX-6 57
SEN00681-01 30 Testing and adjusting
Adjustment ID: 7842 (Transmission clutch IP auto- Adjustment ID: 7843 (Transmission clutch IP man-
matic initial correction) ual initial correction)
q This adjustment code is used to make the q This adjustment code is used to carry out cor-
power train controller recognize the mechani- rection manually when the correction is not
cal condition of the transmission. carried out normally by the operation of IP
a After the power train controller or transmission automatic correction (Adjustment ID: 7842).
is replaced, be sure to carry out this adjust- a Use this adjustment code after the IP correc-
ment once. tion work, if necessary.
58 D155AX-6
30 Testing and adjusting SEN00681-01
Adjustment ID: 7845 (Transmission clutch IP learn- Adjustment ID: 8000 (Blade lift lever neutral posi-
ing display) tion adjustment)
q This adjustment code is used to check the q This adjustment code is used to make the work
information of correction made by the opera- equipment controller recognize the neutral
tion of IP automatic correction (Adjustment ID: position of the lift potentiometer of the blade
7842) or IP manual correction (Adjustment ID: control lever.
7843). a After the work equipment controller or blade
a Use this adjustment code for testing, adjusting, control lever is replaced, be sure to carry out
or troubleshooting when necessary. this adjustment once.
D155AX-6 59
SEN00681-01 30 Testing and adjusting
Adjustment ID: 8001 (Blade lift lever max. raising Adjustment ID: 8002 (Blade lift lever max. lowering
position adjustment) position adjustment)
q This adjustment code is used to make the work q This adjustment code is used to make the work
equipment controller recognize the maximum equipment controller recognize the maximum
raising position of the lift potentiometer of the lowering position of the lift potentiometer of the
blade control lever. blade control lever.
a After the work equipment controller or blade a After the work equipment controller or blade
control lever is replaced, be sure to carry out control lever is replaced, be sure to carry out
this adjustment once. this adjustment once.
60 D155AX-6
30 Testing and adjusting SEN00681-01
Adjustment ID: 8003 (Blade tilt lever neutral posi- Adjustment ID: 8004 (Blade tilt lever rightmost
tion adjustment) position adjustment)
q This adjustment code is used to make the work q This adjustment code is used to make the work
equipment controller recognize the neutral equipment controller recognize the rightmost
position of the tilt potentiometer of the blade position of the tilt potentiometer of the blade
control lever. control lever.
a After the work equipment controller or blade a After the work equipment controller or blade
control lever is replaced, be sure to carry out control lever is replaced, be sure to carry out
this adjustment once. this adjustment once.
D155AX-6 61
SEN00681-01 30 Testing and adjusting
Adjustment ID: 8005 (Blade tilt lever leftmost posi- Adjustment ID: 8006 (Ripper lift lever neutral posi-
tion adjustment) tion adjustment)
q This adjustment code is used to make the work q This adjustment code is used to make the work
equipment controller recognize the leftmost equipment controller recognize the neutral
position of the tilt potentiometer of the blade position of the lift potentiometer of the ripper
control lever. control lever.
a After the work equipment controller or blade a After the work equipment controller or ripper
control lever is replaced, be sure to carry out control lever is replaced, be sure to carry out
this adjustment once. this adjustment once.
62 D155AX-6
30 Testing and adjusting SEN00681-01
Adjustment ID: 8007 (Ripper lift lever max. raising Adjustment ID: 8008 (Ripper lift lever max. lower-
position adjustment) ing position adjustment)
q This adjustment code is used to make the work q This adjustment code is used to make the work
equipment controller recognize the maximum equipment controller recognize the maximum
raising position of the lift potentiometer of the lowering position of the lift potentiometer of the
ripper control lever. ripper control lever.
a After the work equipment controller or ripper a After the work equipment controller or ripper
control lever is replaced, be sure to carry out control lever is replaced, be sure to carry out
this adjustment once. this adjustment once.
D155AX-6 63
SEN00681-01 30 Testing and adjusting
Adjustment ID: 8009 (Ripper tilt lever neutral posi- Adjustment ID: 8010 (Ripper tilt lever max. IN posi-
tion adjustment) tion adjustment)
q This adjustment code is used to make the work q This adjustment code is used to make the work
equipment controller recognize the neutral equipment controller recognize the maximum
position of the tilt potentiometer of the ripper IN position of the tilt potentiometer of the ripper
control lever. control lever.
a After the work equipment controller or ripper a After the work equipment controller or ripper
control lever is replaced, be sure to carry out control lever is replaced, be sure to carry out
this adjustment once. this adjustment once.
64 D155AX-6
30 Testing and adjusting SEN00681-01
Adjustment ID: 8011 (Ripper tilt lever max. BACK Adjustment ID: 8020 (Blade raising current correc-
position adjustment) tion)
q This adjustment code is used to make the work q This adjustment code is used to adjust the sen-
equipment controller recognize the maximum sitivity of start of blade when the blade control
BACK position of the tilt potentiometer of the lever is moved in the raising position with the
ripper control lever. blade fine mode OFF.
a After the work equipment controller or ripper a Use this adjustment code for work when nec-
control lever is replaced, be sure to carry out essary.
this adjustment once.
q Functions of function switches
q Functions of function switches [F3]: Increase adjustment value [Current offset]
[F3]: Unused [F4]: Decrease adjustment value [Current offset]
[F4]: Unused [F5]: Return to adjustment item selecting
[F5]: Return to adjustment item selecting screen (ID inputting screen)
screen (ID inputting screen) [F6]: Save adjustment value
[F6]: Save adjustment value
q Operating method
q Operating method 1) Increase or decrease the adjustment val-
1) Operate the ripper control lever to the ue by pressing [F3] or [F4].
BACK stroke end of the tilting direction 2) Press [F6] and check that the alarm buzz-
and keep it in that position. er sounds.
2) Press [F6] and check that the alarm a If the engine speed has been adjusted, it
buzzer sounds. is displayed. It can be adjusted repeat-
a Even if the adjustment is carried out, the edly, however.
displayed value does not change. a It is not necessary to move the blade dur-
a Even if this adjustment code is turned off, ing adjustment. After finishing adjust-
the adjustment is effective. ment, however, raise the blade and check
a This adjustment code is used to make the that there is not a problem in the actual
controller recognize the maximum BACK operation feel (Check with the blade fine
position of the potentiometer. It is not control mode OFF).
used to adjust the sensitivity of the ripper a Even if this adjustment code is turned off,
control lever. the adjustment is effective.
D155AX-6 65
SEN00681-01 30 Testing and adjusting
Adjustment ID: 8021 (Blade lowering current cor- Adjustment ID: 8022 (Blade raising current correc-
rection) tion (Fine control mode))
q This adjustment code is used to adjust the sen- q This adjustment code is used to adjust the sen-
sitivity of start of blade when the blade control sitivity of start of blade when the blade control
lever is moved in the lowering position with the lever is moved in the raising position with the
blade fine mode OFF. blade fine mode ON.
a Use this adjustment code for work when nec- a Use this adjustment code for work when nec-
essary. essary.
66 D155AX-6
30 Testing and adjusting SEN00681-01
Adjustment ID: 8023 (Blade lowering current cor- Adjustment ID: 8024 (Blade tilting left current cor-
rection (Fine control mode)) rection)
q This adjustment code is used to adjust the sen- q This adjustment code is used to adjust the sen-
sitivity of start of blade when the blade control sitivity of start of blade when the blade control
lever is moved in the lowering position with the lever is moved in the tilting left position.
blade fine mode ON. a Use this adjustment code for work when nec-
a Use this adjustment code for work when nec- essary.
essary.
q Functions of function switches
q Functions of function switches [F3]: Increase adjustment value [Current offset]
[F3]: Increase adjustment value [Current offset] [F4]: Decrease adjustment value [Current offset]
[F4]: Decrease adjustment value [Current offset] [F5]: Return to adjustment item selecting
[F5]: Return to adjustment item selecting screen (ID inputting screen)
screen (ID inputting screen) [F6]: Save adjustment value
[F6]: Save adjustment value
q Operating method
q Operating method 1) Increase or decrease the adjustment val-
1) Increase or decrease the adjustment val- ue by pressing [F3] or [F4].
ue by pressing [F3] or [F4]. 2) Press [F6] and check that the alarm buzz-
2) Press [F6] and check that the alarm buzz- er sounds.
er sounds. a If the engine speed has been adjusted, it
a If the engine speed has been adjusted, it is displayed. It can be adjusted repeat-
is displayed. It can be adjusted repeat- edly, however.
edly, however. a It is not necessary to move the blade dur-
a It is not necessary to move the blade dur- ing adjustment. After finishing adjust-
ing adjustment. After finishing adjust- ment, however, tilt the blade to the left and
ment, however, lower the blade and check check that there is not a problem in the
that there is not a problem in the actual actual operation feel.
operation feel (Check with the blade fine a Even if this adjustment code is turned off,
control mode ON). the adjustment is effective.
a Even if this adjustment code is turned off,
the adjustment is effective.
D155AX-6 67
SEN00681-01 30 Testing and adjusting
Adjustment ID: 8025 (Blade tilting right current cor- Adjustment ID: 9995
rection) (Control brake release mode)
q This adjustment code is used to adjust the sen- q This adjustment code is used to release the
sitivity of start of blade when the blade control control brake (right and left brake ECMV) to
lever is moved in the tilting right position. check the operation of the backup brake
a Use this adjustment code for work when nec- (brake pedal solenoid valve).
essary. a Use this adjustment code for testing, adjusting,
or troubleshooting when necessary.
q Functions of function switches
[F3]: Increase adjustment value [Current offset] q Functions of function switches
[F4]: Decrease adjustment value [Current offset] [F3]: Unused
[F5]: Return to adjustment item selecting [F4]: Unused
screen (ID inputting screen) [F5]: Return to adjustment item selecting
[F6]: Save adjustment value screen (ID inputting screen)
[F6]: Unused
q Operating method
1) Increase or decrease the adjustment val- q Operating method
ue by pressing [F3] or [F4]. When this adjustment code is displayed, its
2) Press [F6] and check that the alarm buzz- function is effective and the control brake (right
er sounds. and left brake ECMV) is kept released.
a If the engine speed has been adjusted, it a After this adjustment code is turned OFF,
is displayed. It can be adjusted repeat- its function is ineffective.
edly, however.
a It is not necessary to move the blade dur-
ing adjustment. After finishing adjust-
ment, 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.
68 D155AX-6
30 Testing and adjusting SEN00681-01
Adjustment ID: 9996 (Sudden stop prevent valve Adjustment ID: 9997
operation mode) (High idle cut mode)
q This adjustment code is used to stop the sud- q This adjustment code is used to limit the high
den stop prevent solenoid valve and right and idle speed.
left brake ECMV to check the operation of the a Use this adjustment code for work when nec-
sudden stop prevent valve. essary.
a Use this adjustment code for testing, adjusting,
or troubleshooting when necessary. q Functions of function switches
[F3]: Increase adjustment value [HIGH IDLE
q Functions of function switches RPM SET MODE]
[F3]: Unused [F4]: Decrease adjustment value [HIGH IDLE
[F4]: Unused RPM SET MODE]
[F5]: Return to adjustment item selecting [F5]: Return to adjustment item selecting
screen (ID inputting screen) screen (ID inputting screen)
[F6]: Unused [F6]: Save adjustment value
D155AX-6 69
SEN00681-01 30 Testing and adjusting
q Operating method
1) Increase or decrease the adjustment val-
ue by pressing [F3] or [F4].
2) Press [F6] and check that the alarm buzz-
er sounds.
a When resetting the limitation of the maxi-
mum 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
30 Testing and adjusting SEN00681-01
1. Selecting menu
Select "08 PM CLINIC" on the Service menu
screen.
D155AX-6 71
SEN00681-01 30 Testing and adjusting
72 D155AX-6
30 Testing and adjusting SEN00681-01
D155AX-6 73
SEN00681-01 30 Testing and adjusting
2. Starting measurement
After the screen of "Fuel Consumption" is dis-
played, start measurement with the function
switches. 4. Finishing measurement
q [F1]: Start Press [F1], and measurement is finished and
q [F2]: Clear the data are displayed on the finishing date
q [F5]: Return to Service menu screen and time side.
a When the screen of "Fuel Consumption" is
displayed, if a data is indicated, it is the 5. Displaying fuel consumption
data of the previous measurement. This If the measurement is finished, the hourly fuel
data is not an obstacle to new measure- consumption calculated from the fuel con-
ment and can be deleted by pressing [F2]. sumption calculated by the engine controller
a If [F1] is pressed, the data is displayed on and the elapsed time are displayed.
the starting date and time side and mea-
surement starts.
a The display unit of the fuel changes
according to the unit set with the initializa-
tion (unit setting) function.
SI and meter: l/h,
inch: gal/h
74 D155AX-6
30 Testing and adjusting SEN00681-01
Display of KOMTRAX Settings (Terminal Status) q [F5]: Return to KOMTRAX Settings screen
The setting condition and operating condition of
KOMTRAX can be checked with "KOMTRAX Set-
tings".
Terminal Status is used to check the setting condi-
tion of the KOMTRAX terminal.
1. Selecting menu
Select "12 KOMTRAX Settings" on the "Ser-
vice Menu" screen.
D155AX-6 75
SEN00681-01 30 Testing and adjusting
Display of KOMTRAX Settings (GPS & Commu- 3. Contents of display of condition of positioning
nication Status) and communication
The setting condition and operating condition of On the screen of "GPS & Communication Sta-
KOMTRAX can be checked with KOMTRAX Set- tus", the following items are displayed.
tings. q Positioning: Positioning condition of GPS
Condition of positioning and communication is used q Communication: Communication environ-
to check the condition of positioning and communi- ment of communication MODEM and con-
cation of the KOMTRAX terminal. necting condi tion of c ommunication
MODEM
1. Selecting menu q Number of message not yet sent: Number
Select "12 KOMTRAX Settings" on the "Ser- of mails in machine monitor not yet sent
vice Menu" screen. q [F5]: Return to KOMTRAX Settings screen
76 D155AX-6
30 Testing and adjusting SEN00681-01
1. Selecting menu
Select "12 KOMTRAX Settings" on the "Ser-
vice Menu" screen.
D155AX-6 77
SEN00681-01 30 Testing and adjusting
78 D155AX-6
SEN00681-01 30 Testing and adjusting
D155AX-6 Bulldozer
Form No. SEN00681-01
2006 KOMATSU
All Rights Reserved
Printed in Japan 05-06 (02)
80 D155AX-6
SEN00682-01
D155AX-6
D155AX-6 1
SEN00682-01 30 Testing and adjusting
2 D155AX-6
30 Testing and adjusting SEN00682-01
1. Machine monitor
1) Remove the 4 mounting bolts each from
covers (1) and (2) and remove those cov-
ers.
2) Remove the 4 mounting bolts each from
covers (3) and (4) and remove those cov-
ers together with the foot rest.
a The 2 bolts on the front window side of the
3) Insert or connect troubleshooting T-adapt-
foot rest are used as the cover mounting
ers in or to connectors EGC1, EGC2, and
bolts, too.
EGC3 of engine controller (7).
3) Remove the 4 mounting bolts of machine
a Since connectors EGC1 and EGC2
monitor (5) and pull out machine monitor
are fixed with screws, loosen those
(5) and switch cover together toward the
screws before disconnecting.
operator's seat.
a When returning connectors EGC1
and EGC2, tighten the screws to the
specified torque.
3 Screw: 3 1 Nm {0.3 0.1 kgm}
D155AX-6 3
SEN00682-01 30 Testing and adjusting
4 D155AX-6
30 Testing and adjusting SEN00682-01
Pm Clinic 1
Machine model Serial No. Service meter
D155AX-6 h
/ /
Specifications
Blade Rear attachment Shoe width
T blade T Multi-shank ripper T 560 mm T
T Semi-U blade T Variable giant ripper T 610 mm
T Full-U blade T Counterweight ( kg) T 660 mm
T T T 710 mm
Working condition
Quarry/Mining Construction Type of soil (Specific gravity: ) Contents of work
T Coal T Construction/Civil engineering T Rock T Dozing %
T Gold T Road T Gravel T Side cutting %
T Limestone T Tunnel T Sand T Ripping %
T T T Clay T Travel %
Check of oil and coolant levels
T Engine coolant level When necessary
T Engine oil level T Damper case oil level T Final drive oil level
T Hydraulic oil level T Power train oil level T
Engine coolant temperature Power train oil temperature Ambient temperature Altitude
Max. range: Max. range: Max. C/Min. C m
Following figure (Left) Following figure (Right)
Operator's opinion Result of visual inspection
D155AX-6 5
SEN00682-01 30 Testing and adjusting
Check positions/Method 1
6 D155AX-6
30 Testing and adjusting SEN00682-01
Check positions/Method 2
D155AX-6 7
SEN00682-01 30 Testing and adjusting
Check positions/Method 3
8 D155AX-6
30 Testing and adjusting SEN00682-01
Machine model Serial No. Service meter User's name Date of execution Inspector
D155AX-6
1. Engine
Accepted
Rejected
Standard
Service limit Measure-
Item Measurement condition Unit value for new
value ment result
machine
Low idling 715 765 715 765
Without deceleration
2,000 2,100 2,000 2,100
High (Adjustment: 0007)
Engine speed idle Normal (Deceleration) rpm 1,825 1,925 1,825 1,925
Decelerator pedal 825 925 825 925
F3 stall 1,560 1,660 1,450
F3 stall + Ripper raise relieve 1,500 1,600 1,395
Boost kPa Min. 117 100
Engine
F3 stall
pressure {mmHg} {Min. 880} {750}
Exhaust Ambient temperature
C
temperature F3 stall 660 700
Blow-by pres- kPa Max. 2.94 3.92
F3 stall
sure {mmH2O} {Max. 300} {400}
Min. 034 0.21
High idle
Engine oil MPa {Min. 3.5} {2.1}
pressure {kg/cm} Min. 010 0.08
Low idle
{Min. 1.0} {0.8}
2. Cooling fan
Accepted
Rejected
Standard
Service limit Measure-
Item Measurement condition Unit value for new
value ment result
machine
Low idle
Speed Adjust- rpm
Fan
D155AX-6 9
SEN00682-01 30 Testing and adjusting
Accepted
Rejected
Standard
Service limit Measure-
Item Measurement condition Unit value for new
value ment result
machine
Monitoring: 32603
pressure 0.29 0.69 0.29 0.69
High idle
MPa {3.0 7.0} {3.0 7.0}
{kg/cm} 1.12 1.52 1.12 1.52
Automatic gear- Low idle
Lockup clutch shift mode {11.5 15.5} {11.5 15.5}
pressure Gear speed: F1 1.12 1.52 1.12 1.52
Travel with no load High idle {11.5 15.5} {11.5 15.5}
2.45 2.85 2.45 2.85
Low idle
Stator clutch {25.0 29.0} {25.0 29.0}
Gear speed: P/N
pressure 2.45 2.85 2.45 2.85
High idle
{25.0 29.0} {25.0 29.0}
Accepted
Rejected
Standard
Service limit Measure-
Item Measurement condition Unit value for new
value ment result
machine
Rejected
Standard
Service limit Measure-
Item Measurement condition Unit value for new
value ment result
machine
10 D155AX-6
30 Testing and adjusting SEN00682-01
Accepted
Rejected
Standard
Service limit Measure-
Item Measurement condition Unit value for new
value ment result
machine
Work equipment
Unload 2.45 3.82 2.45 3.82
control lever: All High idle
pressure {25 39} {25 39}
levers in neutral
Work equipment/HSS oil pressure
Work equip-
26.0 29.0 26.0 29.0
ment relief High idle
{265 295} {265 295}
pressure Cylinder stroke
Work equip- end relief
24.0 26.0 24.0 26.0
ment LS relief High idle MPa {245 265} {245 265}
pressure {kg/cm}
HSS relief 38.2 41.5 38.2 41.5
High idle
pressure Brake: Applied {390 425} {390 425}
HSS LS relief Steering: Relieved 36.2 38.1 36.2 38.1
High idle
pressure {369 389} {369 389}
Control Work equipment
3.97 4.46 3.97 4.46
circuit basic control lever: All High idle
{40.5 45.5} {40.5 45.5}
pressure levers in neutral
Accepted
Rejected
Standard
Service limit Measure-
Item Measurement condition Unit value for new
value ment result
machine
sec
Ripper lower High idle 1.5 2.5 3.5
Ripper tilt in High idle 4.5 5.5 6.2
Accepted
Rejected
Standard
Service limit Measure-
Item Measurement condition Unit value for new
value ment result
machine
Hydraulic oil
C
temperature
Hydraulic
Engine: Stopped
Hydraulic drift
drift
7. Final drive
Accepted
Rejected
Standard
Service limit Measure-
Item Measurement condition Unit value for new
value ment result
machine
D155AX-6 11
SEN00682-01 30 Testing and adjusting
Date Service meter Repair record Date Service meter Repair record
/ / h / / h
/ / h / / h
/ / h / / h
/ / h / / h
/ / h / / h
12 D155AX-6
30 Testing and adjusting SEN00682-01
Machine model Serial No. Service meter User's name Date of execution Inspector
D155AX-6
1. Bushing temperature
D155AX-6 13
SEN00682-01 30 Testing and adjusting
Accepted
Rejected
Clearance Measure-
Item Measurement condition Unit Pin No.
limit ment result
Opening of Measure
mm
track link dimension (a).
14 D155AX-6
SEN00682-01 30 Testing and adjusting
D155AX-6 Bulldozer
Form No. SEN00682-01
2006 KOMATSU
All Rights Reserved
Printed in Japan 05-06 (02)
16 D155AX-6
SEN00851-00
D155AX-6
40 Troubleshooting 1
General information on troubleshooting
General information on troubleshooting.......................................................................................................... 2
Points to remember when troubleshooting........................................................................................... 2
Sequence of events in troubleshooting ................................................................................................ 3
Check before troubleshooting .............................................................................................................. 4
Classification and procedures for troubleshooting ............................................................................... 5
Connector pin Nos. and connection table ............................................................................................ 8
T-boxes and T-adapters table ............................................................................................................ 31
D155AX-6 1
SEN00851-00 40 Troubleshooting
1. When carrying out troubleshooting, do not 3) Check the travel of the control levers.
hurry to disassemble the components. 4) Check the stroke of the control valve
If components are disassembled immediately spool.
any failure occurs: 5) Other maintenance items can be checked
q Parts that have no connection with the fail- externally, so check any item that is con-
ure or other unnecessary parts will be dis- sidered to be necessary.
assembled.
4. Confirming failure
q It will become impossible to find the cause
q Confirm the extent of the failure yourself,
of the failure.
and judge whether to handle it as a real
It will also cause a waste of manhours, parts,
failure or as a problem with the method of
or oil or grease, and at the same time, will also
operation, etc.
lose the confidence of the user or operator.
a When operating the machine to reen-
For this reason, when carrying out trouble-
act the troubleshooting symptoms, do
shooting, it is necessary to carry out thorough
not carry out any investigation or
prior investigation and to carry out trouble-
measurement that may make the
shooting in accordance with the fixed proce-
problem worse.
dure.
5. Troubleshooting
2. Points to ask user or operator
q Use the results of the investigation and
1) Have any other problems occurred apart
inspection in Items 2 4 to narrow down
from the problem that has been reported?
the causes of failure, then use the trouble-
2) Was there anything strange about the
shooting flowchart to locate the position of
machine before the failure occurred?
the failure exactly.
3) Did the failure occur suddenly, or were
a The basic procedure for troubleshoot-
there problems with the machine condition
ing is as follows.
before this?
1) Start from the simple points.
4) Under what conditions did the failure
2) Start from the most likely points.
occur?
3) Investigate other related parts or
5) Had any repairs been carried out before
information.
the failure?
When were these repairs carried out? 6. Measures to remove root cause of failure
6) Has the same kind of failure occurred q Even if the failure is repaired, if the root
before? cause of the failure is not repaired, the
same failure will occur again.
3. Check before troubleshooting
To prevent this, always investigate why
1) Check the oil level
the problem occurred. Then, remove the
2) Check for any external leakage of oil from
root cause.
the piping or hydraulic equipment.
2 D155AX-6
40 Troubleshooting SEN00851-00
D155AX-6 3
SEN00851-00 40 Troubleshooting
4 D155AX-6
40 Troubleshooting SEN00851-00
1. 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 his-
tory:
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" accord-
ing 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 trouble-
shooting corresponding to that phenomenon in the "E mode", "H mode", or "S mode".
D155AX-6 5
SEN00851-00 40 Troubleshooting
Troubleshooting
No. Phenomena looking like troubles Display
E mode H mode S mode
of code
Phenomena related to action code/failure code
1 Action code and failure code are displayed on machine monitor
Accord-
When fault history is checked, failure code is displayed in mechanical
2 ing to dis-
system fault history
played
When fault history is checked, failure code is displayed in electrical code
3
system fault history
When fault history is checked, failure code is displayed in air conditioner
4 E-20
or heater fault history
Phenomena related to engine
5 Starting performance is poor S-1
6 Engine does not start E-3 S-2
7 Engine does not pick up smoothly S-3
8 Engine stops during operation S-4
9 Engine does not rotate smoothly S-5
10 Engine lacks output (or lacks power) S-6
11 Exhaust smoke is black (incomplete combustion) S-7
12 Oil consumption is excessive (or exhaust smoke is blue) S-8
13 Oil is contaminated badly S-9
14 Fuel consumption is excessive S-10
15 Oil is in coolant (or coolant spurts back or coolant level goes down) S-11
16 Oil pressure drops S-12
17 Oil level rises (Entry of coolant/fuel) S-13
18 Coolant temperature becomes too high (overheating) S-14
19 Abnormal noise is made S-15
20 Vibration is excessive S-16
21 Preheater does not operate E-4
Phenomena related to power train
22 Power is low (Drawbar pull is low) H-1
23 Machine does not travel (at 2nd or 3rd gear speed) H-2
24 Machine does not start at any gear speed H-3
25 Machine can travel only forward or in reverse H-4
26 When gear speed or travel direction is changed, time lag is large H-5
27 Machine cannot be steered (Machine does not turn right or left) H-6
28 Steering speed or steering force is low H-7
29 Brake does not work H-8
30 Power train oil is overheated H-9
31 Abnormal sound comes out from around HSS pump or HSS motor H-10
Phenomena related to work equipment
32 Speed of all work equipment is low H-11
33 No work equipment moves H-12
34 Blade lift speed or power is low H-13
35 Blade tilt speed or power is low H-14
6 D155AX-6
40 Troubleshooting SEN00851-00
Troubleshooting
No. Phenomena looking like troubles Display
E mode H mode S mode
of code
36 Ripper lift speed or power is low H-15
37 Ripper tilt speed or power is low H-16
38 Hydraulic drift of blade lift is large H-17
39 Hydraulic drift of blade tilt is large H-18
40 Hydraulic drift of ripper lift is large H-19
41 Ripper pin puller cylinder does not operate H-20
42 Blade does not pitch H-21
43 Abnormal sound comes out from around work equipment pump H-22
Phenomena related to machine monitor
44 When starting switch turned ON, machine monitor displays nothing E-1
When starting switch turned ON (before starting engine), basic check
45 E-2
item (radiator coolant level) lights up
46 Precaution item lights up while engine is running E-5
47 Emergency stop item lights up while engine is running E-6
48 Engine coolant temperature gauge does not indicate normally E-7
49 Fuel level gauge does not indicate normally E-8
Power train oil temperature gauge (multi-gauge) does not indicate
50 E-9
normally
51 Hydraulic temperature gauge (multi-gauge) does not indicate normally E-10
Contents of display by machine monitor are different from applicable
52 E-11
machine
53 Machine monitor does not display some items E-12
54 Function switch does not work E-13
55 Operation mode does not change E-14
56 Gearshift mode does not change E-15
57 Customize function does not operate normally E-16
58 Customize memory function does not normally E-17
59 Float mode does not change E-18
60 Alarm buzzer cannot be stopped E-19
61 Air conditioner does not operate normally E-20
62 When starting switch is turned OFF, service meter is not displayed E-21
63 Machine monitor cannot be set in service mode E-22
64 Ripper pin puller cylinder does not operate E-23
65 Backup alarm does not sound or does not stop E-24
66 Headlamp, rear lamp, and ripper point lamp do not light up E-25
67 Windshield wiper and window washer do not operate E-26
Other phenomena
68 KOMTRAX system does not operate normally E-27
D155AX-6 7
SEN00851-00 40 Troubleshooting
2 799-601-7020
3 799-601-7030
4 799-601-7040
8 D155AX-6
40 Troubleshooting SEN00851-00
6 799-601-7050
8 799-601-7060
12 799-601-7310
14 799-601-7070
D155AX-6 9
SEN00851-00 40 Troubleshooting
16 799-601-7320
10 D155AX-6
40 Troubleshooting SEN00851-00
2 799-601-7090
3 799-601-7110
4 799-601-7120
6 799-601-7130
8 799-601-7340
D155AX-6 11
SEN00851-00 40 Troubleshooting
8 799-601-7140
10
799-601-7150
(White)
12
799-601-7350
(White)
16
799-601-7330
(White)
12 D155AX-6
40 Troubleshooting SEN00851-00
10
(Blue)
12
799-601-7160
(Blue)
16
799-601-7170
(Blue)
D155AX-6 13
SEN00851-00 40 Troubleshooting
5 799-601-2710
9 799-601-2950
13 799-601-2720
14 D155AX-6
40 Troubleshooting SEN00851-00
17 799-601-2730
21 799-601-2740
D155AX-6 15
SEN00851-00 40 Troubleshooting
8 799-601-7180
12 799-601-7190
16 799-601-7210
20 799-601-7220
16 D155AX-6
40 Troubleshooting SEN00851-00
10 799-601-7510
12 799-601-7520
14 799-601-7530
18 799-601-7540
20 799-601-7550
D155AX-6 17
SEN00851-00 40 Troubleshooting
10 799-601-3460
18 D155AX-6
40 Troubleshooting SEN00851-00
Part No.: 08027-10210 (Natural color) Part No.: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
Part No.: 08027-10410 (Natural color) Part No.: 08027-10460 (Natural color)
08027-10420 (Black) 08027-10470 (Black)
Part No.: 08027-10610 (Natural color) Part No.: 08027-10660 (Natural color)
08027-10620 (Black) 08027-10670 (Black)
D155AX-6 19
SEN00851-00 40 Troubleshooting
Part No.: 08027-10810 (Natural color) Part No.: 08027-10860 (Natural color)
08027-10820 (Black) 08027-10870 (Black)
5 799-601-7360
6 799-601-7370
20 D155AX-6
40 Troubleshooting SEN00851-00
D155AX-6 21
SEN00851-00 40 Troubleshooting
799-601-9210
799-601-9210
799-601-9220
799-601-9220
22 D155AX-6
40 Troubleshooting SEN00851-00
799-601-9230
799-601-9230
799-601-9240
799-601-9240
D155AX-6 23
SEN00851-00 40 Troubleshooting
799-601-9250
799-601-9250
799-601-9260
799-601-9260
24 D155AX-6
40 Troubleshooting SEN00851-00
799-601-9270
799-601-9270
799-601-9280
799-601-9280
D155AX-6 25
SEN00851-00 40 Troubleshooting
799-601-9290
799-601-9290
26 D155AX-6
40 Troubleshooting SEN00851-00
2 799-601-9020
Part No.: 08192-12200 (Normal type) Part No.: 08192-12100 (Normal type)
08192-22200 (Fine wire type) 08192-22100 (Fine wire type)
3 799-601-9030
Part No.: 08192-13200 (Normal type) Part No.: 08192-13100 (Normal type)
08192-23200 (Fine wire type) 08192-23100 (Fine wire type)
4 799-601-9040
Part No.: 08192-14200 (Normal type) Part No.: 08192-14100 (Normal type)
08192-24200 (Fine wire type) 08192-24100 (Fine wire type)
6 799-601-9050
Part No.: 08192-16200 (Normal type) Part No.: 08192-16100 (Normal type)
08192-26200 (Fine wire type) 08192-26100 (Fine wire type)
D155AX-6 27
SEN00851-00 40 Troubleshooting
Part No.: 08192-1820! (Normal type) Part No.: 08192-1810! (Normal type)
08192-2820! (Fine wire type) 08192-2810! (FIne wire type)
Part No.: 08192-1920! (Normal type) Part No.: 08192-1910! (Normal type)
08192-2920! (Fine wire type) 08192-2910! (Fine wire type)
28 D155AX-6
40 Troubleshooting SEN00851-00
799-601-9010
2
Part No.: 08192-31200 (Contact size#12) Part No.: 08192-31100 (Contact size#12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
D155AX-6 29
SEN00851-00 40 Troubleshooting
24 799-601-9360
Part No.:7821-93-3110
40
799-601-9350
(A)
Part No.:7821-93-3120
40
799-601-9350
(B)
Part No.:7821-93-3130
30 D155AX-6
40 Troubleshooting SEN00851-00
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Out of kit
Distinction
Part No. Part name
symbol
D155AX-6 31
SEN00851-00 40 Troubleshooting
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Out of kit
Distinction
Part No. Part name
symbol
32 D155AX-6
40 Troubleshooting SEN00851-00
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Out of kit
Distinction
Part No. Part name
symbol
D155AX-6 33
SEN00851-00 40 Troubleshooting
D155AX-6 Bulldozer
Form No. SEN00851-00
2006 KOMATSU
All Rights Reserved
Printed in Japan 02-06 (02)
34 D155AX-6
SEN00716-01
D155AX-6
40 Troubleshooting 1
Troubleshooting by failure and error
codes, Part 1
Troubleshooting by failure and error codes, Part 1 ......................................................................................... 3
Failure codes table.............................................................................................................................. 3
Before carrying out troubleshooting when failure code is displayed ................................................. 10
Information in troubleshooting table .................................................................................................. 14
Failure code [1500L0] Transmission clutch: Abnormal ..................................................................... 16
Failure code [15SAL1] Forward clutch: Fill high ................................................................................ 17
Failure code [15SALH] Forward clutch: Fill low ................................................................................ 18
Failure code [15SBL1] Reverse clutch: Fill high ............................................................................... 19
Failure code [15SBLH] Reverse clutch: Fill low ................................................................................ 20
Failure code [15SEL1] Speed 1st clutch: Fill high............................................................................. 21
Failure code [15SELH] Speed 1st clutch: Fill low .............................................................................. 22
Failure code [15SFL1] Speed 2nd clutch: Fill high ............................................................................ 23
Failure code [15SFLH] Speed 2nd clutch: Fill low ............................................................................. 24
Failure code [15SGL1] Speed 3rd clutch: Fill high ............................................................................ 25
D155AX-6 1
SEN00716-01 40 Troubleshooting
2 D155AX-6
40 Troubleshooting SEN00716-01
D155AX-6 3
SEN00716-01 40 Troubleshooting
4 D155AX-6
40 Troubleshooting SEN00716-01
D155AX-6 5
SEN00716-01 40 Troubleshooting
6 D155AX-6
40 Troubleshooting SEN00716-01
D155AX-6 7
SEN00716-01 40 Troubleshooting
8 D155AX-6
40 Troubleshooting SEN00716-01
D155AX-6 9
SEN00716-01 40 Troubleshooting
10 D155AX-6
40 Troubleshooting SEN00716-01
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SEN00716-01 40 Troubleshooting
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)
12 D155AX-6
40 Troubleshooting SEN00716-01
Fuse box
Power circuit fuse Fuel
Fuse No. Destination of power
(Type of power supply) capacity
FS1-1 Radio
(Unswitched power 1 10A 12V accessory connector (Via DC converter)
supply) 12V accessory socket (Via DC converter)
Additional light relay, additional light
FS1-3 2 20A
Rotary lamp
(Accessory power
supply) 12V accessory connector (Via DC converter)
3 20A
12V accessory socket (Via DC converter)
Radio
Room lamp
FS1-4 4 20A
Cigarette lighter
(Accessory power
supply) Windshield wiper (Via intermittent relay)
5 10A Front wiper, rear wiper
6 10A Left wiper, right wiper
D155AX-6 13
SEN00716-01 40 Troubleshooting
<Contents of description>
Standard value in normal state to judge possible causes
Remarks on judgment
1
<Troubles in wiring harness>
Disconnection
Connector is connected defectively or wiring harness is
broken.
Ground fault
Wiring harness which is not connected to chassis ground
circuit is in contact with chassis ground circuit.
Hot short
Wiring harness which is not connected to power source (24
2 V) circuit is in contact with power source (24 V) circuit.
Short circuit
Independent wiring harnesses are in contact with each
Possible causes other abnormally.
and standard Possible causes of trouble
value in normal (Given numbers are refer-
<Precautions for troubleshooting>
state ence numbers, which do not
(1) Method of indicating connector No. and handling of T-
indicate priority)
adapter
Insert or connect T-adapter as explained below for trouble-
shooting, unless otherwise specified.
3 If connector No. has no marks of "male" and "female",
disconnect connector and insert T-adapters in both male
side and female side.
If connector No. has marks of "male" and "female", dis-
connect connector and connect T-adapter to only male
side or female side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative () lead of tester as
explained below for troubleshooting, unless otherwise
specified.
4 Connect positive (+) lead to pin No. or wiring harness
entered on front side.
Connect negative () lead to pin No. or harness entered
on rear side.
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44 D155AX-6
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D155AX-6 Bulldozer
Form No. SEN00716-01
2006 KOMATSU
All Rights Reserved
Printed in Japan 05-06 (02)
46 D155AX-6
SEN00717-01
D155AX-6
40 Troubleshooting 1
Troubleshooting by failure and error
codes, Part 2
Troubleshooting by failure and error codes, Part 2 ......................................................................................... 4
Failure code [CA111] EMC Critical Internal Failure .............................................................................. 4
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ................................................................. 6
Failure code [CA122] Chg Air Press Sensor High Error ...................................................................... 8
Failure code [CA123] Chg Air Press Sensor Low Error ..................................................................... 10
Failure code [CA131] Throttle Sensor High Error .............................................................................. 12
Failure code [CA132] Throttle Sensor Low Error ............................................................................... 14
Failure code [CA135] Eng Oil Press Sensor High Error..................................................................... 16
Failure code [CA141] Eng Oil Press Sensor Low Error ..................................................................... 18
Failure code [CA144] Coolant Temp Sens High Error........................................................................ 20
Failure code [CA145] Coolant Temp Sens Low Error ........................................................................ 22
Failure code [CA153] Chg Air Temp Sensor High Error ..................................................................... 24
Failure code [CA154] Chg Air Temp Sensor Low Error...................................................................... 26
Failure code [CA187] Sens Supply 2 Volt Low Error.......................................................................... 26
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Possible causes a Prepare with starting switch OFF, then carry out troubleshoot-
and standard ing without turning starting switch ON.
value in normal Wiring harness between EGC1 (female) Resis-
Ground fault in wiring har- Min. 1 Mz
state (37) PIM (female) (1) and chassis ground tance
4 ness (Contact with GND cir-
cuit) Wiring harness between EGC1 (female) Resis-
Min. 1 Mz
(47) PIM (female) (2) and chassis ground tance
Wiring harness between EGC1 (female) Resis-
Min. 1 Mz
(44) PIM (female) (3) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshoot-
ing without turning starting switch ON.
Wiring harness between EGC1 (female)
Resis-
(37) PIM (female) (1) and between EGC1 Min. 1 Mz
tance
Short circuit in wiring har- (female) (47) PIM (female) (2)
5 ness (with another wiring Wiring harness between EGC1 (female)
harness) Resis-
(37) PIM (female) (1) and between EGC1 Min. 1 Mz
tance
(female) (44) PIM (female) (3)
Chassis ground between EGC1 (female)
Resis-
(47) PIM (female) (2) and between EGC1 Min. 1 Mz
tance
(female) (44) PIM (female) (3)
a Prepare with starting switch OFF, then turn starting switch ON
or start engine and carry out troubleshooting.
6 Defective engine controller
EGC1 Voltage
Between (37) (47) Power supply 4.75 5.25 V
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Possible causes a Prepare with starting switch OFF, then carry out troubleshoot-
ing without turning starting switch ON.
and standard
value in normal Wiring harness between EGC1 (female) Resis-
Ground fault in wiring har- Min. 1 Mz
state (37) POIL (female) (1) and chassis ground tance
4 ness (Contact with GND cir-
cuit) Wiring harness between EGC1 (female) Resis-
Min. 1 Mz
(47) POIL (female) (2) and chassis ground tance
Wiring harness between EGC1 (female) Resis-
Min. 1 Mz
(13) POIL (female) (3) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshoot-
ing without turning starting switch ON.
Wiring harness between EGC1 (female)
Resis-
(37) POIL (female) (1) and between EGC1 Min. 1 Mz
tance
Short circuit in wiring har- (female) (47) POIL (female) (2)
5 ness (with another wiring Wiring harness between EGC1 (female)
harness) Resis-
(37) POIL (female) (1) and between EGC1 Min. 1 Mz
tance
(female) (13) POIL (female) (3)
Wiring harness between EGC1 (female)
Resis-
(47) POIL (female) (2) and between EGC1 Min. 1 Mz
tance
(female) (13) POIL (female) (3)
a Prepare with starting switch OFF, then turn starting switch ON
or start engine and carry out troubleshooting.
6 Defective engine controller
EGC1 Voltage
Between (37) (47) Power supply 4.75 5.25 V
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Possible causes a Prepare with starting switch OFF, then turn starting switch ON
and standard or start engine and carry out troubleshooting.
value in normal 6 Defective engine controller EGC1 Voltage
state Between (33) (47) 4.75 5.25 V
Between (25) (47) 0.26 4.6 V
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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.
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B. Check with machine monitor (02 Fault history, 01 monitoring, and 09 reduced cylinder mode operation) Good NG
3 Check of failure code / / / /
Check of monitoring information
Standard value Measured
Code Displayed item Checking condition ISO unit Good NG
(Reference value) value
Low idle r/min 715 765
01002 Engine speed High idle r/min 1,825 1,925
Torque converter stall r/min 1,560 1,660
Final accelerator Low idle % 0
31706
position High idle % 100
Final fuel injection
18600 rate command Torque converter stall mg/st
(by weight)
4
Final common rail
36200 Torque converter stall MPa
pressure command
Common rail pres-
36400 Torque converter stall MPa
sure
Low idle CA
Final injection tim-
36300 High idle CA
ing command
Torque converter stall CA
36500 Boost pressure Torque converter stall kPa
Engine coolant tem-
04107 Low idle C
perature
14200 Fuel temperature Low idle C
Check of reduced cylinder mode operation (Engine speed)
Standard value Measured
Setting Reduced cylinder Checking condition ISO unit Good NG
(Reference value) value
No. 1 cylinder r/min
5 No. 2 cylinder r/min
Reduce No. 3 cylinder r/min
each
cylinder No. 4 cylinder r/min
No. 5 cylinder r/min
No. 6 cylinder r/min
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D155AX-6 Bulldozer
Form No. SEN00717-01
2006 KOMATSU
All Rights Reserved
Printed in Japan 05-06 (02)
70 D155AX-6
SEN00718-01
D155AX-6
40 Troubleshooting 1
Troubleshooting by failure and error
codes, Part 3
Troubleshooting by failure and error codes, Part 3 ......................................................................................... 3
Failure code [CA731] Eng Bkup Speed Sens Phase Error .................................................................. 3
Failure code [CA757] All Continuous Data Lost Error .......................................................................... 3
Failure code [CA778] Eng Bkup Speed Sensor Error .......................................................................... 4
Failure code [CA1228] EGR Valve Servo Error 1 ................................................................................ 6
Failure code [CA1625] EGR Valve Servo Error 2 ................................................................................ 7
Failure code [CA1626] BP Valve Sol Current High Error ..................................................................... 8
Failure code [CA1627] BP Valve Sol Current Low Error .................................................................... 10
Failure code [CA1628] Bypass Valve Servo Error 1............................................................................11
Failure code [CA1619] Bypass Valve Servo Error 2........................................................................... 12
Failure code [CA1631] BP Valve Pos Sens High Error ...................................................................... 14
Failure code [CA1632] BP Valve Pos Sens Low Error ....................................................................... 16
Failure code [CA1633] KOMNET Datalink Timeout Error .................................................................. 18
Failure code [CA1642] EGR Inlet Press Sens Low Error................................................................... 20
D155AX-6 1
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Failure code [CA1653] EGR Inlet Press Sens High Error .................................................................. 22
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
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D155AX-6 Bulldozer
Form No. SEN00718-01
2006 KOMATSU
All Rights Reserved
Printed in Japan 05-06 (02)
64 D155AX-6
SEN00719-01
D155AX-6
40 Troubleshooting 1
Troubleshooting by failure and error
codes, Part 4
Troubleshooting by failure and error codes, Part 4 ......................................................................................... 3
Failure code [DB90KT] WE controller: Abnormality in controller.......................................................... 3
Failure code [DB95KK] WE controller: Source voltage reduction ........................................................ 4
Failure code [DB97KK] WE controller: Source voltage reduction ........................................................ 6
Failure code [DB99KQ] WE controller: Type select signal ................................................................... 8
Failure code [DB9RKR] WE controller: Can communication lost....................................................... 10
Failure code [DBE0KK] PT controller: Source voltage reduction ....................................................... 12
Failure code [DBE0KT] PT controller: Abnormality in controller......................................................... 14
Failure code [DBE6KK] PT controller: Source voltage reduction ....................................................... 16
Failure code [DBE7KK] PT controller: Source voltage reduction ....................................................... 18
Failure code [DBE9KQ] PT controller: Type select signal .................................................................. 20
Failure code [DD12KA] Shift up Sw: Disconnection........................................................................... 22
Failure code [DD12KB] Shift up Sw: Short circuit .............................................................................. 24
Failure code [DD13KA] Shift down Sw: Disconnection ...................................................................... 26
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Related
Method of reproducing failure code: Turn starting switch ON.
information
D155AX-6 3
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Voltage of 5V power supply circuit for work equipment controller sensors is below 4.5 V or above
Contents of
5.5 V.
trouble
Abnormal current flowed in 5V power supply circuit for work equipment controller sensors.
Action of Turns output of 5V power supply circuit OFF, if abnormal current flows.
controller Limits operation of engine and transmission.
Problem that System may not operate normally.
appears on Once machine is stopped, engine speed is limited to medium (half).
machine Once machine is stopped, travel is limited to F1 and R1.
Related
Method of reproducing failure code: Turn starting switch ON.
information
4 D155AX-6
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D155AX-6 5
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Voltage of 5V power supply circuit for work equipment controller sensors is below 4.5 V or above
Contents of
5.5 V.
trouble
Abnormal current flowed in 5V power supply circuit for work equipment controller sensors.
Action of Turns output of 5V power supply circuit OFF, if abnormal current flows.
controller Limits operation of engine and transmission.
Problem that System may not operate normally.
appears on Once machine is stopped, engine speed is limited to medium (half).
machine Once machine is stopped, travel is limited to F1 and R1.
Related
Method of reproducing failure code: Turn starting switch ON.
information
6 D155AX-6
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Circuit diagram related to work equipment controller type select power supply
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Related
Method of reproducing failure code: Turn starting switch ON.
information
14 D155AX-6
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Contents of Voltage of 24V power supply circuit for power train controller sensors is below 17 V or above 30 V.
trouble Abnormal current flowed in 24V power supply circuit for power train controller sensors.
Action of Turns output of 24V power supply circuit OFF, if abnormal current flows.
controller Limits operation of engine and transmission.
Problem that System may not operate normally.
appears on Once machine is stopped, engine speed is limited to medium (half).
machine Once machine is stopped, travel is limited to F1 and R1.
Related
Method of reproducing failure code: Turn starting switch ON.
information
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Circuit diagram related to power train controller 24V sensor power supply
D155AX-6 17
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Contents of Voltage of 5V power supply circuit for power train controller sensors is below 4.5 V or above 5.5 V.
trouble Abnormal current flowed in 5V power supply circuit for power train controller sensors.
Action of Turns output of 5V power supply circuit OFF, if abnormal current flows.
controller Limits operation of engine and transmission.
Problem that System may not operate normally.
appears on Once machine is stopped, engine speed is limited to medium (half).
machine Once machine is stopped, travel is limited to F1 and R1.
Related
Method of reproducing failure code: Turn starting switch ON.
information
18 D155AX-6
40 Troubleshooting SEN00719-01
D155AX-6 19
SEN00719-01 40 Troubleshooting
Possible causes Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
and standard ness (Disconnection in wiring ing without turning starting switch ON.
2
value in normal or defective contact in con- Wiring harness between STC3 (female) (30) Resis-
nector) Max. 1 z
state chassis ground (GND11) tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
Defective power train con-
3 STC3 Voltage
troller
Wiring harness between (30)
Max. 1 V
chassis ground
Circuit diagram related to work equipment controller type select power supply
20 D155AX-6
SEN00719-01 40 Troubleshooting
"NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error.
Related State of shift-up switch signal can be checked with monitoring function.
information (Code: 40905 T/M Sw Input 1)
Method of reproducing failure code: Turn starting switch ON + Operate shift-up switch.
22 D155AX-6
40 Troubleshooting SEN00719-01
D155AX-6 23
SEN00719-01 40 Troubleshooting
"NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error.
Related State of shift-up switch signal can be checked with monitoring function.
information (Code: 40905 T/M Sw Input 1)
Method of reproducing failure code: Turn starting switch ON + Operate shift-up switch.
24 D155AX-6
40 Troubleshooting SEN00719-01
D155AX-6 25
SEN00719-01 40 Troubleshooting
"NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error.
Related State of shift-down switch signal can be checked with monitoring function.
information (Code: 40905 T/M Sw Input 1)
Method of reproducing failure code: Turn starting switch ON + Operate shift-down switch.
26 D155AX-6
40 Troubleshooting SEN00719-01
D155AX-6 27
SEN00719-01 40 Troubleshooting
"NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error.
Related State of shift-down switch signal can be checked with monitoring function.
information (Code: 40905 T/M Sw Input 1)
Method of reproducing failure code: Turn starting switch ON + Operate shift-down switch.
28 D155AX-6
40 Troubleshooting SEN00719-01
D155AX-6 29
SEN00719-01 40 Troubleshooting
"NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error.
Related State of parking brake lever switch signal can be checked with monitoring function.
information (Code: 40905 T/M Sw Input 1)
Method of reproducing failure code: Turn starting switch ON + Operate parking brake lever.
30 D155AX-6
40 Troubleshooting SEN00719-01
Circuit diagram related to parking brake lever switch and solenoid valve
D155AX-6 31
SEN00719-01 40 Troubleshooting
"NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error.
Related State of parking brake lever switch signal can be checked with monitoring function.
information (Code: 40905 T/M Sw Input 1)
Method of reproducing failure code: Turn starting switch ON + Operate parking brake lever.
32 D155AX-6
40 Troubleshooting SEN00719-01
Circuit diagram related to parking brake lever switch and solenoid valve
D155AX-6 33
SEN00719-01 40 Troubleshooting
"NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error.
Related State of brake pedal switch signal can be checked with monitoring function.
information (Code: 40905 T/M Sw Input1)
Method of reproducing failure code: Turn starting switch ON + Operate brake pedal.
34 D155AX-6
40 Troubleshooting SEN00719-01
D155AX-6 35
SEN00719-01 40 Troubleshooting
"NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error.
Related State of brake pedal switch signal can be checked with monitoring function.
information (Code: 40905 T/M Sw Input 1)
Method of reproducing failure code: Turn starting switch ON + Operate brake pedal.
36 D155AX-6
40 Troubleshooting SEN00719-01
D155AX-6 37
SEN00719-01 40 Troubleshooting
38 D155AX-6
SEN00719-01 40 Troubleshooting
40 D155AX-6
40 Troubleshooting SEN00719-01
Circuit diagram related to blade float switch and blade pitch switch
D155AX-6 41
SEN00719-01 40 Troubleshooting
42 D155AX-6
40 Troubleshooting SEN00719-01
Circuit diagram related to blade float switch and blade pitch switch
D155AX-6 43
SEN00719-01 40 Troubleshooting
44 D155AX-6
40 Troubleshooting SEN00719-01
Circuit diagram related to blade float switch and blade pitch switch
D155AX-6 45
SEN00719-01 40 Troubleshooting
46 D155AX-6
40 Troubleshooting SEN00719-01
Circuit diagram related to blade float switch and blade pitch switch
D155AX-6 47
SEN00719-01 40 Troubleshooting
"NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error.
Related State of blade float switch signal can be checked with monitoring function.
information (Code: 70300 Blade Sw Input)
Method of reproducing failure code: Turn starting switch ON + Operate work equipment lock lever.
48 D155AX-6
40 Troubleshooting SEN00719-01
D155AX-6 49
SEN00719-01 40 Troubleshooting
"NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error.
Related State of blade float switch signal can be checked with monitoring function.
information (Code: 70300 Blade Sw Input)
Method of reproducing failure code: Turn starting switch ON + Operate work equipment lock lever.
50 D155AX-6
40 Troubleshooting SEN00719-01
D155AX-6 51
SEN00719-01 40 Troubleshooting
52 D155AX-6
40 Troubleshooting SEN00719-01
D155AX-6 53
SEN00719-01 40 Troubleshooting
54 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
SEN00720-01
D155AX-6
40 Troubleshooting 1
Troubleshooting by failure and error
codes, Part 5
Troubleshooting by failure and error codes, Part 5 ......................................................................................... 3
Failure code [DFA4KX] BL lever 1: Out of normal range ..................................................................... 3
Failure code [DFA4KZ] BL lever: Disconnection or short circuit .......................................................... 3
Failure code [DFA4L8] BL lever: Signal mismatch............................................................................... 4
Failure code [DFA5KA] BL lever 1: Disconnection............................................................................... 6
Failure code [DFA5KB] BL lever 1: Short circuit .................................................................................. 8
Failure code [DFA6KA] BL lever 2: Disconnection............................................................................. 10
Failure code [DFA6KB] BL lever 2: Short circuit ................................................................................ 12
Failure code [DFA7KX] BT lever 1: Out of normal range ................................................................... 14
Failure code [DFA7KZ] BT lever: Disconnection or short circuit ........................................................ 14
Failure code [DFA7L8] BT lever: Signal mismatch............................................................................. 15
Failure code [DFA8KA] BT lever 1: Disconnection............................................................................. 16
Failure code [DFA8KB] BT lever 1: Short circuit ................................................................................ 18
Failure code [DFA9KA] BT lever 2: Disconnection............................................................................. 20
D155AX-6 1
SEN00720-01 40 Troubleshooting
2 D155AX-6
40 Troubleshooting SEN00720-01
D155AX-6 3
SEN00720-01 40 Troubleshooting
4 D155AX-6
SEN00720-01 40 Troubleshooting
6 D155AX-6
40 Troubleshooting SEN00720-01
D155AX-6 7
SEN00720-01 40 Troubleshooting
8 D155AX-6
40 Troubleshooting SEN00720-01
D155AX-6 9
SEN00720-01 40 Troubleshooting
10 D155AX-6
40 Troubleshooting SEN00720-01
D155AX-6 11
SEN00720-01 40 Troubleshooting
12 D155AX-6
40 Troubleshooting SEN00720-01
D155AX-6 13
SEN00720-01 40 Troubleshooting
14 D155AX-6
40 Troubleshooting SEN00720-01
D155AX-6 15
SEN00720-01 40 Troubleshooting
16 D155AX-6
40 Troubleshooting SEN00720-01
D155AX-6 17
SEN00720-01 40 Troubleshooting
18 D155AX-6
40 Troubleshooting SEN00720-01
D155AX-6 19
SEN00720-01 40 Troubleshooting
20 D155AX-6
40 Troubleshooting SEN00720-01
D155AX-6 21
SEN00720-01 40 Troubleshooting
22 D155AX-6
40 Troubleshooting SEN00720-01
D155AX-6 23
SEN00720-01 40 Troubleshooting
24 D155AX-6
40 Troubleshooting SEN00720-01
D155AX-6 25
SEN00720-01 40 Troubleshooting
26 D155AX-6
40 Troubleshooting SEN00720-01
D155AX-6 27
SEN00720-01 40 Troubleshooting
28 D155AX-6
40 Troubleshooting SEN00720-01
D155AX-6 29
SEN00720-01 40 Troubleshooting
30 D155AX-6
40 Troubleshooting SEN00720-01
D155AX-6 31
SEN00720-01 40 Troubleshooting
32 D155AX-6
40 Troubleshooting SEN00720-01
D155AX-6 33
SEN00720-01 40 Troubleshooting
34 D155AX-6
40 Troubleshooting SEN00720-01
D155AX-6 35
SEN00720-01 40 Troubleshooting
36 D155AX-6
40 Troubleshooting SEN00720-01
D155AX-6 37
SEN00720-01 40 Troubleshooting
38 D155AX-6
40 Troubleshooting SEN00720-01
D155AX-6 39
SEN00720-01 40 Troubleshooting
40 D155AX-6
40 Troubleshooting SEN00720-01
D155AX-6 41
SEN00720-01 40 Troubleshooting
42 D155AX-6
40 Troubleshooting SEN00720-01
D155AX-6 43
SEN00720-01 40 Troubleshooting
44 D155AX-6
40 Troubleshooting SEN00720-01
D155AX-6 45
SEN00720-01 40 Troubleshooting
46 D155AX-6
40 Troubleshooting SEN00720-01
D155AX-6 47
SEN00720-01 40 Troubleshooting
48 D155AX-6
40 Troubleshooting SEN00720-01
D155AX-6 49
SEN00720-01 40 Troubleshooting
50 D155AX-6
40 Troubleshooting SEN00720-01
D155AX-6 51
SEN00720-01 40 Troubleshooting
52 D155AX-6
40 Troubleshooting SEN00720-01
D155AX-6 53
SEN00720-01 40 Troubleshooting
54 D155AX-6
40 Troubleshooting SEN00720-01
D155AX-6 55
SEN00720-01 40 Troubleshooting
56 D155AX-6
40 Troubleshooting SEN00720-01
D155AX-6 57
SEN00720-01 40 Troubleshooting
58 D155AX-6
40 Troubleshooting SEN00720-01
D155AX-6 59
SEN00720-01 40 Troubleshooting
Possible causes a Prepare with starting switch OFF, then carry out troubleshoot-
and standard ing without turning starting switch ON.
value in normal Ground fault in wiring har- Wiring harness between STC1 (female) (22)
Resis-
state 4 ness (Contact with GND cir- DIAL (female) (1) or circuit branch end Min. 1 Mz
tance
cuit) and chassis ground
Wiring harness between STC1 (female) (1) Resis-
Min. 1 Mz
DIAL (female) (2) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
Wiring harness between STC1 (female) (22)
DIAL (female) (1) or circuit branch end Voltage Max. 1 V
Hot short (Short circuit with and chassis ground
5
24V circuit) in wiring harness Wiring harness between STC1 (female) (1)
Voltage Max. 1 V
DIAL (female) (2) and chassis ground
Wiring harness between STC1 (female) (21)
DIAL (female) (3) or circuit branch end Voltage Max. 1 V
and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
Defective power train con- STC1 Voltage
6
troller
Between (22) (21) 4.6 5.4 V
Between (1) (21) 0.5 4.5 V
60 D155AX-6
40 Troubleshooting SEN00720-01
D155AX-6 61
SEN00720-01 40 Troubleshooting
D155AX-6 Bulldozer
Form No. SEN00720-01
2006 KOMATSU
All Rights Reserved
Printed in Japan 05-06 (02)
62 D155AX-6
SEN00721-01
D155AX-6
40 Troubleshooting 1
Troubleshooting by failure and error
codes, Part 6
Troubleshooting by failure and error codes, Part 6 ......................................................................................... 4
Failure code [DK30KA] ST lever 1: Disconnection............................................................................... 4
Failure code [DK30KB] ST lever 1: Short circuit .................................................................................. 6
Failure code [DK30KX] ST lever 1: Out of normal range ..................................................................... 8
Failure code [DK30KZ] RL lever: Disconnection or short circuit .......................................................... 8
Failure code [DK30L8] ST lever: Signal mismatch............................................................................... 9
Failure code [DK31KA] ST lever 2: Disconnection............................................................................. 10
Failure code [DK31KB] ST lever 2: Short circuit ................................................................................ 12
Failure code [DK40KA] Brake potentiometer: Disconnection............................................................. 14
Failure code [DK40KB] Brake potentiometer: Short circuit ................................................................ 16
Failure code [DK55KX] FR lever: Out of normal range ...................................................................... 18
Failure code [DK55KZ] FR lever: Disconnection or short circuit ........................................................ 18
Failure code [DK55L8] FR lever: Signal mismatch ............................................................................ 19
Failure code [DK56KA] FR lever 1: Disconnection ............................................................................ 20
D155AX-6 1
SEN00721-01 40 Troubleshooting
2 D155AX-6
SEN00721-01 40 Troubleshooting
4 D155AX-6
40 Troubleshooting SEN00721-01
D155AX-6 5
SEN00721-01 40 Troubleshooting
6 D155AX-6
40 Troubleshooting SEN00721-01
D155AX-6 7
SEN00721-01 40 Troubleshooting
8 D155AX-6
40 Troubleshooting SEN00721-01
D155AX-6 9
SEN00721-01 40 Troubleshooting
10 D155AX-6
40 Troubleshooting SEN00721-01
D155AX-6 11
SEN00721-01 40 Troubleshooting
12 D155AX-6
40 Troubleshooting SEN00721-01
D155AX-6 13
SEN00721-01 40 Troubleshooting
14 D155AX-6
40 Troubleshooting SEN00721-01
D155AX-6 15
SEN00721-01 40 Troubleshooting
16 D155AX-6
40 Troubleshooting SEN00721-01
D155AX-6 17
SEN00721-01 40 Troubleshooting
18 D155AX-6
40 Troubleshooting SEN00721-01
D155AX-6 19
SEN00721-01 40 Troubleshooting
20 D155AX-6
40 Troubleshooting SEN00721-01
D155AX-6 21
SEN00721-01 40 Troubleshooting
22 D155AX-6
40 Troubleshooting SEN00721-01
D155AX-6 23
SEN00721-01 40 Troubleshooting
24 D155AX-6
40 Troubleshooting SEN00721-01
D155AX-6 25
SEN00721-01 40 Troubleshooting
26 D155AX-6
40 Troubleshooting SEN00721-01
D155AX-6 27
SEN00721-01 40 Troubleshooting
28 D155AX-6
40 Troubleshooting SEN00721-01
D155AX-6 29
SEN00721-01 40 Troubleshooting
30 D155AX-6
40 Troubleshooting SEN00721-01
D155AX-6 31
SEN00721-01 40 Troubleshooting
32 D155AX-6
40 Troubleshooting SEN00721-01
D155AX-6 33
SEN00721-01 40 Troubleshooting
34 D155AX-6
40 Troubleshooting SEN00721-01
D155AX-6 35
SEN00721-01 40 Troubleshooting
Possible causes ness (Disconnection in wiring Wiring harness between STC3 (female) (25) Resis-
2 Max. 1 z
and standard or defective contact in con- HSL (female) (1) tance
value in normal nector) Wiring harness between STC3 (female) (3) Resis-
Max. 1 z
state HSL (female) (2) tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
Hot short (Short circuit with
3
24V circuit) in wiring harness Wiring harness between STC3 (female) (3)
HSL (female) (2) or circuit branch end and Voltage Max. 1 V
chassis ground
If causes 1 3 are not detected, power train controller may be
Defective power train con-
4 defective. (Since trouble is in system, troubleshooting cannot be
troller
carried out.)
36 D155AX-6
40 Troubleshooting SEN00721-01
D155AX-6 37
SEN00721-01 40 Troubleshooting
38 D155AX-6
40 Troubleshooting SEN00721-01
Possible causes ness (Disconnection in wiring Wiring harness between STC3 (female) (35) Resis-
2 Max. 1 z
and standard or defective contact in con- HSR (female) (1) tance
value in normal nector) Wiring harness between STC3 (female) (3) Resis-
Max. 1 z
state HSR (female) (2) tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
Hot short (Short circuit with
3
24V circuit) in wiring harness Wiring harness between STC3 (female) (3)
HSR (female) (2) or circuit branch end and Voltage Max. 1 V
chassis ground
If causes 1 3 are not detected, power train controller may be
Defective power train con-
4 defective. (Since trouble is in system, troubleshooting cannot be
troller
carried out.)
D155AX-6 39
SEN00721-01 40 Troubleshooting
40 D155AX-6
40 Troubleshooting SEN00721-01
D155AX-6 41
SEN00721-01 40 Troubleshooting
42 D155AX-6
40 Troubleshooting SEN00721-01
D155AX-6 43
SEN00721-01 40 Troubleshooting
44 D155AX-6
40 Troubleshooting SEN00721-01
D155AX-6 45
SEN00721-01 40 Troubleshooting
46 D155AX-6
40 Troubleshooting SEN00721-01
D155AX-6 47
SEN00721-01 40 Troubleshooting
Possible causes ness (Disconnection in wiring Wiring harness between STC3 (female) (36) Resis-
2 Max. 1 z
and standard or defective contact in con- FAC (female) (1) tance
value in normal nector) Wiring harness between STC3 (female) (23) Resis-
Max. 1 z
state FAC (female) (2) tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
Hot short (Short circuit with
3
24V circuit) in wiring harness Wiring harness between STC3 (female) (23)
FAC (female) (2) or circuit branch end and Voltage Max. 1 V
chassis ground
If causes 1 3 are not detected, power train controller may be
Defective power train con-
4 defective. (Since trouble is in system, troubleshooting cannot be
troller
carried out.)
48 D155AX-6
40 Troubleshooting SEN00721-01
D155AX-6 49
SEN00721-01 40 Troubleshooting
50 D155AX-6
40 Troubleshooting SEN00721-01
D155AX-6 51
SEN00721-01 40 Troubleshooting
52 D155AX-6
SEN00721-01 40 Troubleshooting
54 D155AX-6
40 Troubleshooting SEN00721-01
D155AX-6 55
SEN00721-01 40 Troubleshooting
56 D155AX-6
40 Troubleshooting SEN00721-01
D155AX-6 57
SEN00721-01 40 Troubleshooting
58 D155AX-6
40 Troubleshooting SEN00721-01
D155AX-6 59
SEN00721-01 40 Troubleshooting
Possible causes ness (Disconnection in wiring Wiring harness between STC3 (female) (6) Resis-
2 Max. 1 z
and standard or defective contact in con- S1T (female) (1) tance
value in normal nector) Wiring harness between STC3 (female) (23) Resis-
Max. 1 z
state S1T (female) (2) tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
Hot short (Short circuit with
3
24V circuit) in wiring harness Wiring harness between STC3 (female) (23)
S1T (female) (2) or circuit branch end and Voltage Max. 1 V
chassis ground
If causes 1 3 are not detected, power train controller may be
Defective power train con-
4 defective. (Since trouble is in system, troubleshooting cannot be
troller
carried out.)
60 D155AX-6
SEN00721-01 40 Troubleshooting
D155AX-6 Bulldozer
Form No. SEN00721-01
2006 KOMATSU
All Rights Reserved
Printed in Japan 05-06 (02)
62 D155AX-6
SEN00722-01
D155AX-6
40 Troubleshooting 1
Troubleshooting by failure and error
codes, Part 7
Troubleshooting by failure and error codes, Part 7 ......................................................................................... 3
Failure code [DXH4KB] 1st clutch ECMV: Short circuit........................................................................ 3
Failure code [DXH4KY] 1st clutch ECMV: Short circuit........................................................................ 4
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection................................................................... 5
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit ...................................................................... 6
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit ...................................................................... 7
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection.................................................................... 8
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit ....................................................................... 9
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit ..................................................................... 10
Failure code [DXH7KA] R clutch ECMV: Disconnection .....................................................................11
Failure code [DXH7KB] R clutch ECMV: Short circuit........................................................................ 12
Failure code [DXH7KY] R clutch ECMV: Short circuit........................................................................ 13
Failure code [DXH8KA] F clutch ECMV: Disconnection..................................................................... 14
Failure code [DXH8KB] F clutch ECMV: Short circuit ........................................................................ 15
D155AX-6 1
SEN00722-01 40 Troubleshooting
2 D155AX-6
40 Troubleshooting SEN00722-01
D155AX-6 3
SEN00722-01 40 Troubleshooting
4 D155AX-6
40 Troubleshooting SEN00722-01
Possible causes ness (Disconnection in wiring Wiring harness between STC3 (female) (16) Resis-
2 Max. 1 z
and standard or defective contact in con- S2T (female) (1) tance
value in normal nector) Wiring harness between STC3 (female) (23) Resis-
Max. 1 z
state S2T (female) (2) tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
Hot short (Short circuit with
3
24V circuit) in wiring harness Wiring harness between STC3 (female) (23)
S2T (female) (2) or circuit branch end and Voltage Max. 1 V
chassis ground
If causes 1 3 are not detected, power train controller may be
Defective power train con-
4 defective. (Since trouble is in system, troubleshooting cannot be
troller
carried out.)
D155AX-6 5
SEN00722-01 40 Troubleshooting
6 D155AX-6
40 Troubleshooting SEN00722-01
D155AX-6 7
SEN00722-01 40 Troubleshooting
8 D155AX-6
40 Troubleshooting SEN00722-01
D155AX-6 9
SEN00722-01 40 Troubleshooting
10 D155AX-6
40 Troubleshooting SEN00722-01
Possible causes ness (Disconnection in wiring Wiring harness between STC3 (female) (37) Resis-
2 Max. 1 z
and standard or defective contact in con- SRT (female) (1) tance
value in normal nector) Wiring harness between STC3 (female) (13) Resis-
Max. 1 z
state SRT (female) (2) tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
Hot short (Short circuit with
3
24V circuit) in wiring harness Wiring harness between STC3 (female) (13)
SRT (female) (2) or circuit branch end and Voltage Max. 1 V
chassis ground
If causes 1 3 are not detected, power train controller may be
Defective power train con-
4 defective. (Since trouble is in system, troubleshooting cannot be
troller
carried out.)
D155AX-6 11
SEN00722-01 40 Troubleshooting
12 D155AX-6
40 Troubleshooting SEN00722-01
D155AX-6 13
SEN00722-01 40 Troubleshooting
Possible causes ness (Disconnection in wiring Wiring harness between STC3 (female) (27) Resis-
2 Max. 1 z
and standard or defective contact in con- SFT (female) (1) tance
value in normal nector) Wiring harness between STC3 (female) (13) Resis-
Max. 1 z
state SFT (female) (2) tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
Hot short (Short circuit with
3
24V circuit) in wiring harness Wiring harness between STC3 (female) (13)
SFT (female) (2) or circuit branch end and Voltage Max. 1 V
chassis ground
If causes 1 3 are not detected, power train controller may be
Defective power train con-
4 defective. (Since trouble is in system, troubleshooting cannot be
troller
carried out.)
14 D155AX-6
40 Troubleshooting SEN00722-01
D155AX-6 15
SEN00722-01 40 Troubleshooting
16 D155AX-6
SEN00722-01 40 Troubleshooting
18 D155AX-6
40 Troubleshooting SEN00722-01
D155AX-6 19
SEN00722-01 40 Troubleshooting
20 D155AX-6
40 Troubleshooting SEN00722-01
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40 Troubleshooting SEN00722-01
D155AX-6 23
SEN00722-01 40 Troubleshooting
24 D155AX-6
40 Troubleshooting SEN00722-01
D155AX-6 25
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26 D155AX-6
40 Troubleshooting SEN00722-01
D155AX-6 27
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28 D155AX-6
40 Troubleshooting SEN00722-01
D155AX-6 29
SEN00722-01 40 Troubleshooting
30 D155AX-6
40 Troubleshooting SEN00722-01
D155AX-6 31
SEN00722-01 40 Troubleshooting
32 D155AX-6
40 Troubleshooting SEN00722-01
D155AX-6 33
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34 D155AX-6
40 Troubleshooting SEN00722-01
D155AX-6 35
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36 D155AX-6
40 Troubleshooting SEN00722-01
D155AX-6 37
SEN00722-01 40 Troubleshooting
38 D155AX-6
40 Troubleshooting SEN00722-01
D155AX-6 39
SEN00722-01 40 Troubleshooting
40 D155AX-6
40 Troubleshooting SEN00722-01
D155AX-6 41
SEN00722-01 40 Troubleshooting
42 D155AX-6
40 Troubleshooting SEN00722-01
D155AX-6 43
SEN00722-01 40 Troubleshooting
44 D155AX-6
40 Troubleshooting SEN00722-01
D155AX-6 45
SEN00722-01 40 Troubleshooting
46 D155AX-6
40 Troubleshooting SEN00722-01
D155AX-6 47
SEN00722-01 40 Troubleshooting
48 D155AX-6
40 Troubleshooting SEN00722-01
D155AX-6 49
SEN00722-01 40 Troubleshooting
50 D155AX-6
40 Troubleshooting SEN00722-01
D155AX-6 51
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52 D155AX-6
40 Troubleshooting SEN00722-01
D155AX-6 53
SEN00722-01 40 Troubleshooting
54 D155AX-6
40 Troubleshooting SEN00722-01
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
D155AX-6
40 Troubleshooting 1
Troubleshooting by failure and error
codes, Part 8
Troubleshooting by failure and error codes, Part 8 ......................................................................................... 2
Failure code [DXJ8KA] Blade left 2 EPC: Disconnection ..................................................................... 2
Failure code [DXJ8KB] Blade left 2 EPC: Short circuit ........................................................................ 3
Failure code [DXJ8KY] Blade left 2 EPC: Short circuit ........................................................................ 4
Failure code [DXJ9KA] Blade right 2 EPC: Disconnection................................................................... 5
Failure code [DXJ9KB] Blade right 2 EPC: Short circuit ...................................................................... 6
Failure code [DXJ9KY] Blade right 2 EPC: Short circuit ...................................................................... 7
Failure code [DXJAKA] Q-drop EPC: Disconnection ........................................................................... 8
Failure code [DXJAKB] Q-drop EPC: Short circuit............................................................................. 10
Failure code [DXJAKY] Q-drop EPC: Short circuit............................................................................. 12
Failure code [DXJBKA] S/C ECMV: Disconnection............................................................................ 14
Failure code [DXJBKB] S/C ECMV: Short circuit ............................................................................... 16
Failure code [DXJBKY] S/C ECMV: Short circuit ............................................................................... 18
D155AX-6 1
SEN00723-01 40 Troubleshooting
2 D155AX-6
40 Troubleshooting SEN00723-01
D155AX-6 3
SEN00723-01 40 Troubleshooting
4 D155AX-6
40 Troubleshooting SEN00723-01
D155AX-6 5
SEN00723-01 40 Troubleshooting
6 D155AX-6
40 Troubleshooting SEN00723-01
D155AX-6 7
SEN00723-01 40 Troubleshooting
8 D155AX-6
40 Troubleshooting SEN00723-01
D155AX-6 9
SEN00723-01 40 Troubleshooting
10 D155AX-6
40 Troubleshooting SEN00723-01
D155AX-6 11
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12 D155AX-6
40 Troubleshooting SEN00723-01
D155AX-6 13
SEN00723-01 40 Troubleshooting
14 D155AX-6
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D155AX-6 15
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16 D155AX-6
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D155AX-6 17
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18 D155AX-6
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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
SEN00807-01
D155AX-6
40 Troubleshooting 1
Troubleshooting of electrical system
(E-mode)
Troubleshooting of electrical system (E-mode)............................................................................................... 3
Before carrying out troubleshooting for electrical system .................................................................... 3
Information in troubleshooting table ..................................................................................................... 7
E-1 When starting switch turned ON, machine monitor displays nothing ............................................ 8
E-2 When starting switch turned ON (before startingengine), basic check item lights up.................. 10
E-3 Engine does not start (Engine does not turn) .............................................................................. 12
E-4 Preheater does not operate......................................................................................................... 14
E-5 Precaution item lights up while engine is running........................................................................ 18
E-6 Emergency stop item lights up while engine is running ............................................................... 20
E-7 Engine coolant temperature gauge does not indicate normally................................................... 22
E-8 Fuel level gauge does not indicate normally ............................................................................... 23
E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally ............................. 25
E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally ................................... 26
E-11 Contents of display by machine monitor are different from applicable machine........................ 29
D155AX-6 1
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D155AX-6 3
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4 D155AX-6
40 Troubleshooting SEN00807-01
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 5
SEN00807-01 40 Troubleshooting
Fuse box
Power circuit fuse Fuel
Fuse No. Destination of power
(Type of power supply) capacity
FS1-1 Radio
(Unswitched power 1 10A 12V accessory connector (Via DC converter)
supply) 12V accessory socket (Via DC converter)
Additional light relay, additional light
FS1-3 2 20A
Rotary lamp
(Accessory power
supply) 12V accessory connector (Via DC converter)
3 20A
12V accessory socket (Via DC converter)
Radio
Room lamp
FS1-4 4 20A
Cigarette lighter
(Accessory power
supply) Windshield wiper (Via intermittent relay)
5 10A Front wiper, rear wiper
6 10A Left wiper, right wiper
6 D155AX-6
40 Troubleshooting SEN00807-01
<Contents of description>
Standard value in normal state to judge possible causes
Remarks on judgment
1
<Troubles in wiring harness>
Disconnection
Connector is connected defectively or wiring harness is
broken.
Ground fault
Wiring harness which is not connected to chassis ground
circuit is in contact with chassis ground circuit.
Hot short
Wiring harness which is not connected to power source (24
2 V) circuit is in contact with power source (24 V) circuit.
Short circuit
Independent wiring harnesses are in contact with each
Possible causes other abnormally.
Possible causes of trouble
and standard (Given numbers are refer-
value in normal <Precautions for troubleshooting>
ence numbers, which do
state (1) Method of indicating connector No. and handling of T-
not indicate priority)
adapter
Insert or connect T-adapter as explained below for trouble-
shooting, unless otherwise specified.
3 If connector No. has no marks of "male" and "female",
disconnect connector and insert T-adapters in both male
side and female side.
If connector No. has marks of "male" and "female", dis-
connect connector and connect T-adapter to only male
side or female side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative () lead of tester as
explained below for troubleshooting, unless otherwise
specified.
4 Connect positive (+) lead to pin No. or wiring harness
entered on front side.
Connect negative () lead to pin No. or harness entered
on rear side.
D155AX-6 7
SEN00807-01 40 Troubleshooting
E-1 When starting switch turned ON, machine monitor displays nothing 1
Trouble When starting switch turned ON, machine monitor displays nothing.
When starting switch is turned ON, machine monitor displays KOMATSU logo, screen to input pass-
word (if set), screen of check before starting, screen to check setting of preset, and ordinary screen
Related in order.
information When the engine is started, the battery voltage may lower suddenly, depending on the ambient tem-
perature and the condition of the battery. In this case, the machine monitor goes off for a moment.
This phenomenon is not a failure, however.
8 D155AX-6
40 Troubleshooting SEN00807-01
D155AX-6 9
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10 D155AX-6
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12 D155AX-6
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D155AX-6 13
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14 D155AX-6
40 Troubleshooting SEN00807-01
(2) When starting switch is turned to HEAT position, intake air heater mounting part does not become
Trouble
warm.
Related Check that engine can be turned with starting motor (If engine cannot be turned, carry out trouble-
information shooting for E-3 Engine does not start (Engine does not turn)).
D155AX-6 15
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16 D155AX-6
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18 D155AX-6
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D155AX-6 19
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20 D155AX-6
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D155AX-6 21
SEN00807-01 40 Troubleshooting
(3) Display of coolant temperature gauge is different from actual engine coolant temperature.
Trouble (4) Display of engine coolant temperature gauge is different from display of engine coolant tempera-
ture monitor.
Signals of engine coolant temperature sensor are input to engine controller and then transmitted to
Related machine monitor through communication system.
information Engine coolant temperature can be checked with monitoring function.
(Code: 04107 Coolant Temperature)
22 D155AX-6
40 Troubleshooting SEN00807-01
D155AX-6 23
SEN00807-01 40 Troubleshooting
(3) Display of fuel level gauge is different from actual fuel level.
Trouble
(4) Display of fuel level gauge is different from display of fuel level monitor.
Related Signal voltage of fuel level sensor can be checked with monitoring function.
information (Code: 04200 Fuel Level Sensor Volt)
24 D155AX-6
40 Troubleshooting SEN00807-01
E-9 Power train oil temperature gauge (multi-gauge) does not indicate
normally 1
(1) While power train oil temperature is rising normally, temperature gauge does not rise from white
Trouble range (C).
(2) While power train oil temperature is stabilized normally, temperature gauge rises to red range (H).
Signals of power train oil temperature sensor are input to power train controller and then transmitted
Related to machine monitor through communication system.
information Power train oil temperature can be checked with monitoring function.
(Code: 30100 T/C Oil Temperature)
(3) Display of power train temperature gauge is different from actual power train oil temperature.
Trouble (4) Display of power train oil temperature gauge is different from display of power train oil temperature
monitor.
Signals of power train oil temperature sensor are input to power train controller and then transmitted
Related to machine monitor through communication system.
information Power train oil temperature can be checked with monitoring function.
(Code: 30100 T/C Oil Temperature)
Power train oil temperature gauge and power train oil temperature monitor
D155AX-6 25
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26 D155AX-6
40 Troubleshooting SEN00807-01
D155AX-6 27
SEN00807-01 40 Troubleshooting
(3) Display of hydraulic oil temperature gauge is different from actual hydraulic oil temperature.
Trouble (4) Display of hydraulic oil temperature gauge is different from display of hydraulic oil temperature
monitor.
Related Hydraulic oil temperature can be checked with monitoring function.
information (Code: 04401 Hyd Oil Temperature)
28 D155AX-6
40 Troubleshooting SEN00807-01
D155AX-6 29
SEN00807-01 40 Troubleshooting
Trouble (2) When operation mode is changed, engine output is not changed.
Related Engine output mode recognized by engine controller can be checked with monitoring function.
information (Code: 17500 Engine Power Mode)
Trouble (2) When gearshift mode is changed, gearshift setting of power train is not changed.
Related
information
30 D155AX-6
40 Troubleshooting SEN00807-01
Trouble (2) When setting is changed on customize screen, setting of machine is not changed.
Related
information
Trouble (2) When selection is changed on customize memory screen, setting of machine is not changed.
Related
information
D155AX-6 31
SEN00807-01 40 Troubleshooting
Trouble (2) When float mode is changed, setting of machine is not changed.
Related
information
32 D155AX-6
40 Troubleshooting SEN00807-01
Trouble (2) When air conditioner switch is operated, air conditioner does not operate at all.
Related
information
D155AX-6 33
SEN00807-01 40 Troubleshooting
Trouble (3) Air does not come out (Air flow is insufficient).
Related
information
34 D155AX-6
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D155AX-6 35
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36 D155AX-6
40 Troubleshooting SEN00807-01
(5) Air conditioner fault history: Communication condition "CAN disconnection", Communication condi-
Trouble
tion "Abnormal"
While abnormality in communication is being detected, "CAN disconnection" is displayed.
If abnormality in communication has been detected and reset, "Abnormality" is displayed.
Related
If "CAN disconnection" is displayed as communication condition, communication cannot be carried
information
out normally. Accordingly, condition of other items is not displayed.
Method of reproducing fault history: Turn starting switch ON.
D155AX-6 37
SEN00807-01 40 Troubleshooting
Trouble (7) Air conditioner fault history: Internal air sensor "Abnormality"
If "CAN disconnection" is displayed as communication condition, communication cannot be carried
Related
out normally. Accordingly, this condition is not displayed.
information
Method of reproducing fault history: Turn starting switch ON + Turn air conditioner (A/C) switch ON.
38 D155AX-6
40 Troubleshooting SEN00807-01
Trouble (8) Air conditioner fault history: External air sensor "Unused"
External air sensor is not used in air conditioner system of this machine.
Related
If "CAN disconnection" is displayed as communication condition, communication cannot be carried
information
out normally. Accordingly, this condition is not displayed.
Trouble (9) Air conditioner fault history: Air flow sensor "Abnormality"
If "CAN disconnection" is displayed as communication condition, communication cannot be carried
Related
out normally. Accordingly, this condition is not displayed.
information
Method of reproducing fault history: Turn starting switch ON + Turn air conditioner (A/C) switch ON.
D155AX-6 39
SEN00807-01 40 Troubleshooting
40 D155AX-6
40 Troubleshooting SEN00807-01
Trouble (11) Air conditioner fault history: Air outlet damper "Abnormality"
If "CAN disconnection" is displayed as communication condition, communication cannot be carried
Related
out normally. Accordingly, this condition is not displayed.
information
Method of reproducing fault history: Turn starting switch ON + Turn air conditioner (A/C) switch ON.
D155AX-6 41
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42 D155AX-6
40 Troubleshooting SEN00807-01
D155AX-6 43
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44 D155AX-6
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D155AX-6 45
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46 D155AX-6
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48 D155AX-6
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D155AX-6 49
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50 D155AX-6
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D155AX-6 51
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E-25 Headlamp, rear lamp, and ripper point lamp do not light up 1
Trouble (1) Headlamp does not light up.
Related Only when headlamp switch is set in "Moon" mark position, screen brightness of machine monitor is
information changed for night.
52 D155AX-6
40 Troubleshooting SEN00807-01
D155AX-6 53
SEN00807-01 40 Troubleshooting
Trouble (2) Rear lamp and ripper point lamp do not light up.
Related
information
54 D155AX-6
40 Troubleshooting SEN00807-01
Circuit diagram related to headlamp, rear lamp, and ripper point lamp
D155AX-6 55
SEN00807-01 40 Troubleshooting
56 D155AX-6
40 Troubleshooting SEN00807-01
Trouble (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
Related defective.
information 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.
D155AX-6 57
SEN00807-01 40 Troubleshooting
58 D155AX-6
40 Troubleshooting SEN00807-01
Trouble (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
Related infor- defective.
mation 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.
D155AX-6 59
SEN00807-01 40 Troubleshooting
60 D155AX-6
40 Troubleshooting SEN00807-01
Trouble (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.
Related
information 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.
D155AX-6 61
SEN00807-01 40 Troubleshooting
62 D155AX-6
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D155AX-6 63
SEN00807-01 40 Troubleshooting
Trouble (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.
Related
information 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.
64 D155AX-6
40 Troubleshooting SEN00807-01
D155AX-6 65
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66 D155AX-6
40 Troubleshooting SEN00807-01
Trouble (10) Water does not come out from front window washer.
Before carrying out troubleshooting, check that windshield wiper operates normally.
Related
information If fuse ( -5) is broken, operations of both front window washer and rear window washer become
defective.
Disconnection in wiring har- Wiring harness between fuse (5) CN14 Resis-
Max. 1 z
ness (Disconnection in wiring (female) (3), (5) tance
4
or defective contact in con- Wiring harness between CN14 (female) (6) Resis-
nector) Max. 1 z
WSH1 (female) (3) tance
Wiring harness between WSH1 (female) (4) Resis-
Max. 1 z
chassis ground (GND06) tance
a Prepare with starting switch OFF, then carry out troubleshoot-
ing without turning starting switch ON.
Ground fault in wiring har- Wiring harness between fuse (5) CN14 Resis-
5 ness (Contact with GND cir- (female) (3), (5) or circuit branch end and Min. 1 Mz
tance
cuit) chassis ground
Wiring harness between CN14 (female) (6) Resis-
Min. 1 Mz
WSH1 (female) (3) and chassis ground tance
D155AX-6 67
SEN00807-01 40 Troubleshooting
Trouble (11) Water does not come out from rear window washer.
Before carrying out troubleshooting, check that windshield wiper operates normally.
Related
information If fuse ( -5) is broken, operations of both front window washer and rear window washer become
defective.
Disconnection in wiring har- Wiring harness between fuse (5) CN12 Resis-
Max. 1 z
ness (Disconnection in wiring (female) (3), (5) tance
4
or defective contact in con- Wiring harness between CN12 (female) (6) Resis-
nector) Max. 1 z
WSH2 (female) (3) tance
Wiring harness between WSH2 (female) (4) Resis-
Max. 1 z
chassis ground (GND06) tance
a Prepare with starting switch OFF, then carry out troubleshoot-
ing without turning starting switch ON.
Ground fault in wiring har- Wiring harness between fuse (5) CN12 Resis-
5 ness (Contact with GND cir- (female) (3), (5) or circuit branch end and Min. 1 Mz
tance
cuit) chassis ground
Wiring harness between CN12 (female) (6) Resis-
Min. 1 Mz
WSH2 (female) (3) and chassis ground tance
68 D155AX-6
40 Troubleshooting SEN00807-01
Trouble (12) Water does not come out from right door washer.
Before carrying out troubleshooting, check that windshield wiper operates normally.
Related
information If fuse ( -6) is broken, operations of both right door washer and left door washer become defec-
tive.
Disconnection in wiring har- Wiring harness between fuse (6) CN13 Resis-
Max. 1 z
ness (Disconnection in wiring (female) (3), (5) tance
4
or defective contact in con- Wiring harness between CN13 (female) (6) Resis-
nector) Max. 1 z
WSH2 (female) (1) tance
Wiring harness between WSH2 (female) (2) Resis-
Max. 1 z
chassis ground (GND06) tance
a Prepare with starting switch OFF, then carry out troubleshoot-
ing without turning starting switch ON.
Ground fault in wiring har- Wiring harness between fuse (6) CN13
Resis-
5 ness (Contact with GND cir- (female) (3), (5) or circuit branch end and Min. 1 Mz
tance
cuit) chassis ground
Wiring harness between CN13 (female) (6) Resis-
Min. 1 Mz
WSH2 (female) (1) and chassis ground tance
D155AX-6 69
SEN00807-01 40 Troubleshooting
Trouble (13) Water does not come out from left door washer.
Before carrying out troubleshooting, check that windshield wiper operates normally.
Related
If fuse ( -6) is broken, operations of both right door washer and left door washer become defec-
information
tive.
Disconnection in wiring har- Wiring harness between fuse (6) CN15 Resis-
Max. 1 z
ness (Disconnection in wiring (female) (3), (5) tance
4
or defective contact in con- Wiring harness between CN15 (female) (6) Resis-
nector) Max. 1 z
WSH1 (female) (1) tance
Wiring harness between WSH1 (female) (2) Resis-
Max. 1 z
chassis ground (GND06) tance
a Prepare with starting switch OFF, then carry out troubleshoot-
ing without turning starting switch ON.
Ground fault in wiring har- Wiring harness between fuse (6) CN15 Resis-
5 ness (Contact with GND cir- (female) (3), (5) or circuit branch end and Min. 1 Mz
tance
cuit) chassis ground
Wiring harness between CN15 (female) (6) Resis-
Min. 1 Mz
WSH1 (female) (1) and chassis ground tance
70 D155AX-6
40 Troubleshooting SEN00807-01
D155AX-6 71
SEN00807-01 40 Troubleshooting
a Select "Setting condition of terminal" from "12 Display a Select "Condition of positioning and communication"
of KOMTRAX setting" in the service menu of the from "12 Display of KOMTRAX setting" in the service
machine monitor. menu of the machine monitor.
72 D155AX-6
SEN00807-01 40 Troubleshooting
D155AX-6 Bulldozer
Form No. SEN00807-01
2006 KOMATSU
All Rights Reserved
Printed in Japan 05-06 (02)
74 D155AX-6
SEN00808-00
D155AX-6
40 Troubleshooting 1
Troubleshooting of hydraulic and
mechanical system (H-mode)
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................................... 3
Information in troubleshooting table ..................................................................................................... 3
H-1 Power is low (Drawbar pull is low)................................................................................................ 4
H-2 Machine does not travel (at 2nd or 3rd gear speed) .................................................................... 5
H-3 Machine does not start at any gear speed ................................................................................... 6
H-4 Machine can travel only forward or in reverse.............................................................................. 7
H-5 When gear speed or travel direction is changed, time lag is large............................................... 8
H-6 Machine cannot be steered (Machine does not turn right or left) ................................................. 9
H-7 Steering speed or steering force is low ........................................................................................ 9
H-8 Brake does not work................................................................................................................... 10
H-9 Power train oil is overheated .......................................................................................................11
H-10 Abnormal sound comes out from around HSS pump or HSS motor ........................................ 12
H-11 Speed of all work equipment is low .......................................................................................... 13
H-12 No work equipment moves....................................................................................................... 14
D155AX-6 1
SEN00808-00 40 Troubleshooting
2 D155AX-6
40 Troubleshooting SEN00808-00
Possible causes 2
and standard Possible causes of trouble
<Contents of description>
value in normal (Given numbers are refer-
Standard value in normal state to judge possible causes
state ence numbers, which do
Remarks on judgment
not indicate priority)
3
D155AX-6 3
SEN00808-00 40 Troubleshooting
4 D155AX-6
40 Troubleshooting SEN00808-00
H-2 Machine does not travel (at 2nd or 3rd gear speed) 1
Trouble Machine does not travel (at 2nd or 3rd gear speed).
Related Before carrying out troubleshooting, check that power train oil level is normal.
information Before carrying out troubleshooting, check that transmission main relief pressure is normal (See H-1).
D155AX-6 5
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6 D155AX-6
40 Troubleshooting SEN00808-00
D155AX-6 7
SEN00808-00 40 Troubleshooting
H-5 When gear speed or travel direction is changed, time lag is large 1
Trouble When gear speed or travel direction is changed, time lag is large.
Related
Before carrying out troubleshooting, check that power train oil level is normal.
information
8 D155AX-6
40 Troubleshooting SEN00808-00
H-6 Machine cannot be steered (Machine does not turn right or left) 1
Trouble Machine cannot be steered (Machine does not turn right or left)
Related
Before carrying out troubleshooting, check that oil level in hydraulic tank is normal.
information
D155AX-6 9
SEN00808-00 40 Troubleshooting
10 D155AX-6
40 Troubleshooting SEN00808-00
Malfunction of brake (Drag- 1. Float machine above ground with blade and ripper.
5 2. Run engine at low idle and set transmission gear in F3 or R3.
ging)
3. If track shoe does not turn, brake is dragging.
(Carry out troubleshooting for "H-8 Brake does not work".)
a Start engine and check.
6 Malfunction of brake (Slip) Stall machine at F3. If machine does not stop perfectly, brake is
slipping.
D155AX-6 11
SEN00808-00 40 Troubleshooting
H-10 Abnormal sound comes out from around HSS pump or HSS
motor 1
Trouble Abnormal sound comes out from around HSS pump or HSS motor.
Related Before carrying out troubleshooting, check that oil level in hydraulic tank is normal.
information HSS pump is used for work equipment, too.
12 D155AX-6
40 Troubleshooting SEN00808-00
D155AX-6 13
SEN00808-00 40 Troubleshooting
14 D155AX-6
40 Troubleshooting SEN00808-00
D155AX-6 15
SEN00808-00 40 Troubleshooting
16 D155AX-6
40 Troubleshooting SEN00808-00
D155AX-6 17
SEN00808-00 40 Troubleshooting
18 D155AX-6
40 Troubleshooting SEN00808-00
D155AX-6 19
SEN00808-00 40 Troubleshooting
20 D155AX-6
40 Troubleshooting SEN00808-00
H-22 Abnormal sound comes out from around work equipment pump 1
Trouble Abnormal sound comes out from around work equipment pump.
Related Before carrying out troubleshooting, check that oil level in hydraulic tank is normal.
information Work equipment pump is used for HSS, too.
D155AX-6 21
SEN00808-00 40 Troubleshooting
D155AX-6 Bulldozer
Form No. SEN00808-00
2006 KOMATSU
All Rights Reserved
Printed in Japan 02-06 (02)
22 D155AX-6
SEN00852-01
D155AX-6
40 Troubleshooting 1
Troubleshooting of engine (S-mode)
Troubleshooting of engine (S-mode)............................................................................................................... 3
Method of using troubleshooting chart ................................................................................................. 3
S-1 Starting performance of engine is poor.......................................................................................... 6
S-2 Engine does not start..................................................................................................................... 8
S-3 Engine does not pick up smoothly............................................................................................... 12
S-4 Engine stops during operation ..................................................................................................... 13
S-5 Engine does not rotate smoothly ................................................................................................. 14
S-6 Engine lack output (or lacks power) ............................................................................................ 15
S-7 Exhaust gas is black (incomplete combustion)............................................................................ 16
S-8 Oil consumption is excessive (or exhaust gas is blue) ................................................................ 18
S-9 Oil becomes dirty quickly............................................................................................................. 19
S-10 Fuel consumption is excessive.................................................................................................. 20
S-11 Oil is in coolant (or coolant spurts back or coolant level goes ................................................... 21
S-12 Oil pressure drops ..................................................................................................................... 22
S-13 Oil level rises (Entry of coolant or fuel)...................................................................................... 24
S-14 Coolant temperature becomes too high (Overheating) ............................................................. 26
D155AX-6 1
SEN00852-01 40 Troubleshooting
2 D155AX-6
40 Troubleshooting SEN00852-01
Questions
Items to be drawn from the user or operator. 2
They correspond to A and B in the chart on the A
3
right. The items in A are basic ones. The
4
items in B can be drawn from the user or oper-
ator, depending on their level. 5
[Check items] B 6
Simple check items used by the serviceman to 7
narrow the causes. They correspond to C in C 8
the chart on the right.
Check items
9
[Causes]
10
Items to be narrowed from the questions and
check items. The serviceman narrows down 11
the probable causes from A, B, and C.
Troubleshooting
a
[Troubleshooting]
b
Items used to find out the true cause by verify-
ing the narrowed causes finally in order from c
the most probable one by applying trouble- d
shooting tools or direct inspection.
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 3
SEN00852-01 40 Troubleshooting
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Adjust
Clean
Remedy
4 D155AX-6
40 Troubleshooting SEN00852-01
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
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 5
SEN00852-01 40 Troubleshooting
Defective injector
turns at maximum. This phenomenon does not indi-
cate a trouble, however
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
6 D155AX-6
40 Troubleshooting SEN00852-01
D155AX-6 7
SEN00852-01 40 Troubleshooting
Degree of use of
Operated for long period E E E
machine
When starting switch is Horn does not sound Q Q w
turned ON Horn volume is low w
Battery electrolyte level is low w
Battery terminal is loose w
When starting switch is turned ON, no operating sound comes out from battery relay Q w
When starting switch is turned to START, starting pinion does not move out Q Q w
Check items
When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows out (*1). q
Replace
Replace
Replace
Replace
Correct
Remedy
8 D155AX-6
40 Troubleshooting SEN00852-01
D155AX-6 9
SEN00852-01 40 Troubleshooting
Degree of use of
Operated for long period E E E
machine
Exhaust gas suddenly stopped coming out (when starting again) w Q w w w E E
Filters have not been replaced according to Operation and Maintenance Manual w w E Q
Fuel tank is empty w
Air breather hole of fuel tank cap is clogged Q w
There are rust and water in fuel drained from fuel tank Q Q Q Q Q
There is not fuel in removed fuel filter w w
Fuel is leaking from fuel piping w
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Remedy
Add
10 D155AX-6
40 Troubleshooting SEN00852-01
When air bleeding plug of fuel filter is removed, fuel does not
While engine is rotated flow out Q w w
with starting motor,
When spill hose from injector is disconnected, little fuel spills w
Immediately after engine is started, temperature of exhaust manifold of a cylinder is low w
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
D155AX-6 11
SEN00852-01 40 Troubleshooting
When engine is rotated, abnormal sound comes out from around cylinder head w
When engine is rotated, interference sound comes out from around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w w
Engine hunts (rotation is irregular) Q Q w Q
Blow-by gas is excessive w
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
12 D155AX-6
40 Troubleshooting SEN00852-01
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
Add
D155AX-6 13
SEN00852-01 40 Troubleshooting
There are rust and water in fuel drained from fuel tank Q Q
Fuel is leaking from fuel piping w
Priming pump is too light or too heavy to operate w Q Q
Carry out troubleshooting according to "EGR Valve Servo Error (*1)" indicated by code q
Carry out troubleshooting according to "Bypass Valve Servo Error (*2)" indicated by q
code
When air is bled from fuel system, air comes out q
Troubleshooting
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
Add
14 D155AX-6
40 Troubleshooting SEN00852-01
turbocharger
When engine is rotated, abnormal sound comes out from around cylinder head w
High idle speed is too high Q
High idle speed under no load is normal, but speed suddenly drops when load
is applied w w Q
Engine does not pick up smoothly and combustion is irregular w Q Q w
Engine hunts (rotation is irregular) Q Q Q Q
Blow-by gas is excessive w
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Clean
D155AX-6 15
SEN00852-01 40 Troubleshooting
When engine is rotated, abnormal sound comes out from around cylinder
head w
Torque converter stall speed or pump relief speed is high (Fuel is injected
excessively) Q Q
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q Q w
Blow-by gas is excessive w
When spill hose from injector is disconnected, abnormally much fuel spills w
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Adjust
Clean
Remedy
16 D155AX-6
40 Troubleshooting SEN00852-01
D155AX-6 17
SEN00852-01 40 Troubleshooting
Turbocharger
Worn or damaged valve (stem, guide, or seal)
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
18 D155AX-6
40 Troubleshooting SEN00852-01
Exhaust gas is
Black w
Comes out excessively Q Q w Q
Blow-by gas
Does not come out at all w
See S-7
Check breather and breather hose directly q
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
D155AX-6 19
SEN00852-01 40 Troubleshooting
Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by code q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change q
When spill hose from injector is disconnected, much fuel spills q
Carry out troubleshooting according to "Coolant Temp Sens High (Low) Error (*2)" indicated by
q
code
Confirm with monitoring function on applicable machine side q q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Remedy
20 D155AX-6
40 Troubleshooting SEN00852-01
When hydraulic oil or power train oil is drained, water flows out w
Remedy
D155AX-6 21
SEN00852-01 40 Troubleshooting
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Remedy
Add
22 D155AX-6
SEN00852-01 40 Troubleshooting
When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows out
q
(*1).
Compression pressure is low q
Remove and inspect head cover directly q
Troubleshooting
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
24 D155AX-6
40 Troubleshooting SEN00852-01
D155AX-6 25
SEN00852-01 40 Troubleshooting
Malfunction of thermostat
Malfunction of fan
Low coolant level
Confirm recent repair history
Degree of use of machine Operated for long period E E E E E
Questions
Occurred suddenly Q Q w Q
Overheating
Has continued at low level Q w w Q
Coolant temperature Rises quickly Q w
gauge (if installed) Does not go down from red range w
Radiator coolant level monitor indicates low (if monitor is installed) Q w
Engine oil level has risen and oil is milky w Q
Milky oil is floating on coolant w
There are many bubbles in radiator and coolant spurts back w
When light applied to radiator core, no light passes through w
Dirt and mud are accumulated in radiator shroud and undercover on applicable
Check items
w w
machine side
Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Power train oil temperature enters red range faster than engine coolant
temperature (if oil temperature gauge and coolant temperature gauge are w
installed)
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Add
26 D155AX-6
40 Troubleshooting SEN00852-01
Gradually increased Q Q
Abnormal noise
Suddenly increased Q Q Q Q
Non-specified fuel is used Q
Oil must be added more frequently w
There are metal particles in oil drained from oil filter w w
Air leaks between turbocharger and cylinder head w
When engine is rotated, interference sound comes out from around turbocharger w
When engine is rotated, abnormal sound comes out from around EGR gas
piping w
When engine is rotated, abnormal sound comes out from around cylinder head w w
When engine is rotated, beat noise comes out from around muffler w
Check items
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Adjust
Remedy
D155AX-6 27
SEN00852-01 40 Troubleshooting
Replace
Replace
Replace
Adjust
Adjust
Remedy
28 D155AX-6
SEN00852-01 40 Troubleshooting
D155AX-6 Bulldozer
Form No. SEN00852-01
2006 KOMATSU
All Rights Reserved
Printed in Japan 05-06 (02)
30 D155AX-6
SEN01204-02
D155AX-6
D155AX-6 1
SEN01204-02 50 Disassembly and assembly
1) Necessity of work.
t : Special tools that cannot be substi- a: This mark gives guidance or precautions when
tuted and should always be used doing the procedure.
(installed). [*1] : This mark shows that there are instructions or
q : Special tools that will be useful if avail- precautions for installing parts.
able and are substitutable with com- 6 : This mark shows the amount of oil or coolant
mercially available tools. to be drained.
2) Distinction of new and existing special 4 : Weight of part or component
tools
N: Tools newly developed for this
model. They respectively have a Installation
new part number. q Except where otherwise instructed, installation
R: Tools with upgraded part numbers. of parts is done in the reverse order of removal.
They are remodeled from already q Instructions and precautions for installing parts
available tools for other models. are shown with [*1] mark in the "Removal" sec-
Blank: Tools already available for other tion, identifying which step the instructions are
models. They can be used without intended for.
any modification. q Marks shown in the "Installation" section stand
3) Circle mark Q in sketch column: for the following.
q The sketch of the special tool is pre- k : Precautions related to safety in execution
sented in the section of "Sketches of of work.
special tools". a: This mark gives guidance or precautions when
q Part No. of special tools starting with doing the procedure.
2 : Type of coating material
* *** ****
79 T- - :
means that they can not be supplied 3 : Tightening torque
5
from Komatsu in Japan (i.e. locally : Quantity of oil or coolant to be added
made parts ).
Sketches of special tools
a General tools that are necessary for
q Various special tools are illustrated for the con-
removal or installation are described as
venience of local manufacture.
[1], [2]etc. and their part names, part
numbers and quantities are not described.
2 D155AX-6
50 Disassembly and assembly SEN01204-02
D155AX-6 3
SEN01204-02 50 Disassembly and assembly
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube Heat-resistant seal used to repair engines.
Quick-setting adhesive.
ThreeBond Polyethylene Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container Used mainly to stick metals, rubbers, plastics,
and woods.
Quick-setting adhesive.
Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
Used mainly to stick rubbers, plastics, and
metals.
Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc Used for fitted portions used at high tempera-
648-50 container
tures.
Used to stick or seal gaskets and packings of
LG-1 790-129-9010 200 g Tube
power train case, etc.
Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
Features: Silicon-based heat and cold-resis-
Gasket sealant
tant sealant.
LG-6 790-129-9020 200 g Tube Used to seal flange surfaces and threaded
portions.
Used to seal oil pan, final drive case, etc.
Features: Silicon-based quick-setting sealant.
LG-7 790-129-9070 1 kg Tube Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
Features: Silicon-based, heat and cold-resis-
LG-8
tant, vibration-resistant, impact-resistant seal-
ThreeBond 419-15-18131 100 g Tube
ant.
1207B
Used to seal transfer case, etc.
4 D155AX-6
50 Disassembly and assembly SEN01204-02
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
Used for rough surfaces such as the circle gear
LG-9 top seal which does not need to be clamped,
ThreeBond 790-129-9310 200 g Tube water resistance of the clearance at the welded
1206D area, etc.
Can be coated with paint.
Gasket sealant
LC-G
Can Used for the mounting bolt in the high tempera-
NEVER-SEEZ
ture area of the exhaust manifold and the turbo-
charger, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI Feature: Lithium grease with extreme pressure
SYG2-160LI
G0-LI Various Various lubrication performance.
SYGA-160CNLI
*: For cold district General purpose type.
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
Used for parts under heavy load.
Caution:
Molybdenum SYG2-400M 400 g x 10 Bellows-type Do not apply grease to rolling bearings like
disulfide grease SYG2-400M-A 400 g x 20 container swing circle bearings, etc. and spline.
LM-G (G2-M) SYGA-16CNM 16 kg Can The grease should be applied to work equipment
pins at their assembly only, not applied for
greasing afterwards.
Seizure resistance, heat resistance and water
Hyper White SYG2-400T-A
Grease
D155AX-6 5
SEN01204-02 50 Disassembly and assembly
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
SUNSTAR Used as primer for cab side.
Glass
PAINT PRIMER 20 ml (Using limit: 4 months after date of manu-
container
580 SUPER facture)
SUNSTAR 417-926-3910
Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 container
facture)
facture)
SUNSTAR Ecocart Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months after date of manu-
container
SEAL No. 2505 facture)
Caulking material
6 D155AX-6
50 Disassembly and assembly SEN01204-02
New/Remodel
Sym-
Necessity
Work item Part No. Part name Nature of work and remarks
bol
Sketch
Q'ty
Removal and installation 1 795-630-5500 Standard puller t 1
of fuel supply pump 2 01010-81090 Bolt t 2 Separation of drive gear
assembly 3 01643-31032 Washer t 2
Removal and installation
Tightening of cylinder head
of cylinder head assem- 4 790-331-1110 Wrench q 1
bolt
bly, engine rear seal
5 795-931-1100 Seal puller t 1 Pulling out of oil seal
D155AX-6 7
SEN01204-02 50 Disassembly and assembly
New/Remodel
Sym-
Necessity
Work item Part No. Part name Nature of work and remarks
bol
Sketch
Q'ty
790-431-1031 Block t 1
791-520-4140 Screw t 2
790-101-2360 Plate t 2
791-112-1180 Nut t 2
1 Pulling out of pinion shaft
790-101-2480 Adapter t 2
791T-627-1920 Plate t 1 Q
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 Pulling out and press fitting
2 of sprocket and hub assem-
791T-627-1930 Plate t 1 Q bly
791T-627-1940 Push tool t 1 Q
790-101-2102 Puller t 1
790-101-1102 Hydraulic pump t 1
3 791-627-1280 Installer t 1 Installation of floating seal
790-101-5401 Push tool kit t 1
790-101-5441 Plate 1
Disassembly and assem- 4 Press fitting of oil seal
K 790-101-5421 Grip 1
bly of final drive assembly
01010-51240 Bolt 1
790-101-5401 Push tool kit t 1
790-101-5451 Plate 1
790-101-5421 Grip 1
5 Press fitting of bearing
01010-51240 Bolt 1
791T-627-1950 Plate t 1 Q
791T-627-1960 Plate t 1 Q
790-201-1500 Push tool kit t 1
790-201-1680 Plate 1
6 Press fitting of bearing
790-101-5021 Grip 1
01010-50816 Bolt 1
791-520-4140 Screw t 1
790-101-2420 Adapter t 1
791-112-1180 Nut t 1
Press fitting of bearing
01643-22460 Washer t 1
7
792-785-1120 Plate t 1
791-830-1410 Push tool t 1
790-101-2102 Puller t 1
Press fitting of bearing
790-101-1102 Hydraulic pump t 1
8 D155AX-6
50 Disassembly and assembly SEN01204-02
New/Remodel
Sym-
Necessity
Work item Part No. Part name Nature of work and remarks
bol
Sketch
Q'ty
791T-630-1230 Plate t 1 Q
791-630-1220 Rod t 2
790-101-2510 Block t 1
790-101-2570 Washer t 2
1 Press fitting of idler bushing
Disassembly and assem- 01580-01411 Nut t 2
bly of idler assembly 01643-31445 Washer t 2
790-101-2102 Puller (294 kN {30 ton}) t 1
790-101-1102 Hydraulic pump t 1
2 796-670-1020 Installer t 1 Installation of floating seal
3 791-601-1000 Oil pump t 1 Refilling with oil
791T-130-1010 Bracket t 2 N Q
14 01010-63060 Bolt t 4
01643-33080 Washer t 4
790-401-1700 Lifting tool t 1
22
790-401-1761 Adapter t 1
791-630-1860 Bracket t 1
23
791-630-1870 Bracket t 1
790-101-2310 Block t 1
790-101-2360 Plate t 2
790-445-4130 Screw t 2
15
791-112-1180 Nut t 2
Removal and installation L
790-101-4000 Puller (490 kN {50 ton}) t 1
of No. 1 boggy assembly
790-101-1102 Pump t 1
790-201-2760 Spacer t 1
791-630-1370 Adapter t 1
790-434-1060 Screw t 2
Fixing of boggy
16 01580-13024 Nut t 2
01643-33080 Washer t 1
790-101-4000 Puller (490 kN {50 ton}) t 1
790-101-1102 Pump t 1
17 796-430-1110 Push tool t 1
18 790-701-3000 Seal checker t 1
19 791T-630-1390 Guide t 1 Q
791T-130-1010 Bracket t 2 N Q
14 01010-63060 Bolt t 4
01643-33080 Washer t 4
D155AX-6 9
SEN01204-02 50 Disassembly and assembly
New/Remodel
Sym-
Necessity
Work item Part No. Part name Nature of work and remarks
bol
Sketch
Q'ty
15 790-101-1102 Pump t 1
790-201-2760 Spacer t 1
791-630-1370 Adapter t 1
790-434-1060 Screw t 2
16 01580-13024 Nut t 2
01643-33080 Washer t 2
790-101-4000 Puller (490 kN {50 ton}) t 1
790-101-1102 Pump t 1
10 D155AX-6
50 Disassembly and assembly SEN01204-02
New/Remodel
Sym-
Necessity
Work item Part No. Part name Nature of work and remarks
bol
Sketch
Q'ty
791-675-9701 Remover and installer t 1
791-101-4300 Cylinder (196 kN {20 ton}) t 1 Disassembly and assembly
1
791-101-4200 Puller (294 kN {30 ton}) t 1 of track shoe assembly
791-101-1102 Hydraulic pump t 1
General disassembly and 2 791-932-1110 Plug push tool t 1 Driving of plug (small)
general assembly of track S 3 791-660-7460 Pin brush t 1 Cleaning of pin
shoe assembly
4 791-432-1110 Plug push tool t 1 Driving of plug (large)
5 791-632-1052 Installer t 1 Insertion of link seal
Check of oil supply and air-
6 790-701-3000 Seal checker t 1
tightness
7 791-601-1000 Oil pump t 1 Refilling with oil
791-675-9581 Adapter t 1
791-675-9590 Guide t 1 Disassembly and assembly
1
01010-52460 Bolt t 2 of track shoe assembly
01010-51440 Bolt t 2
790-101-1102 Pump t 1
2 Cylinder Disassembly of 1 link
790-101-4300 t 1
(1,470 kN {150 ton})
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
3 Disassembly of 1 link
791-675-9570 Adapter t 1
04530-12030 Eyebolt t 1
790-101-1102 Pump t 1
Field disassembly and Cylinder
T 790-101-4300 t 1
assembly of 1 link (1,470 kN {150 ton})
791-685-9540 Rod t 1
4 Disassembly of 1 link
791-685-9550 Nut t 3
791-675-5520 Guide t 1
791-675-5530 Pusher t 1
5 Disassembly of 1 link
01010-51030 Bolt t 1
791-685-9620 Extension t 1
790-101-1102 Pump t 1
6 Disassembly of 1 link
790-101-4200 Puller (294 kN {30 ton}) t 1
791-675-5542 Adapter t 1
Assembly of 1 link
791-675-5571 Adapter t 1
7 790-101-1102 Pump t 1
Cylinder Assembly of 1 link
790-101-4300 t 1
(1,470 kN {150 ton})
8 791-675-5580 Guide t 1 Assembly of 1 link
9 791-685-9510 Frame t 1 Assembly of 1 link
D155AX-6 11
SEN01204-02 50 Disassembly and assembly
New/Remodel
Sym-
Necessity
Work item Part No. Part name Nature of work and remarks
bol
Sketch
Q'ty
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
9 01010-51030 Bolt t 1 Assembly of 1 link
791-685-9620 Extension t 1
791-675-5542 Adapter t 1
791-675-5560 Guide t 1
Field disassembly and 790-101-1102 Pump t 1
T
assembly of 1 link Cylinder
790-101-4300 t 1
(1,470 kN {150 ton})
791-675-5560 Guide t 1
10 Assembly of 1 link
791-675-5542 Adapter t 1
790-101-1102 Pump t 1
11 Assembly of 1 link
790-101-4200 Puller (294 kN {30 ton}) t 1
12 791-670-3270 Guide t 1 Assembly of 1 link
791-126-0150 Adapter t 1
791-675-5560 Guide t 1
13 Assembly of 1 link
791-675-9570 Adapter t 1
01010-51030 Bolt t 1
790-101-1102 Pump t 1
1 Expansion of link
790-101-4200 Puller (294 kN {30 ton}) t 1
791-675-9701 Remover and installer t 1
790-101-1102 Pump t 1
2 790-101-4200 Puller (294 kN {30 ton}) t 1
Disassembly and assem- Disassembly and assembly
U Cylinder
bly of master link 790-101-4300 t 1 of track shoe assembly
(1,470 kN {150 ton})
3 791-432-1110 Plug push tool t 1 Driving of plug (large)
Check of oil supply and air-
4 790-701-3000 Seal checker t 1
tightness
5 791-932-1110 Plug push tool t 1 Driving of plug (small)
791T-650-2110 Sleeve t 1 Q
790-201-2770 Spacer t 1
791T-650-2120 Plate t 1 Q
792-104-3940 Bolt t 2
Removal and installation 790-101-2510 Block t 1
V Press fitting of ring
of pivot shaft assembly 790-101-2570 Washer t 2
01580-01613 Nut t 1
Jack assembly
790-105-2300 t 1
(196 kN {20 ton})
790-101-1102 Hydraulic pump t 1
12 D155AX-6
50 Disassembly and assembly SEN01204-02
New/Remodel
Sym-
Necessity
Work item Part No. Part name Nature of work and remarks
bol
Sketch
Q'ty
791T-650-2130 Sleeve t 1 Q
790-101-2420 Adapter t 1
791-502-4140 Screw t 1
Removal and installation
W 790-101-2540 Washer t 2 Pulling out of center pin
of equalizer bar assembly
790-112-1180 Nut t 2
790-101-4000 Puller (294 kN {50 ton}) t 1
790-101-1102 Hydraulic pump t 1
Removal and installation
of operator's cab X 1 793-498-1210 Lifter (Suction cup) t 2 Installation of window glass
(stuck glass)
790-502-1003 Cylinder repair stand t 1 Disassembly and assembly
1
790-101-1102 Hydraulic pump t 1 of hydraulic cylinder
Installation of round head
2 790-102-3802 Multi-wrench t 1
(Blade lift)
790-201-1702 Push tool kit t 1 Press fitting of bushing
790-201-1721 Push tool 1
790-201-1821 Push tool 1 Blade lift
790-201-1841 Push tool 1 Blade tilt
3
790-201-1851 Push tool 1 Ripper lift
790-201-1861 Push tool 1 Ripper tilt
790-101-5021 Grip 1
01010-50816 Bolt 1
790-201-1500 Push tool kit t 1 Press fitting of dust seal
Disassembly and assem- 790-201-1630 Plate 1 Blade lift
bly of hydraulic cylinder Y
790-201-1650 Plate 1 Blade tilt
assembly
4 790-201-1660 Plate 1 Ripper lift
790-201-1670 Plate 1 Ripper tilt
790-101-5021 Grip 1
Press fitting of dust seal
01010-50816 Bolt 1
790-720-1000 Expander t 1 Installation of piston ring
796-720-1670 Ring t 1
Blade lift
07281-01279 Clamp t 1
5 796-720-1690 Ring t 1 Blade tilt
07281-01919 Clamp t 1 Ripper lift
796-720-1720 Ring t 1
Ripper tilt
07281-02429 Clamp t 1
790-102-4300 Wrench t 1 Removal and installation of
6
790-102-4310 Pin t 2 screw-type piston
D155AX-6 13
SEN01204-02 50 Disassembly and assembly
14 D155AX-6
50 Disassembly and assembly SEN01204-02
Note) We will not be liable for any result of use of special tools
manufactured according to the following drawings.
G1: Plate
J: Plate
D155AX-6 15
SEN01204-02 50 Disassembly and assembly
Note) We will not be liable for any result of use of special tools
manufactured according to the following drawings.
K1: Plate
K2: Plate
16 D155AX-6
50 Disassembly and assembly SEN01204-02
Note) We will not be liable for any result of use of special tools
manufactured according to the following drawings.
K2: Push tool
K5: Plate
D155AX-6 17
SEN01204-02 50 Disassembly and assembly
Note) We will not be liable for any result of use of special tools
manufactured according to the following drawings.
K5: Plate
18 D155AX-6
50 Disassembly and assembly SEN01204-02
Note) We will not be liable for any result of use of special tools
manufactured according to the following drawings.
L1: Plate
L19: Guide
D155AX-6 19
SEN01204-02 50 Disassembly and assembly
Note) We will not be liable for any result of use of special tools
manufactured according to the following drawings.
L20, Q20: Plate
M2: Spacer
20 D155AX-6
50 Disassembly and assembly SEN01204-02
Note) We will not be liable for any result of use of special tools
manufactured according to the following drawings.
N1: Plate
D155AX-6 21
SEN01204-02 50 Disassembly and assembly
Note) We will not be liable for any result of use of special tools
manufactured according to the following drawings.
V: Sleeve
V: Plate
22 D155AX-6
50 Disassembly and assembly SEN01204-02
Note) We will not be liable for any result of use of special tools
manufactured according to the following drawings.
W: Sleeve
D155AX-6 23
SEN01204-02 50 Disassembly and assembly
D155AX-6 Bulldozer
Form No. SEN01204-02
2007 KOMATSU
All Rights Reserved
Printed in Japan 10-07 (02)
24 D155AX-6
SEN01205-02
D155AX-6
D155AX-6 1
SEN01205-02 50 Disassembly and assembly
Removal and installation of fuel 3. Remove two fuel tube joint bolts, and remove
supply pump assembly 1 fuel main filter head assembly (5). [*1]
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
1 795-630-5500 Standard puller t 1
A 2 01010-81090 Bolt t 2
3 01643-31032 Washer t 2
Removal
k Disconnect the negative terminal () of the
battery. 4. Remove tubes (6) and (7) between fuel supply
pump and fuel main filter.
1. Open engine hood left cover (1) and remove
side covers, (2) and (3). 5. Remove tube (8) between fuel supply pump
and priming pump. [*2]
2 D155AX-6
50 Disassembly and assembly SEN01205-02
10. Remove stay (20), two covers (21), and two 13. Check that the mounting bolt hole (c) at the top
covers (22), and remove high pressure pipes of cover align to the forcing tap of drive gear.
(23) and (24). [*4] a If they are not aligned, rotate crankshaft
a If the common rail side sleeve nut for high one more turn.
pressure pipe is hard to loose, loosen the
mounting bolts for gate type frame (25). 14. Remove nut (29). [*5]
a Take care not to drop into the case.
D155AX-6 3
SEN01205-02 50 Disassembly and assembly
4 D155AX-6
50 Disassembly and assembly SEN01205-02
[*1]
3 Fuel tube joint bolt:
24.5 34.3 Nm {2.5 3.5 kgm}
[*2]
3 Fuel tube sleeve nut:
43 47 Nm {4.4 4.8 kgm}
[*3]
3 Fuel tube (16) common rail side joint bolt:
17.7 22.6 Nm {1.8 2.3 kgm}
3 Fuel tube (16) supply pump side joint bolt:
14.8 19.6 Nm {1.5 2.0 kgm}
D155AX-6 5
SEN01205-02 50 Disassembly and assembly
Removal and installation of fuel 5. Remove tube (5) and block (6).
injector assembly 1
Removal
a This section explains the procedure for remov-
ing No.1 fuel injector assembly.
6 D155AX-6
50 Disassembly and assembly SEN01205-02
D155AX-6 7
SEN01205-02 50 Disassembly and assembly
Installation
1. Install fuel injector assembly.
1) Check that no foreign material stays inside
injector sleeve.
2) Install O-rings (34) and (35), and gasket
(36) to injector.
a Take care not to install O-ring to
groove (b).
8 D155AX-6
50 Disassembly and assembly SEN01205-02
2. Install high pressure pipe clamp and stay. 3. Install the subsequent procedure in the reverse
1) Temporarily tighten high pressure pipe order of removal.
clamp, stay (16), clamping bolts (38)
through (42), and stay mounting bolt, with [*1]
fingers. 3 Joint bolt: 24.5 34.3 Nm {2.5 3.5 kgm}
2) Tighten permanently high pressure pipe
clamping bolt. [*2]
3 Clamping bolt: 3 Clamping bolt (7): 9.8 1 Nm {1 0.1 kgm}
9.8 1 Nm {1 0.1 kgm}
3) Tighten permanently stay mounting bolt. [*3]
4) Temporarily tighten high pressure pipe 3 Cylinder head cover mounting bolt:
clamp, stay (15), clamping bolts (44) 29.4 34.3 Nm {3.0 3.5 kgm}
through (48), and stay mounting bolt, with
fingers. [*4]
5) Install cover (11). a Install with the notch downward.
a Install with the notch toward cylinder
block side. [*5]
6) Install high pressure pipe clamp (10) and a When installing rocker arm and rocker shaft
gate type frame (9) temporarily. assembly (22), check the ball portion of adjust-
7) Tighten clamping bolt for high pressure ment screw (25) to be inserted securely into
pipe clamp (10) permanently. socket of push rod (23), and tighten mounting
3 Clamping bolt: bolts.
9.8 1 Nm {1 0.1 kgm} a As 3 mounting bolts are different each other,
8) Tighten gate type frame (9) permanently. install them referring to the followings.
9) Tighten high pressure pipe clamp, stay q Mounting bolt (19): Stem length 120mm
(15) and clamping bolts (44) through (48), q Mounting bolt (20): Stem length 90 mm
permanently. q Mounting bolt (21): Stem length 75.2 mm
3 Clamping bolt: 3 Mounting bolts (19), (20) and (21):
9.8 1 Nm {1 0.1 kgm} 93 103 Nm {9.5 10.5 kgm}
10) Tighten permanently stay mounting bolt. a Adjust valve clearance referring to the section
of Testing and adjusting, "Adjusting valve
clearance".
D155AX-6 9
SEN01205-02 50 Disassembly and assembly
[*6] [*7]
a Install wiring harness according to the follow-
ing 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
50 Disassembly and assembly SEN01205-02
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
A 4 790-331-1110 Wrench q 1
Removal
1. Remove the engine hood referring to the sec-
tion "Removal and installation of engine hood 8. Remove two joint bolts (8), and remove fuel
assembly". main filter head assembly (9). [*1]
2. Drain the coolant. 9. Remove two joint bolts (10), and remove corro-
6 Coolant: 82 l sion resistor head assembly (11). [*2]
D155AX-6 11
SEN01205-02 50 Disassembly and assembly
13. Disconnect connector PEVA (19). 19. Remove air intake housing.
1) Remove tube (25) and block (26).
12 D155AX-6
50 Disassembly and assembly SEN01205-02
22. Remove clamp (31). 26. Remove two, upper and lower side, wiring har-
ness clamps (38) at the rear side of intake
23. Remove mounting bolts of bracket (32), and manifold.
move bracket (32) with hose (33).
D155AX-6 13
SEN01205-02 50 Disassembly and assembly
29. Remove stays (43), (44), (45) and (45a) for 32. Remove heat insulation covers, (48), (49) and
high pressure pipe clamp. [*8] (50).
30. Remove water tube (46) in front of intake man- 33. Remove muffler (51).
4
ifold.
Muffler: 55 kg
14 D155AX-6
50 Disassembly and assembly SEN01205-02
35. Remove heat insulation covers (53) and (54), 40. Remove heat insulation cover (62).
and bracket (56).
41. Remove brackets (63), (64), (64a) and (64b)
and remove bypass tube (65). [*12]
37. Remove water tube (58). 42. Remove oil tube (66) and water tube (67). [*13]
D155AX-6 15
SEN01205-02 50 Disassembly and assembly
44. Disconnect connectors CN1 (69), CN2 (70), 48. Remove water tube (82). [*19]
CN3 (71), CN4 (72), CN5 (73) and CN6 (74),
and move wiring harnesses (75) and (76). 49. Remove cylinder head cover (83). [*20]
a To disconnect the connector, push in the
(X) direction with a flat-head screwdriver
[1] placed at the stepped portion (a) while
pressing stopper (b).
16 D155AX-6
50 Disassembly and assembly SEN01205-02
51. Remove three mounting bolts (84) through 5) Remove mounting bolt (100) of holder.
(86), and remove rocker arm and rocker shaft [*25]
assembly (87). 6) Set L type bar [2] under fuel injector
a Loosen lock nut (89), and loosen adjust- assembly inlet connector (e), and remove
ment screw (90) two or three turns to pre- slowly fuel injector assembly (101) with
vent excessive force applied to push rod holder using leverage action. [*26]
(88), when installing rocker arm and a Do not grip the solenoid valve at the
rocker shaft assembly. [*21] top of the injector to pull off the injec-
tor.
D155AX-6 17
SEN01205-02 50 Disassembly and assembly
18 D155AX-6
50 Disassembly and assembly SEN01205-02
D155AX-6 19
SEN01205-02 50 Disassembly and assembly
[*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 [*7] [*8] [*15] [*18]
(BD) to Min. 5 mm. a Install high pressure pipe, clamp, stay and gate
3) Tighten bolt (BC). type frame referring to the section, "Removal
a Do not use an impact wrench. and installation of fuel injector assembly".
2 Threaded part of bolt: Lubricating [*9]
oil (THREEBOND, PANDO 18B) a Tighten intake manifold mounting bolts in the
q When reusing the hose, install it to the numerical order shown below.
clamp mark on it. 3 Mounting bolt: 58.8 73.5 Nm {6 7.5 kgm}
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]
2 EGR tube mounting bolt threaded portion:
Lubricant with molybdenum disulfide
(LM-P)
3 EGR tube mounting bolt, EGR tube and
[*5]
bracket mounting bolt:
a Adjust the tension of air compressor belt, refer-
44.1 53.9 Nm {4.5 5.5 kgm}
ring Testing and adjusting section "Testing and
adjusting of air conditioner compressor belt
[*12]
2
tension".
Threads and seat surface of bypass tube
mounting bolt: Lubricant with molybde-
[*6]
3
num disulfide (LM-P)
3
Joint bolt (37a):
Bypass tube mounting bolt:
9.8 12.7 Nm {1.0 1.3 kgm}
3
44.1 53.9 Nm {4.5 5.5 kgm}
Joint bolt (37b):
19.6 29.4 Nm {2.0 3.0 kgm}
[*13]
3 Oil tube cylinder block side joint bolt:
24.5 34.3 Nm {2.5 3.5 kgm}
20 D155AX-6
50 Disassembly and assembly SEN01205-02
[*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}
[*20]
3 Cylinder head cover mounting bolt:
29.4 34.3 Nm {3.0 3.5 kgm}
[*21]
a When installing rocker arm and rocker shaft
assembly (87), check the ball portion of adjust-
ment screw (90) to be inserted securely into
socket of push rod (88), and tighten mounting
bolts.
a As three mounting bolts are different each
[*25] [*26]
other, install them referring the followings.
a Install the fuel injector assembly referring to
q Mounting bolt (84): Stem length 120mm
the section, "Removal and installation of fuel
q Mounting bolt (85): Stem length 90mm
injector assembly".
q Mounting bolt (86): Stem length 75.2 mm
3 Mounting bolt:
q Refilling with coolant
93 103 Nm {9.5 10.5 kgm}
Add coolant through the coolant filler to the
a Adjust valve clearance referring to the section
specified level. Run the engine to circulate the
of Testing and adjusting, "Adjusting valve
coolant through the system. Then, check the
clearance".
coolant level again.
5 Coolant: 82 l
(For details, see "Table of fuel, coolant
and lubricants")
D155AX-6 21
SEN01205-02 50 Disassembly and assembly
22 D155AX-6
50 Disassembly and assembly SEN01205-02
Installation
q Carry out installation in the reverse order of
removal.
[*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
SEN01205-02 50 Disassembly and assembly
[*3]
a Set radiator assembly according to the follow-
ing 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)
24 D155AX-6
50 Disassembly and assembly SEN01205-02
D155AX-6 25
SEN01205-02 50 Disassembly and assembly
Installation
q Carry out installation in the reverse order of
removal.
[*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
26 D155AX-6
50 Disassembly and assembly SEN01205-02
D155AX-6 27
SEN01205-02 50 Disassembly and assembly
11. Remove reservoir tank (6) with bracket (7). 14. Disconnect fuel hose (10) from fuel pre filter.
12. Disconnect ground (8) at engine left side. 15. Remove after cooler tube (11). [*3]
13. Disconnect fuel hose (9) from fuel supply 16. Sling water tube (12) and remove it. [*4]
pump.
28 D155AX-6
50 Disassembly and assembly SEN01205-02
17. Disconnect starting motor B terminal ST/B (13) 22. Disconnect connector AC05 (22).
and heater hose (14).
23. Remove receiver tank (23) and move.
20. Disconnect fuel spill hose (19). 26. Separate universal joint (27) at the engine
side. [*6]
21. Remove clamp (20), and remove bracket (21).
D155AX-6 29
SEN01205-02 50 Disassembly and assembly
[*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):
29. Sling engine assembly (30) and remove it. 12 15 Nm {1.2 1.5 kgm}
a Check all wires and pipes are removed. 3 Threaded part of hose (M22 x 1.5):
a Remove carefully to avoid any interfer- 20 25 Nm {2.0 2.5 kgm}
ence with the machine body. 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)
30 D155AX-6
50 Disassembly and assembly SEN01205-02
[*4]
2 Engine side tube flange:
Gasket sealant (LG-1)
3 Hose clamp: 8.8 0.5 Nm {90 5 kgcm}
[*5]
3 Hose clamp: 8.8 0.5 Nm {90 5 kgcm}
[*6]
3 Universal joint mounting bolt:
98 123 Nm {10 12.5 kgm}
[*7]
3 Engine mount fixing bolt:
823.8 1029.7 Nm {84 105 kgm}
D155AX-6 31
SEN01205-02 50 Disassembly and assembly
32 D155AX-6
50 Disassembly and assembly SEN01205-02
[*1]
3 Pre cleaner duct and exhaust pipe mounting
bolt: 98 123 Nm {10.0 12.5 kgm}
[*2]
3 Hose clamp: 8.8 0.5 Nm {90 5 kgcm}
D155AX-6 33
SEN01205-02 50 Disassembly and assembly
New/Remodel
3) Remove the front seal with impacts of slide
Necessity
Sym- hammer (SH).
Part No. Part name
Sketch
bol a Remove all the chips.
Q'ty
q Tool A5
5 795-931-1100 Seal puller t 1
A 795-521-1100 Push tool t 1
8
01010-31640 Bolt t 3
Removal
1. Remove the radiator and oil cooler guard
assembly.
34 D155AX-6
50 Disassembly and assembly SEN01205-02
Installation
1. Install front seal (3).
a Before installing the seal, check that the
end corners and lip sliding surface of the
crankshaft and the housing are free from
flaw, burr and rust. (5)
a When installing the seal, do not apply oil
or grease to the shaft and seal lip. Wipe
off the oil from the shaft.
a Never remove inside plastic cylinder (4) of
the replacement seal before installing the
seal.
D155AX-6 35
SEN01205-02 50 Disassembly and assembly
Removal and installation of 3. Install eyebolt [1] to flywheel (2), sling flywheel
engine rear seal 1 (2), and remove bolts (3).
Special tools 4. While moving flywheel (2) toward this side, lift
it off.
k Since the socket part of the flywheel is
New/Remodel
shallow, it may fall suddenly. Take care
Necessity
Sym-
Part No. Part name
not to catch your fingers in the fly-
Sketch
bol
wheel.
Q'ty
4 790-331-1100 Wrench (Angle) t 1 4 Flywheel: 60 kg
5 795-931-1100 Seal puller t 1
795T-421-1210 Push tool t 1 Q
6 01050-31645 Bolt t 4
A
01050-31625 Bolt t 4
795T-421-1220 Push tool t 1 Q
7 01050-31625 Bolt t 4
01050-31645 Bolt t 4
Removal
1. Remove the engine assembly. For details, see
"Removal and installation of engine assembly".
5. Remove rear seal (4) according to the follow-
2. Remove damper assembly (1). For details,
ing procedure.
see "Removal and installation of damper
a Measure the distance from the end of the
assembly".
housing. (5)
1) Before pulling out rear seal (4), drive it in a
little to separate it from housing (5).
36 D155AX-6
50 Disassembly and assembly SEN01205-02
D155AX-6 37
SEN01205-02 50 Disassembly and assembly
1. Procedure for installing standard seal 4) Tighten the 3 bolts evenly to press fit rear
a When installing rear seal (4), do not apply seal (4) until the end of tool A6 (for press
oil or grease to the shaft and seal lip. fitting the seal) reaches the end of crank-
1) Set large inside diameter side (b) of plas- shaft (7).
tic inside cylinder (8) of rear seal (4) to the a Tighten tool A6 (for press fitting the
end of crankshaft (7). seal) first until it reaches the bolt
a Take care not to mistake the direction (stem length 45 mm) and then tighten
of the plastic inside cylinder. the bolt (stem length 25 mm).
a When press fitting the seal, take care
not to damage the lip on the PTO side
with the tool set etc.
a After press fitting the seal, remove the
red sealant layer from its periphery.
38 D155AX-6
50 Disassembly and assembly SEN01205-02
D155AX-6 39
SEN01205-02 50 Disassembly and assembly
a Tighten the mounting bolts according to the fol- a After installing the flywheel, measure the facial
lowing procedure. runout and radial runout with tool [1].
3 Flywheel mounting bolts a Radial runout: Max. 0.30 mm
1st time: 118 4.9 Nm {12 0.5 kgm} a Facial runout: Max. 0.30 mm
2nd time: 1) When using tool A4 (See the
tools list)
Retighten each bolt by 90 +30+0 in
the following order.
2) When not using tool A4
Make marks (f) on each bolt and
flywheel with paint, then retighten
each bolt by 90 +30
+0 in the follow-
ing order.
a After tightening, make 1 punch mark (g) on
each bolt head to indicate the number of tight-
ening time.
40 D155AX-6
50 Disassembly and assembly SEN01205-02
Removal and installation of fuel 6. Remove 6 fuel tank mounting bolts (6) on the
tank assembly 1 right and left sides.
Removal
k Disconnect the cable from the negative ()
terminal of the battery.
Installation
q Carry out installation in the reverse order to
removal.
D155AX-6 41
SEN01205-02 50 Disassembly and assembly
Removal and installation of fan 4. Disconnect wiring harness connector FAR (5)
drive assembly 1 and remove wiring harness clamp.
Installation
q Carry out installation in the reverse order to
removal.
42 D155AX-6
50 Disassembly and assembly SEN01205-02
D155AX-6 43
SEN01205-02 50 Disassembly and assembly
D155AX-6 Bulldozer
Form No. SEN01205-02
2007 KOMATSU
All Rights Reserved
Printed in Japan 10-07 (02)
44 D155AX-6
SEN01206-01
D155AX-6
D155AX-6 1
SEN01206-01 50 Disassembly and assembly
2 D155AX-6
50 Disassembly and assembly SEN01206-01
[*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 min-
utes.
2) Fill (b) portion of inner body (8) with about 80 g
of lithium base extreme pressure grease with
molybdenum disulphide (B).
Dry lubricant with Sumiko lubricant Rocol
A
molybdenum disulphide Dry Splay or equivalent
Kyodo yushi
Molylex No.2 or an
equivalent
Lithium base extreme
Showa Shell Sekiyu
B pressure grease with
Retinax AM or an equiv-
molybdenum disulphide
alent
Nippon Oil Corporation
Molytex or an equivalent
D155AX-6 3
SEN01206-01 50 Disassembly and assembly
[*4] [*5]
3 Damper mounting bolt:
98 123 Nm {10.0 12.5 kgm}
4 D155AX-6
50 Disassembly and assembly SEN01206-01
Special tools
New/Remodel
Necessity
Sym-
Part number Part name
Sketch
bol
Q'ty
791-612-1100 Installer t 1
Puller
F 790-101-4200 t 1
(294 kN {30 ton})
790-101-1102 Hydraulic pump t 1
D155AX-6 5
SEN01206-01 50 Disassembly and assembly
1. Coupling
Remove bolt (3) from cover (2), then remove
holder (4) and coupling (5).
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).
6 D155AX-6
50 Disassembly and assembly SEN01206-01
D155AX-6 7
SEN01206-01 50 Disassembly and assembly
Assembly
Assembly of damper assembly (10)
8 D155AX-6
50 Disassembly and assembly SEN01206-01
D155AX-6 9
SEN01206-01 50 Disassembly and assembly
3. Install collar (7-2) and O-ring to shaft (6). 6. Install coupling (5) and holder (4), and tighten
bolt (3).
3 Mounting bolt:
245.2 308.9 Nm {25.0 31.5 kgm}
10 D155AX-6
50 Disassembly and assembly SEN01206-01
D155AX-6 11
SEN01206-01 50 Disassembly and assembly
10. Remove the clamps for wirings (21) through 15. Remove final drive shaft cover (29).
(23), and move wires.
14. Loosen clamp (27), and move seal (28) out- 17. Disconnect hoses (31) and (32) at the right
ward slightly. [*2] front of power train unit.
12 D155AX-6
50 Disassembly and assembly SEN01206-01
18. Disconnect hose (33) at the lower left front of 21. Remove four mounting bolts (36) at front left
power train unit. and right of power train unit. [*4]
19. Sling power train filter (34) and remove it. 22. Sling power train unit assembly (37) and
4
remove it. [*5]
Power train filter: 20 kg
a Check all wires and pipes are removed.
a Remove carefully to avoid any interfer-
ence with the machine body.
4 Power train unit assembly: 2,400 kg
D155AX-6 13
SEN01206-01 50 Disassembly and assembly
Installation
q Carry out installation in the reverse order of
removal.
[*1]
3 Mount cap fixing bolt:
245 309 Nm {25 31.5 kgm}
[*2]
a Clamp seal of coupling securely at the bulge
portion, and assemble clamp threaded portion
parallel to the cap mounting seat surface.
[*3]
3 Universal joint mounting bolt:
98 123 Nm {10.0 12.5 kgm}
[*4]
3 Mount (front) fixing bolt:
824 1,030 Nm {84 105 kgm}
[*5]
a When installing power train unit assembly,
install it carefully not to damage seal (28).
14 D155AX-6
50 Disassembly and assembly SEN01206-01
D155AX-6 15
SEN01206-01 50 Disassembly and assembly
9. Remove tubes (11) and (12), and remove 12. Temporarily sling PTO, torque converter and
power train and lubrication pump assembly transmission assembly (16), and remove 18
(13). mounting bolts to separate from HSS unit
4
assembly (17). [*2]
Power train and lubrication pump
assembly: 30 kg 4 PTO, torque converter and transmission
assembly: 1,500 kg
16 D155AX-6
50 Disassembly and assembly SEN01206-01
D155AX-6 17
SEN01206-01 50 Disassembly and assembly
18. Remove torque converter valve assembly (25), 20. Sling torque converter assembly (28) and
and remove two sleeves (26). remove it.
a Remove only 10 mounting bolts marked
with a in the figure (nominal length 90
mm). [*4]
4 Torque converter assembly: 130 kg
18 D155AX-6
50 Disassembly and assembly SEN01206-01
Connection [*2]
3 Transmission case mounting bolt:
q Carry out connection in the reverse order of 98 123 Nm {10.0 12.5 kgm}
disconnection.
[*3]
3
[*1] PTO assembly mounting bolts:
a Connect the pressure pick up hose to power 98 123 Nm {10.0 12.5 kgm}
train unit referring to the table which indicates
the band color at the mouthpiece of pressure [*4]
2
pick up hose. Torque converter assembly mounting bolts:
Sym- Liquid adhesive (LT-2)
3
Pressure pick up point Band color Torque converter assembly mounting bolts:
bol
Torque converter lockup clutch pres- 98 123 Nm {10.0 12.5 kgm}
a Yellow red
sure
Torque converter stator clutch pres-
b Yellow blue
sure
c Transmission 1st clutch pressure Red
Yellow
d Transmission 3rd clutch pressure
black
e Transmission R clutch pressure Red blue
White yel-
f Transmission 2nd clutch pressure
low
g Transmission F clutch pressure White blue
h Transmission main relief pressure No color
i Left brake pressure White
j Right brake pressure Yellow
D155AX-6 19
SEN01206-01 50 Disassembly and assembly
D155AX-6 Bulldozer
Form No. SEN01206-01
2007 KOMATSU
All Rights Reserved
Printed in Japan 10-07 (02)
20 D155AX-6
SEN01207-01
D155AX-6
D155AX-6 1
SEN01207-01 50 Disassembly and assembly
Disassembly and assembly of 3) Remove cover (5) from gear and bearing
PTO assembly 1 assembly (6).
Disassembly
1. Lubrication tube
1) Remove shaft lubrication tube (1).
2 D155AX-6
50 Disassembly and assembly SEN01207-01
3. Cooling fan pump drive gear and cover 5) Remove snap ring (14) and remove bear-
assembly ing (15) from cover (12).
1) Remove 6 mounting bolts (10) and set a
guide bolt.
2) Tighten forcing screws into hole (c) to
remove gear and cover assembly (11).
D155AX-6 3
SEN01207-01 50 Disassembly and assembly
3) Remove snap ring (20) and remove bear- 1] Remove bearing (25) and spacer (26)
ing (21) from the case. from gear (24).
a When reusing the bearing and
spacer, keep them so that they
will be combined with the original
outer race.
2] Remove outer race (27) and snap
ring (28) from gear (24).
4 D155AX-6
50 Disassembly and assembly SEN01207-01
D155AX-6 5
SEN01207-01 50 Disassembly and assembly
5) Install gear (24). 2) While holding the inner race side of the
6) Install bearing (25) and tighten plate (22) bearing with push tool [5], install drive
with the bolt to press fit the bearing to the gear (19).
shaft.
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
245.0 308.7 Nm {25.0 31.5 kgm}
6 D155AX-6
50 Disassembly and assembly SEN01207-01
2) Press fit bearing (15) to cover (12) and 5) Install gear and cover assembly (11),
install snap ring (14). meshing it with the idler gear.
2 O-ring: Grease (G2-LI)
2 Mounting bolt; Adhesive (LT-2)
3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
D155AX-6 7
SEN01207-01 50 Disassembly and assembly
3) Install gear and bearing assembly (6) to 2) Install lubrication tube (1).
cover (5). 3 Joint bolt:
34.3 44.2 Nm {3.5 4.5 kgm}
6. Lubrication tube
1) Install lubrication tube (2).
3 Joint bolt:
34.3 44.2 Nm {3.5 4.5 kgm}
8 D155AX-6
50 Disassembly and assembly SEN01207-01
D155AX-6 9
SEN01207-01 50 Disassembly and assembly
4. Piston
1) Remove piston (10). 7. Stator and race assembly
2) Remove 2 seal rings (11) from piston (10). 1) Remove snap ring (16) and stator and
race assembly (17).
10 D155AX-6
50 Disassembly and assembly SEN01207-01
8. Pump
1) Remove snap ring (22) and spacer (23).
2) Remove pump assembly (25) from stator
shaft and clutch assembly (24). 2) Remove stator clutch piston (33).
3) Remove seal ring (34) from stator clutch
piston (33).
4) Remove 5 pins (35) and 10 springs (36)
and remove 2 stator clutch discs (37) and
stator clutch plate (38) from housing (39).
D155AX-6 11
SEN01207-01 50 Disassembly and assembly
5) Disassemble housing and shaft assembly 5] Press the shaft with a press to
according to the following procedure. remove shaft and bearing assembly
1] Remove 6 mounting bolts (40). (48) from housing (49).
2] Using forcing screws, remove shaft
assembly (41).
12 D155AX-6
50 Disassembly and assembly SEN01207-01
D155AX-6 13
SEN01207-01 50 Disassembly and assembly
14 D155AX-6
50 Disassembly and assembly SEN01207-01
3. Snap ring
Install snap ring (21) to the shaft.
D155AX-6 15
SEN01207-01 50 Disassembly and assembly
4. Stator and race assembly 2) Place drive case (14) on turbine gear (15).
1) Install race (19) to stator (20) and install 2
snap rings (18).
16 D155AX-6
50 Disassembly and assembly SEN01207-01
5) Install piston (10). 8) Using push tool [6], push the inner race of
bearing (8) to press fit.
D155AX-6 17
SEN01207-01 50 Disassembly and assembly
6. Input shaft
1) Install bearing (3) and snap ring (2).
18 D155AX-6
50 Disassembly and assembly SEN01207-01
Disassembly and assembly of 3) Remove sleeve (3) and flanges (4) and
transmission assembly 1 (5).
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
791T-615-1300 Puller assembly t 1
1 791T-615-1310 Plate 1 Q
G 01010-82040 Bolt 1
Oil leak tester kit
2 799-301-1600 t 1
(A)
3. Snap ring
Remove snap ring (123) from output shaft
(124).
a Remove the snap ring at this time.
D155AX-6 19
SEN01207-01 50 Disassembly and assembly
3) Using eyebolts [2], sling transmission case 2) Disassemble the input shaft-front cover-
(8), remove 13 tie bolts (9) (used to clamp No. 1 carrier assembly according to the
the transmission case, too), and remove following procedure.
case (8). 1] Remove snap ring (12), No. 2 sun
gear (13) and snap ring (14).
2] Remove snap ring (15), No. 1 sun
gear (16) and collar (17).
5. Tie bolts
Remove 4 remaining tie bolts (9).
20 D155AX-6
50 Disassembly and assembly SEN01207-01
5] Remove snap ring (20) and drive out 8. No. 1 housing assembly
input shaft (21) toward the torque 1) Using eyebolts [4], remove No. 1 housing
converter. assembly (33).
2) Remove No. 1 piston (34) from the hous-
ing.
D155AX-6 21
SEN01207-01 50 Disassembly and assembly
22 D155AX-6
50 Disassembly and assembly SEN01207-01
14. No. 3 disc, plate and spring 16. Output shaft and No. 4 sun gear
1) Remove springs (60). 1) Pull out output shaft (73).
2) Remove springs (61), discs (62) and 2) Remove snap ring (74) from the output
plates (63). shaft.
3) Remove No. 4 sun gear (75).
D155AX-6 23
SEN01207-01 50 Disassembly and assembly
2) Disassemble the No. 4 carrier and No. 3 19. No. 4 disc, plate, spring and guide pin
ring gear assembly according to the fol- 1) Remove spring (89).
lowing procedure. 2) Remove springs (90), No. 4 discs (91) and
1] Remove snap ring (77) and ring gear plates (92).
(127). 3) Remove guide pin (93).
a Push the snap ring inward with a
pin (Diameter: Max. 3 mm) from
outside to warp and remove it.
2] Remove seal rings (78) and (79).
3] Drive in roll pin (80) to pull out shaft
(80A).
4] Remove thrust washer (81), planetary
gear (82) and bearing (83).
5] Remove snap ring (84) to remove
bearing (85) and spacer (86) as an
assembly.
6] Remove bearing (85) from spacer
(86).
24 D155AX-6
50 Disassembly and assembly SEN01207-01
2] Remove snap ring (101) and remove 23. No. 5 disc, plate and spring
No. 4 ring gear (102) from carrier 1) Remove springs (107).
(103). 2) Remove discs (108), plates (109) and
springs (110).
D155AX-6 25
SEN01207-01 50 Disassembly and assembly
1. Output housing
1) Using the push tool, press fit bearing (121)
to spacer (122).
26 D155AX-6
50 Disassembly and assembly SEN01207-01
2) Using the push tool, press fit spacer (122) 3. No. 5 piston
and bearing assembly (121) to output Install No. 5 piston (112) to the output housing.
housing (123).
3) Install snap ring (120). 4. No. 5 ring gear
Install No. 5 ring gear (111).
2. Cover assembly
1) Using the push tool, press fit bearing (119) 5. Guide pin
to cover (118). Install guide pin (93).
2) Install seal rings (117) and (116) to cover
(118). 6. No. 5 disc, plate and spring
1) Install discs (108), plates (109) and
springs (110).
a Install the 3 discs and 2 plates.
2) 2) Install springs (107).
a Free length of spring: 66 mm
D155AX-6 27
SEN01207-01 50 Disassembly and assembly
7. No. 4 housing assembly 2) Using guide bolts, set No. 5 carrier and
1) Fit the seal ring and install No. 4 piston No. 4 ring gear assembly (95) and tighten
(106). mounting bolts (94).
2) Install No. 4 housing assembly (105). 2 Threaded part of mounting bolt:
a Check that the springs are fitted to Adhesive (LT-2)
the grooves. 3 Mounting bolt:
66.2 7.4 Nm {6.75 0.75 kgm}
28 D155AX-6
50 Disassembly and assembly SEN01207-01
11. No. 3 housing assembly 8] Set the No. 3 ring gear to No. 4 car-
1) Fit the seal ring and install No. 3 piston rier and install snap ring (77).
(88). a Check that the snap ring is fitted
2) Install No. 3 housing (87). to the groove.
a Check that the springs are fitted to
the grooves.
D155AX-6 29
SEN01207-01 50 Disassembly and assembly
15. No. 3 carrier assembly 16. No. 3 discs, plates and springs
1) Assemble the No. 3 carrier assembly 1) Install discs (62), plates (63) and springs
according to the following procedure. (61).
1] Using the push tool, press fit bearing a Install the 4 discs and 3 plates.
(72) to the carrier and install snap ring 2) Install springs (60).
(71). a Free length of spring: 70 mm
2] Install bearing (69) to planetary gear
(68). While fitting thrust washers (67)
to both sides of them, set them to the
carrier.
3] Fit ball (70) and install shaft (66).
4] Install seal ring (65).
30 D155AX-6
50 Disassembly and assembly SEN01207-01
4] Install bearing (53) to gear (52). 2) Using eyebolts [5], install No. 2 housing
While fitting thrust washers (51) to and No. 2 carrier assembly (42).
both sides of them, set them to the a Check that the springs are fitted to
carrier. the grooves.
5] Fit ball (54) and install shaft (50). 3) Fit the seal ring and install No. 2 piston
(43).
8] Install No. 2 housing (46) to No. 2 car- 18. Install through bolt guide (40), spring (130) and
rier assembly (45). lubricating oil relief valve (41).
a Press fit the inner race side of
the housing bearing.
9] Install snap ring (44).
D155AX-6 31
SEN01207-01 50 Disassembly and assembly
19. Guide pin 3] Set No. 1 ring gear (23) to No. 1 car-
Install guide pins (35). rier and install snap ring (22).
32 D155AX-6
50 Disassembly and assembly SEN01207-01
9] Install No. 2 sun gear (13) and snap 24. Front cover
ring (12). 1) Install seal ring (121) to front cover (122).
2) Sling input shaft and No. 1 carrier assem- 2) Using eyebolts [6], install front cover
bly (119) and install it, while meshing the (122), while aligning it with the guide pins
No. 2 sun gear with No. 2 planetary gear. and springs. Press fit the inner race side
of bearing (123) and install snap ring
(124).
a Check that the springs are fitted to
the cover.
D155AX-6 33
SEN01207-01 50 Disassembly and assembly
28. Sleeve
Install sleeve (7).
34 D155AX-6
50 Disassembly and assembly SEN01207-01
D155AX-6 35
SEN01207-01 50 Disassembly and assembly
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
791-662-1110 Bracket t 1
1 01010-31685 Bolt t 1
01017-31620 Bolt t 1
H 790-302-1500 Spanner kit t 1
2
09003-09200 Spanner 1
790-302-1500 Spanner kit t 1
3 2) Loosen the hexagon socket head bolts
09003-08290 Spanner 1 evenly. Using eyebolts [1], remove brake
case (5).
Disassembly a Since the brake case is pressed by
the brake spring, loosen the bolts
1. Brake and carrier assembly evenly.
1) Slant HSS case assembly about 15 so a The outside bearing comes off
that tool H1 will be installed vertically. together with the cover.
2) Remove the mounting bolts. Using tool
H1, remove brake and carrier assembly
(1).
a Do not remove the hexagon socket
head bolts.
a Remove the brake and carrier assem-
bly on the opposite side similarly.
36 D155AX-6
50 Disassembly and assembly SEN01207-01
4) Remove brake drum (12), discs and plates 8) Remove ring (21) and remove ring gear
together. (22) from gear (108).
9) Remove snap ring (23) and pull out shaft
(24).
D155AX-6 37
SEN01207-01 50 Disassembly and assembly
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] Hold the pinion securely with a press.
Using tool H2, remove locknut (39).
3] Using push tool [5], remove bevel pin-
ion (40) from cage (41).
38 D155AX-6
50 Disassembly and assembly SEN01207-01
a Only inner race (50) of bearing (55) is 2) Remove lubrication tubes (57) and (58).
left. 3) Remove oil level gauge pipe (59) and suc-
a Remove the gear on the opposite tion tube (60).
side similarly.
D155AX-6 39
SEN01207-01 50 Disassembly and assembly
4) Remove inner race (67) and bearing (68) 3) Remove inner race (75) from bearing (74).
from gear (66). 4) Remove bearing (74).
5) Remove bearing (69) from flange (61).
9. Intermediate gear
8. Right-hand carrier drive gear 1) Remove shaft mounting bolts.
1) Remove bolt (70), plate (71) and gear 2) Using shock hammer [8], pull out shaft
(72). (76) and remove gear (77) and bearing
(78).
40 D155AX-6
50 Disassembly and assembly SEN01207-01
10. Bevel gear shaft and bevel gear assembly 2] Remove right-hand retainer (89) from
1) Remove mounting bolts (85) of the left- shaft (92).
hand retainer.
2) Remove mounting bolts (86) of the right-
hand retainer.
3) Using eyebolts [7], lift off bevel gear shaft
and bevel gear assembly (87).
a Check the quantity and thickness of
the shims on the left side and keep
them.
D155AX-6 41
SEN01207-01 50 Disassembly and assembly
42 D155AX-6
50 Disassembly and assembly SEN01207-01
2] Install inner race (108) to shaft (92) by 7] Support the bevel gear with block
shrink fit. [13]. Using push tool [14], press fit
a Shrink fit temperature: 100 C for retainer assembly (102) to the shaft.
about 30 minutes
D155AX-6 43
SEN01207-01 50 Disassembly and assembly
44 D155AX-6
50 Disassembly and assembly SEN01207-01
5) Push the tooth tip of bevel gear (100) with 3) Install gear assembly (79) to case (80).
push-pull scale [7] to measure the "start- While aligning the bolt holes, install shaft
ing torque" of the bevel gear shaft. (76).
a Starting torque: a When installing the shaft, align the
Max. 3.0 Nm {0.3 kgm} bolt holes.
(At bevel gear tooth tip: Max. 19.6 N
{2.0 kg})
D155AX-6 45
SEN01207-01 50 Disassembly and assembly
4) Using the push tool, install inner race (75) 3) Install lubrication tube (56).
between the shaft and bearing. 3 Joint bolt:
a Hold the shaft from the opposite side. 7.8 9.8 Nm {0.8 1.0 kgm}
5) Install gear (72) and plate (71) and tighten 5. Bevel pinion assembly
bolt (70). 1) Assembly of bevel pinion
3 Mounting bolt: 1] Using the push tool, press fit bearing
98 123 Nm {10.0 12.5 kgm} (109) to bevel pinion (40).
4. Lubrication tubes, oil level gauge pipe and 2] Using the push tool, press fit outer
suction tube races (43) and (107) to cage (41).
1) nstall suction tube (60) and oil level gauge 3] Place bevel pinion (40) on the press
pipe (59). stand and set cage (41).
2) Install lubrication tubes (57) and (58).
3 Joint bolt:
7.8 9.8 Nm {0.8 1.0 kgm}
46 D155AX-6
50 Disassembly and assembly SEN01207-01
4] Press fit bearing (42) to cage (41). 6. Adjustment of backlash and tooth contact
5] Hold the pinion with the press. Using 1) Adjustment of backlash
tool H2, tighten locknut (39). Apply the probe of dial gauge [6] to the
2 Locknut: Adhesive (LT-2) tooth tip at the end of the bevel gear per-
3 Locknut: pendicularly. While fixing the bevel pinion,
696.3 863.0 Nm {71 88 kgm} move the bevel gear forward and back-
a While rotating the cage, tighten ward and read the dial gauge.
the locknut. a Standard backlash: 0.25 0.33 mm
a After tightening the nut, check a Measure the backlash diagonally at 3
that the bevel pinion rotates or more places.
smoothly. a Adjust the backlash by increasing or
decreasing thickness of the right and
left shims. Do not change the total
thickness of both shims, however, so
that the pre-load will not change. (If
the thickness of the shim on one side
is increased, decrease the thickness
of the other side, and vice versa.)
q When backlash is insufficient
Decrease the thickness of the shim
on the right side of the machine and
increase the thickness on the left side
by the same quantity. (Move the bevel
gear in direction (A).)
D155AX-6 47
SEN01207-01 50 Disassembly and assembly
48 D155AX-6
50 Disassembly and assembly SEN01207-01
3) When adjustment is finished, tighten 4) Install flange and gear assembly (63) to
the mounting bolts of the cage and case (62).
bevel pinion assembly to the speci- 5) Install flange (61).
fied torque.
3 Mounting bolts of cage and
bevel pinion assembly:
98 123 Nm {10.0 12.5 kgm}
8. Valve seat
1) Install lubrication tube (52).
D155AX-6 49
SEN01207-01 50 Disassembly and assembly
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
50 Disassembly and assembly SEN01207-01
D155AX-6 51
SEN01207-01 50 Disassembly and assembly
3] Using eyebolts [1], install brake cover q Installation of brake and carrier assembly
assembly (5), while aligning the bolt 1) Slant the steering case assembly about 15
holes of the hub and brake drum. degrees so that tool H1 will be installed verti-
a Tighten the mounting bolts tem- cally.
porarily. 2) Using tool H1, install brake and carrier assem-
a Tighten the hexagon socket head bly (1).
bolts evenly since the springs are 3 Mounting bolt:
working. 98 123 Nm {10.0 12.5 kgm}
a Install the brake and carrier assembly on the
opposite side similarly.
a If rear cover (109) of HSS case (107) was
removed, install new gasket (108).
2 Gasket (Apply to both sides):
Gasket sealant (LG-1)
52 D155AX-6
50 Disassembly and assembly SEN01207-01
D155AX-6 53
SEN01207-01 50 Disassembly and assembly
D155AX-6 Bulldozer
Form No. SEN01207-01
2007 KOMATSU
All Rights Reserved
Printed in Japan 10-07 (02)
54 D155AX-6
SEN02707-01
D155AX-6
D155AX-6 1
SEN02707-01 50 Disassembly and assembly
New/Remodel
steering case.
2) Set right and left support stands [2]
Necessity
Sym-
Part No. Part name
under the main frame on the front
Sketch
bol
side of the machine.
Q'ty
a After setting support stands [1] and [2], set
790-337-1032 Lifting tool t 1
the hydraulic jack and ripper as auxiliary
791-627-1320 Shackle t 2 supports.
J
791T-627-1910 Plate t 1 Q
01010-82080 Bolt t 2
Removal
1. Spread the track assembly. For details, see
"Spreading and installation of track assembly".
2 D155AX-6
50 Disassembly and assembly SEN02707-01
5. Remove drive shaft cover (5). 8. Using tool J, sling final drive assembly (1) and
remove the remaining bolts.
k First, loosen 1 bolt on each of both
sides of the final drive so that the final
drive will not jump out. Then, loosen
all the bolts gradually to pull out the
final drive assembly.
Installation
q Carry out installation in the reverse order to
removal.
[*1], [*2]
3 Final drive mounting bolt:
1,150 1,440 Nm {118 147 kgm}
D155AX-6 3
SEN02707-01 50 Disassembly and assembly
New/Remodel
Necessity
Sym- 2. Drive shaft
Part No. Part name
Sketch
bol
Remove drive shaft (1).
Q'ty
790-431-1031 Block t 1
791-520-4140 Screw t 2
790-101-2360 Plate t 2
791-112-1180 Nut t 2
1
790-101-2480 Adapter t 2
791T-627-1920 Plate t 1 Q
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
3. Shaft
01643-32460 Washer t 2
2 1) Set the final drive assembly to the block.
791T-627-1930 Plate t 1 Q 2) Remove mounting bolts (2).
791T-627-1940 Push tool t 1 Q
790-101-2102 Puller t 1
790-101-1102 Hydraulic pump t 1
3 791-627-1280 Installer t 1
790-101-5401 Push tool kit t 1
790-101-5441 Plate 1
4
K 790-101-5421 Grip 1
01010-51240 Bolt 1
790-101-5401 Push tool kit t 1
790-101-5451 Plate 1
790-101-5421 Grip 1
5
01010-51240 Bolt 1
791T-627-1950 Plate t 1 Q
791T-627-1960 Plate t 1 Q
790-201-1500 Push tool kit t 1
790-201-1680 Plate 1
6
790-101-5021 Grip 1
01010-50816 Bolt 1
791-520-4140 Screw t 1
790-101-2420 Adapter t 1
791-112-1180 Nut t 1
01643-22460 Washer t 1
7
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
4 D155AX-6
50 Disassembly and assembly SEN02707-01
3) Using eyebolts [1], remove shaft (3). 4) Remove floating seal (8) and bearing
outer races (9) and (10).
a Keep the floating seal in a safe place
so that it will not be damaged.
D155AX-6 5
SEN02707-01 50 Disassembly and assembly
7. Carrier assembly
1) Using 3 eyebolts [5], remove carrier
assembly (21).
4) Using eyebolts [3], sling cover assembly
(16). Using 3 forcing screws [4], remove
the cover assembly.
6 D155AX-6
50 Disassembly and assembly SEN02707-01
10. Gear
4] Remove bearing outer races (29) and 1) Remove the gear according to the follow-
(30) from the planetary gear. ing 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 pin-
ion side.
8. Sun gear
Remove thrust washer (31) and sun gear (32).
D155AX-6 7
SEN02707-01 50 Disassembly and assembly
11. Hub and case assembly 4) Remove collar (43) and remove bearing
1) Using tool K2, remove hub assembly (40) (44) from case (36).
and bearing (37).
8 D155AX-6
50 Disassembly and assembly SEN02707-01
2) Remove outer race (48) and oil seal (49) 14. Outer race and oil seal
from cage (47). Remove outer race (55) and oil seal (56) from
case (36).
D155AX-6 9
SEN02707-01 50 Disassembly and assembly
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) Using tool K5, press fit outer race (55) to
case (36).
q Outer race press fitting force:
1 13 kN {0.1 1.4 ton}
10 D155AX-6
50 Disassembly and assembly SEN02707-01
2) Using tool K5, press fit bearing outer race 4] Install determined shim (50) to the
(48) to cage (47). cage and tighten the 6 mounting bolts
q Bearing press fitting force: of cage (47) evenly.
1 13 kN {0.1 1.4 ton} 3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
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 quan-
tity (c) of the shim from the total of
clearances (a) and (b).
D155AX-6 11
SEN02707-01 50 Disassembly and assembly
12 D155AX-6
50 Disassembly and assembly SEN02707-01
4) Using tool K5, press fit 2 bearing outer 2) Tighten gear mounting bolts (38).
races (42) to hub (41). 2 Mounting bolt: Adhesive (LT-2)
q Bearing press fitting force: 3 Mounting bolt:
3 18 kN {0.3 1.8 ton} 230 289 Nm {23.5 29.5 kgm}
5) Using eyebolts [7], set hub assembly (40) 3) Using tool K7, press fit bearing (37) to
to the shaft. case (36).
q Bearing press fitting force:
21 54 kN {2.1 5.5 ton}
5. Gear
1) Using eyebolts [6], sling gear (39). While
slanting the hub, set the gear to the hub. 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}
D155AX-6 13
SEN02707-01 50 Disassembly and assembly
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 identifi- 4) Install holders (23) and tighten bolts (22).
cation mark. 2 Mounting bolt: Adhesive (LT-2)
1) Using tool K6, press fit bearing outer 3 Mounting bolt:
races (29) and (30) to the planetary gear. 230 289 Nm {23.5 29.5 kgm}
q Bearing press fitting force:
10 35 kN {1.0 3.6 ton}
14 D155AX-6
50 Disassembly and assembly SEN02707-01
D155AX-6 15
SEN02707-01 50 Disassembly and assembly
10. Wear guard 3) Using tool K3, press fit floating seal (8).
Install wear guard (12). a Degrease and dry the O-ring and O-
3 Mounting bolt: ring contact surface before installing
824 1,030 Nm {84 105 kgm} the floating seal.
a After installing the floating seal, check
that its tilt is 1 mm or less.
16 D155AX-6
50 Disassembly and assembly SEN02707-01
5) Using tool [10], press fit bearing (7). 2) Tighten mounting bolts (2).
a While rotating the sprocket hub 3 Mounting bolt:
assembly, press fit the bearing. 1,225 1,470 Nm {125 150 kgm}
q Bearing press fitting force:
15 43 kN {1.5 4.4 ton}
D155AX-6 17
SEN02707-01 50 Disassembly and assembly
D155AX-6 Bulldozer
Form No. SEN02707-01
2007 KOMATSU
All Rights Reserved
Printed in Japan 10-07 (02)
18 D155AX-6
SEN01208-01
D155AX-6
D155AX-6 1
SEN01208-01 50 Disassembly and assembly
2 D155AX-6
50 Disassembly and assembly SEN01208-01
Removal and installation of track 2) Set hydraulic jack [2] under the center of
frame assembly 1 the equalizer bar and float the front part of
the machine and then set right and left
Special tools support stands [3] under the main frame
on the front side of the machine.
New/Remodel
3) Set blocks under the front part of the
floated track frame to secure safety during
Necessity
Sym-
Part No. Part name
work.
Sketch
bol
a After setting support stands [1] and
Q'ty
[3], set the hydraulic jack and ripper
791T-130-1010 Bracket t 6 N Q
as auxiliary supports.
KK 01010-63060 Bolt t 12
01643-33080 Washer t 12
Removal
1. Remove the blade assembly. For details, see
"Removal and installation of blade assembly".
D155AX-6 3
SEN01208-01 50 Disassembly and assembly
4 D155AX-6
50 Disassembly and assembly SEN01208-01
Installation [*4]
a Install seal (17) according to the following pro-
q Carry out installation in the reverse order to
cedure.
removal.
1) Reverse seal (17) so that the molded let-
ter (c) face will be on the inside.
[*1]
2
2) With the seal reversed, insert seal (17) in
Threaded part of mounting bolt (1):
pivot shaft (18).
Adhesive (LT-2)
3 Mounting bolt (1): 7
3) Apply engine oil (For details, see "Table of
fuel, coolant and lubricants") to face (d) of
84 981 Nm {80 100 kgm}
track frame assembly (16).
q Add grease (G2-LI) through the grease fitting.
4) Install track frame assembly (16) to the
pivot shaft (18).
[*2]
a Install seal (13) according to the following pro-
cedure.
1) Reverse seal (13) so that the molded let-
ter (a) face will be on the inside.
2) With the seal reversed, insert the seal in
washer (14).
3) Apply engine oil (For details, see "Table of
fuel, coolant and lubricants") to face (b) of
washer (12) at the shaft end.
4) Install washer (12) to the shaft end.
[*3]
a When inserting the track frame assembly, take
care extremely not to damage the seal surface.
D155AX-6 5
SEN01208-01 50 Disassembly and assembly
Removal and installation of idler 7. Remove spring seats (6) and tension springs
assembly 1 (7).
a The above parts are installed between the
Removal support and track frame.
[*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
6 D155AX-6
50 Disassembly and assembly SEN01208-01
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
791T-630-1230 Plate t 1 Q
791-630-1220 Rod t 2
790-101-2510 Block t 1
790-101-2570 Washer t 2
1 01580-01411 Nut t 2
L 01643-31445 Washer t 2
Puller
790-101-2102 t 1
(294 kN {30 ton}) 8. Reverse the idler assembly.
790-101-1102 Hydraulic pump t 1
2 796-670-1020 Installer t 1 9. Remove nut (8), bolt (9) and support (10).
3 791-601-1000 Oil pump t 1
10. Remove ring (11).
Disassembly
1. Remove the oil drain plug to drain the oil.
6 Idler: Approx. 530 590 cc
D155AX-6 7
SEN01208-01 50 Disassembly and assembly
14. Remove floating seal (15) from rings (5) and Assembly
(11).
a Clean all the parts thoroughly and check them
for dirt or damage.
15. Remove floating seal (16) from retainers (6)
and (12).
1. Set tool L1 to idler (1) and press fit bushing
(17).
a When press fitting the bushing, align it
with the mating hole with a plastic hammer
and then press fit it with the press.
a Press fit the bushing so that distance (a)
between the idler end and bushing top will
be 16 0.5 mm.
q Bushing press fitting force:
16 92 kN {1.6 9.4 ton}
8 D155AX-6
50 Disassembly and assembly SEN01208-01
D155AX-6 9
SEN01208-01 50 Disassembly and assembly
11. Using the push tool, press fit ring (6) to dimen- a If oil was added with tool L3, be sure to
sion (d). slant the idler about 10 and check that
a Ring press fitting dimension (d): the oil level is at the bottom of the oil filler
80 0.2 mm as shown below.
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 Idler: 670 730 cc (GO140B)
3 Plug: 160 255 Nm {16.0 26.0 kgm}
10 D155AX-6
50 Disassembly and assembly SEN01208-01
D155AX-6 11
SEN01208-01 50 Disassembly and assembly
Disassembly and assembly of 3) Using push tool [1], pull out piston (9) from
recoil spring assembly 1 yoke (8) with a press.
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
791-685-8006 Compressor t 1
791-635-3160 Extension t 1
M 2 791T-630-2610 Spacer t 1 Q
790-101-1300 Cylinder t 1
790-101-1102 Hydraulic pump t 1
2. Disassembly of yoke and piston assembly 3. Remove holder (13) from recoil spring case
1) Remove snap ring (3), packing (4) and (12).
ring (5). k Never stand in front of or at the rear of
2) Remove bolt (6) and plate (7). the recoil spring assembly to avoid
danger.
12 D155AX-6
50 Disassembly and assembly SEN01208-01
D155AX-6 13
SEN01208-01 50 Disassembly and assembly
14 D155AX-6
50 Disassembly and assembly SEN01208-01
4. Install nut (11) and spacer (19). 6. Install lubricator (18) to cylinder (10) and install
a Eliminate the clearance between the nut the lock plate.
and spacer. a Install the grease fitting at 45 5 out.
(Reference) If there is any clearance, the
spring load is applied to the
threaded part of the nut. The nut
may be damaged and may not be
able to be disassembled next
time.
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).
5. Release the hydraulic pressure gradually to
release the spring tension completely and then
remove recoil spring assembly (1) from tool
M2.
D155AX-6 15
SEN01208-01 50 Disassembly and assembly
16 D155AX-6
50 Disassembly and assembly SEN01208-01
Removal and installation of track Note 1: Sling No. 1 bogie (1) with lever block
roller 1 [1] etc. and fix it. The fixing tool can-
not be used to fix the No. 1 bogie.
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
791T-130-1010 Bracket t 6 N Q
KK 01010-63060 Bolt t 12
01643-33080 Washer t 12
Removal
1. Lower the track assembly tension. For details,
see "Spreading and installation of track assem- 3. Operate the blade and ripper to raise the
bly". machine until track roller assembly (2) floats
above the track shoe.
2. Install tool KK to fix bogie assembly (1). a Operate the blade and ripper slowly while
running the engine at low idle.
D155AX-6 17
SEN01208-01 50 Disassembly and assembly
[*1], [*2]
Install the track roller assembly according to the fol-
lowing 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.
95 kg Adhesive (LT-2)
3 Roller cap mounting bolt:
4 Track roller assembly (double flange): 662 829 Nm {67.5 84.5 kgm}
110 kg
[*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
50 Disassembly and assembly SEN01208-01
Disassembly and assembly of 6. Using the press, remove ring (6), retainer (7)
track roller assembly 1 and plates (4) and (8) from the shaft.
Special tools 7. Remove rings (2) and (6) from retainers (3)
and (7).
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
1 791T-630-1290 Plate t 1 Q
2 791T-630-1330 Push tool t 1 Q
N
3 791-651-1510 Installer t 2
4 791-601-1000 Oil pump t 1
Disassembly
1. Remove the oil filler plug to drain the oil.
6 Track roller: 820 880 cc
8. Remove floating seal (9) from rings (2) and (6).
a Keep the floating seal so that it will not be
2. Set track roller (1) on block [1]. damaged.
3. Remove the mounting bolts. Using forcing 9. Remove floating seal (10) from retainers (3)
screws [2], remove ring (2), retainer (3) and and (7).
plate (4) together. a Keep the floating seal so that it will not be
damaged.
4. Reverse the track roller assembly.
D155AX-6 19
SEN01208-01 50 Disassembly and assembly
Assembly
a Clean all the parts thoroughly and check them
for dirt or damage.
20 D155AX-6
50 Disassembly and assembly SEN01208-01
D155AX-6 21
SEN01208-01 50 Disassembly and assembly
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
791T-130-1010 Bracket t 2 N Q
14 01010-63060 Bolt t 4
01643-33080 Washer t 4
790-401-1700 Lifting tool t 1
22 4. Sling No. 1 bogie assembly (2) with wires so
790-401-1761 Adapter t 1
that it will not lower.
791-630-1860 Bracket t 1
23
791-630-1870 Bracket t 1
790-101-2310 Block t 1
790-101-2360 Plate t 2
790-445-4130 Screw t 2
15 791-112-1180 Nut t 2
Puller
790-101-4000 t 1
L (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 5. Loosen the mounting bolts of roller cap (3)
16
01643-33080 Washer t 1 about 20 mm.
a Loosen both inside and outside bolts.
Puller
790-101-4000 t 1
(490 kN {50 ton})
6. Hit the end of shaft (4) with a plastic hammer,
790-101-1102 Pump t 1 etc. to separate the track roller from the bogie.
17 796-430-1110 Push tool t 1 a Take care not to damage the installed
18 790-701-3000 Seal checker t 1 dowel pin.
19 791T-630-1390 Guide t 1 Q
Removal
1. Remove the undercover.
22 D155AX-6
50 Disassembly and assembly SEN01208-01
7. Set tool L22 and remove roller cap (3). 10. Pulling out of shaft and ring
1) Set tool L15.
2) Push shaft (7) with tool L15 to push out
ring (8) toward the opposite side.
q Pushing out force (Reference):
216 402 kN {22 41 ton}
D155AX-6 23
SEN01208-01 50 Disassembly and assembly
24 D155AX-6
50 Disassembly and assembly SEN01208-01
D155AX-6 25
SEN01208-01 50 Disassembly and assembly
4. Insert cartridge pin assembly (15) in the pin 6. Press fit the cartridge pin on the opposite side
hole. according to steps 4 6.
a Set arrow (b) at the end face of the car-
tridge pin assembly up (in the installed 7. Install covers (6).
state on the machine). a Install the covers to 2 places of inside and
outside.
5. Using tool L20, press fit cartridge pin assembly
(15).
a Push in the cartridge pin assembly with
cover (6).
a Push in the cartridge pin assembly to
machined surface (c) of the track frame.
2 Outside of pin:
Molybdenum disulfide grease (LM-P)
a Press fitting force of cartridge pin assem-
bly: 216 402 kN {22 41 ton}
26 D155AX-6
50 Disassembly and assembly SEN01208-01
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
SEN01208-01 50 Disassembly and assembly
New/Remodel
4 Power train undercover: 270 kg
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
3. Using tool L14, fix bogie assembly (1).
791T-130-1010 Bracket t 2 N Q
14 01010-63060 Bolt t 4 4. Remove cover (2).
a Remove the cover on the opposite side,
01643-33080 Washer t 4
too.
791-630-1360 Spacer t 1
790-101-2310 Block t 1
790-101-2360 Plate t 2
790-445-4130 Screw t 2
15
791-112-1180 Nut t 2
Puller
790-101-4000 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
16
L 01643-33080 Washer t 1 5. Operate the blade and ripper to raise the
machine until the track roller floats above the
Puller
790-101-4000 t 1 track link.
k Set a block between the track roller and
(490 kN {50 ton})
790-101-1102 Pump t 1 track link so that the machine will not
17 796-430-1110 Push tool t 1 lower.
18 790-701-3000 Seal checker t 1
19 791T-630-1390 Guide t 1 Q
6. Set steel plate [2] on the track shoe and block
[1].
790-101-2310 Block t 1 a Set block [1] so that it will fit to the height
790-445-4130 Screw t 2 of the track link.
796T-470-1130 Plate t 1 Q
790-101-2360 Plate t 2
7. Operate the blade and ripper to lower the
20 machine until the track roller of bogie assembly
790-112-1180 Nut t 2 (1) touches steel plate [2].
790-101-4000
Puller
t 1 a Operate the blade and ripper slowly.
(490 kN {50 ton})
790-101-1102 Pump t 1
21 791-601-1000 Oil pump t 1
Removal
1. Spread the track shoe assembly. For details,
see "Spreading and installation of track shoe
assembly".
28 D155AX-6
50 Disassembly and assembly SEN01208-01
8. Pulling out shaft and ring 4) Set pulling tool L16 to pull out rings (6)
1) Set tool L15 and (7).
2) Push shaft (3) with tool L15 to push out q Pulling force (Reference):
ring (4) toward the opposite side. 216 402 kN {22 41 ton}
q Pushing out force (Reference):
216 402 kN {22 41 ton}
D155AX-6 29
SEN01208-01 50 Disassembly and assembly
30 D155AX-6
50 Disassembly and assembly SEN01208-01
a Before installing the floating seal, 5) Using tool L18, check the airtightness of
thoroughly clean, degrease and dry the floating seal.
the O-ring and floating seal contact
surface (hatched areas). Take care
that dirt will not stick to the floating
seal contact surface.
a After inserting the floating seal, check
that its tilt is 1 mm or less and projec-
tion (a) of the seal is 3 5 mm.
3) Install spacer (8) and ring (6) to shaft (3) 4. Slide bogie assembly (1) on the steel plate with
and ring (4). lever block [4] and set it to the mounting posi-
4) Install spacer (9) to ring (6) and press fit tion.
ring (7) with tool [3].
q Press fitting force of ring (7):
3.9 48 kN {0.4 4.9 ton}
2 Area between shaft (3) and ring:
Molybdenum disulfide grease
(LM-P)
D155AX-6 31
SEN01208-01 50 Disassembly and assembly
5. Operate the blade and ripper to raise the 4) Adjust front and rear jacks [6] and [7] to
machine. align the pin holes of the track frame and
bogie assembly.
6. Adjustment procedure for cartridge pin hole k When aligning the pin holes, never
1) Set block [5] and hydraulic jack [6] to the insert your fingers in them.
rear side of the machine. a If it is difficult to align the pin holes by
adjusting the front and rear jacks,
sling the front part of the track on the
opposite side or apply a hydraulic
jack to the bogie assembly to align
the pin holes.
5) Insert guide tool L19 in the pin hole.
32 D155AX-6
50 Disassembly and assembly SEN01208-01
D155AX-6 33
SEN01208-01 50 Disassembly and assembly
New/Remodel
to the procedure in "Removal and installation
of bogie assembly".
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
790-101-2310 Block t 1
790-445-4130 Screw t 2
796T-470-1130 Plate t 1 Q
790-101-2360 Plate t 2
20
Q 791-112-1180 Nut t 2
Puller
790-101-4000 t 1
(490 kN {50 ton})
790-101-1102 Pump t 1
21 791-601-1000 Oil pump t 1
Disassembly 4. Bogies
Disconnect inner bogie (5) and outer bogie (6).
1. Track roller assembly
1) Reverse bogie assembly (1).
2) Remove the roller cap and lift off 2 track
roller assemblies (2).
a Take care not to damage the installed
dowel pin.
4 Track roller assembly
(single flange): 95 kg
4 Track roller assembly
(double flange): 105 kg
34 D155AX-6
50 Disassembly and assembly SEN01208-01
D155AX-6 35
SEN01208-01 50 Disassembly and assembly
36 D155AX-6
50 Disassembly and assembly SEN01208-01
Removal and installation of 4. Pass rope [2] through the link hole and wind it
carrier roller assembly 1 onto carrier roller (3) and stretch it. Loosen the
rope gradually to pull out carrier roller (3) from
Removal support (4). [*1]
1. Remove the track frame top cover and loosen 4 Carrier roller: 45 kg
lubricator (1) to lower the track tension.
k Since the internal pressure of the recoil
spring cylinder is very high, do not
loosen the lubricator more than 1 turn.
If the grease does not come out suffi-
ciently after the lubricator is loosened,
move the machine forward and in
reverse.
Installation
q Carry out installation in the reverse order to
removal.
[*1]
When installing the carrier roller to the support,
make clearance (a) shown in the figure.
2. Using hydraulic jacks [1], raise the track shoe. q Clearance (a): 1.2 mm
2 Support mounting bolt: Adhesive (LT-2)
3. Remove mounting bolts (2).
q Adjust the track shoe assembly tension. For
details, see Testing and adjusting, "Testing and
adjusting track shoe assembly tension".
D155AX-6 37
SEN01208-01 50 Disassembly and assembly
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
1 790-102-1891 Nut wrench t 1
2 791-651-1510 Installer t 1
R
3 791T-630-1350 Spacer t 1
4 791-601-1000 Oil pump t 1
Disassembly
1. Remove the plug to drain the oil.
a While rotating the shaft, drain the oil.
6 Carrier roller: 570 680 cc 7. Remove outer race (7) from the roller.
38 D155AX-6
50 Disassembly and assembly SEN01208-01
D155AX-6 39
SEN01208-01 50 Disassembly and assembly
5. Using tool R1, tighten nut (4) to "58.8 Nm {6 9. Using tool R2, install floating seal (10) to ring
kgm}". (8).
a After tightening the nut, if the nut hole is
not aligned with the shaft hole, align it by 10. Fit the O-ring and install ring (8) while setting it
loosening it. to the dowel pin.
40 D155AX-6
50 Disassembly and assembly SEN01208-01
12. Using tool R3, press fit ring (11). 14. After checking for air leakage, check again that
a Press fit the ring so that dimension (a) the oil supplied in step 8 is still at a proper
from the shaft end to the ring top will be level.
131.95 0.2 mm. a Check of oil level
Remove the oil filler plug, slant the carrier
roller approx. 10, and check the oil level.
D155AX-6 41
SEN01208-01 50 Disassembly and assembly
Removal and installation of pivot 3. Sling pivot shaft assembly (3) and remove the
shaft assembly 1 mounting bolts. Using eyebolts [1], lift off pivot
shaft assembly (3). [*2]
Special tools 4 Pivot shaft assembly: 135 kg
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
791T-650-2110 Sleeve t 1 Q
790-201-2770 Spacer t 1
791T-650-2120 Plate t 1 Q
792-104-3940 Bolt t 2
790-101-2510 Block t 1
V
790-101-2570 Washer t 2
01580-01613 Nut t 1
Jack assembly
790-105-2300 t 1
(196 kN {20 ton})
790-101-1102 Hydraulic pump t 1
Removal
1. Remove the track frame assembly. For details,
see "Removal and installation of track frame
assembly".
42 D155AX-6
50 Disassembly and assembly SEN01208-01
Installation
q Carry out installation in the reverse order to
removal.
[*1]
a Install seal (1) according to the following pro-
cedure.
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]
2 Pivot shaft mounting bolt: Adhesive (LT-2)
3 Pivot shaft mounting bolt:
784 981 Nm {80 100 kgm}
D155AX-6 43
SEN01208-01 50 Disassembly and assembly
44 D155AX-6
50 Disassembly and assembly SEN01208-01
D155AX-6 45
SEN01208-01 50 Disassembly and assembly
Installation
q Carry out installation in the reverse order to
expansion (ordinary).
[*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
50 Disassembly and assembly SEN01208-01
New/Remodel
among the links.
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
Remover and
791-675-9701 t 1
installer
Cylinder
791-101-4300 t 1
1 (196 kN {20 ton})
Puller
791-101-4200 t 1
(294 kN {30 ton})
791-101-1102 Hydraulic pump t 1
S
2 791-932-1110 Plug push tool t 1
3 791-660-7460 Pin brush t 1
4 791-432-1110 Plug push tool t 1
2. Disassembly of link
5 791-632-1052 Installer t 1 1) Set the link assembly on a link press and
6 790-701-3000 Seal checker t 1 hit it with a hammer so that the bushing
7 791-601-1000 Oil pump t 1 will be fitted to the jaw.
a If the link tread, outside of the bush-
a For the general disassembly of the track shoe, ing, etc. are worn, adjust the height of
see "Parts judgment guide, Undercarriage, Oil jaw [1] or guide plate and align disas-
lubricated track" and "Parts judgment guide, sembly jigs [2] and [3] with the pin
Undercarriage, Reversing procedure for oil and bushing so that the link hole will
lubricated track". not be damaged during disassembly
work.
a If the disassembly jigs are not aligned
General disassembly well, the link hole may be damaged
1. Removal of shoe and the pin and bushing may be bro-
Sling the shoe assembly and set it with the ken during disassembly work.
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 47
SEN01208-01 50 Disassembly and assembly
a Using tool S2, drive the small plug of 4) Return the right cylinder and take out the
the pin inward after the disassembly links, pins, bushings, and spacers on the
work so that the workplace will not right and left sides and feed the next 1 set
become dirty. of the link assembly to the jaw.
a If the bushing ends and sealing sur-
faces are damaged, oil will leak.
Accordingly, handle them carefully.
48 D155AX-6
50 Disassembly and assembly SEN01208-01
D155AX-6 49
SEN01208-01 50 Disassembly and assembly
3) If the link, pin, bushing and spacer are 5) Installation of seal assembly
dirty, clean them. Remove the nodules Clean the counterbore portion of the link
sticking to the link and bushing with the carefully and push in the seal to the bot-
grinder. tom by using tool S5.
a Since these parts rust easily, clean a If oil sticks to the counterbore portion
them just before assembling. of the link or seal assembly, the seal
a Do not polish the bushing ends. If will turn and its sealing performance
they are polished, oil may leak. will lower. Accordingly, do not apply
4) If the large plug was pulled out, drive it in any oil. When inserting the seal in the
by using tool S4. counterbore portion, take care that oil
a Clean the pin hole in advance by not stick to the seal.
using tool S3.
50 D155AX-6
50 Disassembly and assembly SEN01208-01
D155AX-6 51
SEN01208-01 50 Disassembly and assembly
52 D155AX-6
50 Disassembly and assembly SEN01208-01
11) Set the left jig on the receiving side and 13) Using a shoe bolt hole pitch gauge, mea-
the right one on the pushing side and sure the distance between the shoe bolt
press fit the left link. holes and check that the result is within
a When press fitting, take care that both the standard range.
seals and spacers will not come off. a If the distance between the shoe bolt
a Link press fitting force: holes is longer than the standard
343 490 kN {35 50 ton} 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.
D155AX-6 53
SEN01208-01 50 Disassembly and assembly
15) Using tool S7, supply oil (G090) until the 16) After supplying oil, drive in the small plug
oil supply pressure rises to 196 294 kPa into the specified position, using tool S2.
{2 3 kg/cm2}. a Apply oil (G090) around the small
a In a cold or very cold district, supply plug.
K O MAT SU genu ine oil ( 150- 09- a Drive in the small plug to the following
19270 for cold district or 195-32- depth.
61990 for very cold district) having Driving depth from end: 7.5 1 mm
better low-temperature characteristics
instead of G090.
a If the oil pressure is heightened too
much, it has bad effects on the seal.
Take care.
54 D155AX-6
50 Disassembly and assembly SEN01208-01
2) When installing a 2-piece shoe, place the When recycling for grease lubricated track
assembled 2-piece shoes on a level place 1. Preparation work
in 1 line with the shoe side up. 1) Cleaning of seal assembly
3) Pull pin-side master link (1) and bushing- Remove the seal assembly from the link
side master link (2) together and set them and divide it into the seal ring (1) and load
to each other by the mating faces. ring (2), and then clean them.
4) Place shoe (3) and fit the mating surfaces a Since the seal ring (1) and load ring
of the links. (2) are deteriorated easily by the
5) Check that master bolts (4) can be tight- cleaning liquid, clean them quickly.
ened easily with the fingers, then connect After cleaning them, wipe off the
the links with the master bolts. cleaning liquid from them.
2 Master bolt:
Molybdenum disulfide grease
(LM-P)
3 Master bolt (Master link)
Initial torque:
590 60 Nm {60 6 kgm}
Retightening angle: 180 10
D155AX-6 55
SEN01208-01 50 Disassembly and assembly
3) Using tools S2 and S4, drive the large and 6) Installation of seal assembly
small plugs into the pin. Clean the counterbore portion of the link
1] Insert each plug through the plug carefully. Using tool S5, push in the seal
insertion window into the guide hole. to the bottom.
a Apply oil to the plug. a If grease sticks to the counterbore
2] Push the bar with the hand until the portion of the link or seal assembly,
plug stops. the seal will turn and its sealing per-
3] Push the plug with the bar to press formance will lower. Accordingly, do
the guide against the pin. not apply any grease.
4] Drive in the bar with a hammer.
a Driving distance (a) from pin end:
Small plug: 7.5 1 mm
Large plug: 6.0 2 mm
a If the plugs were not pulled out of
the pin when the shoe was disas-
sembled, reuse them as they
are.
56 D155AX-6
50 Disassembly and assembly SEN01208-01
D155AX-6 57
SEN01208-01 50 Disassembly and assembly
6) Send the master links and set the next pin 8) Using a shoe bolt hole pitch gauge, mea-
and bushing. sure the distance between the shoe bolt
a When reusing a pin, install it so that holes. When the distance is in the stan-
its side hole will be on the link tread dard range, stop press fitting.
side similarly to a new one. If it is not
installed so, its strength may be low-
ered. Accordingly, indicate the direc-
tion of the side hole on the end face
to prevent a mistake.
a If the outside of the pin is worn, install
it so that the un-worn surface will be
on the traction side. In this case,
install the pin so that its side hole will
be on the link tread side.
3. Installation of shoe
1) Set the link assembly on the bed and
install the shoe with a impact wrench and
a torque wrench.
7) Set the right and left links and operate a When reusing (reversing) the bush-
both pushing jigs to press fit the pin and ing, set the worn outside surface of
bushing simultaneously. the bushing on the shoe fitting side of
a If the pin and bushing have play when the link (set the bushing with the worn
they are press fitted, the seal may outside surface up on the link press).
come off the link. To prevent this, 2 Shoe bolt:
press fit smoothly. If the seal comes Molybdenum disulfide grease
off the link, stop press fitting and set (LM-P)
the seal to the link correctly, then start 3 Shoe bolt (Regular link):
press fitting again. Initial torque:
a Final pressing force for pin and bush- 590 60 Nm {60 6 kgm}
ing: 343 490 Nm {35 50 ton} Retightening angle: 120 10
Final pressing force C 1.8 x Average
press fitting force
(Adjust the relief pressure of the link
press to set the final pressing force.)
58 D155AX-6
50 Disassembly and assembly SEN01208-01
D155AX-6 59
SEN01208-01 50 Disassembly and assembly
Adjustment Precaution
Adjust the dimensions of the press fitting jig of the 1. The link receiving faces of jaw (5) must be ver-
link press to keep the projection of the pin and tical.
bushing constant and keep the installed dimen- 2. Wear plate (6) should be replaceable.
sions 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
Dimensions of jig
a b c
4.5 3.25 50.6
60 D155AX-6
50 Disassembly and assembly SEN01208-01
New/Remodel
New/Remodel
Necessity
Necessity
Sym- Sym-
Part No. Part name Part No. Part name
Sketch
Sketch
bol bol
Q'ty
Q'ty
791-675-9581 Adapter t 1 8 791-675-5580 Guide t 1
791-675-9590 Guide t 1 791-685-9510 Frame t 1
1
01010-52460 Bolt t 2 791-685-9520 Frame t 1
01010-51440 Bolt t 2 791-685-9530 Rod t 1
790-101-1102 Pump t 1 791-685-9540 Rod t 1
2 Cylinder 791-685-9550 Nut t 3
790-101-4300 t 1
(1,470 kN {150 ton}) 791-685-9560 Bolt t 4
791-685-9510 Frame t 1 791-126-0150 Adapter t 1
9
791-685-9520 Frame t 1 01010-51030 Bolt t 1
791-685-9530 Rod t 1 791-685-9620 Extension t 1
791-685-9550 Nut t 1 791-675-5542 Adapter t 1
791-685-9560 Bolt t 1 791-675-5560 Guide t 1
3
791-675-9570 Adapter t 1 T 790-101-1102 Pump t 1
04530-12030 Eyebolt t 1 Cylinder
790-101-4300 t 1
790-101-1102 Pump t 1 (1,470 kN {150 ton})
T Cylinder 791-675-5560 Guide t 1
790-101-4300 t 1 10
(1,470 kN {150 ton}) 791-675-5542 Adapter t 1
791-685-9540 Rod t 1 790-101-1102 Pump t 1
4
791-685-9550 Nut t 3 11 Puller
790-101-4200 t 1
791-675-5520 Guide t 1 (294 kN {30 ton})
791-675-5530 Pusher t 1 12 791-670-3270 Guide t 1
5
01010-51030 Bolt t 1 791-126-0150 Adapter t 1
791-685-9620 Extension t 1 791-675-5560 Guide t 1
13
790-101-1102 Pump t 1 791-675-9570 Adapter t 1
6 Puller 01010-51030 Bolt t 1
790-101-4200 t 1
(294 kN {30 ton})
791-675-5542 Adapter t 1
791-675-5571 Adapter t 1
7 790-101-1102 Pump t 1
Cylinder
790-101-4300 t 1
(1,470 kN {150 ton})
D155AX-6 61
SEN01208-01 50 Disassembly and assembly
Disassembly of 1 link in field 3. Insert the rod of tool T4 from the cylinder side
k Only how to use the tools is explained below. and install it with the nuts (2 pieces).
For details of disassembly and assembly, Pass the rod through the hole of link (1) and
see "General disassembly (or assembly) of install it.
track shoe".
62 D155AX-6
50 Disassembly and assembly SEN01208-01
Assembly of 1 link in field 3. Set link (4) on the opposite side and support it
1. Assemble the link sub-assembly. with tool T8 (guide).
1) Set tool T7 the link end face and press fit
bushing (1).
a Busing press fitting force:
88 304 kN {9 31 ton}
2. Set the link to be connected to link sub-assem- 5. Using tool T11 (294 kN {30 ton} puller) as in
bly (3). the disassembly procedure, push open link (5)
on the bushing side.
D155AX-6 63
SEN01208-01 50 Disassembly and assembly
64 D155AX-6
50 Disassembly and assembly SEN01208-01
New/Remodel
(6) by moving them up and down. Then,
remove pins (8) and (9) from regular link
Necessity
Sym-
Part No. Part name
(7) by pressing them up and down with the
Sketch
bol
press.
Q'ty
Special tool : 1. Gas cutting machine
790-101-1102 Pump t 1
: 2. Tool U2
1 Puller
790-101-4200 t 1
(294 kN {30 ton})
Remover and
791-675-9701 t 1
installer
790-101-1102 Pump t 1
U 2 Puller
790-101-4200 t 1
(294 kN {30 ton})
Cylinder
790-101-4300 t 1
(1,470 kN {150 ton})
3 791-432-1110 Plug push tool t 1
4 790-701-3000 Seal checker t 1
5 791-932-1110 Plug push tool t 1
D155AX-6 65
SEN01208-01 50 Disassembly and assembly
66 D155AX-6
50 Disassembly and assembly SEN01208-01
5) Install the shoe to the link at the connect- 2) Insert pin (9) in bushing (8), set master
ing section. links (10) on the pin side from the right
6) Drive in large plug (6) with tool U3, add oil and left sides, and press fit them with tool
with tool U4, and drive in small plug (7) U2.
with U5. 3) Drive in large plug (11) with tool U3, add
a When press fitting the right and left oil with tool U4, and drive in small plug
master links, take care extremely that (12) with U5.
they will be in parallel (on the bushing
side and pin side).
a Do not damage the mating faces of
the master links and end of the bush-
ing.
a Take care extremely that dirt or sand
will not stick to the seal, spacer, ends
of bushing and tap mating faces of
the master link.
D155AX-6 67
SEN01208-01 50 Disassembly and assembly
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
791T-650-2130 Sleeve t 1 Q
790-101-2420 Adapter t 1
791-502-4140 Screw t 1
790-101-2540 Washer t 2
W 790-112-1180 Nut t 2
Puller
790-101-4000 t 1
(294 kN {50 ton})
Hydraulic pump
790-101-1102 t 1
5. Operate hydraulic jacks [2] slowly to lower the
machine until the equalizer bar reaches the
Removal right and left track frames.
1. Remove the engine undercover and power
6 Disconnect grease hose (5).
train undercover.
4 Engine undercover: 220 kg
4 Power train undercover: 270 kg
68 D155AX-6
50 Disassembly and assembly SEN01208-01
[*1]
2 Threaded part of cover mounting bolt:
Adhesive (LT-2)
3 Cover mounting bolt:
784 981 Nm {80 100 kgm}
[*2]
kWhen aligning the pin holes, never insert
your fingers in them.
a Before installing the side pin, adjust the height
of the main frame with the hydraulic jacks to
align the equalizer bar hole with the track
9. Using tool W, pull out center pin (8). [*3] frame hole.
k Do not operate the hydraulic device in 2 Seal lip: Grease (G2-LI)
front of or under the puller, but operate
as far from the puller as possible. [*3]
kWhen aligning the pin holes, never insert
your fingers in them.
a Before installing the center pin, sling the equal-
izer bar to align the equalizer bar hole with the
main frame hole.
2 Equalizer bar center bushing:
Grease (G2-LI)
[*4]
Install the equalizer bar with the grease fitting side
forward.
D155AX-6 69
SEN01208-01 50 Disassembly and assembly
2. Side bushing
1) Install ring (2) to one side of equalizer bar
(4).
3) Using tool [1], remove spherical bushing 2) Using the press, press fit spherical bush-
(3) from equalizer bar (4). ing (3) to equalizer bar (4).
a Press fitting force for spherical bush-
ing: 27.4 64.7 kN {2.8 6.6 ton}
2 Periphery of spherical bushing:
Molybdenum disulfide grease
(LM-P)
3. Center bushing
Remove center bushing (5) from equalizer bar
(4).
70 D155AX-6
50 Disassembly and assembly SEN01208-01
D155AX-6 71
SEN01208-01 50 Disassembly and assembly
72 D155AX-6
50 Disassembly and assembly SEN01208-01
D155AX-6 73
SEN01208-01 50 Disassembly and assembly
D155AX-6 Bulldozer
Form No. SEN01208-01
2007 KOMATSU
All Rights Reserved
Printed in Japan 10-07 (02)
74 D155AX-6
SEN01209-01
D155AX-6
D155AX-6 1
SEN01209-01 50 Disassembly and assembly
2 D155AX-6
50 Disassembly and assembly SEN01209-01
Installation
q Carry out installation in the reverse order to
removal.
q Bleeding air
Bleed air from each part. For details, see Test-
ing and adjusting, "Bleeding air from each
part".
D155AX-6 3
SEN01209-01 50 Disassembly and assembly
Removal and installation of 3) Disconnect hoses (3), (4), (5) and (6).
hydraulic pump assembly 1 4) Disconnect accumulator (7) and hose
together.
Removal
k Lower the work equipment to the ground
and release the residual pressure in the
piping, referring to Testing and adjusting,
"Releasing residual pressure in hydraulic
circuit". Then, loosen the hydraulic tank
cap gradually to release the internal pres-
sure of the hydraulic tank.
k Disconnect the cable from the negative ()
terminal of the battery.
4 D155AX-6
50 Disassembly and assembly SEN01209-01
9) Disconnect suction tube (16). q Removal of power train and steering lubri-
a Remove the suction tube mounting cating oil pump assembly
bolts on the fuel pump side, too. 1) Disconnect tubes (1), (2) and (3).
2) Sling power train and steering lubricating
oil pump assembly (4), remove 2 mount-
ing bolts (5), and lift off pump assembly
(4).
4 Power train and steering lubricating
oil pump assembly: 30 kg
D155AX-6 5
SEN01209-01 50 Disassembly and assembly
q Bleeding air
q Removal of scavenging pump assembly Bleed air from each part. For details, see Test-
1) Remove suction tube (1). ing and adjusting, "Bleeding air from each
2) Disconnect outlet tube (2). part".
3) Remove the 2 mounting bolts and scav-
enging pump assembly (3).
4 Scavenging pump assembly: 20 kg
6 D155AX-6
50 Disassembly and assembly SEN01209-01
New/Remodel
q Blade lift cylinder
Necessity
Sym-
Part No. Part name 1) Set cylinder assembly (1) to tool Y1.
Sketch
bol
2) Using the hydraulic pump or the
Q'ty
power wrench and tool Y2, remove
790-502-1003
Cylinder repair
t 1
head assembly (2).
1 stand 3) Pull piston rod assembly (3).
790-101-1102 Hydraulic pump t 1 a Put an oil pan under the cylinder
2 790-102-3802 Multi-wrench t 1 to receive the oil.
790-201-1702 Push tool kit t 1
790-201-1721 Push tool 1
790-201-1821 Push tool 1
790-201-1841 Push tool 1
3
790-201-1851 Push tool 1
790-201-1861 Push tool 1
790-101-5021 Grip 1
01010-50816 Bolt 1
790-201-1500 Push tool kit t 1
790-201-1630 Plate 1
Y
790-201-1650 Plate 1
4 790-201-1660 Plate 1 q Blade tilt cylinder, ripper lift cylinder, and
790-201-1670 Plate 1 ripper tilt cylinder
1) Remove the mounting bolt assembly
790-101-5021 Grip 1
and disconnect head assembly (4).
01010-50816 Bolt 1 q Width across flats of blade tilt cyl-
790-720-1000 Expander t 1 inder: 16 mm
796-720-1670 Ring t 1 q Width across flats of ripper lift
and tilt cylinders: 18 mm
07281-01279 Clamp t 1
2) Pull piston rod assembly (5).
5 796-720-1690 Ring t 1 a Put an oil pan under the cylinder
07281-01919 Clamp t 1 to receive the oil.
796-720-1720 Ring t 1
07281-02429 Clamp t 1
790-102-4300 Wrench t 1
6
790-102-4310 Pin t 2
D155AX-6 7
SEN01209-01 50 Disassembly and assembly
8 D155AX-6
50 Disassembly and assembly SEN01209-01
4. Head assembly
1) Remove head assembly (2) or (4).
D155AX-6 9
SEN01209-01 50 Disassembly and assembly
1. Head assembly
1) Assembly of head assembly
10 D155AX-6
50 Disassembly and assembly SEN01209-01
D155AX-6 11
SEN01209-01 50 Disassembly and assembly
12 D155AX-6
50 Disassembly and assembly SEN01209-01
2) Install O-ring (19) and backup ring 5) Install valve (7) to spacer (6) and
(18) to the piston rod and then install install them with the mounting bolts.
piston assembly (17). 2 Mounting bolt:
a Before installing the backup ring, Adhesive (LT-2)
warm it in water at 50 60 C. 3 Mounting bolt:
a Apply grease to the O-ring and 98 123 Nm {10.0 12.5 kgm}
backup ring so that the backup
ring will not open.
3) Fix with spacer (16) and tighten the
mounting bolts.
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
D155AX-6 13
SEN01209-01 50 Disassembly and assembly
14 D155AX-6
50 Disassembly and assembly SEN01209-01
D155AX-6 15
SEN01209-01 50 Disassembly and assembly
D155AX-6 Bulldozer
Form No. SEN01209-01
2007 KOMATSU
All Rights Reserved
Printed in Japan 10-07 (02)
16 D155AX-6
SEN01210-01
D155AX-6
D155AX-6 1
SEN01210-01 50 Disassembly and assembly
1. Remove cap (1) of the lift cylinder assembly. 6. Remove blade assembly (6). [*2]
[*1] a Run the engine and move the machine
a Check the quantity and thickness of the slowly in reverse to disconnect the blade
shims. assembly from the trunnion.
2 D155AX-6
50 Disassembly and assembly SEN01210-01
Installation
q Carry out installation in the reverse order to
removal.
[*1]
a Adjust clearance (a) at the cap mating sur-
faces 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 adjust-
ing, "Adjusting blade".
q Refilling with oil (Hydraulic tank)
Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.
5 Hydraulic oil (For details, see "Table of
fuel, coolant and lubricants"):
Only necessary quantity
[*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 3
SEN01210-01 50 Disassembly and assembly
4 D155AX-6
50 Disassembly and assembly SEN01210-01
10. Sling arm (12), remove the lock plates, pull out
right and left pins (13), and lift off arm (12).
4 Arm: 650 kg
D155AX-6 5
SEN01210-01 50 Disassembly and assembly
3. Sling tilt cylinder assembly (5) and install pin 7. Sling lift cylinder assembly (3), run the engine,
(9). extend the piston rod, align the pin holes,
4
install pin (4), and fix it with the lock plate.
Tilt cylinder assembly: 260 kg
a After installing, lower the rod side to the
arm.
6 D155AX-6
50 Disassembly and assembly SEN01210-01
10. Greasing
After assembling, supply sufficient amount of
grease to each pin.
2 Pin: Grease (G2-LI)
D155AX-6 7
SEN01210-01 50 Disassembly and assembly
D155AX-6 Bulldozer
Form No. SEN01210-01
2007 KOMATSU
All Rights Reserved
Printed in Japan 10-07 (02)
8 D155AX-6
SEN01211-01
D155AX-6
D155AX-6 1
SEN01211-01 50 Disassembly and assembly
Removal
k Disconnect the cable from the negative ()
terminal of the battery.
2 D155AX-6
50 Disassembly and assembly SEN01211-01
[*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.
D155AX-6 3
SEN01211-01 50 Disassembly and assembly
* Among the panes of window glass of the opera- (1): Front window glass
tor's cab, the 3 panes of (1) and (3) on both (2): Both-sided adhesive tape
sides are stuck. In this section, the procedure (3): Door window glass (Left and right)
for replacing the stuck glass is explained. (4): Both-sided adhesive tape (Left and right)
(5): Trim seal (Left and right)
(6): Door handle (Left and right)
4 D155AX-6
50 Disassembly and assembly SEN01211-01
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
Lifter
X 1 793-498-1210 t 2
(Suction cup)
Removal
* Remove the window glass to be replaced
according to the following procedure.
D155AX-6 5
SEN01211-01 50 Disassembly and assembly
6 D155AX-6
50 Disassembly and assembly SEN01211-01
4. Install trim seals (4) to both door window 5. Position the new window glass.
glasses (2). 1) Using tool X1, set the window glass to the
sticking position. Check the clearance
between the window glass and the opera-
tor's cab on the right, left, upper, and lower
sides, and then adjust it evenly.
a Position front window glass (1) from
inside of operator's cab (7). Adjust it
so that the difference between black
coated part and the metal sheet of
operator's cab (7) will be even on the
right, left, upper, and lower sides.
a When positioning each door window
glass (2), align handle holes (d) of
door (9) (on the glass side and door
metal sheet side) first. Then, adjust
a Install each trim seal (4) so that its finish- the door window glass so that the
ing end and starting end will be jointed at positional relationship between it and
position (c) and dimension (b) between door metal sheet will be even all
the corner and position (c) will be 90 mm. around the window.
D155AX-6 7
SEN01211-01 50 Disassembly and assembly
6. Apply adhesive.
2 Adhesive:Sikaflex 256HV
manufactured by Sika Japan
a Do not use primer. 2) Cut the tip of the adhesive nozzle (12) so
a The using limit of the adhesive is 6 months that dimensions (f) and (g) will be as fol-
after the date of manufacture. Do not use lows.
the adhesive after this limit. q Dimension (f) : 10 mm
a Keep the adhesive in a dark place where q Dimension (g): 15 mm
the temperature is below 25C.
a Never heat the adhesive higher than
30C.
a When reusing the adhesive, remove the
all hardened part from the nozzle tip.
8 D155AX-6
50 Disassembly and assembly SEN01211-01
4) Remove release tape of the both-sided a Apply adhesive (13) to dimensions (h)
adhesive tape (3a) on the glass side. and (j) of both-sided adhesive tape
(3) of operator's cab (7).
q Dimension (h): 10 mm
q Dimension (j) : 15 mm
a Apply adhesive (13) higher than both-
sided adhesive tape (3).
a Apply the adhesive evenly.
D155AX-6 9
SEN01211-01 50 Disassembly and assembly
10 D155AX-6
50 Disassembly and assembly SEN01211-01
D155AX-6 11
SEN01211-01 50 Disassembly and assembly
12 D155AX-6
50 Disassembly and assembly SEN01211-01
Removal and installation of floor 5. Disconnect heater hoses (2) and (3).
frame assembly 1
6. Disconnect air conditioner hoses (4) and (5).
Removal [*3]
D155AX-6 13
SEN01211-01 50 Disassembly and assembly
9. Disconnect and remove hose and flange (8) 14. Remove mounting bolts (17) in front of the floor
from flange (9). frame. [*5]
17. Sling pin (20), tighten the bolt to pull out pin
13. Disconnect wiring harness connectors FSB (21), and lift off pin (20).
(13), PL1 (14), FD1 (15) and FD4 (16). [*4]
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
50 Disassembly and assembly SEN01211-01
19. Lift off operator's cab and floor frame assembly Installation
(22).
a When removing, take care extremely that q Carry out installation in the reverse order to
the floor frame assembly will not interfere removal.
with another part.
[*1], [*3]
4 Floor frame assembly: 1,000 kg 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
SEN01211-01 50 Disassembly and assembly
16 D155AX-6
50 Disassembly and assembly SEN01211-01
Installation
10. Remove cover (9).
q Carry out installation in the reverse order to
removal.
[*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
11. Disconnect wiring harness connectors AC01
part and seat of mounting bolt.
(10) and AC02 (11).
3 Threaded part of hose (M16 x 1.5):
12 15 Nm {1.2 1.5 kgm}
12. Disconnect wiring harness clamp (12) and
3 Threaded part of hose (M22 x 1.5):
move wiring harness (13) aside.
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
SEN01211-01 50 Disassembly and assembly
D155AX-6 Bulldozer
Form No. SEN01211-01
2007 KOMATSU
All Rights Reserved
Printed in Japan 10-07 (02)
18 D155AX-6
SEN02708-01
D155AX-6
D155AX-6 1
SEN02708-01 50 Disassembly and assembly
2 D155AX-6
50 Disassembly and assembly SEN02708-01
1. Remove the left lower cover of the operator's 1. Remove the right lower cover of the operator's
seat. seat.
2. Remove 4 mounting bolts (1) of the power train 2. Disconnect wiring harness connectors WEC
controller assembly. (1), WEC (2) and WEC (3). [*1]
3. Move the controller, disconnect wiring harness 3. Remove 4 mounting bolts (4) and work equip-
connectors STC1 (2), STC2 (3) and STC3 (4), ment controller assembly (5).
and remove power train controller assembly
(5). [*1]
Installation
q Carry out installation in the reverse order to
removal.
a Before installing, remove foreign materials
(dirt, water, etc.) from the wiring harness
connector of the work equipment control-
ler assembly.
[*1]
3 Connector mounting screw:
2.82 Nm {0.288 kgm}
Installation
q Carry out installation in the reverse order to
removal.
a Before installing, remove foreign materials
(dirt, water, etc.) from the wiring harness
connector of the power train controller
assembly.
[*1]
3 Connector mounting screw:
2.82 Nm {0.288 kgm}
D155AX-6 3
SEN02708-01 50 Disassembly and assembly
D155AX-6 Bulldozer
Form No. SEN02708-01
2007 KOMATSU
All Rights Reserved
Printed in Japan 10-07 (02)
4 D155AX-6
SEN00616-02
D155AX-6
D155AX-6 1
SEN00616-02 90 Diagrams and drawings
2 D155AX-6
90 Diagrams and drawings SEN00616-02
Power train hydraulic circuit diagram Power train hydraulic circuit diagram
D155AX-6
D155AX-6 3
11213213123
Hydraulic circuit diagram (1/2) Hydraulic circuit diagram (1/2) 1
D155AX-6
SEN00616-02
D155AX-6 5
Hydraulic circuit diagram (2/2) Hydraulic circuit diagram (2/2) 1
D155AX-6
SEN00616-02
D155AX-6 7
90 Diagrams and drawings SEN00616-02
D155AX-6 9
SEN00616-02 90 Diagrams and drawings
D155AX-6 Bulldozer
Form No. SEN00616-02
2007 KOMATSU
All Rights Reserved
Printed in Japan 03-07 (02)
10 D155AX-6
SEN00617-03
D155AX-6
D155AX-6 1
SEN00617-03 90 Diagrams and drawings
2 D155AX-6
Electrical circuit diagram
Electrical circuit diagram D155AX-6
SEN00617-03
D155AX-6 3
90 Diagrams and drawings SEN00617-03
Electrical circuit diagram for inside cab Electrical circuit diagram for inside cab
D155AX-6
D155AX-6 5
11213213123
Connectors table and arrangement drawing D155AX-6 Connectors table and arrangement drawing
D155AX-6
Connector Type of Number Location Address Connector Type of Number Location Address
No. connector of pin No. connector of pin
250 Terminal 1 Starting switch (Terminal B) R-9 HHP DT 3 Work equipment and HSS pump pressure sensor AI-4
255 Terminal 1 Starting switch (Terminal R1) R-8 HNSW DT 2 Horn switch V-9
256 Terminal 1 Starting switch (Terminal R2) R-8 HRN 1 Horn C-2
260 Terminal 1 Starting switch (Terminal BR) R-8 HSL DT 2 HSS left EPC valve U-9
270 Terminal 1 Starting switch (Terminal ACC) R-9 HSR DT 2 HSS right EPC valve T-8
280 Terminal 1 Starting switch (Terminal C) R-9 HSS DT 6 Intermediate connector U-9, AJ-8
A/C DT 2 Air conditioner compressor AE-1 HT Terminal 2 Heater relay (Terminal C) A-5
A/C1 DT 2 Intermediate conncector F-7, AG-8 HT/A Terminal 1 Heater relay (Terminal A) B-5
AC01 YAZAKI 8 Intermediate conncector K-8, AB-8 HT/B Terminal 1 Heater relay (Terminal B) A-4
AC02 SUMITOMO4 4 Intermediate conncector K-9, AB-7 HTD DT 2 Diode H-1
AC03 Relay 5 Air conditioner blower relay AB-5 J1939 DT 3 Service connector AF-8
AC04 Relay 4 Air conditioner compressor relay AB-4 JM01 6 Junction wiring harness AH-4
AC05 S090 2 Air conditioner gas pressure sensor I-1 JM02 7 Junction wiring harness AH-3
ACCN 040 36 Air conditioner controller L-8 JM03 4 Junction wiring harness AH-3
ACD1 DT 2 Diode AB-2 JM04 3 Junction wiring harness AG-2
ACD2 DT 2 Diode AB-2 JM05 3 Junction wiring harness AH-5
ACS DT 2 Diode AE-2 JM06 3 Junction wiring harness AH-5
ACT Relay 5 Engine ACC signal cut relay D-8 JM07 5 Junction wiring harness AF-8
AF1 DT 2 Air cleaner clogging switch (If equipped) E-7 JM08 7 Junction wiring harness AG-8
AL/B Terminal 1 Alternator terminal B AC-4 KEY DT 6 Starting switch R-6
AL/R Terminal 1 Alternator terminal R AC-5 LHD DT 2 Intermediate connector C-3
ASUS DT 2 Service connector (for air suspension seat) AA-8 LHDL DT 2 Left headlamp C-3
AT11 1 Machine monitor F-8 LHDL1 DT 2 Additional left headlamp [Additional headlamp specification]
AT12 1 GPS antenna I-9 LHDL2 DT 2 Additional left headlamp [Additional headlamp specification]
AT21 1 KOMTRAX communication module H-8 LHDR DT 2 Right headlamp C-4
AT22 1 ORBCOMM antenna I-9 LHDR1 DT 2 Additional right headlamp [Additional headlamp specification]
AUX0 1 K-2 LHDR2 DT 2 Additional right headlamp [Additional headlamp specification]
B30L Terminal 1 Circuit breaker (30A) L-2 LMD1 DT 2 Diode Q-8
B30S Terminal 1 Circuit breaker (30A) L-2 LMD2 DT 2 Diode Q-8
B105HL Terminal 1 Circuit breaker (105A) M-3 LMFL Relay 5 Left headlamp relay C-9
B105HS Terminal 1 Circuit breaker (105A) M-3 LMFR Relay 5 Right headlamp relay C-9
B105L Terminal 1 Circuit breaker (105A) M-3 LMRE Relay 5 Rear lamp relay A-9
B105S Terminal 1 Circuit breaker (105A) M-2 LMRP Relay 5 Ripper lamp relay D-7
BKA Relay 5 Backup alarm relay A-8 LREL DT 2 Left rear lamp M-7
BKAL DT 2 Backup alarm M-5 LRER DT 2 Right rear lamp I-9
BKSW DT 3 Brake pedal switch P-6 LRP1 DT 2 Ripper lamp M-6
BNSL 3 Blade float switch T-7 LRP2 DT 3 Intermediate connector M-4
BNSU 3 Blade pitch switch T-7 NE FRAMATONE 3 Engine Ne speed sensor AH-4
BNSW DT 6 Blade control lever (knob switch) V-9 NSF Relay 5 Neutral safety relay C-9
BP DT 2 Bypass valve solenoid AD-6 OPPW DT 2 Intermediate connector V-1
BRB Terminal 1 Battery relay (Contact input terminal) N-3 PAMB FRAMATONE 4 Ambient pressure sensor AH-3
BRC Terminal 3 Battery relay (Contact output terminal) M-3 PBD DT 2 Diode AB-6
BRE Terminal 1 Battery relay (Coil ground terminal) N-1 PBS DT 2 Pedal brake solenoid AL-7
BRK DT 3 Brake pedal potentiometer P-6 PCV1 SUMITOMO 2 Supply pump #1 AD-2
BVRV DT 2 Transmission bevel speed sensor AN-7 PCV2 SUMITOMO 2 Supply pump #2 AD-2
CA1 DT 3 CAN terminal resistance AH-3 PEVA CANNON 4 EGR inlet pressure sensor AC-6
CB1 1 Circuit breaker (20A) C-6 PFUEL AMP 3 Common rail pressure sensor AF-2
CB2 1 Circuit breaker (20A) C-6 PHR Relay 5 Preheat relay B-9
CB3 1 Circuit breaker (20A) C-6 PIM CANNON 4 Charge pressure sensor AH-6
CB4 1 Circuit breaker (20A) B-6 PKD DT 2 Diode AB-6
CB5 1 Circuit breaker (20A) B-6 PKS DT 2 Parking brake solenoid AL-7
CB6 1 Circuit breaker (20A) B-6 PKSW DT 3 Parking brake lever switch L-8, AB-5
CB7 1 Circuit breaker (20A) B-6 PL1 DRC-70A 70 Intermediate connector AB-4, AN-6
CB8 1 Circuit breaker (20A) A-6 PLSW DT 2 Pin puller switch W-9
CB9 1 Circuit breaker (20A) D-6 POIL CANNON 4 Engine oil pressure sensor AG-2
CB30 2 Circuit breaker (30A) L-2 PPL DT 2 Pin puller solenoid valve M-4
CB105 2 Circuit breaker (105A) M-3 PRE DT 2 Pre-lubrication connector W-1
CB105H 2 Circuit breaker (105A) M-3 PRT DT-A 12 Intermediate connector E-7
CBPW DTP 4 Intermediate connector X-9 PT1 DT 3 Pitch angle sensor D-6
CK01 070 14 Z-9 PUMP DT-A 12 Intermediate connector T-7, AI-8
CK02 070 10 Y-9 QDP DT 2 Blade quick drop solenoid valve C-2
CM01 070 18 Machine monitor R-6 RDG DT-A 12 Intermediate connector C-5
CM02 070 12 Machine monitor R-5 RES DT 2 Service connector AG-7
CM03 070 18 Machine monitor R-5 RHT Terminal 1 Intake air heater (Electrical intake air heater) AC-6
CM04 070 12 Machine monitor RLSW SWP 6 Rear lamp switch P-4
CM05 070 8 Machine monitor RSD DT 2 Diode AA-1
CN1 DT 2 Injecter #1 AC-4 S1T DT 2 Transmission 1st clutch ECMV (Solenoid) AK-9
CN2 DT 2 Injecter #2 AC-5 S2T DT 2 Transmission 2nd clutch ECMV (Solenoid) AK-8
CN3 DT 2 Injecter #3 AD-7 S3T DT 2 Transmission 3rd clutch ECMV (Solenoid) AK-8
CN4 DT 2 Injecter #4 AE-7 SBP DT 4 Bypass valve lift sensor AD-6
CN5 DT 2 Injecter #5 AE-7 SBRL DT 2 Left brake ECMV (Solenoid) AM-7
CN6 DT 2 Injecter #6 AH-7 SBRR DT 2 Right brake ECMV (Solenoid) AM-7
DCL DT 3 Decelerator pedal potentiometer P-6 SEGR DT 4 EGR valve lift sensor AC-3
DIAL M 3 Fuel control dial AB-8 SFT DT 2 Transmission F clutch ECMV (Solenoid) AL-7
DSH DRC-70A 70 Intermediate connector P-2, V-1 SFTD 3 Shift-down switch X-1
E22 DT 6 Intermediate connector AG-2 SFTU 3 Shift-up switch Y-1
EG1 DTP 2 Intermediate connector H-1, AH-5 SLS 050 2 Daylight sensor P-7
EG2 DT-B 12 Intermediate connector H-1, AH-5 SLUC DT 2 Torque converter lockup clutch ECMV (Solenoid) AK-1
EGC1 DRC-60 60 Engine controller AH-4 SRT DT 2 Transmission R clutch ECMV (Solenoid) AK-8
EGC2 DRC-50 50 Engine controller AH-4 SRV DT-A 12 Service connector (for CAN communication) V-1
EGC3 DTP 4 Engine controller AG-3 SSP DT 2 Sudden stop prevent valve AN-2
EGPW DTP 2 Intermediate connector L-3 SSTC DT 2 Torque converter stator clutch ECMV (Solenoid) AK-1
EGR DT 2 EGR valve solenoid AC-5 ST DT 2 Starting motor (Terminal R, S) AC-3
EHL 5 Engine hold relay D-9 ST/B Terminal 1 Starting motor (Terminal B) AD-7
ESD DT 3 Service connector (for engine option) U-2 STC1 DRC26-24 24 Power train controller Z-1
F105 DTHD 1 Intermediate connector K-2 STC2 DRC26-40A 40 Power train controller Z-1
F1T DT 2 Transmission 1st clutch ECMV (Fill switch) AL-9 STC3 DRC26-40B 40 Power train controller AA-1
F2T DT 2 Transmission 2nd clutch ECMV (Fill switch) AK-8 SW Terminal 1 Battery relay (Coil signal terminal) N-1
F3T DT 2 Transmission 3rd clutch ECMV (Fill switch) AK-8 TCT DT 2 Torque converter oil temperature sensor AM-2
F30 DTHD 1 Intermediate connector L-3 TFUEL PACKARD 2 Fuel temperature sensor AH-7
FAC DT 2 Fan pump control valve AI-3 TIM PACKARD 2 Charge temperature sensor AH-6
FAR DT 2 Fan reverse solenoid valve C-1 TIP DT 3 Torque converter inlet pressure sensor AM-2
FBRL DT 2 Left brake ECMV (Fill switch) AL-7 TLV1 DT-B 8 Steering/directional/gearshift lever (Potentiometer) Y-1
FBRR DT 2 Right brake ECMV (Fill switch) AM-7 TLV2 DT 6 Steering/directional/gearshift lever (Shift switch) Y-1
FD1 24-31 31 Intermediate connector K-2, AB-4 TMV 24-23 23 Intermediate connector AN-3
FD2 DT-C 12 Intermediate connector L-3 TOP DT 3 Torque converter outlet pressure sensor AM-2
FD3 DT 6 Intermediate connector M-3 TVC DT 2 Work equipment and HSS pump TVC valve AI-3
FD4 24-31 31 Intermediate connector J-2, AB-3 TWTR PACKARD 2 Engine coolant temperature sensor AF-8
FFT DT 2 Transmission F clutch ECMV (Fill switch) AM-9 WEC1 DRC26-24 24 Work equipment controller T-2
FLSW SWP 6 Headlamp switch P-5 WEC2 DRC26-40A 40 Work equipment controller T-3
FLUC DT 2 Torque converter lockup clutch ECMV (Fill switch) AJ-1 WEC3 DRC26-40B 40 Work equipment controller T-5
FLV DT 2 Fuel level sensor M-4 WELK DT 3 Work equipment lock lever switch W-9
FRT DT 2 Transmission R clutch ECMV (Fill switch) AL-9 WEP1 DT 2 Blade lift raise EPC valve T-9
FS11 5 Fuse box A-8 WEP2 DT 2 Blade lift lower EPC valve T-9
FS12 5 Fuse box A-8 WEP3 DT 2 Blade left tilt head EPC valve T-9
FS21 5 Fuse box A-7 WEP4 DT 2 Blade left tilt bottom EPC valve T-9
FS22 5 Fuse box A-7 WEP5 DT 2 Blade right tilt head EPC valve U-9
FSB 24-21 21 Intermediate connector B-9, AB-4 WEP6 DT 2 Blade right tilt bottom EPC valve T-8
FSTC DT 2 Torque converter stator clutch ECMV (Fill switch) AK-1 WEP7 DT 2 Ripper lift raise EPC valve U-9
FTK DT 12 Intermediate connector M-7 WEP8 DT 2 Ripper lift lower EPC valve T-8
G SUMITOMO 3 Engine Bkup speed sensor AD-2 WEP9 DT 2 Ripper tilt in EPC valve U-9
GND Terminal 1 Ground (ROPS) M-3 WEPA DT 2 Ripper tilt back EPC valve T-8
GND03 Terminal 6 Ground (ROPS) M-5 WEPW DT 2 Service connector (Power supply for driving work equipment in emergency) T-8
GND06 Terminal 4 Ground (Fender) J-1 WESL DRC-40A 40 Intermediate connector T-6
GND07 Terminal 1 Ground (Bulkhead) G-1 WLK DT 2 Work equipment lock solenoid valve AJ-6
GND08 Terminal 4 Ground (Guard) [Additional headlamp specification] WLV DT 2 Radiator coolant level sensor C-2
GND09 Terminal 1 Ground (Engine) AE-2 WLV1 DT-B 8 Blade control lever (Potentiometer) T-6
GND11 Terminal 6 Ground (Floor) AB-6 WLV2 DT-B 8 Ripper control lever V-9
GND12 Terminal 6 Ground (Floor) AB-6 WSH DT 4 Intermediate connector X-9
GND20 Terminal 2 Ground (Engine) AF-2 WSH1 DT 6 Window washer tank (Front, left) J-2
HDT DT 2 Hydraulic oil temperature sensor AI-2 WSH2 DT 6 Window washer tank (Rear, right) I-1
SEN00617-03
D155AX-6 7
90 Diagrams and drawings SEN00617-03
D155AX-6 9
SEN00617-03 90 Diagrams and drawings
D155AX-6 Bulldozer
Form No. SEN00617-03
2007 KOMATSU
All Rights Reserved
Printed in Japan 03-07 (02)
10 D155AX-6