Sen00596-05 D155ax-6

SEN00596-05
BULLDOZER
D155AX -6
SERIAL NUMBERS 80001 and up
SEN00598-05
BULLDOZER 1SHOP MANUAL
D155AX-6
Machine model Serial number

D155AX-6 80001 and up
00 Index and foreword 1

Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 4
D155AX-6 1
SEN00598-05 00 Index and foreword
Composition of shop manual 1

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN00596-05
00 Index and foreword SEN00597-05

Index SEN00598-05 q
Foreword and general information SEN00599-01
01 Specification SEN00600-01
Specification and technical data SEN00601-01
10 Structure, function and maintenance standard SEN00602-01

Engine and cooling system SEN00603-00
Power train, Part 1 SEN00604-01
Undercarriage and frame SEN00606-01
Hydraulic system SEN00607-01
Work equipment SEN00608-01
Cab and its attachments SEN00609-01
Electrical system SEN00610-01
20 Standard value table SEN00611-01

Standard service value table SEN00678-01
30 Testing and adjusting SEN00612-01

Testing and adjusting, Part 1 SEN00679-01
40 Troubleshooting SEN00613-01
General information on troubleshooting SEN00851-00
Troubleshooting by failure and error codes, Part 1 SEN00716-01
2 D155AX-6

Troubleshooting of electrical system (E-mode) SEN00807-01
Troubleshooting of hydraulic and mechanical system (H-mode) SEN00808-00
Troubleshooting of engine (S-mode) SEN00852-01
50 Disassembly and assembly SEN00614-02

General information on disassembly and assembly SEN01204-02 q
Engine and cooling system SEN01205-02 q
Power train, Part 1 SEN01206-01 q
Undercarriage and frame SEN01208-01 q
Hydraulic system SEN01209-01 q
Work equipment SEN01210-01 q
Cab and its attachments SEN01211-01 q
Electrical system SEN02708-01 q
90 Diagrams and drawings SEN00615-03

Hydraulic diagrams and drawings SEN00616-02
Electrical diagrams and drawings SEN00617-03
D155AX-6 3
Table of contents 1
00 Index and foreword
Index SEN00598-05
Composition of shop manual....................................................................................................... 2
Table of contents ......................................................................................................................... 4
Foreword and general information SEN00599-01

Safety notice................................................................................................................................ 2
How to read the shop manual ..................................................................................................... 7
Explanation of terms for maintenance standard.......................................................................... 9
Handling electric equipment and hydraulic component............................................................... 11
How to read electric wire code .................................................................................................... 23
Precautions when carrying out operation .................................................................................... 26
Method of disassembling and connecting push-pull type coupler ............................................... 29
Standard tightening torque table ................................................................................................. 32
Conversion table ......................................................................................................................... 36
01 Specification
Specification and technical data SEN00601-01
Specification dimension drawings ............................................................................................... 2
Specifications .............................................................................................................................. 3
Weight table ................................................................................................................................ 9
Table of fuel, coolant and lubricants ............................................................................................ 12
10 Structure, function and maintenance standard

Engine and cooling system ......................................................................................................... 2
Radiator, oil cooler ................................................................................................................... 2
Engine mount........................................................................................................................... 5
Cooling fan pump..................................................................................................................... 6
Cooling fan motor .................................................................................................................... 14
Power train skeleton.................................................................................................................... 2
Overall drawing of power train unit.............................................................................................. 4
Power train hydraulic piping drawing........................................................................................... 6
Damper, universal joint................................................................................................................ 8
Torque converter, PTO ................................................................................................................ 10
Torque converter control valve .................................................................................................... 19
Lockup clutch ECMV, stator clutch ECMV................................................................................... 20
Transmission control ................................................................................................................... 26
Transmission ............................................................................................................................... 28
Transmission ECMV.................................................................................................................... 44
Main relief valve and torque converter relief valve ...................................................................... 50
Lubrication relief valve................................................................................................................. 52
Scavenging pump........................................................................................................................ 53
Power train and steering lubrication pump .................................................................................. 54
HSS system................................................................................................................................. 2
HSS motor................................................................................................................................... 4
Hydraulic, HSS pump .................................................................................................................. 14
Hydraulic oil cooler bypass valve ................................................................................................ 37
Steering, brake control ................................................................................................................ 38
Steering unit ................................................................................................................................ 40
Brake control valve...................................................................................................................... 62
Brake ECMV................................................................................................................................ 64
4 D155AX-6
Parking brake solenoid valve ...................................................................................................... 69

Sudden stop prevention valve..................................................................................................... 71
Final drive.................................................................................................................................... 73
Sprocket ...................................................................................................................................... 78
Track frame ................................................................................................................................. 2
Recoil spring ............................................................................................................................... 4
Idler ............................................................................................................................................. 6
Track roller .................................................................................................................................. 8
Carrier roller ................................................................................................................................ 10
Track shoe................................................................................................................................... 12
Main frame .................................................................................................................................. 18
Suspension ................................................................................................................................. 20
Work equipment hydraulic piping diagram .................................................................................. 2
Work equipment control piping diagram...................................................................................... 5
Work equipment control .............................................................................................................. 6
Hydraulic tank and filter............................................................................................................... 8
Accumulator ................................................................................................................................ 10
PCCS lever ................................................................................................................................. 11
Work equipment lock valve ......................................................................................................... 15
Control valve ............................................................................................................................... 16
Work equipment cylinder............................................................................................................. 52
Piston valve................................................................................................................................. 54
Quick drop valve ......................................................................................................................... 56
Self pressure reducing valve....................................................................................................... 61
Cylinder stay ............................................................................................................................... 2
Blade ........................................................................................................................................... 4
Cutting edge, end bit ................................................................................................................... 6
Ripper.......................................................................................................................................... 8
Cab mount + ROPS pin............................................................................................................... 2
ROPS cab ................................................................................................................................... 3
Air conditioner ............................................................................................................................. 4
Engine control ............................................................................................................................. 2
Engine control system................................................................................................................. 3
Deceleration potentiometer ......................................................................................................... 4
Monitor system............................................................................................................................ 6
Sensors ....................................................................................................................................... 25
Palm command control system ................................................................................................... 28
KOMTRAX system ...................................................................................................................... 31
20 Standard value table

Standard service value table SEN00678-01
Standard value table for engine .................................................................................................. 2
Standard value table for engine ............................................................................................... 2
Standard value table for machine ............................................................................................ 3
30 Testing and adjusting
Testing and adjusting, Part 1....................................................................................................... 3
Tools for testing, adjusting, and troubleshooting ..................................................................... 3
Measuring engine speed ......................................................................................................... 5
Measuring intake air pressure (boost pressure) ...................................................................... 7
D155AX-6 5
Measuring exhaust temperature .............................................................................................. 8

Measuring exhaust gas color................................................................................................... 10
Adjusting valve clearance ........................................................................................................ 11
Measuring compression pressure............................................................................................ 12
Measuring blow-by pressure.................................................................................................... 14
Measuring engine oil pressure................................................................................................. 15
Handling fuel system parts ...................................................................................................... 16
Releasing residual pressure from fuel system......................................................................... 16
Measuring fuel pressure .......................................................................................................... 17
Measuring fuel return rate and fuel leakage ............................................................................ 18
Bleeding air from fuel circuit .................................................................................................... 22
Measuring fuel circuit for leakage ............................................................................................ 24
Testing and adjusting alternator belt tension ........................................................................... 25
Testing and adjusting air conditioner compressor belt tension ................................................ 26
Measuring fan speed ............................................................................................................... 27
Measuring fan circuit oil pressure ............................................................................................ 28
Bleeding air from fan pump...................................................................................................... 29
Adjusting fuel control dial and decelerator pedal ..................................................................... 30
Testing and adjusting, Part 2 ....................................................................................................... 3
Measuring power train oil pressure.......................................................................................... 3
Adjusting transmission output shaft speed sensor .................................................................. 11
Simple test procedure for brake performance ......................................................................... 12
Adjusting brake pedal .............................................................................................................. 13
Adjusting parking brake lever .................................................................................................. 15
Emergency escape method when power train has trouble...................................................... 17
Adjusting idler clearance.......................................................................................................... 20
Testing and adjusting track shoe tension................................................................................. 21
Measuring and adjusting work equipment and HSS oil pressure ............................................ 22
Measuring control circuit basic pressure ................................................................................. 26
Measuring work equipment lock solenoid valve output pressure ............................................ 27
Emergency operation method when work equipment has trouble........................................... 28
Measuring ripper pin puller solenoid valve output pressure .................................................... 30
Testing parts which cause hydraulic drift of blade and ripper .................................................. 31
Measuring internal leakage of work equipment cylinder.......................................................... 32
Releasing residual pressure from work equipment cylinder .................................................... 33
Bleeding air from work equipment cylinder.............................................................................. 33
Adjusting work equipment lock lever ....................................................................................... 34
Adjusting blade ........................................................................................................................ 35
Adjusting operator's cab .......................................................................................................... 37
Special functions of machine monitor (EMMS) ........................................................................ 2
Handling of power supply circuit of engine controller .............................................................. 2
Preparation work for troubleshooting of electrical system ....................................................... 3
Pm Clinic.................................................................................................................................. 5
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
6 D155AX-6
T-boxes and T-adapters table.................................................................................................. 31

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
Failure code [15SGLH] Speed 3rd clutch: Fill low ................................................................... 26
Failure code [15SJL1] L/U: Fill high......................................................................................... 28
Failure code [15SJLH] L/U: Fill low ......................................................................................... 30
Failure code [2301L1] Right brake: Fill high ............................................................................ 32
Failure code [2301LH] Right brake: Fill low............................................................................. 33
Failure code [2302L1] Left brake: Fill high .............................................................................. 34
Failure code [2302LH] Left brake: Fill low ............................................................................... 35
Failure code [7RFAKA] ECM HOLD RELAY: Disconnection ................................................... 36
Failure code [AA10NX] Air Cleaner Clogging.......................................................................... 38
Failure code [AB00MA] Battery Charge Abnormal .................................................................. 40
Failure code [B@BAZG] Eng Oil PressLow ............................................................................ 42
Failure code [B@BCNS] Eng Water Overheat ........................................................................ 42
Failure code [B@BCZK] Eng Water Level Low ....................................................................... 43
Failure code [B@CENS] T/C Oil Overheat.............................................................................. 43
Failure code [B@HANS] Hyd Oil Overheat ............................................................................. 44
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
Failure code [CA221] Ambient Press Sens High Error............................................................ 28
Failure code [CA222] Ambient Press Sens Low Error............................................................. 30
Failure code [CA227] Sens Supply 2 Volt High Error .............................................................. 32
Failure code [CA234] Eng Overspeed..................................................................................... 34
Failure code [CA238] Ne Speed Sens Supply Volt Error......................................................... 36
Failure code [CA263] Fuel Temp Sensor High Error ............................................................... 38
Failure code [CA265] Fuel Temp Sensor Low Error ................................................................ 39
Failure code [CA271] PCV1 Short Error .................................................................................. 40
Failure code [CA272] PCV1 Open Error.................................................................................. 41
Failure code [CA273] PCV2 Short Error .................................................................................. 42
Failure code [CA274] PCV2 Open Error.................................................................................. 43
D155AX-6 7
Failure code [CA322] Inj #1 (L#1) Open/Short Error ............................................................... 44

Failure code [CA342] Calibration Code Incompatibility ........................................................... 50
Failure code [CA351] Injectors Drive Circuit Error................................................................... 52
Failure code [CA352] Sens Supply 1 Volt Low Error ............................................................... 54
Failure code [CA386] Sens Supply 1 Volt High Error .............................................................. 56
Failure code [CA441] Battery Voltage Low Error ..................................................................... 58
Failure code [CA442] Battery Voltage High Error .................................................................... 58
Failure code [CA449] Rail Press Very High Error .................................................................... 59
Failure code [CA451] Rail Press Sensor High Error................................................................ 60
Failure code [CA452] Rail Press Sensor Low Error................................................................. 62
Failure code [CA553] Rail Press High Error ............................................................................ 62
Failure code [CA554] Rail Press Sensor In Range Error......................................................... 63
Failure code [CA559] Rail Press Low Error ............................................................................. 64
Failure code [CA689] Eng Ne Speed Sensor Error ................................................................. 68
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
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
8 D155AX-6

Failure code [DB90KT] WE controller: Abnormality in controller ............................................. 3
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 [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
Failure code [DD13KB] Shift down Sw: Short circuit ............................................................... 28
Failure code [DD14KA] Parking lever Sw: Disconnection ....................................................... 30
Failure code [DD14KB] Parking lever Sw: Short circuit........................................................... 32
Failure code [DDDDKA] Back up brake Sw: Disconnection .................................................... 34
Failure code [DDDDKB] Back up brake Sw: Short circuit........................................................ 36
Failure code [DDDDKX] Back up brake Sw: Signal mismatch ................................................ 38
Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection.............................................. 40
Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit ................................................. 42
Failure code [DDN9KA] WEQ Knob Sw (up): Disconnection .................................................. 44
Failure code [DDN9KB] WEQ Knob Sw (up): Short circuit...................................................... 46
Failure code [DDNLKA] Weq lock Sw: Disconnection ............................................................. 48
Failure code [DDNLKB] Weq lock Sw: Short circuit................................................................. 50
Failure code [DDTSL1] S/C: Fill high....................................................................................... 52
Failure code [DDTSLH] S/C: Fill low ....................................................................................... 54
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
Failure code [DFA9KB] BT lever 2: Short circuit...................................................................... 22
Failure code [DFAAKX] RL lever 1: Out of normal range ........................................................ 24
Failure code [DFAAKZ] RL lever: Disconnection or short circuit ............................................. 24
Failure code [DFAAL8] RL lever: Signal mismatch.................................................................. 25
Failure code [DFABKA] RL lever 1: Disconnection.................................................................. 26
Failure code [DFABKB] RL lever 1: Short circuit ..................................................................... 28
Failure code [DFACKA] RL lever 2: Disconnection ................................................................. 30
Failure code [DFACKB] RL lever 2: Short circuit ..................................................................... 32
Failure code [DFADKX] RL lever 1: Out of normal range ........................................................ 34
Failure code [DFADKZ] RL lever: Disconnection or short circuit ............................................. 34
Failure code [DFADL8] RL lever: Signal mismatch ................................................................. 35
Failure code [DFAEKA] RL lever 1: Disconnection.................................................................. 36
Failure code [DFAEKB] RL lever 1: Short circuit ..................................................................... 38
Failure code [DFAFKA] RL lever 2: Disconnection.................................................................. 40
D155AX-6 9
Failure code [DFAFKB] RL lever 2: Short circuit...................................................................... 42

Failure code [DGT1KA] T/C oil temp sensor: Abnormal .......................................................... 44
Failure code [DGT1KX] T/C oil temp sensor: Abnormal .......................................................... 46
Failure code [DH21KA] Weq pressure sensor: Disconnection ................................................ 48
Failure code [DH21KB] Weq pressure sensor: Short circuit .................................................... 50
Failure code [DHT5KA] T/C in-pressure sensor: Disconnection.............................................. 52
Failure code [DHT5KB] T/C in-pressure sensor: Short circuit ................................................. 54
Failure code [DHT7KA] T/C out-pressure sensor: Disconnection ........................................... 56
Failure code [DHT7KB] T/C out-pressure sensor: Short circuit ............................................... 58
Failure code [DK10KX] Fuel control Dial: Out of normal range ............................................... 60
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
Failure code [DK56KB] FR lever 1: Short circuit...................................................................... 22
Failure code [DK57KA] FR lever 2: Disconnection .................................................................. 24
Failure code [DK57KB] FR lever 2: Short circuit...................................................................... 26
Failure code [DKH1KA] Pitch angle sensor: Disconnection .................................................... 28
Failure code [DKH1KB] Pitch angle sensor: Short circuit ........................................................ 30
Failure code [DLT3KA] T/M out-speed sensor: Disconnection ................................................ 32
Failure code [DLT3KB] T/M out-speed sensor: Abnormal ....................................................... 33
Failure code [DW7BKA] Fan rev EPC: Disconnection............................................................. 34
Failure code [DW7BKB] Fan rev EPC: Short circuit ................................................................ 35
Failure code [DWN1KA] Hss EPC1: Disconnection ................................................................ 36
Failure code [DWN1KB] Hss EPC1: Short circuit .................................................................... 37
Failure code [DWN1KY] Hss EPC1: Short circuit .................................................................... 38
Failure code [DWN2KA] Hss EPC2: Disconnection ................................................................ 39
Failure code [DWN2KB] Hss EPC2: Short circuit .................................................................... 40
Failure code [DWN2KY] Hss EPC2: Short circuit .................................................................... 41
Failure code [DWN3KA] Ssp solenoid: Disconnection ............................................................ 42
Failure code [DWN3KB] Ssp solenoid: Short circuit ................................................................ 44
Failure code [DWN3KY] Ssp solenoid: Short circuit ................................................................ 46
Failure code [DWN5KA] Fan pump solenoid: Disconnection .................................................. 48
Failure code [DWN5KB] Fan pump solenoid: Short circuit ...................................................... 49
Failure code [DXA0KA] TVC Sol.: Disconnection.................................................................... 50
Failure code [DXA0KB] TVC Sol.: Short circuit ....................................................................... 51
Failure code [DXA0KY] TVC Sol.: Short circuit ...................................................................... 52
Failure code [DXH1KA] Lock-up ECMV: Disconnection .......................................................... 54
Failure code [DXH1KB] Lock-up ECMV: Short circuit.............................................................. 56
Failure code [DXH1KY] Lock-up ECMV: Short circuit.............................................................. 58
Failure code [DXH4KA] 1st clutch ECMV: Disconnection........................................................ 60
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
10 D155AX-6
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
Failure code [DXH8KY] F clutch ECMV: Short circuit.............................................................. 16
Failure code [DXHBKA] Right brake ECMV: Disconnection.................................................... 18
Failure code [DXHBKB] Right brake ECMV: Short circuit ....................................................... 20
Failure code [DXHBKY] Right brake ECMV: Short circuit ....................................................... 22
Failure code [DXHCKA] Left brake ECMV: Disconnection ...................................................... 24
Failure code [DXHCKB] Left brake ECMV: Short circuit.......................................................... 26
Failure code [DXHCKY] Left brake ECMV: Short circuit.......................................................... 28
Failure code [DXHRKA] Blade up EPC: Disconnection........................................................... 30
Failure code [DXHRKB] Blade up EPC: Short circuit .............................................................. 31
Failure code [DXHRKY] Blade up EPC: Short circuit .............................................................. 32
Failure code [DXHSKA] Blade down EPC: Disconnection ...................................................... 33
Failure code [DXHSKB] Blade down EPC: Short circuit.......................................................... 34
Failure code [DXHSKY] Blade down EPC: Short circuit.......................................................... 35
Failure code [DXHTKA] Blade left 1 EPC: Disconnection ....................................................... 36
Failure code [DXHTKB] Blade left 1 EPC: Short circuit ........................................................... 37
Failure code [DXHTKY] Blade left 1 EPC: Short circuit ........................................................... 38
Failure code [DXHUKA] Blade right 1 EPC: Disconnection..................................................... 39
Failure code [DXHUKB] Blade right 1 EPC: Short circuit ........................................................ 40
Failure code [DXHUKY] Blade right 1 EPC: Short circuit ........................................................ 41
Failure code [DXHWKA] Ripper up EPC: Disconnection ........................................................ 42
Failure code [DXHWKB] Ripper up EPC: Short circuit ............................................................ 43
Failure code [DXHWKY] Ripper up EPC: Short circuit ............................................................ 44
Failure code [DXHXKA] Ripper down EPC: Disconnection..................................................... 45
Failure code [DXHXKB] Ripper down EPC: Short circuit ........................................................ 46
Failure code [DXHXKY] Ripper down EPC: Short circuit ........................................................ 47
Failure code [DXHYKA] Ripper Tilt In EPC: Disconnection..................................................... 48
Failure code [DXHYKB] Ripper Tilt In EPC: Short circuit ........................................................ 49
Failure code [DXHYKY] Ripper Tilt In EPC: Short circuit ........................................................ 50
Failure code [DXHZKA] Ripper Tilt Back EPC: Disconnection ................................................ 51
Failure code [DXHZKB] Ripper Tilt Back EPC: Short circuit.................................................... 52
Failure code [DXHZKY] Ripper Tilt Back EPC: Short circuit.................................................... 53
Failure code [DXJ4KA] Weq lock Sol.: Disconnection............................................................. 54
Failure code [DXJ4KB] Weq lock Sol.: Short circuit ................................................................ 55
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 11
Troubleshooting of electrical system (E-mode) SEN00807-01

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
E-12 Machine monitor does not display some items .............................................................. 29
E-13 Function switch does not work ....................................................................................... 29
E-14 Operation mode does not change.................................................................................. 30
E-15 Gearshift mode does not change ................................................................................... 30
E-16 Customize function does not operate normally .............................................................. 31
E-17 Customize memory function does not normally ............................................................. 31
E-18 Float mode does not change.......................................................................................... 32
E-19 Alarm buzzer cannot be stopped ................................................................................... 32
E-20 Air conditioner does not operate normally (including air conditioner fault history) ......... 33
E-21 When starting switch is turned OFF, service meter is not displayed .............................. 46
E-22 Machine monitor cannot be set in service mode............................................................ 46
E-23 Ripper pin puller cylinder does not operate.................................................................... 48
E-24 Backup alarm does not sound or does not stop............................................................. 50
E-25 Headlamp, rear lamp, and ripper point lamp do not light up .......................................... 52
E-26 Windshield wiper and window washer do not operate ................................................... 56
E-27 KOMTRAX system does not operate normally .............................................................. 72
Troubleshooting of hydraulic and mechanical system (H-mode) SEN00808-00
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
H-13 Blade lift speed or power is low ..................................................................................... 15
H-14 Blade tilt speed or power is low ..................................................................................... 16
H-15 Ripper lift speed or power is low .................................................................................... 17
H-16 Ripper tilt speed or power is low .................................................................................... 18
H-17 Hydraulic drift of blade lift is large .................................................................................. 18
H-18 Hydraulic drift of blade tilt is large .................................................................................. 19
H-19 Hydraulic drift of ripper lift is large.................................................................................. 19
H-20 Ripper pin puller cylinder does not operate ................................................................... 20
H-21 Blade does not pitch ..................................................................................................... 20
H-22 Abnormal sound comes out from around work equipment pump .................................. 21
12 D155AX-6
Troubleshooting of engine (S-mode) SEN00852-01

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 down)............................. 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
S-15 Abnormal noise is made ................................................................................................ 27
S-16 Vibration is excessive .................................................................................................... 28
50 Disassembly and assembly

General information on disassembly and assembly SEN01204-02
How to read this manual ............................................................................................................. 2
Coating materials list................................................................................................................... 4
Special tool list ............................................................................................................................ 7
Sketches of special tools............................................................................................................. 14
Removal and installation of fuel supply pump assembly............................................................. 2
Removal and installation of fuel injector assembly ..................................................................... 6
Removal and installation of cylinder head assembly .................................................................. 11
Removal and installation of radiator assembly............................................................................ 22
Removal and installation of aftercooler assembly ....................................................................... 25
Removal and installation of engine assembly ............................................................................. 27
Removal and installation of engine hood assembly .................................................................... 32
Removal and installation of engine front seal ............................................................................. 34
Removal and installation of engine rear seal .............................................................................. 36
Removal and installation of fuel tank assembly .......................................................................... 41
Removal and installation of fan drive assembly .......................................................................... 42
Removal and installation of fan motor assembly......................................................................... 43
Removal and installation of damper assembly............................................................................ 2
Disassembly and assembly of damper assembly ....................................................................... 5
Removal and installation of power train unit assembly ............................................................... 11
Disconnection and connection of power train unit assembly ...................................................... 15
Disassembly and assembly of PTO assembly ............................................................................ 2
Disassembly and assembly of torque converter assembly ......................................................... 9
Disassembly and assembly of transmission assembly ............................................................... 19
Disassembly and assembly of HSS case assembly ................................................................... 36
Removal and installation of HSS motor assembly ...................................................................... 53
Removal and installation of final drive assembly ........................................................................ 2
Disassembly and assembly of final drive assembly .................................................................... 4
Removal and installation of track frame assembly ...................................................................... 3
Removal and installation of idler assembly ................................................................................. 6
D155AX-6 13
Disassembly and assembly of idler assembly............................................................................. 7

Removal and installation of recoil spring assembly..................................................................... 11
Disassembly and assembly of recoil spring assembly ................................................................ 12
Removal and installation of track roller ....................................................................................... 17
Disassembly and assembly of track roller assembly................................................................... 19
Removal and installation of No. 1 bogie assembly...................................................................... 22
Removal and installation of No. 2, No, 3 and No. 4 bogie assemblies........................................ 28
Disassembly and assembly of bogie assembly........................................................................... 34
Removal and installation of carrier roller assembly..................................................................... 37
Disassembly and assembly of carrier roller assembly ................................................................ 38
Removal and installation of pivot shaft assembly........................................................................ 42
Spreading and installation of track shoe assembly ..................................................................... 44
General disassembly and assembly of track shoe ...................................................................... 47
Disassembly and assembly of 1 link in field ................................................................................ 61
Disassembly and assembly of master link .................................................................................. 65
Removal and installation of equalizer bar assembly ................................................................... 68
Disassembly and assembly of equalizer bar assembly............................................................... 70
Removal and in4stallation of segment teeth ............................................................................... 72
Removal and installation of hydraulic tank assembly .................................................................. 2
Removal and installation of hydraulic pump assembly................................................................ 4
Disassembly and assembly of hydraulic cylinder assembly........................................................ 7
Removal and installation of blade assembly ............................................................................... 2
Disassembly and assembly of multi-shank ripper ....................................................................... 4
Removal and installation of operator's cab assembly ................................................................. 2
Removal and installation of operator's cab glass (Stuck glass)................................................... 4
Removal and installation of floor frame assembly....................................................................... 13
Removal and installation of air conditioner unit assembly........................................................... 16
Removal and installation of engine controller assembly ............................................................. 2
Removal and installation of power train controller assembly ...................................................... 3
Removal and installation of work equipment controller assembly ............................................... 3
90 Diagrams and drawings

Hydraulic diagrams and drawings SEN00616-02
Power train hydraulic circuit diagram .......................................................................................... 3
Hydraulic circuit diagram (1/2)..................................................................................................... 5
Hydraulic circuit diagram (2/2)..................................................................................................... 7
Electrical diagrams and drawings SEN00617-03
Electrical circuit diagram ............................................................................................................. 3
Electrical circuit diagram for inside cab ....................................................................................... 5
Connectors table and arrangement drawing ............................................................................... 7
14 D155AX-6
D155AX-6 15
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 80001 and up
00 Index and foreword 1

Foreword and general information
Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling electric equipment and hydraulic component .................................................................................11
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
D155AX-6 1
Safety notice 1 (Rev. 2007/02)

Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before weld in g wo rk , al way s wear wel din g
operating the machine. gloves, apron, shielding goggles, cap and
1) Before carrying out any greasing or other clothes suited for welding work.
repairs, read all the safety plates stuck to 8) Before starting work, warm up your body
the machine. For the locations of the thoroughly to start work under good condi-
safety plates and detailed explanation of tion.
precautions, see the Operation and Main-
tenance Manual. Safety points
2) Decide a place in the repair workshop to
keep tools and removed parts. Always 1 Good arrangement
keep the tools and parts in their correct 2 Correct work clothes
places. Always keep the work area clean 3 Following work standard
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas 4 Making and checking signs
provided for smoking. Never smoke while Prohibition of operation and handling by
5
working. unlicensed workers
3) When carrying out any operation, always 6 Safety check before starting work
wear safety shoes and helmet. Do not
wear loose work clothes, or clothes with Wearing protective goggles
7
(for cleaning or grinding work)
buttons missing.
q Always wear safety glasses when hit- Wearing shielding goggles and protectors
8
ting parts with a hammer. (for welding work)
q Always wear safety glasses when 9 Good physical condition and preparation
grinding parts with a grinder, etc.
Precautions against work which you are
4) When carrying out any operation with 2 or 10
not used to or you are used to too much
more workers, always agree on the oper-
ating procedure before starting. Always
inform your fellow workers before starting 2. Preparations for work
any step of the operation. Before starting 1) Before adding oil or making any repairs,
work, hang UNDER REPAIR warning park the machine on hard and level
signs in the operator's compartment. ground, and apply the parking brake and
5) Only qualified workers must carry out work block the wheels or tracks to prevent the
and operation which require license or machine from moving.
qualification. 2) Before starting work, lower the work
6) Keep all tools in good condition, learn the equipment (blade, ripper, bucket, etc.) to
correct way to use them, and use the the ground. If this is not possible, insert
proper ones of them. Before starting work, the lock pin or use blocks to prevent the
thoroughly check the tools, machine, fork- work equipment from falling. In addition,
lift, service car, etc. be sure to lock all the control levers and
hang warning signs on them.
2 D155AX-6
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.
D155AX-6 3
4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is seen well
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
4 D155AX-6
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
8. Precautions for disconnecting and con-

necting hoses and tubes in air conditioner
circuit
1) Disconnection
k Collect the air conditioner refrigerant
(R134a) from the air conditioner circuit
in advance.
a Ask professional traders for collecting
and filling operation of refrigerant
(R134a).
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas (R134a) gets in
your eyes, you may lose your sight.
Accordingly, when collecting or filling
it, you must be qualified for handling
the refrigerant and put on protective
goggles.
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.
a Example of O-ring (Fitted to every joint of

hoses and tubes)
a For tightening torque, see the precautions for

installation in each section of "Disassembly
and assembly".
6 D155AX-6
How to read the shop manual 1
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.
1. Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword

This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard

This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.
20. Standard value table

This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting

This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
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.
50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
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.
2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
D155AX-6 7
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 )
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.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving stan-

a Caution
dards are necessary when performing work.
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.
2 Coat Places to be coated with adhesives, etc. during 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
Explanation of terms for maintenance standard 1

The maintenance standard values necessary for judgment of products and parts are described by the follow-
ing terms.
1. Standard size and tolerance

q To be accurate, the finishing size of parts
is a little different from one to another.
q To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the standard size and the range of differ-
ence from the standard size is called the
tolerance.
q The tolerance with the symbols of + or is
indicated on the right side of the standard
size.
Example:
Standard size Tolerance
0.022
120
0.126
a The tolerance may be indicated in the text

and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (0.022/0.126)
q Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
0.030 +0.046
60
0.076 +0
D155AX-6 9
2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the standard clear- between them is increased to a certain
ance, which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the clearance limit.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
standard value, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value interference limit.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the diameter of a hole of a part be replaced or repaired.
shown in the given standard size and tol-
erance table is smaller than that of the
mating shaft, the difference between those
diameters is called the interference.
q The range (A B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the standard interference.
q After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4. Repair limit and allowable value

q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the repair
limit.
q If a part is worn to the repair limit must be
replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value below
which the product can be used without
causing a problem is called the allowable
value.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
10 D155AX-6
Handling electric equipment and hydraulic component 1

To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on Handling electric equipment and
Handling hydraulic equipment (particularly gear oil and hydraulic oil).
Points to remember when handling electric

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harness

1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
D155AX-6 11
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.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-cir-
cuited by the water, so if any water gets in,
immediately dry the connector or take
other appropriate action before passing
electricity through it.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
12 D155AX-6
3. Removing, installing, and drying connec-

tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connec-
tors apart.
a Never pull with one hand.
2] When removing from clips

q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.
q When removing a connector from a

clip, pull the connector in a parallel
direction to the clip for removing stop-
pers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.
3] Action to take after removing connec-

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
D155AX-6 13
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
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
D155AX-6 15
4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as fol-
lows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oi l a nd wa ter fr om t he c om -
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
16 D155AX-6
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.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
D155AX-6 17
Points to remember when handling hydraulic equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
1. Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2. Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4. Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
18 D155AX-6
5. Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
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.
D155AX-6 19
Connectors newly used for Tier 3 engines

1. Slide lock type 2. Pull lock type (PACKARD-2)
(FRAMATOME-3, FRAMATOME-2) q 107 170, 12V140 engine
q 107 170, 12V140 engines q Various temperature sensors
q Various pressure sensors and NE Example)
speed sensor Intake air temperature sensor in
Examples) intake manifold: TIM
Intake air pressure in intake manifold: Fuel temperature sensor: TFUEL
PIM (125, 170, 12V140 engines) Oil temperature sensor: TOIL
Oil pressure sensor: POIL Coolant temperature sensor: TWTR,
(125, 170, 12V140 engines) etc.
Oil pressure switch Disconnect the connector by pulling lock
(107, 114 engines) (B) (on the wiring harness side) of connec-
Ne speed sensor of flywheel housing: tor (2) outward.
NE (107 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
Disconnect connector (1) according to the fol-

lowing procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connec-
tor (1) toward you.
a Even if lock (L2) is pressed, connec-
tor (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screw-
driver while press lock (L2), and then
pull out connector (1) toward you.
20 D155AX-6
3. Push lock type

q 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the fol-

lowing procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q 114 engine
q 107, 114 engine

Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)
3) While pressing lock (D), pull out connector

(4) in the direction of the arrow.
q 107 engine
a If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
D155AX-6 21
q 125 170, 12V140 engine 4. Turn-housing type (Round green connector)

4) While pressing lock (E) of the connector, q 140 engine
pullout connector (5) in the direction of the Example)
arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure in common rail: PFUEL etc. 1) Disconnect connector (6) according to the
(AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
2) Connect the connector according to the

following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it clicks.
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22 D155AX-6
How to read electric wire code 1

a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by 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.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indi-
cated.)
1. Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(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
Heat-resis- Conduc- Annealed copper for elec-

General wiring in extremely
tant low-volt- tor tric appliance
AEX 50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
D155AX-6 23
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
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
f of nominal No. denotes flexible.
24 D155AX-6
3. Color codes table
(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.
4. Types of circuits and color codes
(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
Precautions when carrying out operation 1

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work

q If the coolant contains antifreeze, dispose of it correctly.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep in a safe place.
q When raising components, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Sleeve nut (elbow end)
number
02 07376-70210 02789-20210
03 07376-70315 02789-20315
04 07376-70422 02789-20422
05 07376-70522 02789-20522
06 07376-70628 02789-20628
10 07376-71034 07221-21034
12 07376-71234 07221-21234
2) Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
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
26 D155AX-6
2. Precautions when carrying out installation work

q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 3 drops of adhesive.
q When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
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.
3. Precautions when completing the operation

1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, Bleeding air.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see Disassembly and assembly.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
D155AX-6 27
4) Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to Troubleshooting and Disassembly
and assembly.
28 D155AX-6
Method of disassembling and connecting push-pull type coupler 1

k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
D155AX-6 29
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
contacts contact surface (a) of the hexag-
30 D155AX-6
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
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-
D155AX-6 31
Standard tightening torque table 1

1. Table of tightening torques for bolts and nuts
a Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using
torque wrench)
a The following table corresponds to the bolts in Fig. A.
Thread diameter of bolt Width across flats Tightening torque

mm mm Nm kgm
6 10 11.8 14.7 1.2 1.5
8 13 27 34 2.8 3.5
10 17 59 74 6.0 7.5
12 19 98 123 10.0 12.5
14 22 153 190 15.5 19.5
16 24 235 285 23.5 29.5
18 27 320 400 33.0 41.0
20 30 455 565 46.5 58.0
22 32 610 765 62.5 78.0
24 36 785 980 80.0 100.0
27 41 1,150 1,440 118 147
30 46 1,520 1,910 155 195
33 50 1,960 2,450 200 250
36 55 2,450 3,040 250 310
39 60 2,890 3,630 295 370
a The following table corresponds to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 9.8 0.6 1.0
8 13 13.7 23.5 1.4 2.4
10 14 34.3 46.1 3.5 4.7
12 27 74.5 90.2 7.6 9.2
a Fig. A a Fig. B
32 D155AX-6
2. Table of tightening torques for split flange bolts

a Unless there are special instructions, tighten split flange bolts to the torque below.

mm mm Nm kgm
10 14 59 74 6.0 7.5
12 17 98 123 10.0 12.5
16 22 235 285 23.5 29.5
3. Table of tightening torques for O-ring boss piping joints

a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Thread diameter Width across flats Tightening torque Nm {kgm}

Nominal No.
mm mm Range Target
02 14 35 63 { 3.5 6.5} 44 { 4.5}
03,04 20 Varies depending 84 132 { 8.5 13.5} 103 {10.5}
05,06 24 on type of connec- 128 186 {13.0 19.0} 157 {16.0}
10,12 33 tor. 363 480 {37.0 49.0} 422 {43.0}
14 42 746 1,010 {76.0 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal Thread diameter Width across flats Tightening torque Nm {kgm}

No. mm mm Range Target
08 8 14 5.88 8.82 {0.6 0.9} 7.35 {0.75}
10 10 17 9.81 12.74 {1.0 1.3} 11.27 {1.15}
12 12 19 14.7 19.6 {1.5 2.0} 17.64 {1.8}
14 14 22 19.6 24.5 {2.0 2.5} 22.54 {2.3}
16 16 24 24.5 34.3 {2.5 3.5} 29.4 {3.0}
18 18 27 34.3 44.1 {3.5 4.5} 39.2 {4.0}
20 20 30 44.1 53.9 {4.5 5.5} 49.0 {5.0}
24 24 32 58.8 78.4 {6.0 8.0} 68.6 {7.0}
30 30 32 93.1 122.5 { 9.5 12.5} 107.8 {11.0}
33 33 107.8 147.0 {11.0 15.0} 127.4 {13.0}
36 36 36 127.4 176.4 {13.0 18.0} 151.9 {15.5}
42 42 181.3 240.1 {18.5 24.5} 210.7 {21.5}
52 52 274.4 367.5 {28.0 37.5} 323.4 {33.0}
D155AX-6 33
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. -
Thread diame-
No. of across Thread size Number of
Range Target ter (mm) (Ref-
hose flats (mm) threads, type of
erence)
thread
34 54 { 3.5 5.5} 9/16-18UN 14.3
02 19 44 { 4.5}
34 63 { 3.5 6.5} 14
22 54 93 { 5.5 9.5} 74 { 7.5} 11/16-16UN 17.5
03
24 59 98 { 6.0 10.0} 78 { 8.0} 18
04 27 84 132 { 8.5 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 186 {13.0 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 245 {18.0 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 245 {18.0 25.0} 216 {22.0} 33
(12) 46 197 294 {20.0 30.0} 245 {25.0} 36
(14) 55 246 343 {25.0 35.0} 294 {30.0} 42
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.
Thread size Tightening torque

mm Nm kgm
6 82 0.81 0.20
8 10 2 1.02 0.20
10 12 2 1.22 0.20
12 24 4 2.45 0.41
14 36 5 3.67 0.51
34 D155AX-6
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.
Thread size Tightening torque

inch Nm kgm
1/16 31 0.31 0.10
1/8 82 0.81 0.20
1/4 12 2 1.22 0.20
3/8 15 2 1.53 0.20
1/2 24 4 2.45 0.41
3/4 36 5 3.67 0.51
1 60 9 6.12 0.92
D155AX-6 35
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
1. Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a hori-
zontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches (B)

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
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
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
36 D155AX-6
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
Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
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
Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
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
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
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
28.3 19 2.2 8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

27.8 18 0.4 8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
27.2 17 1.4 7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
26.7 16 3.2 7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
26.1 15 5.0 6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
25.6 14 6.8 6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

25.0 13 8.6 5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
24.4 12 10.4 5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
23.9 11 12.2 4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
23.3 10 14.0 3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
22.8 9 15.8 3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

22.2 8 17.6 2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
21.7 7 19.4 2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
21.1 6 21.2 1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
20.6 5 23.0 1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
20.0 4 24.8 0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

19.4 3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
18.9 2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
18.3 1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
40 D155AX-6
D155AX-6 41
D155AX-6 Bulldozer
2007 KOMATSU
All Rights Reserved
42 D155AX-6
SEN00601-01
D155AX-6

D155AX-6 80001 and up
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
Specification dimension drawings
Sigma-tilt dozer + Variable Semi U-tilt dozer + Variable

Item Unit
multiple shank ripper multiple shank ripper
A Overall length mm 8,285 8,336
B Overall height (with ROPS) mm 3,390 3,390
C Overall width mm 4,125 4,125
Sigma-tilt dozer + Variable Semi U-tilt dozer + Variable

Item Unit
giant ripper giant ripper
A Overall length mm 8,285 8,336
B Overall height (with ROPS) mm 3,390 3,390
C Overall width mm 4,125 4,125
2 D155AX-6
Specifications
Machine model D155AX-6
Serial number 80001 and up

Bare tractor 29,800
With Sigma-tilt dozer + variable multi-shank
ripper + ROPS cab + air conditioner + 560mm 39,500
Weight
HD shoe + side cover kg

With semi U-tilt dozer + variable multi-shank
ripper + ROPS cab + air conditioner + 560mm 39,650
HD shoe + side cover
Minimum turning radius (F1, center of machine) mm 2.1
Gradeability deg. 30
Stability (front, rear, left, right) deg. 35
1st 3.8
Transmission speed ranges
Performance
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

ripper + ROPS cab + air conditioner + side kPa 105.84 {1.08}
cover {kg/cm2}
With semi U-dozer + variable multi-shank
ripper + ROPS + cab + air conditioner + 105.84 {1.08}
560mm HD shoe + side cover
Overall height Overall width Overall length
Bare tractor 4,860

With semi U-tilt dozer + tractor 8,316
Dimensions
mm
8,285
ripper
Bare tractor 2,765
With semi U-dozer + tractor mm 4,125
ripper 4,125
To top of exhaust pipe 3,306

To top of cab mm 2,210
(to top of control lever)
With ROPS cab installed 3,390
D155AX-6 3

Track gauge 2,000
Dimensions
Length of track on ground 3,050

Track shoe width (Standard) mm 560
Minimum ground clearance
450
(To bottom surface of undercover)
Name SAA6D140E-5
4-cycle, water-cooled, in-line, vertical type,
Type of engine direct injection, with turbocharger, aftercooler
and (EGR) cooler
No. of cylinders - Bore x Stroke mm 6 140 x 165
Piston displacement l {cc} 15.24 {15,240}
Flywheel horsepower kW {HP}/rpm 239 {320}/1,900
Performance
Engine
Max. torque Nm {kgm}/rpm 1,715 {175}/1,300

Max. speed at no load rpm 2,050
Min. speed at no load rpm 740
Min. fuel consumption ratio g/kWh {g/HPh} 212 {158}
Starting motor 24V, 11kW
Alternator 24V, 75A
Battery 12V, 170Ah x 2
Radiator core type Rectangle wave fin
Torque converter 3-element, 1-stage, 2-phase
Planetary gear, multiple disc clutch,
hydraulically actuated, (electrically type)
Transmission force-feed lubrication gear pump,
forward 3-speed, reverse 3-speed,
electrically actuated type
Variable swash plate type (HPV190)
MPa
Max. delivery pressure: 39.6 {404}
Power train system
Hydraulic, HSS pump {kg/cm2}

l/min
Theoretical delivery: 427/2,249
MPa Fixed swash plate type (KMF140)
HSS motor
{kg/cm2} Max. pressure: 41.2 {420}
Spiral bevel gear, force-feed lubrication
Bevel gear shaft
gear pump
HSS steering system Differential planetary gear, hydraulic motor

drive, electric motorized, hydraulically actuated
HSS
Wet type, multiple clutch disc, spring boosted,

Master brake
hydraulically actuated, pedal operated
Final drive Spur gear 1-stage, planetary gear 1-stage,

splash type lubrication
4 D155AX-6

Suspension Rigid, balancing beam type
Undercarriage
Carrier roller 2 each side

Track roller 7 each side
Assembly type, single grouser,
Track shoe (shoe width: 560 mm)
42 each side, pitch: 228.6 mm
Lubrication pump + power train (tandem) Gear type (SAR(3)100 + (3)40)
Scavenging pump (tandem) Gear type (SAR(4) + 140)
1+3+3 tandem spool type, hydraulically
Variable multi-shark ripper type
assisted type, electrical control
Control valve
For ripper tilt + Ripper tilt

For ripper lift + Ripper lift
For blade lift
For blade tilt + (Blade lift + blade tilt + steering)
For steering
Type Reciprocal, piston type
Dimensions of blade lift
Cylinder bore mm 110

Work equipment hydraulic system
Piston rod outer diameter mm 75
Max. piston stroke mm 1,404
Max. distance between pins mm 2,093
Min. distance between pins mm 687.5

Dimensions of blade tilt Dimensions of blade tilt

Hydraulic cylinder
(For sigma-tilt dozer)
Max. piston stroke mm 205
Min. distance between pins mm 1,190

(For semi U-dozer)
D155AX-6 5

Dimensions of ripper tilt Dimensions of ripper lift (For sigma-tilt dozer tilt and pitch)

Dimensions of blade

Work equipment hydraulic system

Hydraulic cylinder
Hydraulic tank Box type (control valve externally installed)

Fan drive system
MPa Variable swash plate (LPV45)

Cooling fan pump {kg/cm2} Max. delivery pressure: 31.9 {325}
l/min Theoretical delivery pressure: 103/2,296
MPa Fixed swash plate (LMF65)
Cooling fan motor
{kg/cm2} Max. delivery pressure: 31.9 {325}
6 D155AX-6

Hydraulic sigma-tilt dozer
Type Hydraulic semi U-tilt dozer
Hydraulic U-tilt dozer
Blade support method Brace type (right tilt cylinder)
Blade lifting height (from ground level) mm 1,311
Performance
Blade lowering depth (from ground level) mm 627

Max. blade tilt mm 1,000
Sigma tilt dozer
Blade cutting angle variation deg. 5

Blade capacity (SAE) m3 9.4
Dimensions
Blade width mm 4,130

Blade height mm 1,790
Blade cutting angle deg. 46
Work equipment
Performance

Semi U-tilt dozer

Dimensions

Performance

Full U-dozer

Dimensions

D155AX-6 7

Variable multi-shank ripper Full U-dozer + pitch Semi U-tilt dozer + pitch Sigma-tiltd ozer + pitch
Max. tilt mm 1,000

Performance
Max. pitch angle deg. 5
Max. pitch-back angle deg. 5
Max. tilt mm 1.000

Performance
Max. tilt mm 1,080

Performance
Work equipment

Dimensions Performance Dimensions Performance
Max. digging depth mm 903
Max. lifting height mm 950
Ripping angle of point 30 70
Max. beam width mm 2,320
Shank positions 2
Max. digging depth mm 1,255

Variable giant ripper
Max. lifting height mm 950
Ripping angle of point 30 70
Max. beam width mm 1,401
Shank positions No. of holes 3
8 D155AX-6
Weight table
k This weight table is for reference in handling or transporting components.

Engine, damper assembly 1,900
Engine assembly 1,759
Damper assembly 120
Universal joint 18
Engine mount parts (wiring) 3
Radiator assembly
333
(including built-in oil cooler hydraulic cooler and codenser)
Fuel tank assembly (when empty) 383
Fuel tank assembly (when full) 913
Power train unit assembly 2,351
Torque converter, PTO assembly 500
Transmission assembly 625
HSS assembly 932
Brake valve assembly
6
(2-ECMV assembly, secondary brake valve)
Power train filter assembly 16.5
Scavenging pump 20
Power train, lubrication pump 28
Hydraulic HSS pump 106
HSS motor 67
Coolong fan pump 25
Coolong fan motor 25
Final drive assembly 1,395 x 2
Sprocket teeth (12 x 9) x 2
Hull frame assembly 4,426
Track group assembly (each side) 3,822
Track frame 1,340
Idler assembly 326
Recoil spring assembly 508
Bogie, track roller assembly 525 x 3
Track roller assembly (single flange x1) 93 x 4
(double flange x1) 105 x 3
Carrier roller assembly 45 x 2
D155AX-6 9

Track shoe assembly (560 mm, wet type) 2,260 x 2
Pivot shaft assembly (Left)
119
(When dual tilt spcification, Left and right)
Pivot shaft assembly (Right) 136
Equalizer bar 231
Hydraulic tank assembly (including hydraulic filter) 99
Control valve
123
(Blade lift + blade tilt + ripper lift + ripper tilt + steering)
Engine underguard 220
Transmission underguard 280
Operators seat 55
Sigma U-tilt dozer assembly 5,364 (Standard 4,937)
Blade 3,200 (Standard 2,929)
Straight frame 1,687 (Standard 1,531)
Tilt brace 97 x 1
Center brace 250 x 1
Tilt cylinder assembly 130
Sigma dual-tilt dozer assembly 5,400 (Standard 4,973)
Pitch cylinder assembly 130 x 2
Semi U-tilt dozer assembly 5,623 (Standard 4,962)
Tilt brace 97 x 1
Tilt cylinder assembly 130
Blade lift cylinder assembly 165 x 2
Multi-shank ripper assembly 4,330
Bracket, beam, arm 2,300
Shank 266 x 3
Lift cylinder assembly 184 x 1
Tilt cylinder assembly 252 x 1
10 D155AX-6

Giant ripper assembly 3,090
Bracket, beam, arm 1,850
Shank 333 x 1
Lift cylinder assembly 184 x 1
Tilt cylinder assembly 252 x 1
Pin puller cylinder assembly 7
Cab assembly 410
Dashboard 54
Floor frame (including air conditioner unit) 611
Side cover 20
Air conditioner unit assembly 10
D155AX-6 11
Table of fuel, coolant and lubricants

a For details of the notes (Note 1, Note 2 - - -) in the table, see Operation and Maintenance Manual.
12 D155AX-6
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
D155AX-6 Bulldozer
2007 KOMATSU
All Rights Reserved
14 D155AX-6
SEN00603-00
D155AX-6

D155AX-6 80001 and up
10 Structure, function and

maintenance standard 1
Engine and cooling system
Engine and cooling system ............................................................................................................................. 2
Radiator, oil cooler ............................................................................................................................... 2
Engine mount ....................................................................................................................................... 5
Cooling fan pump ................................................................................................................................. 6
Cooling fan motor............................................................................................................................... 14
D155AX-6 1
SEN00603-00 10 Structure, function and maintenance standard

Radiator, oil cooler 1
Radiator
2 D155AX-6
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
Oil cooler
1. Hydraulic cooler A: Power train oil cooler outlet port

2. Power train oil cooler B: Power train oil cooler inlet port
Outline
q The power train oil cooler is built in the lower
tank of the radiator.
Power train Hydraulic

oil cooler cooler
Rectangle
Core type PTO-OL
wave (4.0P)
Inner fin type TF8-C TF6-P
Built in lower
Cooling method Air cooled
tank
Heat dissipation area (m2) 2.47 4.51
4 D155AX-6
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
Cooling fan pump 1

Type: LPV45
P1: Pump discharge port

PAEPC: EPC output pressure pickup plug
PEPC: EPC valve basic pressure input port
PS: Pump suction port
TO: Drain port
1. Servo valve
2. Air bleeder
6 D155AX-6
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
Function q Cylinder block (7) seals the pressurized oil to

q The pump converts the engine rotation trans- valve plate (8) and carries out relative rotation.
mitted to its shaft to oil pressure and delivers q This surface is designed so that the oil pres-
pressurized oil corresponding to the load. sure balance is maintained at a suitable level.
q It is possible to change the delivery by chang- q The oil inside each cylinder chamber of cylin-
ing the swash plate angle. der block (7) is suctioned and discharged
through valve plate (8).
Structure
q Cylinder block (7) is supported to shaft by
spline (11).
q Shaft (1) is supported with front and rear bear-
ings (12).
q The end of piston (6) has a spherical hollow
and is combined with shoe (5).
q Piston (6) and shoe (5) form a spherical bear-
ing.
q Shoe (5) is kept pressed against plane (A) of
rocker cam (4) and slid circularly.
q Rocker cam (4) slides around ball (13).
q Piston (6) carries out relative movement in the
axial direction inside each cylinder chamber of
cylinder block (7).
8 D155AX-6
Operation of pump q With the condition of center line (X) of rocker

q Cylinder block (7) rotates together with shaft cam (4) has swash plate angle (a) to axial
(1), and shoe (5) slides on flat surface (A). direction of cylinder block (7), flat surface (A)
q At this time, rocker cam (4) slants around ball functions as cam against shoe (5).
(13). As a result, angle (a) between center line q In this way, piston (6) slides on the inside of
(X) of rocker cam (4) and the axis of cylinder cylinder block (7), so a difference between vol-
block (7) changes. umes (E) and (F) is created inside cylinder
q Angle (a) is called the swash plate angle. block (7).
q A single piston (6) sucks and discharges the oil
by the amount (F) - (E).
q As cylinder block (7) rotates and the volume of
chamber (E) becomes smaller, the pressurized
oil is discharged.
q On the other hand, the volume of chamber (F)
grows larger and, in this process, the oil is suc-
tioned.
D155AX-6 9
q As center line (X) of rocker cam (4) matches Control of delivery

the axial direction of cylinder block (7) (swash q If the swash plate angle (a) becomes larger,
plate angle (a) = 0), the difference between the difference between volumes (E) and (F)
volumes (E) and (F) inside cylinder block (7) be c o me s la r g er a nd pu m p d el i v er y ( Q )
becomes 0. increases.
q Suction and discharge of pressurized oil is not q Swash plate angle (a) is changed with servo
carried out in this state. Namely pumping piston (10).
action is not performed. (Actually, however, the q Servo piston (10) reciprocates straight accord-
swash plate angle is not set to 0) ing to the signal pressure of the servo valve.
q This straight motion is transmitted to rocker
cam (4).
q Rocker cam (4) supported with ball (13) slides
around ball (13).
q Swash plate angle (a) is in proportion to the

pump delivery.
10 D155AX-6
Servo valve
P: EPC valve basic pressure 1. Plug

PE: Control piston pressure 2. Lever
PH: Pump discharge pressure 3. Retainer
T: Drain port 4. Seat
5. Spool
6. Piston
7. Sleeve
8. Spring
D155AX-6 11
Function q Then, the land of the servo piston pressure

q The servo valve controls the current input to passage is connected to the pump discharge
the EPC valve and the pump delivery (Q) so passage by the notch of spool (5) and the dis-
that they will be related as shown in the dia- charge pressure is led to the servo piston.
gram. q When the rocker cam is pushed up by the
servo piston, a position feedback is applied
and lever (2) moves to compress spring (8).
q When spool (5) is pushed back, the pump dis-
charge circuit and the servo piston circuit are
cut off.
q Pressure in the servo piston chamber drops
and the rocker cam returns in the direction of a
maximum swash plate angle.
q These processes are repeated until the swash
plate is fixed to a position where the EPC out-
put pressure is balanced with spring (8) force.
q The greater the EPC output pressure, the
smaller the swash plate angle. Conversely, the
smaller the EPC output pressure, the greater
q The output pressure of the EPC valve flows in the swash plate angle.
the piston chamber to push piston (6).
q Piston (6) pushes spool (5) until it is balanced
with the spring.
12 D155AX-6
Cooling fan motor 1

Type: LMF110(65)
P: From fan pump Specifications

T: From cooler to tank Type: LMF110(65)
TC: To tank Capacity: 65.1 cc/rev
Rated speed: 1,250 rpm
Rated flow: 81.4 l/mm
Check valve crack pressure: 78.5 kPa {0.8 kg/cm2}
14 D155AX-6
1. Output shaft 7. End cover

2. Case 8. Center spring
3. Thrust plate 9. Check valve
4. Piston assembly 10. Pilot valve
5. Cylinder block 11. Spool for reversible valve
6. Valve plate 12. Safety valve
Unit: mm
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
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
2. Suction valve
Function 2) When the pump is stopped

q If the fan pump stops, the pressurized oil does q If the engine is stopped and the input revolu-
not flow into the motor. Since the motor contin- tion of the fan pump lowers to 0 rpm, the pres-
ues revolution because of the force of inertia, surized oil from the pump is not supplied to
however, the pressure on the outlet side of the port (P) any more. As the pressurized oil is not
motor rises. supplied to the (MA) side of the motor, the
q When the oil stops flowing in from inlet port (P), motor speed lowers gradually to stop.
suction valve (1) sucks in the oil on the outlet q If the motor shaft is revolved by the force of
side and supplies it to port (MA) where there is inertia while the oil flow in the port (P) is reduc-
not sufficient oil to prevent cavitation. ing, the oil in port (T) on the outlet side is sent
by the suction valve (1) to the (MA) side to pre-
Operation vent cavitation.
1) When pump is started

q If the pressurized oil from the pump is supplied
to port (P) and the pressure on (MA) side rises
and starting torque is generated in the motor,
the motor starts revolution.The pressurized oil
on the motor outlet (MB) side of the motor
returns through port (T) to the tank.
D155AX-6 17
3. Operation of reversible valve
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
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
D155AX-6 Bulldozer
2005 KOMATSU
All Rights Reserved
20 D155AX-6
SEN00604-01
D155AX-6

D155AX-6 80001 and up

Power train, Part 1
Power train skeleton ....................................................................................................................................... 2
Overall drawing of power train unit ................................................................................................................. 4
Power train hydraulic piping drawing .............................................................................................................. 6
Damper, universal joint ................................................................................................................................... 8
Torque converter, PTO .................................................................................................................................. 10
Torque converter control valve...................................................................................................................... 19
Lockup clutch ECMV, stator clutch ECMV .................................................................................................... 20
Transmission control ..................................................................................................................................... 26
Transmission................................................................................................................................................. 28
Transmission ECMV ..................................................................................................................................... 44
Main relief valve and torque converter relief valve........................................................................................ 50
Lubrication relief valve .................................................................................................................................. 52
Scavenging pump ......................................................................................................................................... 53
Power train and steering lubrication pump.................................................................................................... 54
D155AX-6 1
Power train skeleton 1
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
1. Engine (SAA6D140E-5) 10. Bevel gear

2. Damper 11. HSS unit
3. Universal joint 12. HSS motor (KMF140)
4. Scavenging pump (SAR(4)140) 13. Brake
5. Hydraulic, HSS pump (HPV190) 14. Final drive
6. PTO 15. Sprocket
7. Power train lubricating pump 16. Track shoe
(SAR(3)100+(3)40) 17. Cooling fan pump (LPV45)
8. Torque converter 18. Cooling fan motor (LMF65)
9. Transmission
D155AX-6 3
Overall drawing of power train unit 1
4 D155AX-6
1. HSS unit Outline

2. Transmission q The power train unit can be broadly divided
3. Power train, lubricating pump into torque converter, PTO (7), transmission
(SAR(3)100+(3)40) (2), and HSS unit (1).
4. Power train oil strainer So, a fter the power train unit h as be en
5. HSS motor (KMF140) removed, it can be disassembled into the
6. Main relief, torque converter relief valve torque converter, PTO (7), transmission (2),
7. Torque converter, PTO and HSS unit (1).
8. Scavenging pump (SAR(4)140) q HSS unit consists of the bevel pinion unit,
9. Cooling fan pump (LPV45) bevel gear shaft, HSS motor, planetary gear
10. Hydraulic, HSS pump (HPV190) and brake.
11. Brake control valve
D155AX-6 5
Power train hydraulic piping drawing 1
6 D155AX-6
1. Hydraulic, HSS pump (HPV190)

2. Centralized pressure detection port
3. Power train, lubrication pump
(SAR(3)100+(3)40)
5. HSS motor (KMF140)
6. Main relief, torque converter relief valve
7. Power train oil filter
8. Scavenging pump (SAR(4)140)
9. Power train oil cooler
(built in radiator lower tank)
A: Left brake oil pressure pickup port (LB)

AA: Right brake oil pressure pickup port (RB)
B: 3rd transmission clutch oil pressure pickup port
(3RD)
C: 2nd transmission clutch oil pressure pickup
port (2ND)
D: 1st transmission clutch oil pressure pickup port
(1ST)
E: Reverse transmission clutch oil pressure pickup
port (R)
F: Forward transmission clutch oil pressure pickup
port (F)
G: Transmission main relief oil pressure pickup
port (TM)
H: Lockup clutch oil pressure pickup port (LC)
J: Stator clutch oil pressure pickup port (SC)
D155AX-6 7
Damper, universal joint 1
8 D155AX-6
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
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
Torque converter, PTO 1

a PTO: Abbreviation for Power Take Off
A: From power train pump D: From transmission case

B: To power train oil cooler E: To transmission case
C: From main relief valve F: From power train oil cooler
10 D155AX-6
D155AX-6 11
1. Work equipment, HSS pump mounting port

2. Cooling fan pump mounting port
3. Scavenging pump mounting port
4. Power train and steering lubrication pump
Mounting port
5. Torque converter case
6. Coupling
7. Input shaft (number of teeth: 58)
8. PTO idler gear (number of teeth: 66)
9. PTO idler gear shaft
10. Lockup clutch housing
11. Turbine
12. Drive case
13. Race
14. Stator
15. Pump
16. Retainer
17. Stator clutch front housing
18. Pump shaft
19. Stator clutch rear housing
20. Stator shaft
21. Stator clutch hub
22. Stator clutch plate
23. Stator clutch disc
24. Stator clutch piston
25. Transmission input shaft
26. Lockup clutch plate
27. Lockup clutch disc
28. Lockup clutch piston
29. Turbine boss
30. PTO Gear A (number of teeth: 49)
31. PTO Gear B (number of teeth: 48)
32. Scavenging pump drive gear
(number of teeth: 56)
33. Torque converter control valve
34. Power train oil strainer
35. Sleeve
12 D155AX-6
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.
Conditions for lockup range and torque con-

verter range
Torque converter output shaft speed
Torque converter
Lockup range
range
Forward
Min. 1,313 rpm Max. 1,262 rpm
1st
Forward
2nd
Forward
Min. 1,366 rpm Max. 1,355rpm
3rd
Reverse
1st
Reverse
2nd
Reverse
3rd
D155AX-6 13
14 D155AX-6
Unit: mm
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
Inner diameter of the seal ring +0.030 Repair by hard

contact surface of the stator 65 +0.025 65.1 chrome plating
shaft or replace
3 Width 3 -0.01 2.7
Wear of the trans- -0.03
mission input shaft Replace
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
Inner diameter of the seal ring +0.040 Repair by hard

5 contact surface of the retainer 150 +0.025 150.5 chrome plating
or replace
6 Backlash between the input 0.198 0.484

shaft and the PTO idler gear
7 Backlash between the PTO 0.198 0.484

idler gear and PTO gear A
8 Backlash between the PTO 0.198 0.484

idler gear and PTO gear B
Backlash between the input
9 shaft and the scavenging pump 0.198 0.484
drive gear
Thickness of the 5.0 0.1 4.5
lockup clutch disc Replace
10 Thickness of the 5.0 0.1 4.5
lockup clutch plate
Overall thickness of 15.0 0.17 13.9
the lockup clutch assembly
Thickness of the stator clutch 5.0 0.1 4.5
disc
11 Thickness of the stator clutch 5.0 0.1 4.5

plate
Overall thickness of the stator 15.0 0.17 13.9
clutch assembly
D155AX-6 15
Unit: mm
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
Fitting tolerance of Outer -0.025 +0.010 -0.025

the scavenging diameter 85 -0.015 -0.025 0.025
15 pump
drive gear Inner 45 +0.018 -0.025 -0.030
bearing diameter +0.002 -0.012 -0.002
Installation Installation Installation
16 Stator clutch Free length length load Free length load
return spring
85.3 N 72.6 N
35 27 {8.7 kg} 32.9 {7.4 kg}
16 D155AX-6
Power transmitting route
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
Oil flow
q The oil flows through the main relief valve and

its pressure is reduced to below the set pres-
sure by the torque converter relief valve. It then
flows in inlet port (A), goes through the oil pas-
sages of torque converter case (1), stator
clutch front housing (2), pump shaft (3) and
retainer (4), and flows into pump (5).
q The oil is given centrifugal force by pump (5)
and flows in turbine (6) to transfer its energy to
turbine (6).
q The oil from turbine (6) is sent to stator (7) and
flows into pump (5) again.A part of the oil, how-
ever, is sent through outlet port (B) to the
power train oil cooler.
18 D155AX-6
Torque converter control valve 1
A: From power train pump

B: Stator clutch oil pressure pickup port (SC)
C: Lockup clutch oil pressure pickup port (LC)
1. Torque converter oil filter

2. Stator clutch ECMV
3. Lockup clutch ECMV
D155AX-6 19
Lockup clutch ECMV, stator clutch 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 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
1. Fill switch connector

2. Proportional solenoid connector
3. Pressure detection valve
4. Fill switch
5. Proportional solenoid
6. Pressure control valve
7. Nameplate (*1)
20 D155AX-6
ECMV for lockup clutch Operation

Outline When traveling in torque converter range
q This valve is used to switch the clutch in order
to regulate the clutch oil pressure to the set
pressure.
Since the modulation waveform is used for the
pressure application characteristics to the
clutch, ECMV is capable of connecting the
lockup clutch smoothly, thereby reducing
shocks resulting from gear shift. Above also
prevents generation of peak torque in the
power train. These arrangements make the
machine comfortable to operator and enhance
durability of the power train.
When changing from torque converter travel to

direct travel
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
When traveling in direct range

(Torque converter travel o direct travel)
During filling Pressure adjustment
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
ECMV for stator clutch

Outline Operation
q This valve acts to set the lockup clutch oil pres- When traveling in direct range
sure to the set pressure, and also to switch the
lockup clutch.
It forms a modulation wave pattern, so the sta-

tor clutch is engaged smoothly to reduce the
shock when shifting gear. In addition, it pre-
vents generation of peak torque in the power
train. As a result, it provides a comfortable ride
for the operator and greatly increases the
durability of the power train.
Direct travel o torque converter travel
q When traveling in direct (lockup) range, current

does not flow to proportional solenoid (1).
Pressure control valve (3) drains the oil from
clutch port (A) through drain port (T), and sta-
tor clutch is released.
detection valve (4).
D155AX-6 23
When traveling in torque converter range

(Direct travel o torque converter travel)
During filling Pressure adjustment
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
D155AX-6 25
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
1. Brake pedal Lever positions

2. Lock lever A: Neutral
3. PCCS lever B: Forward
(Forward-Reverse, Gear shift) C: Reverse
3A. UP switch D: OFF
(Gear is shifted up each time this switch is E: Shift UP
pressed.) F: Shift DOWN
3B. DOWN switch G: Free
(Gear is shifted down each time this switch H: Lock
is pressed.)
4. Transmission neutral lock
5. Transmission control valve
26 D155AX-6
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
Transmission 1
28 D155AX-6
A: 1st clutch pressure pickup port (1ST) K: To torque converter

B: 3rd clutch pressure pickup port (3RD) L: To scavenging pump
C: R clutch oil pressure pickup port (R) M: To torque converter case
D: 2nd clutch pressure pickup port (2ND) N: From torque converter case
E: F clutch oil pressure pickup port (F) P: To R clutch
F: From power train pump R: To 3rd clutch
G: To brake control valve S: To 1st clutch
H: From steering case T: To 2nd clutch
J: From power train oil cooler U: To F clutch
D155AX-6 29
30 D155AX-6
1. Transmission ECMV Outline

2. Main relief valve and torque converter relief q The transmission adopted is a forward 3-gear
valve speed and reverse 3-gear speed transmission
3. Transmission case which consists of the planetary gear mecha-
4. Sleeve nisms and the disc clutches.
5. Transmission input shaft q Out of the 5 sets of planetary gear mecha-
6. Tie bolt nisms and disc clutches, 2 clutches are fixed
7. R ring gear (hub) hydraulically by the operation of ECMV to
8. R planetary pinion (number of teeth: 26) select 1 rotation direction and 1 gear speed.
9. R ring gear (number of internal teeth: 86) q The transmission transfers the power received
10. F planetary pinion (number of teeth: 24) by the transmission input shaft to the output
11. F ring gear (number of internal teeth: 91) shaft while changing the gear speed (forward
12. 3rd planetary pinion (number of teeth: 35) 1st-3rd or reverse 1st-3rd) by any combination
13. 3rd ring gear (number of internal teeth: 89) of the F, R clutches and 3 speed clutches.
14. 2nd planetary pinion (number of teeth: 31)
15. 2nd ring gear (number of internal teeth: 91)
16. 1st ring gear (number of internal teeth: 91) Number of plates and disk used
17. 1st planetary pinion (number of teeth: 27)
Number of
18. Transmission output shaft Clutch No.
plates
Number of discs
(3rd sun gear)(number of teeth: 19)
R clutch 6 6
19. 1st clutch housing
20. 1st clutch piston F clutch 6 7
21. 1st sun gear (number of teeth: 37) 3rd clutch 3 4
22. 1st carrier 2nd clutch 3 4
23. 2nd clutch housing
1st clutch 2 3
24. 2nd clutch piston
25. 2nd sun gear (number of teeth: 29)
26. 2nd carrier
27. 3rd clutch housing Combinations of clutches at respective gear
28. 3rd clutch piston speeds and reduction ratio
29. 3rd carrier Reduction
30. F clutch housing Gear speed Operated clutches
ratio
31. F clutch piston Forward 1st F x 1st 1.705
32. F carrier
Forward 2nd F x 2nd 1.151
33. R clutch housing
34. F sun gear (number of teeth: 44) Forward 3rd F x 3rd 0.540
35. R clutch piston Neutral *
36. Washer spring Reverse 1st R x 1st 1.406
37. Clutch plate
Reverse 2nd R x 2nd 0.949
38. Clutch disc
39. Piston return spring Reverse 3rd R x 3rd 0.445
40. R carrier *: The 1st, 2nd, or 3rd clutch is filled with low-pressure
41. Front housing oil.
42. R sun gear (number of teeth: 34)
D155AX-6 31
32 D155AX-6
Unit: mm
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
Total thickness of F clutch

7 assembly consisting of 7 discs 57.0 0.36 53.3
and 6 plates
Total thickness of the 3rd clutch
and 3 plates
Total thickness of the 2nd clutch
and 3 plates
Total thickness of 1st clutch Replace
and 2 plates
11 Thickness of the clutch disc 5.4 0.1 4.9
12 Thickness of the clutch plate 3.2 0.1 2.9
-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
Wear of front hous- -0.01

Width 4.0 3.60
ing, F clutch housing, -0.04
15
and 3rd carrier
-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
Unit: mm
-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
When clutch is disengaged (released) Oil passage in speed clutch

a The figure shows the case in which 1st gear
speed is selected.
q As the oil from ECMV is stopped, piston (2) is

pushed back rightward by return spring (6).
q The friction force between plates (3) and discs q When the steering/directional/gear shift lever is
(4) is released and ring gear (1) is released. set in the neutral position, the 1st, 2nd, or 3rd
speed is selected.
q The piston chamber of the clutch correspond-
ing to the selected gear speed is filled with oil
by electronically controlling the hydraulic circuit
of each clutch.
q When the steering/directional/gear shift lever is
shifted from the neutral position to thefor-
ward or reverse position, the pump is
required to supply oil of quantity to fill the pis-
ton chamber of the F clutch or R clutch.
q When the gear speed is changed from for-
ward 1st to forward 2nd, the pump is
required to supply oil of only quantity to fit the
plate and disc of the 2nd clutch together since
the F clutch has been filled with the oil.
q The time lag in the gear shifting operation is
reduced by controlling the oil in the clutch cir-
cuit as explained above.
D155AX-6 35
Power transmitting route

Forward 1st speed
36 D155AX-6
F ring gear (4) of F clutch and 1st ring gear (19) of 1st clutch are fixed hydraulically.
The power from torque converter

O
Input shaft (1)
O
F sun gear (2)
O
F planetary pinion (3)
O
F carrier (10)
O
3rd carrier (11)
O
3rd planetary pinion (12)
O
3rd ring gear (13)
O
2nd carrier (14)
O
2nd planetary pinion (15)
O
2nd ring gear (16)
O
1st carrier (17)
O
1st planetary pinion (18)
O
1st sun gear (20) 2nd sun gear (21)
O
Output shaft (22)
D155AX-6 37
Forward 2nd speed
38 D155AX-6
F ring gear (4) of F clutch and 2nd ring gear (16) of 2nd clutch are fixed hydraulically.

O
Input shaft (1)
O
F sun gear (2)
O
O
F carrier (10)
O
3rd carrier (11)
O
O
3rd ring gear (13)
O
2nd carrier (14)
O
O
2nd sun gear (21)
O
Output shaft (22)
D155AX-6 39
Forward 3rd speed
40 D155AX-6
F ring gear (4) of F clutch and 3rd ring gear (13) of 3rd clutch are fixed hydraulically.

O
Input shaft (1)
O
F sun gear (2)
O
O
F carrier (10)
O
3rd carrier (11)
O
O
Output shaft (22)
D155AX-6 41
Reverse 1st speed
42 D155AX-6
R ring gear (7) of R clutch and 1st ring gear (19) of 1st clutch are fixed hydraulically.

O
Input shaft (1)
O
R sun gear (5)
O
R planetary pinion (6)
O
R ring gear (9)
(R carrier (8) is fixed with R ring gear (7) = R
ring gear (9) rotation direction is opposite to
input shaft (1))
O
F carrier (10)
O
3rd carrier (11)
O
O
3rd ring gear (13)
O
2nd carrier (14)
O
O
2nd ring gear (16)
O
1st carrier (17)
O
1st planetary pinion (18)
O
1st sun gear (20) 2nd sun gear (21)
O
Output shaft (22)
D155AX-6 43
Transmission ECMV 1
44 D155AX-6
AF: To F clutch Operation table of ECMV

AR: To R clutch ECMV
A1: To 1st clutch sgear F R 1st 2nd 3rd
A2: To 2nd clutch speed
A3: To 3rd clutch N Q Q Q
P: From power train pump
F1 Q Q
T: Drain
Dr: Drain F2 Q Q
PF: F clutch oil pressure pickup port F3 Q Q
PR: R clutch oil pressure pickup port
R1 Q Q
P1: 1st clutch oil pressure pickup port
P2: 2nd clutch oil pressure pickup port R2 Q Q
P3: 3rd clutch oil pressure pickup port R3 Q Q
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
1. Fill switch
3. Body (upper)
4. Body (lower)
6. Filter
8. Sleeve
46 D155AX-6
Outline of ECMV ECMV and proportional solenoid

q The ECMV consists of 1 pressure control valve q For each ECMV, 1 proportional solenoid is
and 1 fill switch. installed.
q Pressure control valve The proportional solenoid generates thrust
A proportional solenoid in this valve receives a shown below according to the command cur-
current sent from the controller and this valve rent from the controller.
converts it to an oil pressure. The thrust generated by the proportional sole-
q Fill switch noid is applied to the pressure control valve
This switch detects that the clutch is filled with spool to generate oil pressure as shown in the
oil and has the following functions. figure below. Accordingly, the thrust is changed
1. Outputs a signal (a fill signal) to the controller by controlling the command current to operate
to notify that filling is completed when the the pressure control valve to control the flow
clutch is filled with oil. and pressure of the oil.
2. Keeps outputting signals (fill signals) to the
controller to notify whether oil pressure is Current - propulsion force characteristics of
applied or not while oil pressure is applied to proportional solenoid
the clutch.
Propulsion force - Hydraulic pressure charac-

teristics of proportional solenoid
Range A: Before shifting gear (When draining)

Range B: During filling ECMV and fill switch
Range C: Pressure adjustment q For each ECMV, 1 fill switch is installed.
Range D: During filling (During triggering) If the clutch is filled with oil, the fill switch is
Point E: Start of filling turned ON by the pressure of the clutch. The
Point F: Finish of filling oil pressure is built up according to this signal.
a The logic is so made that the controller will not
recognize completion of filling even if the fill
switch is turned ON during triggering (Range
D).
D155AX-6 47
Operation of ECMV Before shifting gear (when draining) (Range A

q ECMV is controlled with the command current in chart)
sent from the controller to the proportional
solenoid and the fill switch output signal.
The relationship between the proportional
solenoid command current of ECMV, clutch
input pressure, and fill switch output signal is
shown below.
q Under the condition where any current is not

sent to the proportional solenoid (1), pressure
control valve (3) drains the oil from clutch port
(A) through drain port (T).
Range A: Before shifting gear (When draining) detection valve (4).
Range B: During filling
Range C: Pressure adjustment
Range D: During filling (During triggering)
Point E: Start of filling
Point F: Finish of filling
a The logic is so made that the controller will not
recognize completion of filling even if the fill
switch is turned ON during triggering (Range
D).
q When gear is shifted with gear shift switch, the
clutch is compressed by piston. If high pres-
sure is suddenly applied, the piston suddenly
engages clutch, causing sudden start of
machine and excessive shock.
ECMV reduces a shock at the start of the
machine by increasing the oil pressure applied
to the piston gradually to set pressure, and
puts clutch smoothly engaged. It aims to
increase durability of power transmitting route
and enhances an operator comfort.
48 D155AX-6
During filling (Range B in chart) Pressure adjustment (Range C in chart)
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
Main relief valve and torque converter relief valve 1
Unit: mm
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
Replace
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
Outline Operation of main relief valve
Torque converter relief valve

q The torque converter relief valve maintains the
oil pressure in the torque converter inlet circuit
always below the set pressure in order to pro-
tect the torque converter from abnormally high
pressure.
Set pressure:
1.06 0.05 MPa {10.8 0.5 kg/cm2}
(Cracking pressure)
Main relief valve

q The main relief valve is keeping each hydraulic
circuit of the transmission and the parking
q The oil from the hydraulic pump flows to cham-
brake at set pressure.
ber (F) through the filter, port (C) of the relief
Set pressure:
valve and orifice (a) of main relief valve (1).
3.18 0.1 MPa {32.4 1.0 kg/cm2}
(Engine at rated speed)
Operation
Operation of torque converter relief valve
q As the oil pressure in the circuit goes beyond

the set pressure, the oil conducted to chamber
(F) pushes piston (2) and the resulting reaction
force pushes spool (1) leftward, opening ports
(C) and (E).
Above operation conducts the oil from port (E)
q The oil from the main relief valve is conducted to the torque converter.
to the torque converter through port (E) and, at
the same time, also conducted to chamber (G)
through orifice (b) of torque converter relief
valve (3).
q As the oil pressure to the torque converter
rises beyond the set pressure, the oil con-
ducted to chamber (G) pushes piston (4) and
the resulting reaction force pushes torque con-
verter relief valve (3) rightward, opening ports
(E) and (A).
As the result, the oil in port (E) is drained
through port (A).
D155AX-6 51
Lubrication relief valve 1
Unit: mm
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}
2. F clutch housing Outline

3. R clutch housing q The oil leaving the torque converter passes
4. Piston through the power train oil cooler built in the
radiator lower tank. It then goes through the
A: From oil cooler lubrication relief valve and lubricates the trans-
B: Drain mission and PTO.
C: Drain q The lubrication relief valve is installed to the
right side face of the F clutch housing. It keeps
the lubricating oil pressure below the set pres-
sure.
Specified value
Normal pressure 0.14 0.05
(MPa{kg/cm2}) {1.4 0.5}
Cracking pressure 0.30 0.03
(MPa{kg/cm2}) {3.0 0.3}
52 D155AX-6
Scavenging pump 1
Type: SAR(4)140
Unit: mm
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

3 Pin driving depth -0.5
21
-0.5
4 Spline shaft rotating torque 9.8 14.7 Nm {1.0 1.5 kgm}
Standard Delivery
Delivery amount Rotation speed Delivery pressure
delivery limit
Oil: SAE10WCD (rpm) MPa{kg/cm2}
(l/min) (l/min)
Oil temperature: 45 55C
2,200 2.94{30} 300 266
Outline
q The scavenging pump is installed to the torque
converter case and is driven with the power
from the engine. It returns the oil collected in
the bottom of the transmission case to the
steering case.
D155AX-6 53
Power train and steering lubrication pump 1

Type: SAR(3)100+(3)40
1. Power train pump Outline

2. Steering lubrication pump q The power train pump and the steering lubrica-
tion pump are installed to the torque converter
case. They are driven by the power from the
engine to supply the oil pressure to the torque
converter, the transmission and the steering
unit.
54 D155AX-6
Unit: mm
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
D155AX-6 Bulldozer
2007 KOMATSU
All Rights Reserved
56 D155AX-6
SEN00605-01
D155AX-6

D155AX-6 80001 and up

Power train, Part 2
HSS system .................................................................................................................................................... 2
HSS motor ...................................................................................................................................................... 4
Hydraulic, HSS pump.................................................................................................................................... 14
Hydraulic oil cooler bypass valve .................................................................................................................. 37
Steering, brake control .................................................................................................................................. 38
Steering unit .................................................................................................................................................. 40
Brake control valve ....................................................................................................................................... 62
Brake ECMV ................................................................................................................................................. 64
Parking brake solenoid valve ........................................................................................................................ 69
Sudden stop prevention valve....................................................................................................................... 71
Final drive ..................................................................................................................................................... 73
Sprocket ........................................................................................................................................................ 78
D155AX-6 1
HSS system 1
2 D155AX-6
1. PCCS lever Outline

2. Power train controller q HSS system is an abbreviation for the Hydro-
3. Control valve static Steering System.
4. Hydraulic, HSS pump q The HSS system consists of a set of control
5. Engine valve, hydraulic, HSS pump, and HSS motor
6. EPC valve as shown in the figure. It turns the machine
7. Hydraulic tank continuously without lowering the travel speed
8. Sprocket by making a difference in speed between both
9. Final drive tracks.
10. HSS motor q The power train controller controls the EPC
11. HSS open circuit valve of the control valve to control the revolv-
12. Servo valve ing direction and revolving speed of the HSS
13. Engine throttle controller motor according to the tilting direction and
angle of the PCCS lever. The HSS motor acts
A: FORWORD REVERSE signal on the planetary gear mechanism of the bevel
B: STEERING signal gear shaft to make a difference in speed
C: Engine control information between both sprockets. As a result, the
D: Work equipment pressure signal machine turns.
E: CAN communication network q The power train controller senses the engine
speed and oil pressure at each part and con-
trols the hydraulic, HSS pump and control
valve to drive the hydraulic, HSS pump so that
the engine will not stall.
q The engine speed signal and other engine
control information items are sent and received
through the CAN communication network
which connects the engine throttle controller
and power train controller.
D155AX-6 3
HSS motor 1
Type: KMF140
PA: From control valve 1. HSS motor

PB: From control valve 2. Check valve
T: To tank 3. Counterbalance valve
4. Relief valve
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
D155AX-6 5
6 D155AX-6
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
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
Operation of piston motor
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
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
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
2) Safety valve
(Both operated safety valve.)
Function q As the pressure goes above the set pressure,

q When the operation of the steering is finished, [Difference in areas of circles (D1) and (D2) x
counterbalance valve closes the circuit at the Pressure] compresses spring (2).
inlet and outlet ports of the motor. q Poppet (1) is moved leftward and the pressur-
q Since the motor is rotated by inertial force, ized oil flows into chamber (MA) of the oppo-
pressure in the motor outlet port side is abnor- site circuit.
mally increased, potentially resulting in dam-
ages on the motor and piping.
q The safety valve releases this abnormal pres-
sure to the inlet port side of the motor in order
to prevent damages to the equipment.
Bidirectional action
(1) When pressure in chamber (MB) has become
high (when rotating clockwise)
q When the operation of the steering is finished,
the check valve of the counterbalance valve
closes the circuit at outlet ports (MB).
q The motor tries to continue rotation resorting to
inertial force, thus pressure on the outlet port
(MB) is increased.
D155AX-6 11
(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
D155AX-6 13
Hydraulic, HSS pump 1

Type: HPV190
14 D155AX-6
Outline
q This pump consists of a variable displacement
swash plate type piston pump, PC valve, and
EPC valve.
IM: PC mode selector current

PA: Pump discharge port
PB: Pump discharge pressure input port
PD1: Case drain port
PD2: Drain plug
PEN: Control pressure pickup port
PEPC: EPC basic pressure port
PEPCC: EPC basic pressure pickup port
PLS: Load pressure input port
PLSC: Load pressure pickup port
PM: PC mode selector pressure pickup port
PS: Pump suction port
1. Front pump
2. LS valve
3. PC valve
4. PC-EPC valve
D155AX-6 15
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
Function q Piston (6) carries out relative movement in the

q The pump converts the engine rotation trans- axial direction inside each cylinder chamber of
mitted to its shaft to oil pressure and delivers cylinder block (7).
pressurized oil corresponding to the load. q Cylinder block (7) seals the pressurized oil to
q It is possible to change the delivery by chang- valve plate (8) and carries out relative rotation.
ing the swash plate angle. q This surface is designed so that the oil pres-
sure balance is maintained at a suitable level.
Structure q The oil inside each cylinder chamber of cylin-
q Cylinder block (7) is supported to shaft (1) by der block (7) is suctioned and discharged
spline (12). through valve plate (8).
q Shaft (1) is supported by each bearing (13).
q The end of piston (6) has a spherical hollow
and is combined with shoe (5).
q Piston (6) and shoe (5) form a spherical bear-
ing.
q Rocker cam (4) has flat surface (A), and shoe
(5) is always pressed against this surface while
sliding in a circular movement.
q Rocker cam (4) conducts high pressure oil to
cylinder surface (B) with cradle (2), which is
secured to the case, and forms a static pres-
sure bearing when it slides.
D155AX-6 17
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)
q With center line (X) of rocker cam (4) at swash

plate angle (a) in relation to the axial direction
of cylinder block (7), flat surface (A) acts as a
cam in relation to shoe (5).
q In this way, piston (6) slides on the inside of
cylinder block (7), so a difference between vol-
umes (E) and (F) is created inside cylinder
block (7).
q A single piston (6) sucks and discharges the oil
by the amount (F) (E).
q As cylinder block (7) rotates and the volume of
chamber (E) becomes smaller, the pressurized
oil is discharged.
q On the other hand, the volume of chamber (F)
grows larger and, in this process, the oil is suc-
tioned.
18 D155AX-6
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
1. LS valve
PA: Pump port 1. Sleeve

PDP: Drain port 2. Piston
PLP: LS control pressure output port 3. Spool
PLS: LS pressure input port 4. Spring
PP: Pump port 5. Seat
PPL: Control pressure input port 6. Sleeve
PSIG: Drain port 7. Plug
8. Locknut
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
LS pressure (PLS), and delivery (Q) is as
shown in the diagram.
20 D155AX-6
Operation
1) When the control valve is situated at neutral
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
2) Action for the direction of maximizing the pump delivery
q When the difference between pump discharge

pressure (PP) and LS pressure (PLS), in other
words, LS differ ential press ure ( P LS)
becomes smaller [for example, when the area
of opening of the control valve becomes larger
and pump discharge pressure (PP) drops],
spool (6) is pushed to the left by the combined
force of LS pressure (PLS) and the force of
spring (4).
q When spool (6) moves, port (D) and port (E)
are interconnected and connected to the PC
valve.
q The PC valve is connected to the drain port, so
the pressure across circuits (D) and (K)
becomes drain pressure (PT). (The operation
of the PC valve is explained later.)
q The pressure at the large piston diameter end
of servo piston (10) becomes drain pressure
(PT), and pump discharge pressure (PP)
always enters the small diameter end port (J),
so servo piston (10) is pushed to the left, and
moves the swash plate in the direction to make
the delivery larger.
22 D155AX-6
3) Action for the direction of minimizing the pump delivery
q When servo piston (10) moves to the right (in

the direction of delivery smaller), LS differential
pressure ( PLS) becomes larger [for example,
when the area of opening of the control valve
becomes smaller and pump discharge pres-
sure (PP) rises], pump discharge pressure
(PP) pushes spool (6) to the right.
q When spool (6) moves, pump discharge pres-
sure (PP) flows from port (C) to port (D), and
from port (K), it enters the large piston diame-
ter end.
q Pump discharge pressure (PP) also enters the
small piston diameter end, but because of the
difference in area between the large and the
small piston diameter ends of servo piston
(10), servo piston (10) is pushed to the right.As
a result, it moves in the direction to make the
swash plate angle smaller.
D155AX-6 23
4) When servo piston is balanced
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
2. PC valve
PA: Pump port 1. Wiring

PA2: Pump pressure pilot port 2. Cover
PDP: Drain port 3. Seat
PM: Mode selector pressure pilot port 4. Retainer
PPL: Control pressure output port (to LS valve) 5. Spool
6. Pin
7. Servo piston assembly
8. Plug
Function
q When the pump discharge pressure (PP) is
high, the PC valve controls the pump so that
no more oil than the constant flow (in 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
Operation
1) When pump controller is normal
(1) When the load on the actuator is small and pump discharge pressure (PP) is low
Action of PC-EPC valve solenoid (1)

q Command current (X) is being sent to PC-EPC
valve solenoid (1) from the pump controller.
q This command current (X) works on PC-EPC
valve and output the signal pressure to
changes the force of pushing piston (2).
q Spool (3) stops at a position where the com-
bined force pushing spool (3) by the spring set
pressure of spring (4) and pump discharge
pressure (PP) is balanced.
q The pressure [port (C) pressure] output from
PC valve is changed depending on the above
position.
26 D155AX-6
D155AX-6 27
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
q Port (C) of the PC valve is connected to port

(E) of the LS valve.
q Pump discharge pressure (PP) is applied to
the small piston diameter end of servo piston
(9), port (A) and port (B).
q When pump discharge pressure (PP) is small,
spool (3) is on the left.
q Ports (C) and (D) are connected, and the pres-
sure entering the LS valve becomes drain
pressure (PT).
q If port (E) and port (G) of the LS valve are con-
nected, the pressure entering the large diame-
ter end of the piston from port (J) becomes
drain pressure (PT), and servo piston (9)
moves to the left side.
q The pump delivery will be set to the increasing
trend.
q Spring (4) extends as servo piston (9) moves
and weakens the spring force.
q As the spring force is weakened, spool (3)
moves to the right, the connecting between
port (C) and port (D) is shut off and the pump
discharge pressure ports (B) and (C) are con-
nected.
q The pressure on port (C) rises and the pres-
sure on the large diameter end of the piston
also rises. Thus, the leftward move of servo
piston (9) is stopped.
q The stop position for servo piston (9) [ = pump
delivery] is decided at the point where the force
of spring (4) and the pushing force of PC-EPC
valve by solenoid and the pushing force cre-
ated by pressure (PP) acting on spool (3) are
in balance.
D155AX-6 29
(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
q The relationship between pump discharge

pressure (PP) and pump delivery (Q) is shown
in the diagram.
q If command current (X) sent to PC-EPC valve

solenoid (1) increases, the relationship
pump delivery (Q) moves parallel in proportion
to the pushing force of PC-EPC valve solenoid.
q Because the pushing force of PC-EPC valve
solenoid (1) is added to the pushing force of
spool (3) to the right by pump discharge pres-
sure (PP), the relationship between pump dis-
charge pressure (PP) and pump delivery (Q)
moves from (A) to (B) in accordance with the
increase of command current (X).
D155AX-6 31
2) As the emergency pump drive switch is turned on due to failure on the pump controller
(1) When the main pump is under light load
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
(2) When the main pump is under heavy load
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
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
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
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
Hydraulic oil cooler bypass valve 1
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
Steering, brake control 1

a Regarding the transmission-related description of the operation of the PCCS lever, see Transmission
control.
a PCCS: Palm Command Control System
38 D155AX-6
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
Steering unit 1
(Bevel gear shaft, HSS and brake)
a HSS: Abbreviation for Hydrostatic Steering System
40 D155AX-6
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
42 D155AX-6
D155AX-6 43
1. Bevel gear speed sensor

2. Drain plug
3. Drain valve
4. HSS motor mounting port
6. Output shaft
7. Case
8. Cylinder
9. Brake spring
10. Brake piston
11. Brake plate
12. Brake disc
13. Brake drum
14. Brake hub
15. Tube
16. Bevel gear shaft
17. Bevel gear (number of teeth: 32)
18. Gear A (number of teeth: 45)
19. Sun gear (number of teeth: 34)
20. Pinion shaft
21. Planetary pinion (number of teeth: 35)
22. Ring gear (number of internal teeth: 104)
23. Hub
24. Carrier
25. Bevel gear shaft bearing B
26. Bevel gear shaft bearing A
27. Shim A (for bevel gear adjustment)
28. Retainer
29. Shim B (for bevel gear adjustment)
30. Nut (for bevel gear shaft)
31. Spacer
32. Nut (for bevel pinion)
33. Cage
34. Shim C (for bevel pinion adjustment)
35. Bevel pinion bearing
36. Bevel pinion (number of teeth: 17)
37. Gear B (number of teeth: 16)
38. Shaft
39. HSS motor
40. Drive gear (number of teeth: 19)
41. Gear D (number of teeth: 28)
42. Gear C (number of teeth: 16)
44 D155AX-6
Outline
Bevel gear shaft Brake

q The engine power is transmitted through the q The brake is connected to the L.H. and R.H.
torque converter to the transmission. Then, the HSS respectively. It controls the power trans-
bevel gear shaft system engages bevel pinion mitted from HSS to final drive to brake the
(36) with bevel gear (17) to turn the engine machine.
power at a right angle into the lateral direction q Brake adopts wet multiple disc clutch type and
and reduce the rotation speed. spring-boosted type, and it is hydraulic actu-
q The bevel gear shaft system adopts the spiral ated type which activates brake control valve
bevel gear at bevel pinion (36) and bevel gear (5) by the operation of brake pedal.
(17), and it adopts the splash lubrication with q It adopts forced lubrication which sends oil
the oil from the steering lubrication pump and from steering lubrication pump and scavenging
the scavenging pump for lubrication. pump to case (7) and brake drum (13) through
q The bevel gear shaft system consists of bevel passage inside steering case, and then to
pinion (36), bearing (35) which supports bevel brake disc (12) and brake plate (11).
pinion, cage (33), bevel gear (17) which q When the engine is stopped, back pressure of
meshes with the bevel pinion, bevel gear shaft brake piston (10) descends even if the brake
(16), bearing (25) and (26) which support bevel pedal is not depressed, which initiates the
shaft gear, and retainer (28). brake to operate. However, parking brake
lever must be in lock position, because the
HSS brake is released as the oil pressure within
q HSS is constructed from transfer area which the circuit rises when the engine is restarted.
transmits rotation of HSS motor (39) to gear A q The brake consists of brake hub (14) attached
(18) by turning it in reverse direction, and the to carrier (24), brake disc (12) meshed with the
planet area which adjusts inputs from ring gear brake hub, brake drum (13), brake plate (11)
(22) and sun gear (19) and then outputs to car- whose outside perimeter meshes with brake
rier (24).It changes the turning of the machine drum (13), brake piston (10) and brake spring
by turning off the rotation of HSS motor (39), or (9) which bring brake disc and brake plate
by making it move in normal rotation or reverse together, and cylinder (8) which supports all of
rotation. them, case (7) and output shaft (6).
q The transfer unit employs a spur gear speed Brake drum (13) and case (7) are fixed to the
reduction mechanism and is lubricated with oil steering case.
splashed by the steering lubrication pump and Also, output shaft (6) meshes to brake hub (14)
scavenging pump. by spline and is held by spacer (31) in the axial
q Planet area adopts forced lubrication with oil direction.
from steering lubrication pump and scavenging
pump for lubrication.
q The transfer unit consists of drive gear (40)
connected to the HSS motor (39) by spline,
gear D (41) meshed with the drive gear, gear C
(42) meshed with gear D, gear B (37) con-
nected to shaft (38), gear A (18) supported by
the bearing on the bevel gear shaft and the
steering case to support these parts.
q The planet area consists of sun gear (19),
planetary pinion (21), pinion shaft (20), ring
gear (22), hub (23) meshed with bevel gear
shaft (16) and ring gear (22), and carrier (24)
attached to brake hub (14).
D155AX-6 45
46 D155AX-6
Unit: mm
Replace
1 Brake disc Thickness 4.5 0.1 4.0
Repair or
Strain 0.05 0.14
replace
Thickness 2.9 0.1 2.6 Replace

2 Brake plate
Repair or
Strain 0.05 0.15
replace
Total assembled thickness of 6
3 41.5 0.33 38.3
plates and 5 discs
Inner diameter of the seal ring +0.035
100 100.5
contact surface of the retainer +0.035
4 0.01
Width 3 2.7
Wear of the bevel 0.03
gear shaft seal ring
Thickness 4 0.12 3.85
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
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}
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
48 D155AX-6
Unit: mm
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
6 2.0 Adjust the shim
cage
D155AX-6 49
Operation of steering unit
When steering is at Neutral (straight travel)
Rotation direction of HSS motor

PCCS lever Neu-
Left turn Right turn
steering operation tral
PCCS lever for- Free, Neu- Neu-
ward and reverse not For- Rev For- Rev
switching opera- speci- tral ward erse tral ward erse
(*) (*)
tion fied
Rotation direction
of HSS motor
viewed from left Stop Left Left Right Right Right Left
side of machine
*: Counter-rotation
50 D155AX-6
When steering operation of PCCS lever is at "neutral", HSS motor (7) is stopped.
The power from transmission

O
Bevel pinion (1)
O
Bevel gear (2)
O
Bevel gear shaft (3)
O
Hub (4)
O
Ring gear (5)
O
Planetary pinion (6)
O
Carrier (15)
O
Brake hub (16)
O
Output shaft (17)
D155AX-6 51
When steering operation is at Left turn (forward travel)
*A: Transmission output

*B: HSS motor output
*C: Combined output
*1. Transmission output speed

*2. HSS motor output speed
*3. Left bevel gear shaft output speed (*1-*2)
*4. Right bevel gear shaft output speed (*1+*2)
52 D155AX-6
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)

O
Carrier (15)
O
Brake hub (16)
O
Output shaft (17)
D155AX-6 53
When steering operation is at Left turn (reverse travel)

*C: Combined output

*3. Left bevel gear shaft output speed (*1-*2)
*4. Right bevel gear shaft output speed (*1+*2)
54 D155AX-6
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.
(Reverse) (Clockwise, viewing from the left
side of the machine body.)
O
O O
O O
O O
Hub (4) Gear B (12)
O O
(Clockwise, viewing from the left (Counteclockwise, viewing from
side of the machine body.) the left side of the machine body.)
O O

O
Carrier (15)
O
Brake hub (16)
O
Output shaft (17)
D155AX-6 55
When steering operation is at Right turn (forward travel)

*C: Combined output

*3. Left bevel gear shaft output speed (*1+*2)
*4. Right bevel gear shaft output speed (*1-*2)
56 D155AX-6
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.
(Forward) (Clockwise, viewing from the left
side of the machine body.)
O
O O
O O
O O
Hub (4) Gear B (12)
O O
(Counterclockwise, viewing from (Counterclockwise, viewing from
the left side of the machine body.) the left side of the machine body.)
O O

O
Carrier (15)
O
Brake hub (16)
O
Output shaft (17)
D155AX-6 57
When steering operation is at Right turn (reverse travel)

*C: Combined output

*3. Left bevel gear shaft output speed (*1+*2)
*4. Right bevel gear shaft output speed (*1-*2)
58 D155AX-6
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.
(Reverse) (Counterclockwise, viewing from
the left side of the machine body.)
O
O O
O O
O O
Hub (4) Gear B (12)
O O
(Counterclockwise, viewing from (Clockwise, viewing from the left
the left side of the machine body.) side of the machine body.)
O O

O
Carrier (15)
O
Brake hub (16)
O
Output shaft (17)
D155AX-6 59
Brake operation
When the brake is released When the brake is applied
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
D155AX-6 61
Brake control valve 1
62 D155AX-6
P: From power train pump Outline

L: From scavenging pump, steering lubrication q The brake control valve consists of 2 ECMVs,
pump parking brake solenoid valve and the sudden
PS: To the pin puller solenoid valve stop prevention valve installed on the valve
LB: To left brake seat, to control the brake.
LL: To left brake lubrication circuit q The brake control valve is located in the circuit
RB: To right brake between the power train pump and the brake
RL: To right brake lubrication circuit piston, and consists of 2 sets of brake ECMV
BSL: To bevel gear shaft and planet area bearing (L.H. and R.H.).
lubrication circuit q The brake control valve sends the oil from the
BPL: To the bevel pinion bearing lubrication circuit power train pump to the brake to control left-
TFL: To HSS transfer area lubrication circuit and-right disc clutches.
DLB: Drain (L.H. brake) q The controller sends signals to each ECMV
DRB: Drain (R.H. brake) according to the right or left stroke of the
DB: Drain (Sudden stop prevention valve) PCCS lever and adjusts the gradual or sharp
DBP: Drain (Sudden stop prevention valve pilot) turns.
DPB: Drain (Parking brake) q If the brake pedal is depressed, the controller
PLB: Left brake oil pressure pickup port sends commands to the brake ECMV accord-
PRB: Right brake oil pressure pickup port ing to the pedal stroke to apply the L.H. and
R.H. brake, thus stopping the machine.
1. L.H. brake ECMV q The controller, connected electrically to the
2. R.H. brake ECMV PCCS lever and the brake pedal operates the
3. Steering oil filter brake by controlling each ECMV and solenoid
4. Valve seat valve.
5. Parking brake solenoid valve q The sudden stop prevention valve is installed
6. Sudden stop prevention valve to prevent the machine from stopping sud-
7. Check valve denly, when an abnormality takes place in the
electric system.
q When the parking brake lever is set in the
lock position, the controller sends signals to
the parking brake solenoid valve to drain the oil
between the L.H. and R.H. brake ECMV and
the brake pistons to operate the brake. Also
the parking brake solenoid valve is connected
electrically to the brake pedal.
D155AX-6 63
Brake ECMV 1
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
the circuit to the piston chamber of brake.
4. Fill switch
7. Nameplate (*1)
64 D155AX-6
Outline of ECMV
q The ECMV consists of 1 pressure control valve
and 1 fill switch.
q Pressure control valve
A proportional solenoid in this valve receives a
current sent from the controller and this valve
converts it to an oil pressure.
q Fill switch
This 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.
ECMV and proportional solenoid

q One proportional solenoid is mounted for
each ECMV.
The propulsion force is generated accord-
ing to the command current from the con-
troller.
The propulsion force generated by the
proportional solenoid is actuated on the
spool of the pressure control valve and
generates the oil pressure. Accordingly, by
controlling the amount of the command
current, the propulsion force changes and
the pressure control valve is actuated,
then the oil flow and oil pressure is con-
trolled.
ECMV and fill switch

q For each ECMV, 1 fill switch is installed.
If the clutch is filled with oil, the fill switch
is turned ON by the pressure of the
clutch. The oil pressure is built up accord-
ing to this signal.
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
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)
q When the PCCS lever is in neutral position

and the brake pedal is released, proportional
solenoid (1) of the brake ECMV is energized
and pushes ball (2) to the left and closes the
sealing part.
q The oil in port (P) of the brake ECMV flows in
chamber (B) and pushes valve (3) to the left to
connect port (P) with port (A) and disconnect
chamber (B) from port (DR).At this time, the oil
flows in the back pressure port of the brake
piston. As the oil pressure rises, the brake pis-
ton is pushed to the left to compress the brake
spring, then the brake is released.
q When the parking brake lever is set in the
free position, the pilot pressure of brake
ECMV port (S) remains, because the parking
brake solenoid valve is de-energized.
66 D155AX-6
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
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)
q When the brake pedal is depressed, propor-

tional solenoids (1) of L.H. and R.H. brake
ECMV are de-energized to open the sealing
part of ball (2).
q The controller outputs the command current to
proportional solenoids (1) according to the
brake pedal stroke.
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.
q When the brake pedal is depressed fully, the
brake pedal switch is turned ON, and the
parking brake solenoid valve is energized to
drain the pilot pressure of the brake ECMV port
(S).This carries out the same function as when
the parking brake lever is set at the lock posi-
tion.
68 D155AX-6
Parking brake solenoid valve 1
P: From brake ECMV

T: Drain
Dr: Drain
1. Parking brake lever solenoid valve

2. Brake pedal solenoid valve
3. Connector for parking brake lever solenoid valve
4. Connector for brake pedal solenoid valve
Solenoid valve
5. Coil (ON-OFF type)
6. Push pin
7. Spring
8. Spool
9. Body
D155AX-6 69
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
Sudden stop prevention valve 1
A: From power train pump

B: From brake ECMV
dr1: Drain
dr2: Drain
1. Sudden stop prevention valve
EPC valve
2. Coil (proportional type)
3. Push pin
4. Valve
5. Ball
6. Spool
7. Body
D155AX-6 71
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
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
74 D155AX-6
1. Floating seal 10. No.1 pinion

2. Sun gear 11. Final drive case
3. Carrier 12. Bearing cage
4. Sprocket boss 13. No.1 gear
5. Sprocket teeth 14. No.1 gear hub
6. Cover 15. Shaft
7. Planetary gear 16. Wear guard
8. Ring gear 17. Pivot shaft
9. Cover
Unit: mm
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
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
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)
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
Path of power transmission
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
D155AX-6 77
Sprocket 1
Unit: mm
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
Sprocket tooth shape of full scale
D155AX-6 79
D155AX-6 Bulldozer
2007 KOMATSU
All Rights Reserved
80 D155AX-6
SEN00606-01
D155AX-6

D155AX-6 80001 and up

Undercarriage and frame
Track frame ..................................................................................................................................................... 2
Recoil spring ................................................................................................................................................... 4
Idler ................................................................................................................................................................. 6
Track roller ...................................................................................................................................................... 8
Carrier roller .................................................................................................................................................. 10
Track shoe .................................................................................................................................................... 12
Main frame .................................................................................................................................................... 18
Suspension ................................................................................................................................................... 20
D155AX-6 1
Track frame 1
1. Equalizer bar Outline

2. Pivot shaft q The track rollers are mounted on an K-shaped
3. Idler bogie. This increases the actual ground con-
4. Track frame tact area between the track shoes and the
5. Carrier roller ground on rough surfaces, and helps increase
the drawbar pull.
6. Sprocket
q The K-shaped bogies are equipped with rubber
7. Sprocket cover guard pads to absorb the shock from the ground sur-
8. Track roller face.
9. Track roller support guard
10. Minor bogie Track roller, bogie
11. Major bogie
Track roller flange type arrangement
12. First bogie
1st 2nd 3rd 4th 5th 6th 7th
S D S D S D S
D: Double
S: Single
2 D155AX-6
Unit: mm
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
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
Unit: mm
Press-fitting force for
1 392 kN {40 ton} Adjust
idler yoke
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
4 Recoil spring length load load
314 kN 288 kN
859 656 804
{32,000 kg} {29,400 kg}
D155AX-6 5
Idler 1
6 D155AX-6
Unit: mm
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
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
Track roller 1
8 D155AX-6
Unit: mm
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
Carrier roller 1
10 D155AX-6
Unit: mm
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
Track shoe 1
Dry type
a P portion shows the link of bushing press fitting end.
12 D155AX-6
Unit: mm
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
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
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
Sealed and lubricated track
a P portion shows the link of bushing press fitting end.
14 D155AX-6
Unit: mm
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
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
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
Single shoe, heavy duty shoe
Unit: mm
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
D155AX-6 17
Main frame 1
18 D155AX-6
1. Main frame
2. Cage
3. Clamp
4. Cover
5. Seal
6. Coupling
7. Cap
8. Plate
Unit: mm
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
Suspension 1
20 D155AX-6
1. Equalizer bar 6. Pivot shaft

2. Pivot shaft assembly 7. Seal cage
3. Cover 8. Seal
4. Thrust plate 10. Side pin
5. Thrust plate 11. Center pin
Unit: mm
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}

Clearance between center size Shaft Hole clearance limit
13 pin and bushing
0.036 +0.279 0.249
95 0.090 +0.213 0.369 1.0
14 Clearance between side pin 70 0.030 +0.046 0.030 1.0

and bushing 0.060 +0.046 0.106
Standard Tolerance Standard Interference
Interference between size Shaft Hole interference limit
15
side pin boss and bushing Replace
130 +0.033 0.028 0.043
+0.015 0.068 0.101 bushing
16 Interference between pivot 179 +0.083 0.053 0.096

shaft and seal stopper ring +0.043 0.093 0.176

Clearance between pivot size Shaft Hole clearance limit
17
shaft and bushing (outer)
148 0.145 +0.099 0.180 1.0
0.208 +0.035 0.307
18 Clearance between pivot 175 0.145 +0.095 0.170 1.0

shaft and bushing (inner) 0.208 +0.025 0.303
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
D155AX-6 Bulldozer
2007 KOMATSU
All Rights Reserved
22 D155AX-6
SEN00607-01
D155AX-6

D155AX-6 80001 and up

Hydraulic system
Work equipment hydraulic piping diagram ...................................................................................................... 2
Work equipment control piping diagram ......................................................................................................... 5
Work equipment control .................................................................................................................................. 6
Hydraulic tank and filter .................................................................................................................................. 8
Accumulator .................................................................................................................................................. 10
PCCS lever ....................................................................................................................................................11
Work equipment lock valve ........................................................................................................................... 15
Control valve ................................................................................................................................................. 16
Work equipment cylinder .............................................................................................................................. 52
Piston valve................................................................................................................................................... 54
Quick drop valve ........................................................................................................................................... 56
Self pressure reducing valve......................................................................................................................... 61
D155AX-6 1
Work equipment hydraulic piping diagram 1

Semi U-dozer
1. Blade tilt cylinder 5. Hydraulic tank

2. R.H. blade lift cylinder 6. Hydraulic, HSS pump
3. Accumulator 7. L.H. blade lift cylinder
4. Control valve 8. Oil cooler
2 D155AX-6
Multi-shank ripper
1. Control valve
2. Divider block
3. Ripper lift cylinder
4. Ripper tilt cylinder
D155AX-6 3
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
Work equipment control piping diagram 1

Blade, ripper control
1. Accumulator 3. Work equipment lock valve

2. Control valve 4. Self pressure reducing valve
D155AX-6 5
Work equipment control 1
6 D155AX-6
1. Work equipment lock lever

2. Blade control lever
3. Ripper control lever
4. Work equipment lock switch
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
Hydraulic tank and filter 1
1. Pressure valve 7. Strainer

2. Drain valve 8. Suction valve
3. Drain plug 9. Spring
4. Cover 10. Hydraulic filter element
5. Cover 11. Oil filler cap
6. Hydraulic tank 12. Sight gauge
8 D155AX-6
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
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
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
(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
Function
1. Operating effort characteristics

(For blade and ripper)
q It has the following characteristic for both
longitudinal and lateral operations.
q Free return (operation effort characteristic
diagram)
2) Operation for left and right steering

q Free return
(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
2. Output voltage characteristics

q The control unit is installed to the left control
stand and the control lever is installed directly
onto it.
q The operating angle (stroke) of the control
levers sensed with potentiometers and signal
voltages are output to the transmission,
steering controller.
q A potentiometer is installed in each of longitudinal
d ir ec t io n an d l at er al d i r ec t i on . E a c h
potentiometer outputs 2 signal voltages which are
opposite to each other as shown in the figure at
right.
14 D155AX-6
Work equipment lock valve 1
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
Control valve 1
Outline
q This manual explains the 5-spool valve (single
tilt specification) and 6-spool valve (dual tilt
specification).
A1: To HSS motor

A2: To blade tilt cylinder head
A3: To blade lift cylinder head
A4: To ripper cylinder head
A5: To ripper tilt cylinder bottom
B1: To HSS motor
B2: To blade tilt cylinder bottom
B3: To blade lift cylinder bottom
B4: To ripper lift cylinder bottom
B5: To ripper tilt cylinder head
IA1: Connector (from controller)
IB1: Connector (from controller)
LS: To pump LS valve
P: Pump port
PC: Pump pressure pickup port plug
PEPC1: EPC valve basic pressure input port
(from self pressure reducing valve)
T: Drain port
TS: To tank
1. EPC valve
16 D155AX-6
Outside view
5-spool valve (single tilt specification)
D155AX-6 17
A1: To HSS motor

A3: To blade lift cylinder head
A5: To ripper cylinder head
A6: To ripper tilt cylinder bottom
B1: To HSS motor
B2: To blade tilt cylinder bottom
B3: To blade lift cylinder bottom
B4: To blade ripper cylinder bottom
B5: To ripper lift cylinder bottom
B6: To ripper tilt cylinder head
LS: To pump LS valve
P: Pump port
PC: Pump pressure pickup port plug
T: Drain port
TS: To tank
1. EPC valve
18 D155AX-6
6-spool valve (dual tilt specification)
D155AX-6 19
Sectional view
(1/8)
5-spool valve
20 D155AX-6
(2/8)
6-spool valve
D155AX-6 21
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
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}
20 108.3 x 29.5 81
21 97.7 x 29.5 81
valve spring {46.2 kg} {37 kg}
22 109.4 x 29.5 81
192 N 154 N
23 Unload valve spring 86.7 x 30 66
{19.6 kg} {15.7 kg}
22 D155AX-6
(3/8)
5-spool valve
1. LS relief valve (for work equipment valve)

2. LS check valve (for work equipment valve)
3. LS check valve (for steering valve)
4. Preset check valve
D155AX-6 23
(4/8)
6-spool valve
1. LS relief valve (for work equipment valve)

2. LS check valve (for work equipment valve)
3. LS check valve (for steering valve)
4. Preset check valve
24 D155AX-6
(5/8)
1. Main relief valve 3. Unload valve

2. LS relief valve (for steering valve) 4. Suction valve
Unit: mm
Free length
x outer Replace spring if
5 Suction valve spring diameter damaged or
6.4 N 5.1 N deformed.
64.9 x 12.5 56
{0.65 kg} {0.52 kg}
D155AX-6 25
(6/8)
a Suction valve spring is the same as section E-E.
1. EPC valve
2. Suction valve
26 D155AX-6
(7/8)
a Section H-H is only for 6-spool valve.
D155AX-6 27
1. EPC valve
2. Suction valve
3. LS bypass valve
Unit: mm
Free length
x outer Replace spring if
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
(8/8)
a Suction valve spring is the same as section HH-HH.
1. EPC valve
2. Suction valve
D155AX-6 29
Operation of control valve

At hold (operation of unload valve)
Function q When the pressurized oil is supplied from the

q When the main spool (1) is at the hold posi- pump, the pressure in chamber (D) rises, and
tion, it drains the excess oil discharged by the main spool (1) is pushed to the right by pres-
pump, and prevents the pressure from being sure which is determined by the cross-sec-
formed in the circuit from rising. tional area of piston (3) receiving the pressure.
q When the received pressure becomes larger
Operation than set load of spring (2), the main spool (1)
q When the main spool (1) is at the hold posi- moves to the right and connects the passage
tion, the pump discharge pressure passes from between chamber (A) and chamber (B), so the
oil from the pump is drained.
chamber A through throttle (4) to chamber
q Main spool (1) is balanced at a position that
(D).Chambers (C') and (C) are connected to
matches the supply of oil from the pump.
the drain circuit.
q Actually, the amount of oil supplied from the
pump is small, so the pressure in the circuit is
almost the same as the set load of spring (2).
30 D155AX-6
Control of oil flow
1. Steering valve
1) At hold
Function q Chamber (G) is drained through chamber (H)

q Use of the CLSS circuit (Closed Center Load to chamber (F).
Sensing System) makes it possible to control q Since the pump discharge pressure is acting
the oil flow by adjusting the area of opening of on the left end of spool (3) of the steering prior-
the spool driven by the EPC valve regardless ity valve, it compresses spring (4) and moves
of the load. to the right to the maximum stroke position.
q In this condition, the area of the opening to
Operation steering spool (1) is at its minimum.
q When the steering spool (1) is at the hold
position, the pump discharge pressure is sent
from chamber (A) through the notch in spool
(3) of the steering priority valve, and passes
through chamber (B) to chamber (C).
D155AX-6 31
2) When steering to the left
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
q If the oil flow is too large, the differential pres-

sure of steering spool (1) becomes larger, so
pressure compensation valve spool (3) moves
in the direction to throttle the oil flow.
q On the other hand, if the oil flow is too small,
pressure compensation valve spool (3) moves
in the direction to increase the oil flow.
q LS valve of the pump is controlled so that the
differential pressure between pump discharged
pressure (P) and LS pressure (LS) (LS differ-
ential pressure: PLS) remains constant, so a
suitable amount of oil flows to ensure that the
loss of pressure at the control valve ( PLS') is
equal to PLS.
q The loss of pressure in the control valve is
determined by the area of the opening of steer-
ing spool (1), so the oil flow matches the open-
ing of steering spool (1).
q The return oil flow from HSS motor (6) passes
through chamber (E) and chamber (F), and is
drained.
D155AX-6 33
2. Work equipment valve

(Blade lift, blade tilt, ripper lift, ripper tilt)
a The diagram shows the blade lift valve and steering valve.
34 D155AX-6
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
3. Meter-out control when blade moves down under its own weight
36 D155AX-6
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
4. Meter-out control when blade moves down under its own weight
(work equipment lever at float)
38 D155AX-6
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
At relief
1. Steering valve
a The diagram shows the condition at relief for steering LS relief valve (5).
40 D155AX-6
P1 = P3 + P4 = Differential pressure between ports (M) and (E)

P2 = Differential pressure between ports (E) and (N)
P3 = Differential pressure between ports (M) and (B)
P4 = Differential pressure between ports (B) and (E)
LS = P1 + P2 = Differential pressure between ports (M) and (N) = 2.0 MPa {20 kg/cm2}
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
2. Blade lift, blade tilt, ripper lift and ripper tilt

a The diagram shows the relief condition of work equipment LS relief valve (5) with the blade tilt at the end
of its stroke.
42 D155AX-6
P1 = P3 + P4 = Differential pressure between ports (M) and (P)

P2 = Differential pressure between ports (P) and (N)
P3 = Differential pressure between ports (M) and (B)
P4 = Differential pressure between ports (B) and (P)
LS = P1 + P2 = Differential pressure between ports (M) and (N) = 2.0 MPa {20 kg/cm2}
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
3. Compound operation of steering and blade tilt

a The diagram shows the relief condition of LS relief valves (4) and (5) at steering stall with the blade tilt at
the end of its stroke.
44 D155AX-6
= 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
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
Function When pump swash plate does not reach maxi-

q The steering valve is equipped with steering mum angle
priority valve spool (3), so if the steering valve q When the maximum oil flow from the pump is
and the downstream work equipment valve are greater than the sum of the flow demanded by
operated at the same time, priority is given to the steering valve and work equipment valve,
the flow of oil to the steering valve, and the rest an amount of oil that matches the opening of
of the oil discharged from the pump goes to the steering spool (1) flows to the steering valve.
work equipment valve. q An amount of oil decided by the pump dis-
charge pressure, the load pressure and the
Operation area of the spool opening, flows to the work
q When steering spool (1) is operated by EPC equipment valve.
valve output pressure (PI) and the oil flows, a
differential pressure is created between cham- When pump swash plate is at maximum angle
bers (C) and (D). q When the maximum flow of oil from the pump
q Steering priority valve spool (3) is controlled by is smaller than the sum of the oil flow
this differential pressure, and at the same time, demanded by the steering valve and work
the pump swash plate angle is controlled at equipment valve.
PLS = 2.0 MPa {20 kg/cm2}, and the flow of
oil to the steering valve is fixed. 1) When steering valve load Z work equipment
q For details, see 1. Steering valve of Control valve load.
of oil flow. q An amount of oil that matches the opening of
q In this condition, if downstream work equip- steering spool (1) flows to the steering valve,
ment blade lift spool (2) is operated, the pump and the remaining oil flows to work equipment
discharge pressure momentarily drops. valve.
q At this point, the differential pressure between
chambers (C) and (D) becomes smaller, and 2) When steering valve load > work equipment
steering priority valve spool (3) is moved to the valve load.
left by the pressure in chamber (E) in the direc- q Pump discharge pressure (P) is determined by
tion to throttle the opening to the work equip- the steering valve load, but in this condition, if
ment valve. the downstream work equipment valve where
q At the same time, PLS becomes smaller, so the load is smaller is operated, the difference
the pump swash plate angle moves in the max- in pressure will cause the oil to try to flow to the
imum direction to supply an oil flow to make up work equipment valve, so the pump discharge
the amount that the pressures drops. pressure will drop.
q Steering priority valve spool (3) increases the
size of the opening to the steering system,
while at the same time reducing the size of the
opening to the work equipment in order to
ensure the flow of oil to the steering system.
q In this condition, the flow of oil is divided in pro-
portion to the difference in pressure between
differential pressure (P) (P1) and differential
pressure (P) (P2).
The bigger (P1) (P2) is, the smaller the flow of oil
to the steering system becomes.
D155AX-6 47
2. Compound operation of blade lift and blade tilt

a The diagram shows the condition when the blade lift and blade tilt are operated at the same time.
48 D155AX-6
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.
When pressure (P2) Z (P3)

q Blade lift valve load pressure (P3) is sent to the
pump LS valve through LS passage (O).
1) When pump swash plate does not reach maxi-

mum angle
q When the maximum flow of oil from the pump
i s g r e a te r th a n t h e t o ta l o f t h e o i l f l o w
demanded by the blade tilt valve and blade lift
valve, an oil flow that matches the opening of
the spool flows to both the blade tilt valve and
blade lift valve.
2) When pump swash plate is at maximum angle

q When the maximum flow of oil from the pump
i s s m a l l e r t ha n t h e t o ta l o f th e o i l fl o w
demanded by the blade tilt valve and blade lift
valve, the flow of oil to the blade tilt valve and
blade lift valve is divided according to differen-
tial pressure (PO) (P2) and differential pres-
sure (PO) (P3).
q In other words, more oil flows to (P2) where
the load is small.
a In cases where the blade is raised above

ground and the blade tilt valve and blade lift
valve for raise are operated at the same time,
the blade tilt valve load pressure is smaller
than the blade lift valve load pressure, so the
flow of oil to the blade tilt valve is given priority.
In addition, the oil flow demanded by the blade
tilt valve is smaller, so the condition is just as if
priority was given to the oil flow for the blade tilt
valve.
When pressure (P2) = (P3)

(P) (P2) C (P) (P3), so an oil flow proportional to
the size of the spool opening is distributed to each
spool.
D155AX-6 49
Unload valve preset system

a The diagram shows the condition with preset check valve (3) open immediately after blade lift valve is
operated.
50 D155AX-6
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
Work equipment cylinder 1

Blade lift cylinder
Blade tilt cylinder
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
Unit: mm
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
Piston valve 1 2. Piston valve OPEN

Just before piston rod (1) reaches the end of
For blade lift cylinder its stroke, the tip of valve (6) contacts the cylin-
Outline der bottom, so valve (6) and piston valve (3)
q The piston valve is installed on the piston in stop at that position and do not move further.
the blade lift cylinder. When the piston reaches Only piston (2) moves further.
its stroke end, the valve releases the oil from When this happens, the oil at the cylinder
the hydraulic pump to reduce the oil pressure head, which was sealed by piston valve (3),
being exerted on the piston. escapes from piston valve seats (4) and (5),
When the blade is tilted, the blade is subject to and the pressure inside the cylinder stops ris-
a tortional force owing to the uneven position ing.
of the pistons in the two cylinders; that is the
piston on one side is still moving while the pis-
ton on the other side has reached its stroke
end.
The piston valves are installed to prevent the
tortional force from occurring. When one of the
pistons reaches its stroke end, its piston valve
opens to relieve the oil pressure.
In addition the piston valve relieves the shock
which occurs when the piston comes into con-
tact with the cylinder head or the bottom and
serves to reduce the subsequent surge pres-
sure in the cylinder by letting the oil escape
from the cylinder before the piston reaches its
stroke end.
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
D155AX-6 55
Quick drop valve 1

(For blade lift cylinder)
56 D155AX-6
IQDV: Electric current to switch QDV

PB1: To left blade lift cylinder bottom
PB2: To right blade lift cylinder bottom
PH1: To left blade lift cylinder head
PH2: To right blade lift cylinder head
PP: EPC valve basic pressure port (from self pressure reducing valve)
TS: Seal drain port
VB: From control valve blade raise
VH: From control valve blade lower
1. Body
2. Main spool
3. Plate
4. Body
5. Selector valve spool
6. EPC valve
Unit: mm
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
Free length
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
1. No circulating condition
q Fine control of lowering blade (Stroke of lever is less than 70%.)
q QDV mode: OFF
Outline q Since the quick drop valve electronically con-

q QDV: Abbreviation of Quick Drop Valve trols the operation of the PCCS lever, the con-
q The quick drop valve is installed between the troller and EPC valve (QDV is built-in), it is
control valve and the blade lift cylinder. possible to select ON-OFF.
q When the blade control lever is set in lower
position, the quick drop valve prevents a vac- Operation
uum on the cylinder bottom side and shortens q Because command current (X) from the con-
time lag in starting digging. troller to the EPC valve is 0A, main spool (2) is
q The blade lowering speed is mostly decided by not switched.
the pump delivery. However, it can be height- q The circuits between port (VH) and port (PH) /
ened by installing the quick drop valve. port (VB) and port (PB), are shut off.
q The pressure oil of the lift cylinder head flows
from port (VH) to tank (T) through the control
valve.
58 D155AX-6
2. Circulating condition
q Lowering blade (Stroke of lever is more than 70%.)
q QDV mode: ON
Operation q The pressurized oil which has been flowing to

q 1,000 mA of command current (X) flows from port (PB) merges with the pressure oil from
controller to EPC valve and the pilot pressure port (VB) and flows into the lift cylinder bottom.
from the EPC valve is taken to chamber (a) at q The blade lowering speed is increased by the
the main spool. quantity of oil flowing into the lift cylinder bot-
q Main spool (1) moves to the right and the cir- tom.
cuits between port (VH) and port (PH)/port q Vacuum on the lift cylinder bottom is pre-
(VB) and port (PB), get into circulating condi- vented.
tion.
q Most of the pressurized oil which has been
flowing from port (PH) to port (VH), circulates
and flows to port (PB).
D155AX-6 59
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
Operation q The lift cylinder bottom is connected to the cir-

q Under the circulating condition of blade lower- cuit between port (PB) and port (VB), this
ing, if the blade gets tensed, the lift cylinder enables the blade to be tensed under no circu-
bottom pressure rises. lating condition.
q If the lift cylinder bottom pressure becomes
3.43 MPa {35kg/cm2} or more, selector valve
spool (2) moves to the left.
q The pilot pressure from the EPC valve is
blocked and pressure chamber (a) of main
spool (1) is connected to drain circuit (TS).
q Main spool (1) moves to the right by the force
of spring (3).
60 D155AX-6
Self pressure reducing valve 1
T: To tank
P1: From pump
P2: To fan motor
PR: Supply to PPC valve and EPC valve
D155AX-6 61
1. Valve (sequence valve) 6. Spring (pressure reducing valve main)

2. Spring 7. Valve (pressure reducing valve)
3. Screw 8. Spring (safety valve)
4. Poppet 9. Ball
5. Spring (pressure reducing valve pilot) 10. Filter
62 D155AX-6
Unit: mm
Free length
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
Operation
At engine stop (total low pressure)
q Spring (6) pushes the poppet (5) to the seat,

and the circuit between ports (PR) and (T) is
closed.
q Spring (7) pushes valve (8) to the left side, and
the circuit between port (P1) and port (PR) is
open.
q Spring (3) pushes the valve (2) to the upper
side, and the circuit between ports (P1) and
(P2) is closed.
64 D155AX-6
When load pressure (P2) is lower than output pressure (PR) of the self pressure reducing valve.
q The spring (3) and the pressure (PR) [0 MPa

{0kg/cm2} at the time of engine stop] pushes
valve (2) in the direction to close the circuit
between ports (P1) and (P2). When the
hydraulic oil enters (P1) port, the expression
[pressure (P1) C Spring (3) force + (area d x
(PR) pressure)] holds, and the self pressure
reducing valve will adjust the openings of ports
(P1) and (P2) so that pressure (P1) can be
maintained higher than pressure (PR).
q When (PR) pressure rises above set pressure,
poppet (5) opens and hydraulic oil flows
through the route, from (PR) port, through hole
(a) in spool (8), through poppet (5) opening to
the tank port (T).
q Therefore, differential pressure occurs around
hole (a) in spool (8) and spool (8) moves from
port (P1) in the direction to close (PR) opening.
Then (P1) pressure is reduced and adjusted to
a certain pressure [set pressure] with the
opening and is supplied as (PR) pressure.
D155AX-6 65
At raise of load pressure (P2)
q When load pressure (P2) rises due to digging

or other operations, pump delivery increases
and (P1) pressure rises. Then the expression
{(P1) pressure > Spring (3) force + [area d x
(PR) pressure]} will hold, and valve (2) will
move to the below side till the stroke end. As a
result, the opening between ports (P1) and
(P 2) inc reases and pass age resi stance
becomes smaller, reducing engine horsepower
loss.
q When (PR) pressure rises above set pressure,
poppet (5) opens and hydraulic oil flows
through the route, from (PR) port, through hole
(a) in spool (8), through poppet (5) opening to
the tank port (T).
q Therefore, differential pressure occurs around
hole (a) in spool (8) and spool (8) moves from
port (P1) in the direction to close (PR) opening.
Then (P1) pressure is reduced and adjusted to
a certain pressure [set pressure] with the
opening and is supplied as (PR) pressure.
66 D155AX-6
In the case of abnormal high pressure
q When (PR) pressure of the self pressure

reducing valve rises abnormally high, ball (10)
will separate from the seat against spring (9)
force to flow the hydraulic oil to output ports
(PR) o (T) so as to reduce (PR) pressure. As a
result, the equipment [PPC valve, EPC valve,
etc.], to which the oil pressure is supplied, is
protected from the abnormal high pressure.
D155AX-6 67
D155AX-6 Bulldozer
2007 KOMATSU
All Rights Reserved
68 D155AX-6
SEN00608-01
D155AX-6

D155AX-6 80001 and up

Work equipment
Cylinder stay ................................................................................................................................................... 2
Blade............................................................................................................................................................... 4
Cutting edge, end bit....................................................................................................................................... 6
Ripper ............................................................................................................................................................. 8
D155AX-6 1
Cylinder stay 1
1. Yoke
2. Dust seal
3. Bushing
4. Bushing
5. Grease nipple
2 D155AX-6
Unit: mm
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
Blade 1
Sigma-tilt dozer
4 D155AX-6
Unit: mm
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
Replace
Clearance between trunnion 0.5 +0.5
12 195 0.5 1.5 8
D155AX-6 5
Cutting edge, end bit 1
Unit: mm
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
D155AX-6 7
Ripper 1
Variable multi-shank ripper
8 D155AX-6
Unit: mm
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
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
15 Wear of point
335 225
16 Wear of protector 115 90
D155AX-6 9
Variable giant ripper
10 D155AX-6
Unit: mm
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
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
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
15 Wear of point
335 225
16 Wear of protector 115 90
D155AX-6 11
D155AX-6 Bulldozer
2007 KOMATSU
All Rights Reserved
12 D155AX-6
SEN00609-01
D155AX-6

D155AX-6 80001 and up

Cab and its attachments
Cab mount + ROPS pin .................................................................................................................................. 2
ROPS cab ....................................................................................................................................................... 3
Air conditioner ................................................................................................................................................. 4
D155AX-6 1
Cab mount + ROPS pin 1
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
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
Air conditioner 1
Air conditioner piping
1. Condenser 10. Air outlet for foot

2. Hot water return piping 11. Receiver tank
3. Hot water pick-up piping 12. Refrigerant piping
4. Front window defroster 13. Valve (hot water outlet)
5. Side window defroster 14. Air conditioner compressor
6. Air outlet for face 15. Valve (hot water inlet)
7. Air outlet for center
8. Air outlet for rear A: Fresh air
9. Air conditioner unit B: Recirculated air
4 D155AX-6
D155AX-6 5
D155AX-6 Bulldozer
2007 KOMATSU
All Rights Reserved
6 D155AX-6
SEN00610-01
D155AX-6

D155AX-6 80001 and up

Electrical system
Engine control ................................................................................................................................................. 2
Engine control system..................................................................................................................................... 3
Deceleration potentiometer............................................................................................................................. 4
Monitor system................................................................................................................................................ 6
Sensors......................................................................................................................................................... 25
Palm command control system..................................................................................................................... 28
KOMTRAX system........................................................................................................................................ 31
D155AX-6 1
Engine control 1
1. Decelerator pedal Outline

2. Decelerator potentiometer q The throttle signals of the fuel control dial are
3. Starter switch sent to the power train controller and pro-
4. Fuel control dial cessed together with the 3rd throttle signal,
5. Battery relay and then sent as the throttle commands
together with the throttle signals of the deceler-
6. Battery
ator pedal to the engine throttle controller. The
7. Power train controller engine throttle controller controls the engine
8. Starter according to the commands.
9. Fuel supply pump
2 D155AX-6
Engine control system 1
Outline q The information of the engine throttle controller

q The engine throttle controller receives the fuel is possessed jointly by the other controllers
control dial signal of the 1st throttle, decelera- through the network and used for the optimum
tor pedal signal of the 2nd throttle, and 3rd control of the engine and machine body.
throttle signal which is the control signal from q The auto deceleration is a function of setting
the power train controller, and then controls the the engine speed low temporarily when the
fuel supply pump according to the command travel direction is changed from F3, R3, F2,
signal having the lowest engine speed. and R2 (to protect the transmission clutch).
The control signals of the 3rd throttle are as q The neutral deceleration is a function of limit-
follows. ing the high idle speed when the transmission
(1) Auto deceleration (F3, R3, F2, R2) is set in neutral.
(2) Neutral deceleration
q The power train controller calculates a proper
engine speed from information items (1), (2),
etc.
and sends it as the 3rd throttle signal to the
engine throttle controller.
D155AX-6 3
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
D155AX-6 5
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
Processing in machine monitor (Common to all specifications)

Display of machine monitor
Contents and conditions of processing Method Flow of signals
1. Display of travel direction and gear speed.
F1, R3, etc. are notified by CAN according to infor- CAN
mation of power train controller.
2. Display of gauges of fuel level, engine coolant tempera-
ture, etc.
Controller converts the sensor signals into gauge CAN
numbers and sends them to the machine monitor by
CAN.
3. Display of trouble
When the machine has a trouble, the corresponding
failure code is notified to the machine monitor by Each sensor/solenoid-controller-
CAN. machine monitor
Which one should be turned on, the buzzer or the
caution lamp, is notified, too.
1) In normal state
User code, service code CAN
2) In trouble history display mode
The service code (6-digit code) and the following
items are displayed
Time after first occurrence
Time after latest occurrence
Number of past occurrences
The machine monitor displays the code.
Display of monitoring condition

1. The communication conditions of each sensor, each so-
lenoid, and CAN are displayed.
The item Nos. and device conditions are notified to
CAN
the machine monitor by CAN. Each sensor-controller-machine
The machine monitor displays the items and each monitor
value.
2. Each items is selected by using the cursor switches and
CAN
confirmation switch.
Other items
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
Machine monitor
Outline Precautions on the machine monitor display

q The machine monitor has the functions to dis- q The liquid crystal display panel may have black
play various items and the functions to select spots (which do not light up) or bright spots
modes and electric parts. (which stay on).
q The machine monitor has a CPU (Central Pro- Products having 10 or less black or bright
cessing Unit) in it to process, display, and out- spots conform the product specification; such
put the information. the condition is quite normal.
q The monitor display employs an LCD (Liquid q Battery voltage may suddenly drop at engine-
Crystal Display). The switches are flat sheet start due to ambient temperature or the condi-
switches. tion of the battery. The machine monitor dis-
play may temporarily disappear if it happens; it
is quite normal.
q Continuous operation of the machine monitor
may display blue bright spots on the screen
having a black background; it is quite normal.
The screen normally displayed on the monitor
has a blue or white background. For this rea-
son, blue spots will not cause any problem
(since the liquid crystal lights up red, blue, and
green spots when displaying white).
8 D155AX-6
Input and output signals CN-CM03

Pin No. Signal name Input/
CN-CM01 output
Input/ 1 RS232C CD for communication terminal Input
Pin No. Signal name
output 2 RS232C RXD for communication terminal Input
1 Battery power (+24V constantly) Input 3 RS232C SG for communication terminal
2 Battery power (+24V constantly) Input Signal GND for communication terminal
4 control

3 Battery power GND
4 Battery power GND 5 Communication terminal selection signal Input
Input/ 6 RS232C RTS for communication terminal Output
5 Wake-up Output 7 RS232C TXD for communication terminal Output
6 Relay output Output 8 RS232C DTR for communication terminal Output
7 Chassis signal GND 9 RS232C DTR for communication terminal Input
8 Hydraulic oil pressure 10 RS232C CTS for communication terminal Input
9 Fuel level Input 11 RS232C RI for communication terminal Input
10 NC(*) 12 Power GND for communication terminal
11 Charge amount Input Input CH1 for communication terminal
13 status
Input
12 Chassis analog signal GND
13 Light switch Input Output for communication terminal
14 power control
Output
14 Key switch (ACC) Input Output CH1 for communication terminal
15 Key switch (C) Input 15 control
Output
16 Preheating Input 16 Output CH2 for communication terminal
Output
control
17 NC(*)
Input CH2 for communication terminal
18 NC(*) 17 status Input
*: Never connect to NC or malfunctions or failures will Electric power supply for communication
occur. 18 terminal
Output
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
5 Electric power supply GND for camera
6 Camera signal GND1
D155AX-6 9
Monitor control, display portion
1. Gear shift mode selector switch 9. Fuel level

2. Buzzer cancel switch 10. Travel gear speed gear shift mode preset
3. Working mode selector switch 11. Guidance icon
4. Engine coolant temperature 12. Function switch
5. Multi gauge 13. Custom switch
6. Pilot display 14. Custom memory switch
7. Service meter, clock 15. Float mode switch
8. Hydraulic mode display 16. Air conditioner switch
10 D155AX-6
D155AX-6 11
Machine monitor display

Display
Symbol Display item Display range Display method
category
Displays when engine is stopped and

starting switch is ON
Radiator coolant level Below low level
Display when normal: OFF
Display when abnormal: ON
When sensor is abnormal

Check
Display when normal: OFF

Engine oil pressure or when wiring harness is
disconnected
Displays when starting switch is ON

and engine is running
Battery charge When charge is defective Display when normal: OFF
CAUTION lamp flashes
Below 49.0kPa
Engine oil pressure
{0.5kg/cm2}
Radiator coolant level Below low level
When at highest level on

engine coolant
temperature gauge
Engine coolant tempera-
Above 102C:
ture Displays when starting switch is ON
Symbol ON
and engine is running
Caution
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
When replacement time

Maintenance of filter or oil has been
passed
Lights according to required time

determined by engine controller
based.
Pilot
Preheating When preheating It also lights at the time of manual pre-

heat by setting starting switch at pre-
heat position (turning it
counterclockwise).
12 D155AX-6
Display
Symbol Display item Display range Display method
category
Engine coolant
temperature
Torque converter oil

Indicative applicable temperature
temperature
Gauges
Hydraulic oil temperature
Fuel level Indicative applicable level
Service meter
From 0 to 99999 Actuated when the engine is rotating
(Hours meter)
D155AX-6 13
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
Machine speed Battery voltage
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
Hydraulic, HSS pump oil pressure Engine speed
1. 0 MPa 4. 30 MPa 1. 500 rpm 4. 2,000 rpm

2. 10 MPa 5. 40 MPa 2. 1,000 rpm 5. 2,500 rpm
3. 20 MPa 6. 50 MPa 3. 1,500 rpm 6. 3,000 rpm
Engine oil pressure Drawbar pull
1. 0.0 MPa 4. 0.4 MPa 1. 0 W 4. 0.6 W

2. 0.2 MPa 5. 0.5 MPa 2. 0.2 W 5. 0.8 W
3. 0.3 MPa 6. 0.7 MPa 3. 0.4 W 6. 1.0 W
D155AX-6 15
Guidance icon and function switch

The function switches differ depending on the screen display. Each guidance icon shows the function of the
switch below it.
Switches with no guidance icon are disabled.
The functions shown by the guidance icons are as shown in the table below.
Symbol Switch Item Function
F6 Enter Enters selected/set item.
F5 Return Returns to previous screen.
F4 Select service meter/clock Selects service meter and clock alternately.
F5 Select maintenance screen Selects maintenance screen.
F6 Select user mode screen Selects user mode screen.
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).
Selects item on lower side (Selects top item after bottom

F3 Select item
item)/Resets holding of monitoring.
Selects item on upper side (Selects bottom item after top

F4 Select item
item)/Holds monitoring.
Selects page on lower side (Selects top page after bottom

F1 Select item
page).
Selects page on upper side (Selects bottom page after top

F2 Select item
page).
Returns selected item to default setting. (Used for

F2 Return to default setting
adjustment of screen.)
Starts operation. (Used to start measurement of split fuel

F1 Start
consumption on fuel consumption display screen.)
Stops operation. (Used to stop measurement of split fuel

F1 Stop
consumption on fuel consumption display screen.)
F1/F2 Clear Clears selected/displayed item
F1 Set Executes setting.
Select of single and dual mode

F1 Change tilt mode
(Only dual-tilt dozzer specification)
F2 Change multi gauge Change of multi gauge items
16 D155AX-6
Air conditioner control switch

To operate the air conditioner, use the air condi-
tioner control switches.
Service meter/time selector function

q Pressing F4 on the normal screen when the
9a : Specifies airflow service meter is displayed in the top center of
9b : Specifies temperature the screen switches the display to the time,
9c : AUTO and doing so when the time is displayed
9d : A/C switches the display to the service meter.
9e : Switches among air blowing modes
9f : Switches between inside air and outside air
9g : OFF
9a to 9c : Enables entered information simulta-
neously with switching to the air condi-
tioner control screen below.
9d to 9f : Switches to the air conditioner control
screen below. Another pressing switches
among modes.
9g : Turns OFF the air conditioner function without
switching to the air conditioner screen.
If you do no operation at least 5 sec. with the air

conditioner control screen displayed, the window
returns to the normal window.
a When communication with the air conditioner
is disconnected, or spurting-out damper,
A/M damper, or refrigerant has a problem,
the following screen appears.
D155AX-6 17
Maintenance function
q Pressing F5 on the normal screen switches to
the maintenance screen.
F5 : Cancels the reset to return to the maintenance

table screen.
F6 : Resets the remaining time to return to the nor-
mal screen.
No operation at least 30 sec. : Returns to the nor-
mal screen.
q The table below shows the maintenance items

and replacement intervals. The time remaining
to maintenance is reduced as the machine is
operated.
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
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
q To reset the maintenance time carelessly, it is User mode 1

locked by the password. q Pressing F6 on the normal screen enters the
user mode, switching to the user menu screen.
q In user mode, you can specify items relating to
the machine monitor and machine shown
below.
Utility screen select
Multi gauge select
Screen adjustment
Clock adjustment
Language setting
Message display
Fan reverse mode
q The default password is 000000.

q Enabling the password lock on an attachment-
equipped machine locks the attachment set-
ting screen at the same time.
a For information on changing the maintenance
password, see Maintenance password change
function in the Testing and adjusting section.

F5 : Returns to the normal screen.
F6 : Switches to the setting screen for the selected
item.
mal screen.
(In user mode, no switch operation at least 30 sec.
returns to the previous screen.)
Utility screen select

q If utility screen select is selected with switch
F6, (1) Standard Display, (2) Load Display, or
(3) Body Pitch Display can be selected.
q Select an item with switch F3 or F4 and con-
firm that item with switch F6.
D155AX-6 19
Multi gauge select

q On this screen, the gauges displayed at the
center can be selected.
q Select an item with switch F3 or F4 and con-
firm that item with switch F6.
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
Body Pitch Display

q The horizontal axis indicates the time and the
vertical axis indicates the pitch angle of the
body.
q The graph on the screen is updated and
scrolled to the left at intervals of several sec-
onds.
20 D155AX-6
Screen adjustment F6 : Moves to the setup items of the selected (high-

q Selecting the Screen adjustment from the user lighted) item.
menu and pressing F6 switches to the screen q The adjustment methods for the camera
adjustment screen. screen and normal screen are the same.
q From this menu, you can adjust the brightness, q The background when adjusting the camera
contrast, and luminance of the machine moni- screen is the No. 1 camera image.
tor screen.
q When the light switch is in Night mode ON, the
night mode screen is adjustable.
q When the light switch is in Daytime mode ON
or OFF, the daytime mode screen is adjust-
able.

F5 : Cancels changes you made before confirming
them with F6 to return to the menu screen.
F6 : Moves to the setup items of the selected (high-
lighted) item.
F2 : Returns all adjusted values to the defaults.
F3 : Decreases the value indicated by the indicator Clock adjustment
one graduation left.
q Selecting the Clock adjustment from the user
F4 : Increases the value indicated by the indicator
one graduation right. menu and pressing F6 switches to the clock
F5 : Cancels changes you made before confirming adjustment screen.
them with F6 to return to the menu screen. q On this screen, you can change the setting of
F6 : Confirms the changes and moves to the next the time displayed on the normal screen.
item.
q For a camera-equipped machine, the bright-
ness, contrast, and illuminance of the camera
screen are also adjustable.
q For a camera-equipped machine, selecting
Sc reen adjus tment fro m the us er menu
switches to the screen for selecting a screen
you want to adjust.
1) Time setting
Set the clock time. If the time setting item
is not highlighted, press F6 to highlight it.
The time display part is highlighted.

F3 : Advances the clock one hour.
F4 : Sets the clock back one hour.
F5 : Cancels changes you made before
confirming them with F6 to return to
F4 : Selects (highlights) an item one up. the user menu.
F5 : Cancels changes you made before confirming F6 : Confirms the changes and moves to
them with F6 to return to the menu screen. minute setting.
D155AX-6 21
The minute display part is highlighted.

F3 : Advances the clock one min.
F4 : Set the clock back one min.
the use menu.
F6 : Confirms the changes and moves to
the 12/24 display mode.
2) 12/24 display mode

Specify time display to 12-hour display
(AM/PM) or 24-hour display. If the item of
12/24 display mode is not highlighted,
press F6 to highlight it. F3 : Selects (highlights) an item one down.
F3 : Moves to the item one right. F4 : Selects (highlights) an item one up.
F4 : Moves to the item one left. F5 : Cancels the changes to return to the user menu.
F5 : Cancels the changes to return to the F6 : Cancels the changes to return to the user menu.
user menu.
F6 : Confirms the changes and moves to Message display
summer time.
q For a KOMTRAX-equipped machine, you can
view notification from the sales representative.
3) Summer time
When there is a message, the message moni-
Selecting ON for this sets the time forward
tor appears on the upper left of the normal
one hour. Setting OFF returns to the ordi-
screen.
nary time.
q The lighting green monitor indicates that there
F3 : Moves to the item one right.
are messages to be read.
F4 : Moves to the item one left.
q The lighting blue monitor appears when you
have not sent replies yet after opening mes-
sages which accept replies.
the user menu screen.
F6 : Confirms the changes and moves to
the time setting.
a Summer time (daylight saving time) is

a system to lead a life according to
the one-hour advanced time in order
to make efficient use of daylight time.
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
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.
F6 : Returns to the user mode screen.
q Under messages that accept replies, Value to

be entered with 10-key: [ ] appears.If it
appears, enter the selected item number pro-
vided in the message using the switches of the
machine monitor, and press F6.
q Do you want to transmit the entered value?
appears under the message. Press F6 and the
entered value will be sent.
Precautions for using fan reverse mode

a q In this mode, the fan cannot be reversed
while the engine is running.
q When running the fan in reverse, set
q Messages will be deleted when their validity
the travel lock in the LOCK position.
expire or a new message is received.
q While the fan is running in reverse, the
q When no message has not been received, No
machine cannot travel.
message appears at the blue part of the top of
q When resetting the reverse running,
the screen.
turn the starting switch OFF to stop the
q Separately from the message display for users
engine.
above, the service menu is provided with mes-
q When using this mode, warm up the
sage display for service.
engine sufficiently. If the engine is not
warmed up, air may not be supplied
sufficiently.
D155AX-6 23
Service meter check function Display LCD check function

q If you continuously pressing auto-deceleration q Continuously pressing the buzzer cancel
switch (1) and buzzer cancel switch (2) at the switch (1) and F2 at the same time on the
same time when setting the starting switch to password input screen or normal screen
the OFF position, the service meter will appear causes the entire LCD to light in white.
on the screen in 3 to 5 sec. Release F2 and buzzer cancel switch in order.
If any part of the display is black, the LCD is
broken.
q When these switches are released, the LCD

goes out.
a Continuous operation of the machine monitor q Pressing any function switch returns to the pre-
may display blue bright spots on this screen; it vious screen.
is quite normal.
24 D155AX-6
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
Engine oil pressure sensor
1. Plug 4. Diaphragm
2. Contact ring 5. Spring
3. Contact 6. Terminal
Engine coolant temperature sensor

Torque converter oil temperature sensor
Hydraulic oil temperature sensor
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
D155AX-6 25
Coolant level sensor
1. Float 4. Wire
2. Sensor 5. Connector
3. Tube
Fuel level sensor
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
Engine speed sensor

Bevel gear speed sensor
1. Magnet 4. Boots
2. Terminal 5. Connector
3. Case
Pitch angle sensor
1. Body 3. Wire
2. Tube 4. Connector
D155AX-6 27
Palm command control system 1
1. Machine monitor (Multi-information)

2. Preset mode switch
3. Engine throttle controller
4. Power train controller
5. Engine speed sensor
6. Transmission control valve
7. Steering control valve
8. Transmission output shaft speed sensor
28 D155AX-6
Gearshift mode function

Outline
There are the auto gearshift mode and manual
gearshift mode in the gearshift mode. These
modes are changed to each other each time gear-
shift mode switch (1) is pressed.
1. Auto gearshift mode (Dozing mode)
q If a load is applied, the gear is shifted down
automatically. When the load is removed, the
gear is shifted up to the set maximum gear
speed automatically.
q The torque converter lockup operates accord-
ing to loads and the maximum gear speed is
selected automatically. In this mode, less fuel
is consumed and more production is obtained.
2. Manual gearshift mode (Ripping mode)
q If a load is applied, the gear is shifted down
automatically. When the load is removed,
however, the gear is not shifted up automati-
cally.
Gear shift operation

q Set a gear by pressing (a) or (b) of the steer-
ing/directional/gearshift lever.
(a) Shift-up switch
(b) Shift-down switch
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
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.
Shift-up switch: Each time this switch is

pressed, the maximum gear speed is
heightened to the next range.
Shift-down switch: Each time this switch is
lowered to the next range.
B: Manual gearshift mode

B: Manual gearshift mode 5. Changing maximum speed during travel
6. Setting preset (gear speed at start) 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.
Shift-up switch: Each time this switch is

heightened to the next range.
Shift-down switch: Each time this switch is
lowered to the next range.
a When the starting switch is turned ON, the

auto gearshift mode ([F1 R1]) is set. When
the gearshift mode is changed, [F1 R1] is
selected initially.
30 D155AX-6
KOMTRAX system 1
q The KOMTRAX system consists of a KOMTRAX

terminal modem, communication antenna,
machine monitor, and GPS antenna.
q This system transmits various kinds of
machine information wirelessly. Persons to
operate the KOMTRAX can refer to the infor-
mation at office to provide various kinds of ser-
vices for customers.
q Information transmittable from the KOMTRAX
system includes the following.
1. Operation map
2. Service meter
3. Position information
4. Error history
and others.
a To provide the services, you need to make an
arrangement for starting the KOMTRAX ser-
vice separately.
D155AX-6 31
KOMTRAX terminal modem 1

TH300
1. Communication antenna connection

2. Connector A (14 poles)
3. Connector B (10 poles)
Outline Input and output signals

q The KOMTRAX communication modem is a Connector A
wireless communication device to transmit var- Input/
ious kinds of machine information or GPS posi- Pin No. Signal name
output
tion information the monitor obtains from A-1 Power (12V) Input
n e tw o r k s i g n al s o r i n p ut s i g n a l s i n t h e A-2 NC(*1)
machine. The communication modem can A-3 NC(*1)
transmit information via the communication A-4 Electric power supply switching Output
antenna. A-5 NC(*1)
q The modem is provided with a LED lamp as a A-6 NC(*1)
display unit. The LED is used for maintenance. A-7 GND
A-8 GND
A-9 NC(*1)
A-10 NC(*1)
A-11 NC(*1)
A-12 NC(*1)
A-13 NC(*1)
A-14 NC(*1)
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
D155AX-6 33
D155AX-6 Bulldozer
2007 KOMATSU
All Rights Reserved
34 D155AX-6
SEN00678-01
D155AX-6

D155AX-6 80001 and up
20 Standard value table 1

Standard service value table
Standard service value table ........................................................................................................................... 2
Standard value table for engine ........................................................................................................... 2
Standard value table for machine......................................................................................................... 3
D155AX-6 1
SEN00678-01 20 Standard value table
Standard service value table 1

Standard value table for engine 1
Engine SAA6D140E-5
Cate- Standard value for

Item Measurement condition Unit Service limit value
gory new machine
High idle rpm 2,100 (0/-50) 2,100 (0/-50)

Engine coolant
Speed temperature: Within Low idle rpm 740 (+20/0) 740 (+20/0)
operating range
Rated speed rpm 1,900 1,900
Engine coolant temperature: Within

operating range
Intake air pressure kPa Min. 117 100
Power train oil temperature: Within
(Boost pressure) {mmHg} {Min. 880} {750}
operating range
Torque converter: Stalled
Exhaust Whole speed range
C 660 700
temperature (Outside temperature: 20C)
%
At sharp Max. 25 35
Engine coolant (Bosch
acceleration (Max. 2.5) {3.5}
Exhaust gas color temperature: Within index)
operating range (Bosch
High idle Max. 1.0 2.0
index)
Intake valve mm 0.35

Valve clearance Normal temperature
Exhaust valve mm 0.57
Compression MPa Min. 4.1 2.8

Engine
Engine oil pressure {kg/cm2} {Min. 42} {29}

Compression
temperature:
pressure Engine
40 60C rpm 200 250 200 250
speed
operating range
kPa Max. 2.94 3.92
Blow-by pressure Power train oil temperature: Within
{mmH2O} {Max. 300} {400}
operating range
Torque converter: Stalled
SAE0W30EOS,
MPa Min. 0.34 0.21
SAE5W40EOS, High idle
{kg/cm2} {Min. 3.5} {2.1}
SAE10W30DH,
Engine oil pressure SAE15W40DH
SAE30DH Oil MPa Min. 0.10 0.08
Engine oil temperature: Low idle {kg/cm2} {Min. 1.0} {0.8}
Min. 80 C
Oil temperature Whole speed range (In oil pan) C 90 110 120
Between water pump pulley

Alternator belt alternator pulley
mm 13 16 13 16
tension Deflection under finger pressure of
98 N {10 kg}
Between compressor pulley fan
Air compressor belt pulley
mm Approx. 10 Approx. 10
tension Deflection under finger pressure of
59 N {6 kg}
2 D155AX-6
Standard value table for machine 1

gory new machine
operating range
Decelerator pedal Power train oil temperature: Within
rpm 875 50 875 50
speed operating range
Hydraulic oil temperature: Within
operating range
Engine: High idle
Auto deceleration Decelerator pedal speed:
Press pedal rpm 1,875 50 1,875 50
speed
Auto deceleration speed:
Engine speed
Set all levers in neutral

operating range
Torque converter Power train oil temperature: Within rpm 1,610 50 1,450
stall speed operating range
operating range
Engine: High idle
Torque converter Select P mode
stall speed + Work Torque converter stall speed: F3
rpm 1,550 50 1,395
equipment relief Torque converter stall speed + Work
speed equipment relief speed: F3 + Ripper
raise
Hydraulic oil
temperature: Within
operating range
Min. speed rpm
Fan: Set in 100%
mode
Engine: Low idle
Fan motor speed
Cooling fan
Hydraulic oil
temperature: Within
operating range
Max. speed rpm 1,250 50 1,250 50
Fan: Set in 100%
mode
Engine: High idle
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

gory new machine
N o Raise mm 72 10 72 10
N o Lower mm 72 10 72 10
Stop engine
Stroke of control lever/pedal
Blade control lever

Center of lever knob
N o Left tilt mm 53 10 53 10
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
N o In mm 80 10 80 10
N o Out mm 80 10 80 10
No N 56.9 6.9 56.9 6.9

Forward/ Forward {kg} {5.8 0.7} {5.8 0.7}
Reverse travel No
PCCS lever
N 50.1 6.9 50.1 6.9

Stop engine Reverse {kg} {5.2 0.7} {5.2 0.7}
Center of lever grip N 24.5 4.9 24.5 4.9
N o Left
{kg} {2.5 0.5} {2.5 0.5}
Steering
N 27.5 4.9 27.5 4.9
N o Right
{kg} {2.8 0.5} {2.8 0.5}
Stop engine N 49.0 9.8 49.0 9.8
Decelerator pedal
Operating effort of control lever/pedal
Center of pedal {kg} {5.0 1.0} {5.0 1.0}

Engine: Low idle N 411.6 78.4 411.6 78.4
Brake pedal
Center of pedal {kg} {42.0 8.0} {42.0 8.0}
N 39.2 5.9 39.2 5.9
N o Raise
{kg} {4.0 0.6} {4.0 0.6}
N 39.2 9.8 39.2 9.8
N o Lower
{kg} {4.0 1.0} {4.0 1.0}
Stop engine
Blade control lever/ Lower o N 9.8 4.9 9.8 4.9
switch Float {kg} {1.0 0.5} {1.0 0.5}
Lower o Float: Switch
N 29.4 5.9 29.4 5.9
N o Left tilt
{kg} {3.0 0.6} {3.0 0.6}
No N 29.4 5.9 29.4 5.9
Right tilt {kg} {3.0 0.6} {3.0 0.6}
N 19.6 4.9 19.6 4.9
N o Raise
{kg} {2.0 0.5} {2.0 0.5}
N 19.6 4.9 19.6 4.9
N o Lower
Stop engine {kg} {2.0 0.5} {2.0 0.5}
Center of lever knob N 24.5 4.9 24.5 4.9
N o In
{kg} {2.5 0.5} {2.5 0.5}
N 24.5 4.9 24.5 4.9
N o Out
{kg} {2.5 0.5} {2.5 0.5}
4 D155AX-6

gory new machine
MPa 0.05 0.49 0.05 0.49
Low idle
Torque converter {kg/cm2} {0.5 5.0} {0.5 5.0}
inlet pressure Power train oil temper- MPa Max. 1.0 Max. 1.0
ature: Within operating High idle {kg/cm2} {Max. 10.0} {Max. 10.0}
range
PCCS lever: Neutral MPa 0.05 0.29 0.05 0.29
Low idle
Torque converter Display by monitoring {kg/cm2} {0.5 3.0} {0.5 3.0}
outlet pressure MPa 0.29 0.69 0.29 0.69
High idle
{kg/cm2} {3.0 7.0} {3.0 7.0}
MPa 2.81 3.11 Min. 2.62
Power train oil temper- Low idle
Transmission main {kg/cm2} {28.7 31.7} {Min. 26.7}
ature: Within operating
relief pressure range MPa 3.04 3.33 Min. 2.84
High idle
PCCS lever: Neutral {kg/cm2} {31.0 34.0} {Min. 29.0}
(Main relief pressure) MPa 1.32 0.20 1.32 0.20
(Stator clutch pressure) Low idle
Torque converter {kg/cm2} {13.5 2.0} {13.5 2.0}
lockup clutch Brake pedal: Press
MPa 1.32 0.20 1.32 0.20
(Other than above) High idle
{kg/cm2} {13.5 2.0} {13.5 2.0}
MPa 2.65 0.20 2.65 0.20
Torque converter Low idle
{kg/cm2} {27.0 2.0} {27.0 2.0}
stator clutch
pressure MPa 2.65 0.20 2.65 0.20
High idle
{kg/cm2} {27.0 2.0} {27.0 2.0}
MPa 2.45 2.75 Min. 2.26
Low idle
Transmission F {kg/cm2} {25.0 28.0} {Min. 23.0}
Power train oil pressure
clutch pressure MPa 2.60 2.89 Min. 2.40

High idle
{kg/cm2} {26.5 29.5} {Min. 24.5}
MPa 2.65 2.94 Min. 2.45
Low idle
Transmission R {kg/cm2} {27.0 30.0} {Min. 25.0}
clutch pressure Power train oil temper- MPa 2.79 3.09 Min. 2.60
ature: Within operating High idle {kg/cm2} {28.5 31.5} {Min. 26.5}
range
MPa 2.81 3.11 Min. 2.62
PCCS lever: Neutral Low idle
Transmission 1st {kg/cm2} {28.7 31.7} {Min. 26.7}
(Main relief pressure)
clutch pressure (Stator clutch pressure) High idle MPa 3.04 3.33 Min. 2.84
Brake pedal: Press {kg/cm2} {31.0 34.0} {Min. 29.0}
(Other than above) MPa 2.60 2.89 Min. 2.40
Low idle
Transmission 2nd {kg/cm2} {26.5 29.5} {Min. 24.5}
High idle
{kg/cm2} {28.0 31.0} {Min. 26.0}
MPa 2.81 3.11 Min. 2.62
Low idle
Transmission 3rd {kg/cm2} {28.7 31.7} {Min. 26.7}
High idle
{kg/cm2} {31.0 34.0} {Min. 29.0}
Transmission lubri-
MPa 0.05 0.29 0.05 0.29
cating oil pressure High idle
{kg/cm2} {0.5 3.0} {0.5 3.0}
(Reference)
MPa 2.75 0.29 2.16
Low idle
Steering right brake {kg/cm2} {28.0 3.0} {22.0}
pressure Power train oil MPa 2.75 0.29 2.16
temperature: Within High idle
{kg/cm2} {28.0 3.0} {22.0}
operating range
PCCS lever: Neutral MPa 2.75 0.29 2.16
Low idle
Steering left brake Brake pedal: Release {kg/cm2} {28.0 3.0} {22.0}
pressure MPa 2.75 0.29 2.16
High idle
{kg/cm2} {28.0 3.0} {22.0}
D155AX-6 5

gory new machine
Flat ground F1 km/h 3.8 0.2 3.8 0.2
Engine coolant
temperature: Within F2 km/h 7.5 0.4 7.5 0.4
Power train performance
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}
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
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
range Raise sec 3.0 4.0 3.0 4.0

Work equipment
Engine: High idle

Select P mode
Blade lift Apply no load to blade.
Measure time required
to move blade from
ground level to raise
stroke end Lower sec 1.0 1.7 1.0 1.7
For measuring posture,
see Fig. 1
6 D155AX-6

gory new machine
Hydraulic oil
temperature: Within
operating range Left tilt sec 1.8 2.8 3.1
Engine: High idle
Select P mode
Blade tilt Apply no load to blade
to move blade from left
tilt end to right tilt end Right tilt sec 1.8 2.8 3.1
see Fig. 2
Hydraulic oil
temperature: Within
Work equipment speed
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)
to move ripper from
ground level to raise Lower sec 1.5 2.5 3.5
end
see Fig. 3
Work equipment
Hydraulic oil tempera-

ture: Within operating
range Tilt in sec 4.5 5.5 6.2
Engine: High idle
Select P mode
Ripper tilt Apply no load to ripper
to move ripper from tilt
in end to tilt back end Tilt back sec 3.7 4.7 6.1
see Fig. 4
operating range
Engine: Low idle
Select P mode.
Blade Blade control lever: Set to stroke end sec Max. 1.7 2.5
Lower blade from max. rising position
and measure time after blade comes
in contact with ground until idler is
lifted
Time lag

operating range
Engine: Low idle
Select P mode
Ripper control lever: Set to stroke
Ripper sec Max. 1.5 1.5
end
Lower ripper from max. rising posi-
tion and measure time after ripper
comes in contact with ground until
sprocket is lifted
D155AX-6 7

gory new machine
operating range
Hydraulic drift Stop engine
mm Max. 50/15 minutes 200/15 minutes
of lifted blade Measure reduction of blade bottom
height h in 15 minutes
For measuring posture, see Fig. 5
Hydraulic drift of work equipment

operating range
Hydraulic drift
Stop engine
of machine mm Max. 50/5 minutes 70/5 minutes
Measure reduction of idler center
lifted by blade
operating range
Work equipment
Hydraulic drift
Stop engine
Measure reduction of idler center
tilted by blade
operating range
Hydraulic drift
Stop engine
Measure reduction of sprocket center
lifted by ripper
Leakage from cylinder
Blade lift
cc/min Max. 3.0 12
cylinder
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
Postures and procedures for measuring performance
Fig. 1: Blade lift speed Fig. 4: Ripper tilt speed
Fig. 2: Blade tilt speed Fig. 5: Hydraulic drift of lifted blade
Fig. 3: Ripper lift speed Fig. 6: Hydraulic drift of machine lifted by blade
D155AX-6 9
Fig. 7: Hydraulic drift of machine tilted by blade
Fig. 8: Hydraulic drift of machine lifted by ripper
10 D155AX-6
D155AX-6 Bulldozer
2006 KOMATSU
All Rights Reserved
12 D155AX-6
SEN00679-01
D155AX-6

D155AX-6 80001 and up
30 Testing and adjusting 1

Testing and adjusting, Part 1
Testing and adjusting, Part 1........................................................................................................................... 3
Tools for testing, adjusting, and troubleshooting .................................................................................. 3
Measuring engine speed...................................................................................................................... 5
Measuring intake air pressure (boost pressure)................................................................................... 7
Measuring exhaust temperature .......................................................................................................... 8
Measuring exhaust gas color ............................................................................................................. 10
Adjusting valve clearance ...................................................................................................................11
Measuring compression pressure ...................................................................................................... 12
Measuring blow-by pressure .............................................................................................................. 14
Measuring engine oil pressure ........................................................................................................... 15
Handling fuel system parts ................................................................................................................. 16
Releasing residual pressure from fuel system ................................................................................... 16
Measuring fuel pressure..................................................................................................................... 17
Measuring fuel return rate and fuel leakage....................................................................................... 18
Bleeding air from fuel circuit............................................................................................................... 22
Measuring fuel circuit for leakage ...................................................................................................... 24
D155AX-6 1
SEN00679-01 30 Testing and adjusting
Testing and adjusting alternator belt tension ...................................................................................... 25

Testing and adjusting air conditioner compressor belt tension........................................................... 26
Measuring fan speed.......................................................................................................................... 27
Measuring fan circuit oil pressure....................................................................................................... 28
Bleeding air from fan pump ................................................................................................................ 29
Adjusting fuel control dial and decelerator pedal................................................................................ 30
2 D155AX-6
Testing and adjusting, Part 1 1

Tools for testing, adjusting, and troubleshooting 1
Sym-
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:
1 {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester 1
Measuring fuel pressure H {600 kg/cm2}
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:
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
Sym-
Q'ty
Testing and adjusting item Part No. Part name Remarks
bol
Pressure gauge:
Measuring power train oil {25, 60, 400, 600 kg/cm2}
M
pressure
{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:
1 {25, 60, 400, 600 kg/cm2}
Measuring and adjusting
work equipment and HSS Q Pressure gauge: 58.8 MPa
oil pressure {600 kg/cm2}
799-101-5220 Nipple 2
2 Size: 10 1.25 mm
07002-11023 O-ring 2
Pressure gauge:
Measuring control circuit 1 {25, 60, 400, 600 kg/cm2}
R
basic pressure Pressure gauge: 58.8 MPa
{600 kg/cm2}
2 799-401-3200 Adapter 1 Size: 03
Pressure gauge:
Testing work equipment 1 {25, 60, 400, 600 kg/cm2}
lock solenoid valve output S
{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:
Measuring ripper pin puller 1 {25, 60, 400, 600 kg/cm2}
solenoid valve output U
{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
Measuring engine speed 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.
a Measure the engine speed 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 2. Measuring low idle speed
q Working mode: P mode 1) Start the engine and set the fuel control
q Gearshift mode: Either Auto or Manual dial in the low idle (MIN) position.
2) Set the PCCS lever, blade control lever,
1. Preparation work and ripper control lever in neutral and
Measure the engine speed with the Adjustment measure the engine speed.
function in the service mode of the machine a The parking brake lever and work
monitor. equipment lock lever may be kept in
a For the operating method of the machine the LOCK position.
monitor, see Special functions of machine
monitor (EMMS). 3. Measuring high idle speed
1) Measuring low idle speed, decelerator 1) Start the engine and set the fuel control
pedal speed, auto-deceleration speed, dial in the high idle (MAX) position.
torque converter stall speed, and torque 2) Set the PCCS lever, blade control lever,
converter stall speed + work equipment and ripper control lever in neutral and
relief speed (full stall speed): measure the engine speed.
q Adjustment code: 0530 (Stall mode) a The parking brake lever and work
a When stalling the torque converter for equipment lock lever may be kept in
a purpose other than measuring the the LOCK position.
engine speed, be sure to use this a When measuring the high idle speed,
adjustment code, too. be sure to select adjustment code
[0007] (If adjustment code [0530] is
selected, the auto-deceleration speed
is measured).
4. Measuring decelerator pedal speed

1) Start the engine and set the fuel control
dial in the high idle (MAX) position.
and ripper control lever in neutral, press
the decelerator pedal to the stroke end,
and measure the engine speed.
a The parking brake lever and work
equipment lock lever may be kept in
the LOCK position.
2) Measuring high idle speed:
q Adjustment code: 0007 (Reset engine
5. Measuring auto-deceleration speed
deceleration)
a Only when this code is selected, the
dial in the high idle (MAX) position.
engine can be operated and tested
with the auto-decelerator reset.
and ripper control lever in neutral and
measure the engine speed.
D155AX-6 5
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.
7. Measuring torque converter stall + work

equipment relief speed (Full stall speed)
dial in the low idle (MIN) position.
2) Operate the shiftup (UP) switch of the
PCCS lever and set the preset mode dis-
play section to [F3-R3].
6 D155AX-6
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.
5. Turn the starting switch ON and set the
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.
ating range
ing range
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.
6. While running the engine at high idle, stall the

torque converter and measure the intake air
pressure (boost pressure).
a For the procedure for stalling the torque
converter, see Measuring engine speed.
a Normally, the intake air pressure (boost
pressure) should be measured while the
engine is operated at the rated output. In
the field, however, an approximate value
can be obtained by stalling the torque con-
verter.
3. Install nipple [1] of boost gauge kit A and con-

nect gauge [2].
7. After finishing measurement, remove the mea-

suring instruments and return the removed parts.
D155AX-6 7
Measuring exhaust temperature 1

a Measuring instruments for exhaust tempera-
ture
Symbol Part No. Part name
B 799-101-1502 Digital thermometer

tion.
k Install and remove the measuring instru-
ments after the exhaust manifold is cooled.
a Measure the exhaust temperature under the
following conditions. 4. When measuring maximum exhaust tempera-
q Engine coolant temperature: Within oper- ture for troubleshooting
ating range Operate the machine actually and measure the
q Power train oil temperature: Within operat- maximum exhaust temperature.
ing range a Use the PEAK mode of the thermometer.
q Hydraulic oil temperature: Within operat- a The exhaust temperature largely depends
ing range on the outside air temperature (intake air
temperature of the engine). Accordingly, if
1. Open the engine right side cover and right any abnormal value is obtained, correct it
mudguard. by the following calculation.
q Corrected value [C] = Measured
2. Remove 1 exhaust temperature pickup plug (1) value + 2 (20 Outside air tempera-
from the exhaust manifold. ture)
a You may measure the exhaust tempera-
ture at either front or rear plug.
5. Procedure for measuring exhaust temperature

periodically for preventive maintenance (Pm
3. Install sensor [1] of digital thermometer B and clinic)
connect them to meter [2]. a If the torque converter is stalled simply,
a Clamp the wiring harness of the digital the torque converter oil is overheated
thermometer so that it will not touch a hot before the exhaust temperature is stabi-
part during measurement. lized. Accordingly, measure according to
the following procedure.
1) Turn the starting switch ON and set the
machine monitor to Adjustment function of
the service mode.
a For the operating method, see Spe-
cial functions of machine monitor
(EMMS).
8 D155AX-6
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.

suring instruments and return the removed
parts.
D155AX-6 9
Measuring exhaust gas color 1

a Measuring instruments for exhaust gas color
1 799-201-9001 Handy smoke checker
C Commercially
2 Smoke meter
available

tion.
k Be careful not to touch any hot part of the 2) Connect the probe hose, receptacle of the
engine when removing or installing the accelerator switch, and air hose to smoke
measuring tools. meter C2.
a If an air source and an electric power source a Limit the supplied air pressure to 1.5
are not available in the field, use handy smoke MPa {15 kg/cm}.
checker C1. When recording official data, use 3) Connect the power cable to a receptacle
smoke meter C2. of AC 100 V.
a Measure the exhaust gas color under the fol- a Before connecting the cable, check
lowing condition. that the power switch of the smoke
q Engine coolant temperature: Within oper- meter is turned OFF.
ating range 4) Loosen the cap nut of the suction pump
1. Measuring with handy smoke checker C1 and fit the filter paper.
1) Stick a sheet of filter paper to smoke a Fit the filter paper securely so that the
checker C1. exhaust gas will not leak.
2) Insert the exhaust gas intake pipe in 5) Turn power switch of smoke meter C2
exhaust pipe (1). ON.
3) Start the engine.
4) Accelerate the engine suddenly or run it at
high idle and operate the handle of smoke
checker C1 so that the filter paper will
absorb the exhaust gas.
6) Start the engine.

7) Accelerate the engine suddenly or run it at
high idle and press the accelerator pedal
of smoke meter C2 and collect the
exhaust gas into the filter paper.
8) Place the contaminated filter paper on the
5) Remove the filter paper and compare it
clean filter paper (at least 10 sheets) in the
with the attached scale.
filter paper holder and read the indicated
6) After finishing measurement, remove the
value.
measuring instrument and return the
removed parts.
2. Measuring with smoke meter C2 removed parts.
1) Insert probe [1] of smoke meter C2 in the
outlet of exhaust pipe (1) and fix it to the
exhaust pipe with a clip.
10 D155AX-6
Adjusting valve clearance 1

a Measuring instruments for valve clearance
Commercially
D Thickness gauge
available

tion.
a Adjust the valve clearance under the following
condition.
5. While fixing adjustment screw (3), loosen lock-
q Engine coolant temperature: Normal tem-
nut (4).
perature
a After setting the No. 1 cylinder to the com-
pression top dead center, adjust the valve
1. Remove the engine hood assembly and air
clearance of the No. 1 cylinder.
cleaner together.
6. Insert thickness gauge D in the clearance
4 Engine hood assembly: 170 kg between rocker arm (5) and cross head (6) and
adjust the valve clearance with adjustment
2. Remove all cylinder head covers (1).
screw (3).
a With the clearance gauge inserted, turn
the adjustment screw to a degree that you
can move the thickness gauge lightly.
a Valve clearance
Intake valve : 0.35 mm
Exhaust valve: 0.57 mm
7. While fixing adjustment screw (3), tighten lock-
nut (4).
3 Locknut:
45.1 51.0 Nm {4.6 5.2 kgm}
a After tightening the locknut, check the
valve clearance again.
3. Remove the inspection plate on the right of the

radiator guard.
4. Rotate the crankshaft forward to bring the

stamped "1.6TOP" line (a) of the damper to
pointer (2) and set the No. 1 cylinder to the
compression top dead center.
a Rotate the crankshaft with the hexagonal
part at the end of the water pump drive
shaft.
a When the No. 1 cylinder is at the compres-
sion top dead center, the rocker arm of the
No. 1 cylinder can be moved by the valve 8. After adjusting the No. 1 cylinder, rotate the
clearance with the hand. If the rocker arm crankshaft forward by 120 to set the stamped
cannot be moved, the No. 1 cylinder is not TOP line of each cylinder to pointer (2) accord-
at the compression top dead center. In ing to the firing order and adjust the valve
this case, rotate the crankshaft one more clearance.
turn. q Firing order: 153624
9. After finishing adjustment, return the removed
parts.
3 Cylinder head cover mounting bolt:
29.4 34.3 Nm {3.0 3.5 kgm}
D155AX-6 11
Measuring compression pressure1 a Disconnect the terminal of the injector wir-

ing harness on the injector side and the
a Measuring tools for compression pressure bracket on the rocker housing side and
Symbol Part No. Part name r em o v e th e i n j ec t o r wi r i ng h ar ne s s
(Loosen the 2 terminal nuts alternately).
1 795-502-1590 Compression gauge
a Pass a wire under the fuel path projected
E 795-471-1330 Adapter sideways and pull up the injector (Do not
2
6261-71-6150 Gasket pry the injector top up).

tion.
a When measuring the compression pressure,
take care not to burn yourself on the exhaust
manifold, muffler, etc. or get caught in a rotat-
ing part.
a Measure the compression pressure under the
following conditions.
q Engine oil temperature: 40 60 C
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.
6. Install rocker arm assembly (2) and adjust the

valve clearance.
3 Rocker arm mounting bolt:
93 103 Nm {9.5 10.5 kgm}
a See Adjusting valve clearance.
3. Bring the cylinder to be tested to the compres-

sion top dead center and remove rocker arm
assembly (2).
a For the procedure for bringing each cylin-
der to the compression top dead center,
see Adjusting valve clearance.
4. Disconnect fuel high-pressure tube (3) and

injector wiring harness (4) and remove injector
(5) and wiring harness.
12 D155AX-6
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:
prevent electric leakage and ground Engine oil

fault. 3) Tighten sleeve nut (15) of the fuel high-
pressure tube temporarily.
4) Tighten bolt (13) permanently.
3 Bolt: 58.8 73.5 Nm {6 7.5 kgm}
5) Tighten sleeve nut (15) permanently.
3 Sleeve nut:
39.2 49.0 Nm {4 5 kgm}

machine monitor to Monitoring function of the
service mode.
q Monitoring code: 01002 Engine Speed
functions of machine monitor (EMMS). a Install the injector wiring harness accord-
ing to the following procedure.
1) Install the injector wiring harness to the
rocker arm housing and fix the connector
side with the plate.
2) Fix the intermediate clamp with the clip.
3) Tighten the nut on the injector side.
3 Nut: 2 0.2 Nm {0.2 0.02 kgm}
4) Secure the clamp and spacer with the
bolt.
3 Rocker arm assembly mounting
bolt: 93 103 Nm {9.5 10.5 kgm}
a Adjust the valve clearance. For details,

see Adjusting valve clearance.
9. Rotate the engine with the starting motor and 3 Cylinder head cover mounting bolt:
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.

parts.
D155AX-6 13
Measuring blow-by pressure 1 value is judged abnormal, check for

increase of oil consumption, bad exhaust
a Measuring instrument for blow-by pressure gas color, deterioration of oil, high deterio-
Symbol Part No. Part name ration speed of oil, etc. which are related
to the abnormal blow-by pressure.
F 799-201-1504 Blow-by checker

tion.
a Measure the blow-by pressure under the fol-
lowing conditions.
ating range
ing range
ing range
1. Open the engine left side cover and left mud- suring instruments and return the removed
guard. parts.
2. Install nozzle [1] and hose [2] of blow-by

checker F to the end of breather hose (1) and
connect them to gauge [3].
3. While running the engine at high idle, stall the

torque converter and measure the blow-by
pressure.
a For the procedure for stalling the torque
converter, see Measuring engine speed.
a Normally, the blow-by pressure should be
measured while the engine is operated at
the rated output. In the field, however, an
approximate value can be obtained by
stalling the torque converter.
a If it is impossible to run the engine at the
rated output or stall the torque converter,
measure while the engine is running at
high idle. The value obtained in this case
is about 80% of the blow-by pressure at
the rated output.
a The blow-by pressure may vary largely
with the engine condition. If the measured
14 D155AX-6
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
799-101-5002 Hydraulic tester
1
G 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester

tion.
a Measure the engine oil pressure under the fol-
lowing condition.
ating range 5. After finishing measurement, remove the mea-
1. Open the engine left side cover and left mud- parts.
guard.
2. Remove engine oil pressure pickup plug (1)

from the cylinder block.
3. Install nipples [1] and [2] of hydraulic tester G1

and connect them to hydraulic tester G2.
a Since the size of the plug hole is R1/4,
quick nipples (799-101-5210) may be
used instead of nipples [1] and [2].
D155AX-6 15
Handling fuel system parts 1 Releasing residual pressure from

a Precautions for testing and maintaining fuel fuel system 1
system a Pressure is generated in the low-pressure cir-
The common rail fuel injection system (CRI) cuit and high-pressure circuit of the fuel sys-
consists of more precise parts than the con- tem while the engine is running.
ventional fuel injection pump and nozzle. If for- Low-pressure circuit:
eign matter enters this system, it can cause a Feed pump Fuel filter Supply pump
trouble. High-pressure circuit:
When testing and maintaining the fuel system, Supply pump Common rail Injector
take care more than the past. If dust, etc. a The pressure in both low-pressure circuit and
sticks to any part, wash that part thoroughly high-pressure circuit lowers to a safety level
with clean fuel. automatically 30 seconds after the engine is
a Precautions for replacing fuel filter cartridge stopped.
Be sure to use the Komatsu genuine fuel filter a Before the fuel circuit is tested and its parts are
cartridge. removed, the residual pressure in the fuel cir-
Since the common rail fuel injection system cuit must be released completely. Accordingly,
(CRI) consists of more precise parts than the observe the following.
conventional fuel injection pump and nozzle, it k Before testing the fuel system or removing
employs a high-efficiency special filter to pre- its parts, wait at for least 30 seconds after
vent foreign matter from entering it. If a filter stopping the engine until the residual pres-
other than the genuine one is used, the fuel sure in the fuel circuit is released. (Do not
system may have a trouble. Accordingly, start the work just after stopping the engine
never use such a filter. since there is residual pressure.)
16 D155AX-6
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

tion.
a Test only the fuel pressure in the low-pressure
circuit from the feed pump through the fuel fil-
ter to the supply pump.
k Since the pressure in the high-pressure cir-
cuit from the supply pump through the
common rail to the injector is very high, it
cannot be measured.
1. Open the engine left side cover and remove
fuel pressure pickup plug (1) from the top of
parts.
3 Plug: 7.84 9.8 Nm {0.8 1.0 kgm}
the fuel filter.
2. Install adapter H3 and elbow [1] and nipple [2]

of hydraulic tester H1 and connect them to
hydraulic tester H2.
D155AX-6 17
Measuring fuel return rate and fuel leakage 1
a Measuring instruments for return rate and fuel

leakage
1 6151-51-8490 Spacer
2 6206-71-1770 Joint
3 Commercially available Hose
J
4 Commercially available Hose
5 Commercially available Measuring cylinder
6 Commercially available Stopwatch
a Prepare an oil pan of about 20 l to receive the

fuel flowing out during the test.
tion.
18 D155AX-6
1. Preparation work 5) Connect test hose J3 to the end of joint

1) Open the engine left side cover and left J2.
mudguard. a Bind the connecting part of the test
2) Remove tube (3) between supply pump hose with a wire, etc. to prevent it
(1) and common rail (2). from coming off.
a In the figure, 1 oil filter is removed a The above is the preparation work for
temporarily from the common rail measuring the leakage from the pres-
side. sure limiter.
a Disconnect both ends of the tube,
loosen the clamp, and move the tube
to the opposite side of the cylinder
block.
2. Testing leakage from pressure limiter

1) Lay test hose J3 so that it will not slacken
and put its end in the oil pan.
3) Insert spacer J1 on supply pump (1) side
machine monitor to Monitoring function of
and tighten the removed joint bolt again.
the service mode.
a Connect the return pipe to the fuel
q Monitoring code:
tank again, too.
01002 Engine Speed
a Be sure to fit the gaskets to both ends
a For the operating method, see "Spe-
of the spacer.
(EMMS)".
4) Insert joint J2 on common rail (2) side and

tighten the removed joint bolt again.
a In the figure, 1 oil filter is removed
temporarily from the common rail
side.
a Be sure to fit the gaskets to both ends
of the joint.
D155AX-6 19
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.
(EMMS)".
4) After finishing measurement, stop the

engine.
3. Testing return rate from injector

a Keep the hose on the pressure limiter side
connected and keep its end in the oil pan
while measuring the return rate from the
injector.
1) Disconnect return hose (5) of return block
(4) and connect test hose J4.
a Stop the return hose with a plug, etc.
and fix it to the fuel tank.
Plug: 07376-70315
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
20 D155AX-6
4) Run the engine at high idle and stall the

torque converter. After the engine speed
is stabilized, measure the return rate in 1
minute with measuring cylinder J5.
a For the procedure for stalling the
torque converter, see Measuring
engine speed.
a You may measure the return rate for
20 seconds and judge by multiplying
the result by 3.
a If the supply pump is not supplying
fuel, the engine speed may not rise.
In this case, record the engine speed,
too, during the measurement.
a If the return rate (spill) from the injec-
tor is in the following range, it is nor-
mal.
Torque converter Limit of return rate
stall speed (rpm) (spill) (cc/min)
1,600 960
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1.200
5) After finishing measurement, stop the

engine.
4. Work after finishing measurement

After finishing all measurement, remove the
measuring instruments and return the removed
parts.
D155AX-6 21
Bleeding air from fuel circuit 1
a If fuel is used up or if a fuel circuit part is re-

moved and installed, bleed air from the fuel cir-
cuit according to the following procedure.
1. Open the engine left side cover.
2. Remove fuel prefilter (1) and fill it with fuel.

a Fill the fuel prefilter with clean fuel and
take care that dirt will not enter it.
a Check that the cap is fitted to part (a)
(central hole) of the fuel prefilter, and then
add fuel through part (b) (holes around the
central hole).
a After filling the fuel prefilter with fuel,
3. Install fuel prefilter (1) to the filter head.
remove the cap from part (a).
a Apply engine oil thinly over the packing on
a If clean fuel is not available, do not
the fuel prefilter side.
remove the prefilter but fill it with the fuel
a After the packing of the fuel prefilter
by operating priming pump (4).
touches the sealing face of the filter head,
a Do not add fuel to fuel main filter (2) from
tighten the fuel prefilter 3/4 turns.
outside.
22 D155AX-6
7. Start the engine with the starting motor.

a The air in the high-pressure circuit is bled
automatically if the engine is cranked.
a If the engine does not start, there may be
still air in the low-pressure circuit. In this
case, repeat the above procedure from
step 4.
4. Remove air bleed plug (3) of fuel main filter (2)

and operate priming pump (4).
a Operate the priming pump until the fuel
flows out of the plug hole and install the
plug.
3 Air bleed plug:
7.8 9.8 Nm {0.8 1.0 kgm}
5. Remove air bleed plug (5) of the fuel main filter

and operate priming pump (4).
flows out of the plug hole and install the
plug.
3 Air bleed plug:
7.8 9.8 Nm {0.8 1.0 kgm}
6. Loosen air bleeder (6) of the supply pump and

operate priming pump (4) 90 100 times.
flows out of the air bleeder and tighten the
air bleeder. Then, operate the priming
pump several times more until it becomes
heavy.
a Air bleeder: 4.9 6.9 kgm {0.5 0.7 kgm}
D155AX-6 23
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.
1. Spray color checker (developer) over the joints

of the fuel supply pump, common rail, fuel
injector, and high-pressure piping.
2. Run the engine at speed below 1,000 rpm and

stop it after its speed is stabilized.
3. Check the fuel piping and devices for fuel leak-

age.
a Check mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If any fuel leakage is detected, repair it
and inspect again from step 1.
4. Run the engine at low idle.

age.
for fuel leakage.
6. Run the engine at high idle.

age.
for fuel leakage.
8. Run the engine at high idle and load it.

a Relieve the ripper circuit by raising the rip-
per.
24 D155AX-6
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.
2. Press the intermediate point of the belt

between alternator pulley and water pump pul-
ley with a finger and measure deflection (a) of
the belt.
a Pressing force:
Approx. 98 N {Approx. 10 kg}
a Deflection (a): 13 16 mm
7. After testing and adjusting, return the removed

parts.
Adjusting
a If the deflection is out of the standard range,
adjust it according to the following procedure.
1. Remove the 2 mounting bolts and belt cover

(1).
a Remove the belt cover only when replac-
ing the belt.
2. Loosen 2 mounting bolts (3) of alternator (2),

and then loosen lock bolt (4) of the adjustment
rod.
3. Loosen locknut (5) of the adjustment rod and

move alternator (2) with adjustment nut (6) to
adjust the tension of the belt.
4. While fixing adjustment nut (6), tighten locknut

(5).
5. Tighten locknut (4) of the adjustment rod and 2

mounting bolts (3) of alternator (2).
D155AX-6 25
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
tion.
Testing
1. Open the engine left side cover and left mud-
guard.
2. Press the intermediate point of the belt

between the supply pump pulley and compres-
sor pulley with a finger and measure deflection
(a) of the belt.
5. After testing and adjusting, return the removed
a Pressing force:
parts.
Approx. 59 N {Approx. 6 kg}
a Deflection (a): 10 mm
Adjusting
a If the deflection is out of the standard range,
adjust it according to the following procedure.
1. Loosen 4 bracket mounting bolts (1).
2. Loosen locknut (2) and move compressor (4)

and bracket as a unit with adjustment bolt (3)
to adjust the belt tension.
3. While fixing adjustment nut (3), tighten locknut

(2).
4. Tighten 4 bracket mounting bolts (1).

a Check for breakage of the pulleys, wear of
the V-grooves, contact of the belts and V-
grooves, and contact of the belt covers
and rotating parts.
a If the belt is lengthened to the adjustment
limit, cut, or cracked, replace it with new
one.
a If the V-belt is replaced, adjust its tension
again after 1 operating hour.
26 D155AX-6
Measuring fan speed 1 a If this adjustment code is displayed, the

fan speed is kept at 100% speed in accor-
a Measuring instrument for fan speed dance with the engine speed, regardless
Symbol Part No. Part name of the state of the machine.
K 795-205-1100 Tachometer kit

tion.
a Measure the fan motor speed under the follow-
ing condition.
ing range
1. Open the radiator mask and remove the fan

net. 6. While running the engine at low idle and high
idle, measure the fan speed
2. Stick 1 reflection tape [1] of tachometer kit K to
fan (1)
3. Set probe [2] to the reflection tape with stand

[3] and connect it to tachometer [4].
k Take care that the probe will not inter-
fere with the fan.
a Rotate the fan with the hand and check
that the probe can sense the rotation of
the reflection tape.

parts.
4. Close the radiator mask.

k Before starting the engine, be sure to
close the radiator mask. Do not start
the engine while the radiator mask is
open.
5. Start the engine and set the machine monitor

to Adjusting function of the service mode.
a Adjustment code: 1005 (Fan 100% mode)
a For the operating method, see "Special
functions of machine monitor (EMMS)".
D155AX-6 27
Measuring fan circuit oil

pressure 1
a Measuring instruments for fan circuit oil pres-
sure
1
790-261-1204 Digital hydraulic tester
L 2 799-401-3400 Adapter (05)
799-101-5220 Nipple (10 x 1.25 mm)
3
07002-11023 O-ring
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.
3. Install adapter L2 and connect the discon-

nected hose again.
4. Install nipple L3 and connect it to oil pressure

gauge [2].
a When using an analog oil pressure gauge,
use one of 39.2 MPa {400 kg/cm}.
28 D155AX-6
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
a Before starting the following work, check that
the hydraulic oil level is normal.
1. Remove the left step cover.
2. Loosen air bleeder (1) and leave it for 15 min-

utes.

parts.
3. After 15 minutes, start the engine and run it at

low idle.
4. After oil flows out of air bleeder (1), tighten air

bleeder (1) and stop the engine.
3 Air bleeder:
7.8 9.8 Nm {0.8 1.0 kgm}
D155AX-6 29
Adjusting fuel control dial and decelerator pedal 1

tion.
1. Outline of fuel control system

q The following signals are input as rotation
command signals to the engine controller.
1) Fuel control dial potentiometer signal
2) Decelerator pedal potentiometer sig-
nal
3) 3rd throttle signal (Power train con-
troller)
DIAL: Fuel control dial
q The engine controller controls the fuel
PEDAL: Decelerator pedal
control system of the engine (CRI system)
ROD: Decelerator pedal rod
according to the one of the above input
POTENTIO: Decelerator pedal potentiometer
signals which indicates the lowest engine
ENG-ECU: Engine controller
speed.
P/T-ECU: Power train controller
q Adjust the decelerator pedal speed and
ENGINE: Engine unit (CRI devices)
high idle speed with the decelerator pedal
[KOMNET]: KOMNET communication circuit (3rd
linkage.
throttle signal)
30 D155AX-6
2. Preparation work 5. Work after adjustment

1) Remove the right cover of the dashboard After finishing all adjustment, return the
and the right foot rest as a unit. removed parts.
2) Start the engine and set the machine mon-
itor to Adjusting function of the service
mode.
q Adjustment code:
0007 (Engine decelerator cut)
(EMMS)".
3. Adjusting decelerator pedal speed

With the fuel control dial in the high idle posi-
tion (MAX), press decelerator pedal (1) to stop-
per bolt (2) and check that the decelerator
pedal speed is normal.
q Decelerator pedal speed: 875 50 rpm
a If the decelerator pedal speed is abnor-
mal, adjust installed dimension (a) of stop-
per bolt (2).
q Standard installed dimension a) of stopper
bolt: 35.0 mm
4. Adjusting high idle speed

With the fuel control dial in the high idle posi-
tion (MAX), release decelerator pedal (1) and
check that the high idle speed is normal.
q High idle speed: 2,050 50 rpm
a If the high idle speed is abnormal, adjust it
according to the following procedure.
q When the engine speed is above 1,950
rpm:
Lower the engine speed below 1,900 rpm
temporarily with stopper bolt (3) to elimi-
nate the play of the decelerator pedal, and
then adjust the engine speed to the high
idle.
q When the engine speed is below 1,950
rpm:
Adjust the engine speed to the high idle
speed with stopper bolt (3).
q Standard installed dimension (b) of stop-
per bolt: 34.8 mm
D155AX-6 31
D155AX-6 Bulldozer
2006 KOMATSU
All Rights Reserved
32 D155AX-6
SEN00680-01
D155AX-6

D155AX-6 80001 and up

Testing and adjusting, Part 2................................................................................................................ 3
Measuring power train oil pressure ...................................................................................................... 3
Adjusting transmission output shaft speed sensor ..............................................................................11
Simple test procedure for brake performance.................................................................................... 12
Adjusting brake pedal......................................................................................................................... 13
Adjusting parking brake lever ............................................................................................................. 15
Emergency escape method when power train has trouble ................................................................ 17
Adjusting idler clearance .................................................................................................................... 20
Testing and adjusting track shoe tension ........................................................................................... 21
Measuring and adjusting work equipment and HSS oil pressure....................................................... 22
Measuring control circuit basic pressure............................................................................................ 26
Measuring work equipment lock solenoid valve output pressure....................................................... 27
Emergency operation method when work equipment has trouble ..................................................... 28
Measuring ripper pin puller solenoid valve output pressure............................................................... 30
Testing parts which cause hydraulic drift of blade and ripper............................................................. 31
D155AX-6 1
Measuring internal leakage of work equipment cylinder .................................................................... 32

Releasing residual pressure from work equipment cylinder............................................................... 33
Bleeding air from work equipment cylinder ........................................................................................ 33
Adjusting work equipment lock lever .................................................................................................. 34
Adjusting blade................................................................................................................................... 35
Adjusting operator's cab ..................................................................................................................... 37
2 D155AX-6

Measuring power train oil
pressure 1
a Measuring instruments for power train oil pres-
sure
M

work equipment lock lever in the LOCK a Since the inlet pressure and outlet pressure of
position. the torque converter are measured with the
a Measure the power train oil pressure under the Monitoring function of the service mode of the
following condition. machine monitor, there are not oil pressure
q Power train oil temperature: pickup plugs for them in the centralized pres-
Within operating range sure pickup section.
a Since the power trail oil pressure pickup plugs
(centralized pressure pickup section) are
installed inside the right step cover, remove
that cover when measuring the power train oil
pressure.
a Pressure pickup plugs and gauges to be
used
Oil pressure
Oil pressure to be
No. Stamp gauge
measured
(MPa {kg/cm})
Transmission main relief
1 TM 5.9 {60}
pressure
Torque converter lockup
2 LU 2.5 {25}
clutch pressure
Torque converter stator
3 SC 5.9 {60}
clutch pressure
Transmission forward
4 F 5.9 {60}
clutch pressure
Transmission reverse
5 R 5.9 {60}
clutch pressure
Transmission 1st clutch
6 1ST 5.9 {60}
pressure
Transmission 2nd clutch
7 2ND 5.9 {60}
pressure
Transmission 3rd clutch
8 3RD 5.9 {60}
pressure
Steering right brake
9 RB 5.9 {60}
pressure
Steering left brake pres-
10 LB 5.9 {60}
sure
Torque converter inlet Machine

pressure monitor
11
Torque converter outlet Machine

pressure monitor
D155AX-6 3
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.
3) Set the gearshift mode and preset range

4) After finishing measurement, remove the as follows with the gearshift mode selector
measuring instruments and return the switch and shiftup or shiftdown switch.
removed parts. q Gearshift mode:
Auto gearshift (Dozing)
q Preset range: F1-R1
4) Set the machine monitor to Monitoring
function of the service mode.
q Monitoring code:
31520 T/M Fill Sw Input 2
(EMMS).
4 D155AX-6
3. Measuring torque converter stator clutch

pressure (SC)
1) Connect oil pressure gauge [1] of hydrau-
lic tester M to oil pressure pickup plug (3).
a When using an analog oil pressure
gauge, use one of 5.9 MPa {60 kg/
cm}.
5) Set the PCCS lever in the forward position

to run the track shoe idle.
k Take care not to get caught in a
rotating part of the track shoe dur-
ing measurement.
a Keep the steering system in neutral.
6) While running the engine at high idle,
when L/U Fill Sw in the monitoring item is 2) Start the engine and set the PCCS lever in
turned ON, measure the lockup clutch the fully neutral position.
pressure. a The parking brake lever may be set in
the LOCK position.
3) While running the engine at low idle and
high idle, measure the stator clutch pres-
sure.

measuring instruments and return the
removed parts.
removed parts.
D155AX-6 5
4. Measuring transmission forward clutch 6) After finishing measurement, remove the

pressure (F) measuring instruments and return the
1) Connect oil pressure gauge [1] of hydrau- removed parts.
gauge, use one of 5.9 MPa {60 kg/ 5. Measuring transmission reverse clutch
cm}. pressure (R)
cm}.
2) Start the engine and set the parking brake

lever in the FREE position.
as follows with the gearshift mode selector
switch and shiftup or shiftdown switch.
q Gearshift mode: 2) Start the engine and set the parking brake
Manual gearshift (Ripping) lever in the FREE position.
q Preset range: F2-R2 3) Set the gearshift mode and preset range
4) While pressing the brake pedal, set the as follows with the gearshift mode selector
direction of PCCS lever in the forward switch and shiftup or shiftdown switch.
position and shift up the gear to the 3rd q Gearshift mode:
gear speed with the shiftup switch. Manual gearshift (Ripping)
a Keep the steering system in neutral. q Preset range: F2-R2
a Check that [F3] is displayed in the 4) While pressing the brake pedal, set the
gear speed display section. direction of PCCS lever in the reverse
5) While running the engine at high idle, position and shift up the gear to the 3rd
measure the forward clutch pressure. gear speed with the shiftup switch.
k Since the torque converter is q Keep the steering system in neutral.
stalled, keep pressing the brake q Check that [R3] is displayed in the
pedal securely and keep your right gear speed display section.
foot on the decelerator pedal for 5) While running the engine at high idle,
safety until the work is finished. measure the reverse clutch pressure.
k Since the torque converter is
stalled, keep pressing the brake
pedal securely and keep your right
foot on the decelerator pedal for
safety until the work is finished.
6 D155AX-6

k Do not increase the engine speed
to high idle during measurement.

removed parts.
6. Measuring transmission 1st clutch pres-

sure (1ST) 6) After finishing measurement, remove the
1) Connect oil pressure gauge [1] of hydrau- measuring instruments and return the
lic tester M to oil pressure pickup plug (6). removed parts.
cm}. 7. Measuring transmission 2nd clutch pres-
sure (2ND)
cm}.

q Gearshift mode:
Manual gearshift (Ripping) 2) Start the engine and set the parking brake
q Preset range: F1-R1 lever in the FREE position.
4) While pressing the brake pedal, set the 3) Set the gearshift mode and preset range
direction of PCCS lever in the forward as follows with the gearshift mode selector
position. switch and shiftup or shiftdown switch.
a Keep the steering system in neutral. q Gearshift mode:
a Check that [F1] is displayed in the Manual gearshift (Ripping)
gear speed display section. q Preset range: F2-R2
5) While running the engine at low idle, mea- 4) While pressing the brake pedal, set the
sure the 1st clutch pressure. direction of PCCS lever in the forward
position.
D155AX-6 7

a Check that [F2] is displayed in the
gear speed display section.
5) While running the engine at low idle, mea-
sure the 2nd clutch pressure.
Manual gearshift (Ripping)

4) While pressing the brake pedal, set the
direction of PCCS lever in the forward
position and shift up the gear to the 3rd
gear speed with the shiftup switch.
a Check that [F3] is displayed in the
gear speed display section.
5) While running the engine at low idle, mea-
sure the 3rd clutch pressure.
6) After finishing measurement, remove the pedal securely and keep your right
measuring instruments and return the foot on the decelerator pedal for
removed parts. safety until the work is finished.
8. Measuring transmission 3rd clutch pres-
sure (3RD) 6) After finishing measurement, remove the
1) Connect oil pressure gauge [1] of hydrau- measuring instruments and return the
lic tester M to oil pressure pickup plug (8). removed parts.
cm}.

q Gearshift mode:
8 D155AX-6
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 hydraulic 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 position.
tion.

4) After finishing measurement, remove the measuring instruments and return the
measuring instruments and return the removed parts.
removed parts.
D155AX-6 9
11. Measuring torque converter inlet pressure

and outlet pressure
the service mode.
q Monitoring code:
32601 T/C In Pressure,
32603 T/C Out Pressure
(EMMS).
2) Start the engine and set the PCCS lever in

the fully neutral position.
a The parking brake lever may be set in
the LOCK position.
3) While running the engine at low idle and
high idle, measure the inlet pressure and
outlet pressure of the torque converter.
10 D155AX-6
Adjusting transmission output 5. After finishing adjustment, return the removed

shaft speed sensor 1 parts.
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
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.
2. Screw in sensor (1) until its tip touches the

tooth tip of bevel gear (2).
2 Threads: Gasket sealant (LG-5)
3. Return sensor (1) by the specified angle.

a Returning angle of sensor: 1/2 1 turn
a Adjust clearance (a) between the sensor
tip and gear tooth tip to 0.75 1.5 mm.
4. While fixing sensor (1), tighten nut (3).

3 Nut: 49.0 68.6 Nm {5 7 kgm}
D155AX-6 11
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
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
1. Set the blade and ripper in the travel position

on a level place.
2. Run the engine and set the parking brake lever

in the FREE position.
3. Set the gearshift mode and preset range as fol-

lows with the gearshift mode selector switch
and shiftup or shiftdown switch.
q Gearshift mode:
Manual gearshift (Ripping)
4. While pressing the brake pedal, set the direc-

tion of PCCS lever in the forward position.
k If this test is carried out in the 1st gear
position, the brake will be overloaded.
Accordingly, be sure to carry out in the
2nd gear speed.
a Check that [F2] is displayed in the gear
speed display section.
5. Press the decelerator pedal and set the fuel

control dial in the high idle (MAX) position.
12 D155AX-6
Adjusting brake pedal 1
a Adjusting tool for brake pedal

N 79A-264-0091 Push-pull scale

position.
a Tighten the locknut of the rod securely and
bend the cotter pin securely.
a When adjusting the brake pedal, remove the
left cover of the dashboard and left foot rest as
a unit. 2) Adjust installed dimension (b) of stopper
(2) so that dimension (a) will be 80 mm.
1. Adjusting brake potentiometer q Dimension (b) = 35.5 mm (Reference
1) Turn the starting switch ON and set the value)
machine monitor to Adjusting function of 3) Adjust installed dimension (b) of stopper
the service mode. (2) so that the brake pedal potentiometer
a Adjustment code: 0005 voltage will be the specified voltage when
(Brake pedal potentiometer initial cor- brake pedal (1) is released.
rection) q Brake pedal voltage: 2,500 50 mV
a For the operating method, see "Spe- 4) Referring to "Special functions of machine
cial functions of machine monitor monitor (EMMS), Service mode 07, Adjust-
(EMMS)". ment (Adjustment ID: 0005)", perform initial
correction of the brake pedal potentiome-
ter.
D155AX-6 13
2. Adjusting brake pedal pressing effort

a While brake pedal (1) is released, adjust
installed dimension (d) of return spring (5).
1) Loosen nut (8).
2) Turn double nut (7) to adjust the brake
pedal pressing effort.
a Turn the 2 nuts together. Do not loosen
them from each other.
q Adjustment dimension (d) of rod
(Installed dimension of return spring):
92 0.5 mm
q Assembly dimension (e) of rod:
127 mm
3. Adjusting brake limit switch

1) Press brake pedal (1). When the brake
pedal potentiometer voltage is in the fol-
lowing range, fix the brake pedal.
q Brake pedal voltage:
3,940 4,150 mV
2) Adjust the installed position of brake limit
switch (6) so that it will be turned ON at
this position.
q Backup brake active Sw ON
3) After adjusting, return the brake pedal
slowly and check that brake limit switch
(6) is turned OFF in the voltage range
shown in 1).
q Backup brake active Sw OFF
4. Measuring brake pedal pressing force

1) Operate the brake pedal with the foot and
check that it moves smoothly.
2) Using push-pull scale N, measure the
pressing force to start operation of the
brake.
q Pressing force to start operation:
49 N {5 kg}
3) Using push-pull scale N, measure the
pressing force at the stroke end of the
brake pedal.
q Pressing force at stroke end:
461 N {47 kg}
5. Work after finishing adjustment

After finishing adjustment, return the removed
parts.
14 D155AX-6
Adjusting parking brake lever 1
k Stop the machine on level ground, lower q Brake oil pressure (At high idle)
Parking brake lever Oil pressure
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}
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).
2. Checking brake oil pressure

Run the engine and check that the brake oil
pressure is as follows when parking brake
lever (3) is set in the FREE position and LOCK
position.
a For the method of measuring the brake oil
pressure, see Measuring power train oil
pressure.
D155AX-6 15
3. Checking limit switch

the service mode.
a Monitoring code:
40905 T/M Sw Input 1
(EMMS)".
2) Check that the limit switch signal is input

normally when parking brake lever (3) is
set in the FREE position and LOCK posi-
tion.
q FREE position:
Travel lock NC OFF, Travel lock NO
ON
q LOCK position:
Travel lock NC ON, Travel lock NO
OFF
16 D155AX-6
Emergency escape method when

power train has trouble 1
a Tools for emergency escape
19M-06-32820 Switch assembly
1
P 17A-06-41410 Wiring harness
2 790-190-1601 Pump assembly
1. Emergency escape method with switch box

(Using P1)
a If the machine cannot be moved because
of a trouble in the electric system of the 3) Disconnect neutral safety relay NSF (2)
power train control unit (travel direction, and connect pins No. 3 and No. 5 of the
gear speed, steering), escape according connector on the wiring harness side.
to the following procedure. a Direct coupling circuit: NSF (female)
a The engine must be startable for the fol- No. 3 io No. 5
lowing procedure. a If connector PL1 is disconnected, a
a If the engine cannot be started, see Emer- model selection error is made and
gency escape method with brake releas- neutral safety relay NSF is not driven.
ing device (Using P2). The above operation is performed to
k Do not turn the starting switch ON or
prevent this.
k If the engine is started by this
start the engine before preparing the
switch assembly and wiring harness method, the neutral safety function
P1 completely. d o e s n o t w o r k . A c c o r d i n g l y,
1) Connect wiring harness [2] to switch before starting the engine, set the
assembly [1] of emergency escape device parking brake lever in the LOCK
P1. position and set the PCCS lever in
k Set the all gear speed switches of the fully neutral position.
switch assembly [1] in the OFF k Start the engine by this method
position and set the directional only in an emergency. If the engine
switch in the P position to prevent does not start in another case, be
the machine from starting sud- sure to carry out troubleshooting
denly. and repair the trouble.
2) Open the left fender inspection cover and

connect wiring harness [2] to connector
PL1 (1).
a The male housing and female hous-
ing of connector PL1 are fixed with
screws.
a Connect the wiring harness to both
male side and female side of connec-
tor PL1.
D155AX-6 17
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.
3) Remove the fuel tank undercover and dis-

connect supply hose (3) of the pin puller
solenoid valve.
6) After moving the machine, remove the

instruments used and return the removed
parts.
a Check that the seal at the joint of con-
nector PL1 is not projected or
removed and then tighten the screws
to the specified torque.
3 Screw of connector PL1:
2.83 0.28 Nm {0.288 0.028 kgm}
2. Escape method with brake releasing device

(Using P2)
a If the engine cannot be started and the 4) Connect end hose [4] of pump assembly
parking brake cannot be released, escape P2 to the hose side.
according to the following procedure. a Since the hose on the machine side is
1) Assemble pump assembly P2. face seal type, use a nipple of face
seal type on the pump assembly P2
side.
a Stop the solenoid valve side with a
cap nut, etc.
Cap nut: 02789-00315

parking brake lever in the FREE position.
18 D155AX-6
6) Operate the volume pump to raise the

brake releasing oil pressure to the initial
pressure.
q Initial pressure: Approx. 2.74 MPa
{Approx. 28 kg/cm}
a Since the accumulator is installed in
the circuit, the handle must be oper-
ated 30 50 times to raise the oil
pressure.
a If the oil pressure does not rise above
a certain level, the relief valve may be
set to low pressure. In this case,
adjust the set pressure of the relief
valve.
7) Tow the machine to a safe place.
a The brake releasing oil pressure low-
ers gradually because of internal
leakage and the brake is applied
again in about 1 minute. Accordingly,
work quickly.
a If the brake releasing pressure lowers
to about 1.57 MPa {about 16 kg/cm},
the brake is applied. In this case,
operate the volume pump again to
raise the brake releasing pressure to
the initial pressure.
D155AX-6 19
Adjusting idler clearance 1
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
Testing and adjusting track shoe

tension 1
position.
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
1. Remove cover (2).
2. When the tension is too high

Loosen plug (3) to discharge the grease.
k Since the high-pressure grease may
spout out, do not loosen the plug more
than 1 turn.
3 Plug: 59 88 Nm {6 9 kgm}
3. When tension is low

Add grease through grease fitting (4).
a If the track shoe is not tensed well, drive
the machine forward and in reverse
slowly.
D155AX-6 21
Measuring and adjusting work

equipment and HSS oil pressure 1
a Measuring and adjusting instruments for work
equipment and HSS oil pressure
1
Q
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring

the work equipment to the ground, stop the 3) Run the engine at high idle and set the
engine, and set the parking brake lever and blade control lever and ripper control lever in
work equipment lock lever in the LOCK neutral and measure the unload pressure.
position. a The work equipment lock lever may
a When measuring and adjusting the work be set in the LOCK position.
equipment and HSS oil pressure, remove the k Do not operate the work equipment
control valve cover. or steer the machine with the oil
pressure gauge of 5.9 MPa {60 kg/
4 Control valve cover: 25 kg cm} installed. If you do so, the oil
pressure gauge will be broken.
Measuring
a Measure the work equipment and HSS oil
pressure under the following condition.
ing range
a The unload pressure, work equipment oil pres-
sure, and HSS oil pressure can be checked
with the monitoring function of the service
mode of the machine monitor (See 4).
1. Measuring unload pressure

1) Remove P oil pressure pickup plug (1)
from the control valve.

removed parts.
2. Measuring work equipment oil pressure
1) Remove P oil pressure pickup plug (1)
and LS oil pressure pickup plug (2) from
the control valve.
2) Install nipple Q2 and connect it to oil pres-

sure gauge [1] of hydraulic tester Q1.
cm}.
22 D155AX-6
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}.
3) Start the engine and set the work equip-

ment lock lever in the FREE position.
4) Run the engine at high idle, operate the
blade control lever and ripper control lever 2) Start the engine, set the parking brake
to relieve each cylinder at a stroke end, lever in the FREE position, and keep
and measure the work equipment relief pressing the brake pedal.
pressure and work equipment LS relief 3) Run the engine at high idle, set the PCCS
pressure. lever in the right or left steering position to
a The work equipment relief pressure is relief the steering circuit, and measure the
measured on the P-stamp side and HSS relief pressure and HSS LS relief
the work equipment LS relief pres- pressure.
sure is measured on the LS-stamp k Since the steering circuit is re-
side. lieved, keep pressing the brake
k Do not steer the machine with the pedal securely and keep your right
oil pressure gauge of 39.2 MPa foot on the decelerator pedal for
{400 kg/cm} installed. If you do safety until the work is finished.
so, the oil pressure gauge will be a The HSS relief pressure is measured
broken. on the P-stamp side and the HSS LS
relief pressure is measured on the
LS-stamp side.

removed parts. 4) After finishing measurement, remove the
removed parts.
D155AX-6 23
4. Measuring with machine monitor Adjusting

1) Turn the starting switch ON and set the 1. Adjusting unload pressure
machine monitor to Monitoring function of a The unload pressure cannot be adjusted.
the service mode.
q Monitoring code: 2. Adjusting work equipment oil pressure
70700 Hydraulic Pump Pressure 1 a If the work equipment oil pressure is
a For the operating method, see Spe- abnormal, adjust it with work equipment
cial functions of machine monitor LS relief valve (3) according to the follow-
(EMMS). ing procedure.
a The 5-spool valve of the single tilt specifi-
cation is shown in the figure (The dual tilt
machine has the 6-spool valve).
2) Start the engine and measure each oil

pressure.
a The measuring condition of each oil
pressure is the same with 1 3 1) While fixing adjustment nut (4), loosen
above. locknut (5).
a Only the oil pressures on the P-stamp 2) Adjust the pressure by rotating adjustment
side (unload pressure, work equip- nut (4).
ment relief pressure, and HSS relief a If the adjustment nut is
pressure) can be measured with the q rotated to the right, the pressure
monitoring function. The oil pres- is heightened.
sures on the LS-stamp side (work q rotated to the left, the pressure is
equipment LS relief pressure and lowered.
HSS LS relief pressure) cannot be a Quantity of adjustment per turn of
measured. adjustment nut: Approx. 19.6 MPa
{Approx. 200 kg/cm}
3) While fixing adjustment nut (4), tighten
locknut (5).
3 Locknut: 39 49 Nm {4 5 kgm}
4) After finishing measurement, check the

work equipment oil pressure according to
the above measuring method.
24 D155AX-6
3. Adjusting HSS oil pressure

a If the HSS oil pressure is abnormal, adjust
it with HSS LS relief valve (6) according to
a The 5-spool valve of the single tilt specifi-
cation is shown in the figure (The dual tilt
machine has the 6-spool valve).
1) While fixing adjustment screw (7), loosen

locknut (8).
2) Adjust the pressure by rotating adjustment
screw (7).
a If the adjustment screw is
q rotated to the right, the pressure
is heightened.
q rotated to the left, the pressure is
lowered.
a Quantity of adjustment per turn of ad-
justment screw:
Approx. 15.1 MPa
{Approx. 154 kg/cm}
3) While fixing adjustment screw (7), tighten
locknut (8).
3 Locknut:
68.6 78.5 Nm {7 8 kgm}
4) After finishing measurement, check the

HSS oil pressure according to the above
measuring method.
D155AX-6 25
Measuring control circuit basic

pressure 1
a Measuring instruments for control circuit basic
pressure
1
R 709-261-1204 Digital hydraulic tester
2 799-401-3200 Adapter (03)
a The control circuit basic pressure is the pres-

sure lowered by the self-pressure reducing
valve of the fan circuit. It is used commonly for
the EPC valves of the control valve (steering, 4. Run the engine at high idle, set the blade con-
blade, and ripper), HSS circuit charge, fan trol lever and ripper control lever in neutral,
pump control, and blade lift cylinder quick drop and measure the control circuit basic pressure.
EPC valve. a The work equipment lock lever may be set
k Stop the machine on level ground, lower in the LOCK position.
position.
a Measure the control circuit basic pressure
under the following condition.
ing range
1. Remove the control valve cover and discon-

nect accumulator inlet hose (1).
4 Control valve cover: 25 kg

suring instrument and return the removed
parts.
a The control circuit basic pressure cannot be

adjusted.
2. Install adapter R2 and connect the discon-

nected hose again.
3. Install nipple [1] of hydraulic tester R1 and con-

nect it to oil pressure gauge [2].
26 D155AX-6
Measuring work equipment lock

solenoid valve output pressure 1
a Measuring instruments for work equipment
lock solenoid valve output pressure
1
S 790-261-1204 Digital hydraulic tester
2 799-401-3200 Adapter (03)

engine, and set the parking brake lever and 4. Run the engine at high idle, set the work equip-
work equipment lock lever in the LOCK ment lock lever in the LOCK position and
position. FREE position, and measure the solenoid
a Measure the work equipment lock solenoid valve output.
valve output pressure under the following con- a If the output pressure is as follows, the
dition. operation of the work equipment lock sole-
q Hydraulic oil temperature: Within operat- noid valve is normal.
ing range
Work equipment
Output pressure
1. Remove the control valve cover and discon- lock lever
nect control valve inlet hose (1). LOCK position 0 MPa {0 kg/cm}
4 Control valve cover: 25 kg Same as control circuit
FREE position basic pressure (See stan-
dard value table)
2. Install adapter S2 and connect the discon-

nected hose again.
3. Install nipple [1] of hydraulic tester S1 and con- suring instrument and return the removed
nect it oil pressure gauge [2]. parts.
D155AX-6 27
Emergency operation method 3. Disconnect connector WLK of the work equip-

when work equipment has trouble1 ment lock solenoid valve and connect it to the
male side of wiring harness T.
a Tools for emergency operation
T 17A-06-41421 Wiring harness
a If the blade or ripper cannot be moved be-

cause of a trouble in the work equipment con-
trol s ystem, oper ate it ac cording to the
a The engine must be startable for the following
procedure.
k Do not turn the starting switch ON or start
the engine before preparing wiring harness
T completely.
a Connector on machine side to be con-
1. Install wiring harness T in the operator's cab nected
and check where to connect each connector. Connector on Connector on wiring
q WLK: To work equipment lock solenoid machine side harness T side
under floor
WLK (male) WLK
q WEPW: To power supply connector
above control valve
q WEPX: To EPC solenoid above control 4. Remove the control valve cover.
valve 4 Control valve cover: 25 kg
q WEPY: To EPC solenoid above control
valve 5. Remove the plug of power supply connector
WEPW above the control valve and connect
connector WEPW of wiring harness T to the
female side.
2. Remove the floor cover from the front of the

operator's seat.
4 Floor cover: 20 kg a Connector to be connected
Connector on machine Connector on wiring
side harness T side
WEPW (female) WEPW
28 D155AX-6
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).
8. After finishing operation of the work equip-

ment, remove the tools used and return the
removed parts.
a Connectors to be connected (The follow-

ing table is for the dual tilt specification.
WEP5 and WEP6 are not connected to
the single tilt specification.)
Connectors on machine side
Device/Operating direction No. Band color
Raise WEP1 Green
Blade lift
Lower WEP2 Green/Black
Retract WEP3 Brown
Blade tilt left
Extend WEP4 Brown/Black
Retract WEP5 Blue
Blade tilt right
Extend WEP6 Blue/Black
Raise WEP7 Yellow
Ripper lift
Lower WEP8 Yellow/Black
In WEP9 Red
Ripper tilt
Back WEPA Red/Black
Connectors on wiring harness T side
Device/Operating direction No. Band color
UP WEPX
LIFT
DOWN WEPY
D155AX-6 29
Measuring ripper pin puller

solenoid valve output pressure 1
a Measuring instruments for ripper pin puller
solenoid valve output pressure
1
U 790-261-1204 Digital hydraulic tester
2 799-401-3200 Adapter (03)

work equipment lock lever in the LOCK 4. Run the engine at high idle, set the pin puller
position. switch in the pull-out position and push-in posi-
a Measure the ripper pin puller solenoid valve tion, and measure the solenoid valve output
output pressure under the following condition. pressure at each position.
q Power train oil temperature: a If the output pressure is as follows, the
Within operating range operation of the ripper pin puller solenoid
valve is normal.
1. Remove the undercover of the fuel tank and
Tested Pin puller
disconnect ripper pin puller solenoid valve Output pressure
hose switch
hose (1) or (2).
Same as transmission
q Hose (1): Pin puller cylinder head side
Pull-out main relief pressure
q Hose (2): Pin puller cylinder bottom side (1) (See standard value table)
Push-in 0 MPa {0 kg/cm}
Pull-out 0 MPa {0 kg/cm}
(2) Same as transmission

Push-in main relief pressure
(See standard value table)
2. Install adapter U2 and connect the discon-

nected hose again.
3. Install nipple [1] of hydraulic tester U1 and con-

nect oil pressure gauge [2].
suring instrument and return the removed
parts.
30 D155AX-6
Testing parts which cause

hydraulic drift of blade and ripper1
a If the blade or ripper drifts hydraulically, check
to see if the cause is on the cylinder packing
side or control valve side according to the fol-
lowing procedure.
1. Set the cylinders to be tested in the following

positions and stop the engine.
1) Blade lift cylinder
Brace the blade to raise the front side of
the machine body.
a Since the blade lift cylinder is
equipped with a piston valve, do not 2. Turn the starting switch ON and set the work
extend it to the stroke end. equipment lock lever in the FREE position.
3. Extend the cylinder to be tested with the corre-

sponding lever and check its movement.
q If the lowering speed is increased, the cyl-
inder packing is defective.
q If the lowering speed does not change, the
control valve is defective.
a If the pressure in the accumulator is lost,
run the engine for about 10 seconds to
heighten the pressure in the accumulator.
[Reference]
Reason why the lowering speed is increased when
the cylinder packing is the cause of the hydraulic
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
Measuring internal leakage of q Hose (2): Ripper lift cylinder

work equipment cylinder 1 q Hose (3): Ripper tilt cylinder
Head: 07378-11000 (Size #10)
a Measuring instruments for internal leakage of O-ring: 07000-13032 (Size #10)
work equipment cylinder
Commercially
V Measuring cylinder
available
position.
a Since the blade lift cylinder is equipped with a
piston valve, its internal leakage cannot be
measured.
a Measure the internal leakage of work equip-
ment cylinder under the following condition.
q Hydraulic oil temperature: Within operat- 3. Run the engine at high idle and apply the relief
ing range pressure to the cylinder bottom side.
q Blade tilt cylinder:
1. Extend the cylinder to be measured to the Operate to tilt blade to left.
stroke end and set the machine in the measur- q Ripper lift cylinder:
ing position. Operate to lower ripper.
1) Blade tilt cylinder q Ripper Tilt cylinder:
Tilt the blade to the left end. Operate to tilt ripper forward (in).
2) Ripper lift cylinder
Pull out the shank pin and lower the ripper 4. After 30 second, measure leakage in 1 minute
to the end. with measuring cylinder V.
3) Ripper tilt cylinder
Tilt the ripper forward (in) to the end.
k Release the residual pressure from the
cylinder circuit. For details, see Re-
leasing residual pressure from work
equipment cylinder.
2. Disconnect hoses (1), (2), and (3) on the head

side of the tested cylinder and stop the hose
side with a plug or a flange.
a When working on the blade tilt cylinder
hoses, remove the hose cover of the frame.
k Take care not to disconnect the hoses
on the bottom side.
q Hose (1): Blade tilt cylinder
5. After finishing measurement, return the re-
Plug: 07376-70422 (Size #04)
moved parts.
O-ring: 02896-11012 (Size #04)
a Bleed air from the cylinder circuit. For de-
tails, see Bleeding air from work equip-
ment cylinder.
32 D155AX-6
Releasing residual pressure from Bleeding air from work equipment

work equipment cylinder 1 cylinder 1
a When disconnecting the piping between the a If the work equipment cylinder is removed and
control valve and work equipment cylinder, installed or its piping is disconnected and con-
release the residual pressure from the circuit nected, bleed air from its circuit according to
according to the following procedure. the following procedure.
k Stop the machine on level ground, lower a Before performing the following operation,
the work equipment to the ground, stop the check that the hydraulic oil level is normal.
work equipment lock lever in the LOCK 1. Run the engine at low idle for about 5 minutes.
position.
2. While running the engine at low idle, extend
1. Loosen oil filler cap (1) of the hydraulic tank and retract the cylinder to be bled 4 5 times.
gradually to release the residual pressure from a Move the piston rod to about 100 mm
the tank. before the stroke end and never relieve
the oil.
3. While running the engine at high idle, carry out

the operation in step 2.
4. While running the engine at low idle, move the

cylinder to the stroke end to relieve the oil.
2. Turn the starting switch ON and set the work

equipment lock lever in the FREE position.
3. Operate the blade control lever and ripper

control lever to each direction.
a If the control lever is operated 2 3 times,
the residual pressure in the accumulator is
released.
4. Run the engine at low idle for about 10 sec-

onds to increase the pressure in the accumula-
tor, then stop it.
5. Repeat steps 2 4 above 2 3 times.
D155AX-6 33
Adjusting work equipment lock lever 1
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).
position.
a Tighten the locknut of the rod securely and
a When adjusting the work equipment lock lever,
remove the control valve cover.
4 Control valve cover: 25 kg
1. Set work equipment lock lever (1) in the LOCK

position.
2. Set and install limit switch (2) to sliding surface

(a) of lever (3).
a Just set the roller of the limit switch to the
5. Check that the limit switch signal is input nor-
sliding surface. Do not move it.
mally when work equipment lock lever (1) is
set in the FREE position and LOCK position.
3. Set work equipment lock lever (1) in the FREE
q FREE position:
position and check that limit switch (2) oper-
Work equipment lock NC OFF, Work
ates normally.
equipment lock NO ON
q Stroke of limit switch: 2.5 3 mm
q LOCK position:
Work equipment lock NC ON, Work equip-
ment lock NO OFF
machine monitor to Monitoring function of the
service mode.
34 D155AX-6
Adjusting blade 1
a If the blade is removed and installed or disas-

sembled and reassemble, adjust it according
to the following procedure.
a The above figure shows the blade of the dual
tilt specification.
1. Adjusting shims for assembly

1) Adjust the shim of tilting section (1) (1
place).
a After reassembling the tilting section,
supply grease to it.
2 Tilting section: Grease (G2-LI)
Adjusted Adjusted Standard Standard shim

point clearance clearance thickness
1 a See note. 4 mm
a Adjust the shim so that the play of the

ball in the axial direction will be less
than 1 mm and the ball can rotate
smoothly.
D155AX-6 35
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
3) Adjust the shim of lifting section (3) (2

places).
Adjusted Adjusted Standard Standard shim 3) If both tilt distances are not the same,
point clearance clearance thickness adjust installed dimension (d) of brace (4)
3 c Max. 1 mm 4 mm according to the following procedure.
q e1 > e2:
Increase installed dimension (d)
slightly.
q e1 < e2:
Decrease installed dimension (d)
slightly.
36 D155AX-6
Adjusting operator's cab 1

a If the operator's cab is removed and installed
or disassembled and transported and assem-
bled in the field, test and adjust it according to
1. Measuring internal pressure of cab

a Criterion
Criterion:
Measured value X 88.2 Pa {9 mmH2O}
a Measurement condition
q Engine speed: High idle
q Fan speed: Fan 100% mode
q EXTERNAL/INTERNAL air 7) Start the engine and set the machine mon-
changeover switch: itor to Adjusting function of the service
EXTERNAL position mode.
q Air conditioner fan switch: High (FULL) a Adjustment code:
1) Prepare a transparent vinyl hose. 1005 (Fan 100% mode)
q Outside diameter: 6 mm, Length: a For the operating method, see Spe-
3,000 mm cial functions of machine monitor
2) Secure the inside end of the hose to the (EMMS).
top of the seatback with a tape.
3) Remove 1 bolt (1) under the left console
box. Pass the other end of the hose
through the bolt hole and take it out of the
top of battery cover (2) on the left side of
the cab.
8) Run the engine at high idle and measure

water level difference (c) in hose [1].
q (a): Inside of cab (Pressurized)
q (b): Out of cab (Ambient pressure)
q (c): Measured value (Internal pres-
sure of cab)
4) Seal the clearance between the hole of a If the measured value (internal pres-
bolt (1) and hose [1] with tape (3). sure of the cab) is lower than the
5) Pour water in the hose up to about half standard value, check the seals of the
and bend the hose in a U-shape. h o l e s fo r w i r i n g h a r n e s s e s a n d
6) Secure hose [1] to the outside of the cab optional parts in the cab.
and set the water level in the vinyl hose
out of the cab to that in the cab. 2. Checking searing performance
1) Close all the openings (doors and win-
dows) of the cab.
2) Splash water around the hatched part of
the cab at the rate of about 19 l/min for 10
minutes.
a At this time, it is not necessary to
splash pressurized water.
3) Splash water horizontally from a hose over
the contact portions of seal (4) between
the cab and floor frame.
D155AX-6 37
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.
3. Testing and adjusting door lock (damper

rubber)
a Close the door and check the relationship
between the operator's cab and door 4. Testing and adjusting door lock (latch and
(damper rubber portions). If there is any striker)
abnormality, adjust it. a Close the door and check the relationship
1) Stick adhesive tape [2] to the contact face between the operator's cab and door
of damper rubber (6) of door (5). (latch and striker). If there is any abnor-
a Check both sides, 2 places on each mality, adjust it.
side. 1) Move door (5) in the closing direction and
2) Open and close door (5) 2 3 times. check the engaging condition of latch (8)
3) Check the contact portions of adhesive and striker (9).
tape [2] and operator's cab. a Check quantity of misalignment (f)
q Normal: between center of latch (d) and center
When the door is closed, the damper of striker (e) from the direction of A.
rubber comes in contact lightly (No q Normal: Quantity of misalignment (f)
adjustment is required). is 0.5 mm or less.
q Abnormal:
When the door is closed, the damper
rubber does not come in contact or
comes in contact so strongly that the
adhesive tape is removed (Adjust-
ment is required).
2) Tighten the mounting bolts of striker (9)

temporarily. Then, open and close door
(5) 2 3 times to align latch (8) with striker
(9).
3) Check the engagement of latch (8) and
striker (9).
4) Tighten the mounting bolts of striker (9)
securely.
38 D155AX-6
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)
4) Loosen the mounting bolts of striker (10).

5) While setting striker (10) upright, tighten
the mounting bolts.
5. Testing and adjusting open lock (latch and

striker)
a Check the relationship between the opera-
tor's cab and door (latch and striker) while
the door is locked open. If there is any
fault, adjust the open lock.
1) Check the relationship between the open
lock latch and striker from the direction of
B.
a Move the door in the opening direc-
tion and check the engagement of the
latch and striker.
D155AX-6 39
6. Testing and adjusting open lock (stopper

rubber)
a Check the relationship between the opera-
tor's cab and door (stopper rubber) while
the door is locked open. If there is any
fault, adjust the open lock.
1) Lock the door open and move it in the for-
ward and reverse directions to check that
it does not have play.
a Check both sides, 2 places on each
side.
2) Check that the operating effort of the
unlock lever is not large.
3) Loosen the locknut of stopper rubber (12)
(upper one).
4) Loosen the locknut of stopper rubber (13)

(lower one).
5) Adjust the height of stopper rubbers (12)

and (13) according to the trouble.
a If there is play, project (heighten) the
stopper rubber until the play is elimi-
nated.
a If the door is not locked easily or the
unlock lever is heavy, return (lower)
the stopper rubber in the range that
the door does not have play.
6) While fixing stopper rubbers (12) and (13),
tighten the locknuts.
40 D155AX-6
D155AX-6 Bulldozer
2006 KOMATSU
All Rights Reserved
42 D155AX-6
SEN00681-01
D155AX-6

D155AX-6 80001 and up

Special functions of machine monitor (EMMS) .................................................................................... 2
D155AX-6 1
Testing and adjusting, Part 3 1

Special functions of machine monitor (EMMS) 1
Air conditioner specification
2 D155AX-6
Heater specification Upper section of machine monitor (Display sec-

tion)
(a): Multi-display
a The figure shows an example of display of sym-
bols and gauges in the ordinary display mode
(The contents of display depend on the condi-
tion of the machine and operating method).
a When the engine is started, the battery voltage
may lower suddenly, depending on the ambi-
ent temperature and the condition of the bat-
tery. In this case, the machine monitor goes off
for a moment. This phenomenon is not a fail-
ure, however.
Upper section of machine monitor (Switch sec-
tion)
[F1]: F1 function switch
a The function of each function switch is indi-
cated by graphic mark in the multi-display (a)
above that function switch.
a If the graphic mark of a function switch is not
displayed, that function switch is not working.
Lower section of machine monitor (Switch sec-
tion)
[1]: Numeral 1 input switch/Operation mode selec-
tor switch
[2]: Numeral 2 input switch/Gearshift mode selec-
tor switch
[3]: Numeral 3 input switch/Customize switch
[4]: Numeral 4 input switch/Buzzer cancel switch
[5]: Numeral 5 input switch/Float mode switch
[6]: Numeral 6 input switch/Customize memory
switch
[7]: Numeral 7 input switch/Air conditioner or heat-
er switch
er switch
er switch
er switch
Switch having no numerals: Air conditioner or
heater switch
a Each switch has the function indicated by
graphic mark and the function of inputting a
numeral.
a The machine monitor automatically judges
which function of each switch is currently effec-
tive, according to the display condition of multi-
display (a).
a The difference between the air conditioner
specification and heater specification is only
the functions of the switches in this section.
D155AX-6 3
t Ordinary functions and special functions of machine monitor

The machine monitor has the ordinary functions and special functions and displays information of various
types on the multi-display.
Some items are displayed automatically according to the internal setting of the machine monitor and the oth-
ers are displayed according to the operation of the switches.
1. Ordinary functions: Operator mode
The items in this mode are displayed ordinarily. The operator can display and set them by operating the
switches (Display and setting of some items need special operations of the switches).
2. Special functions: Service mode
The items in this mode are not displayed ordinarily. Each serviceman can display them by operating the
switches specially. This mode is used for special setting, testing, adjusting, or troubleshooting.
Page Page
Operator mode (Outline) Service mode
5p 16 p
A Display of KOMATSU logo 5p 01 Monitoring 17 p
Mechanical system "Abnormality
A Display of screen to input password 6p 24 p
Record"
02 Abnormal- Electrical system "Abnormality
A Display of check before starting 6p 25 p
ity Record Record"
Air conditioner "Abnormality Record"/
A Display of warning after check before starting 6p 35 p
Heater "Abnormality Record"
A Display of ending of maintenance interval 6p 03 Maintenance Record 36 p
A Display of check of preset 7p 04 Maintenance Mode Change 37 p
A Display of ordinary screen 7p 05 Phone Number Entry 39 p
A Display of end screen 7p Key-on Mode 40 p
B Selection of operation mode 7p Setting of unit 41 p
B Selection of gearshift mode 8p o 06 Default Setting of maintenance password 42 p
B Customizing operation 8p Setting of camera 43 p
Special operations
B Operation of customize memory 8p Setting of ECO display 44 p

B Selection of float mode 8p 07 Adjustment 45 p
B Operation to cancel alarm buzzer 8p 08 PM CLINIC 71 p
B Operation of air conditioner/heater 9p 09 Cylinder Cut-Out 72 p
B Selection of dual tilt (Dual tilt specification) 9p 10 No Injection 73 p
Operation to display camera mode
B 10 p 11 Fuel Consumption 74 p
(if camera is installed)
B Operation to display clock and service meter 10 p Terminal Status 75 p
B Check of maintenance information 11 p 12 KOMTRAX GPS & Communication Status 76 p
Setting and display of user mode Settings
B 11 p Modem S/N 77 p
(including KOMTRAX messages for user)
C Display of caution monitor 12 p 13 Service Message 78 p
C Display of action code and failure code 12 p
O (Special operations)
Function of checking display of LCD
D 14 p
(Liquid Crystal Display)
D Function of checking service meter 14 p
D Function of changing maintenance password 15 p
a Classification of operator mode

A: Display/Function from time when starting switch is turned ON to time when screen changes to ordi-
nary screen and display after starting switch is turned OFF
B: Display/Function when switch of machine monitor is operated
C: Display/Function when certain condition is satisfied
D: Display/Function which needs special operation of switch
4 D155AX-6
t Operator mode (Outline) a Display pattern of operator mode

a Only outline of the operator mode is described The contents of display from the time when
in this section. For details of contents/opera- starting switch is turned ON to the time when
tion of each function/display, see "the Struc- screen changes to ordinary screen depends on
ture, function and maintenance standard, or the setting and condition of the machine.
Operation and Maintenance Manual". a: When engine start lock is set effective
a The following are the displays or functions of b: When engine start lock is set ineffective
the operator mode explained in this section c: When there is abnormal item in check-
(including some items which need special before-starting items
operations). d: When there is maintenance item which is
not maintained after specified interval
Display pattern
a b c d Display of KOMATSU logo
When the s tarting switch is turned ON, the
Display of KOMATSU logo 1 1 1 1
KOMATSU logo is displayed for 2 seconds.
Display of screen to input password 2 After the KOMATSU logo is displayed for 2 sec-
Display of check before starting 3 2 2 2 onds, the screen changes to "Display of screen to
Display of warning after check before input password" or "Display of check before start-
3 ing".
starting
Display of ending of maintenance inter-
3
val
Display of check of preset 4 4 4 4
Display of ordinary screen 5 4 5 5
Display of end screen
Selection of operation mode
Selection of gearshift mode
Customizing operation
Operation of customize memory
Selection of float mode
Operation to cancel alarm buzzer
a The following screen may be displayed instead
Operation of air conditioner/heater
of the above "Display of screen to input pass-
Selection of dual tilt (Dual tilt specification) word screen".
Operation to display camera mode a If this screen is displayed, call the person
(if camera is installed) responsible to operation of KOMTRAX in your
Operation to display clock and service meter Komatsu distributor and ask for remedy.
Check of maintenance information
Setting and display of user mode
(including KOMTRAX messages for user)
Display of caution monitor
Display of action code and failure code
O (Special operations)
Function of checking display of LCD (Liquid Crystal Dis-
play)
Function of checking service meter
Function of changing maintenance password
D155AX-6 5
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.
Display of ending of maintenance interval

When the check before starting is carried out, if a
maintenance item is near or after the end of the set
interval, the maintenance monitor is displayed for
Display of check before starting 30 seconds to urge the operator to maintenance.
When the screen changes to the check-before- a This screen is displayed only when the mainte-
starting screen, the check before starting is carried nance function is effective. The color of the
out for 2 seconds. maintenance monitor (yellow or red) indicates
a If any abnormality is detected by the check the length of the time after the maintenance
before starting, the screen changes to "Display interval.
of warning after check before starting" or "Dis- a Set or change the maintenance function in the
play of ending of maintenance interval". service mode.
a If no abnormality is detected by the check
before starting, the screen changes to "Display
of check of preset".
a The monitors (3 pieces) displayed on the
screen are the items under the check before
starting.
6 D155AX-6
Display of check of preset Display of end screen

If the check before starting is finished normally, the When the starting switch is turned OFF, the end
screen to check the preset (gear speed at start) is screen is displayed for 5 seconds.
displayed for 2 seconds. a Another message may be displayed on the
a After display of check of preset is finished, the end screen, depending on the message dis-
sc re en ch anges to "Di spl ay of ordi nary play function of KOMTRAX.
screen".
Selection of operation mode

Display of ordinary screen While the ordinary screen is displayed, press the
If the machine monitor starts normally, the ordinary operation mode selector switch, and the operation
screen is displayed. mode monitor (a) changes.
a Service meter (a) or a clock is displayed at the a Each time the switch is pressed, the operation
center upper section of the screen (The ser- mode changes between [P (Power)] and [E
vice meter or clock is selected with [F4]). (Economy)].
a Power train oil temperature gauge (b) is dis-
played on the multi-gauge section (It is turned
ON and OFF with the user mode function or
[F2]).
a ECO gauge (c) is displayed at the right end of
the screen (It is turned ON and OFF in the ser-
vice mode).
D155AX-6 7
Selection of gearshift mode Operation of customize memory

While the ordinary screen is displayed, press the While the ordinary screen is displayed, press the
gearshift mode selector switch, and the gearshift customize memory switch, and you can select the
mode monitor (a) in the gear speed display section recorded setting of customization.
changes.
a Each time the switch is pressed, the gearshift
mode changes between [Dozing (Automatic
gearshift)] and [Ripping (Manual gearshift)].
a If dozing (automatic gearshift) is selected,
AUTO symbol (b) is displayed in the gear
speed display section.
Selection of float mode

While the ordinary screen is displayed, press the
float mode switch, and the float mode monitor (a)
changes.
a Each time the switch is pressed, the float mode
changes between [ON (Float is effective)] and
Customizing operation [OFF (Float is ineffective)].
While the ordinary screen is displayed, press the a If the float mode is turned ON, float mode mon-
customize switch, and you can change the setting itor (a) is displayed. If the former is turned
of the machine. OFF, the latter is put out.
a If the customize memory switch is operated a The float mode switch sets the float button of
while the above screen is displayed, up to 5 the blade control lever effective or ineffective.
settings can be saved. It does not float the blade.
Operation to cancel alarm buzzer

While the alarm buzzer is sounding, if the buzzer
cancel switch is pressed, the alarm buzzer stops.
a Even if the buzzer cancel switch is pressed,
the screen does not change.
8 D155AX-6
Operation of air conditioner/heater Selection of dual tilt (Dual tilt specification)

While the ordinary screen is displayed, press the air While the ordinary screen is displayed, press [F1],
conditioner switch or heater switch, and the Air- and the dual tilt monitor (a) changes.
conditioner Adjustment screen or Heater Adjust- a Each time [F1] is pressed, the dual tilt mode
ment screen is displayed. changes between [ON (Dual)] and [OFF (Sin-
a While the Air-conditioner Adjustment screen or gle)].
Heater Adjustment screen is displayed, if you a If the dual tilt mode is turned ON, dual tilt mode
do not touch any switch for 5 seconds, the monitor (a) is displayed. If the former is turned
screen changes to the ordinary screen. OFF, the latter is put out.
a Air conditioner specification a [F1] sets the single tilt or dual tilt mode of the
blade of dual tilt specification. It does not fix
the tilt or pitch function of the blade control
lever.
a Heater specification
D155AX-6 9
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
a Up to 3 cameras can be connected. If the

camera mode is selected, however, only the
image of camera 1 is always displayed. a Display of clock
a If a caution is generated in the camera mode,

the caution monitor is displayed at the left
upper of the screen.
a When an error that there is a user code occurs
in the camera mode, if the machine stops for
10 seconds, the screen changes to the ordi-
nary screen and displays the error information.
a When 2 or more cameras are connected, the
image of one of them or the images of 2 of
them can be displayed.
a If 2-camera image display [F4] is selected, the
image of camera 1 is displayed on the left side
of the screen and the image of camera 2 is dis-
played on the right side. The image of camera
3 is displayed only singly.
a If the images of 2 cameras are displayed
simultaneously, images are displayed at inter-
vals of 1 second on the right and left screen.
10 D155AX-6
Check of maintenance information Setting and display of user mode

While the maintenance monitor or ordinary screen (including KOMTRAX messages for user)
is displayed, press [F5], and the maintenance table While the ordinary screen is displayed, press [F6],
screen is displayed. and the user menu screen is displayed.
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
q For service: Display of action code and failure code

A message transmitted from the KOMTRAX If an abnormality which displays an action code and
base station for the service. Even if it is a failure code occurs on the ordinary screen or
received, nothing is displayed on the ordinary camera mode screen, all the information of the
screen. To see the contents of the message, abnormality is displayed.
operate "KOMTRAX message display" in the (a) : Action code (3 digits)
service menu. (b) : Failure code (5 or 6 digits)
(c) : Telephone mark
(d) : Telephone No.
Display of caution monitor a This screen is displayed only when an abnor-
If an abnormality which displays a caution monitor mality (failure code) for which an action code is
occurs on the ordinary screen or camera mode set occurs.
screen, the caution monitor is displayed large for a a The telephone mark and telephone No. are
moment and then displayed at (a) in the screen. displayed only when the telephone No. is reg-
a On the camera mode screen, the caution mon- istered in the service mode.
itor blinks at the left upper of the screen when a If multiple abnormalities occur simultaneously,
the caution is generated. all the codes are displayed repeatedly in order.
a Since the information of the displayed failure
code is recorded in the fault history in the ser-
vice mode, check the details in the service
mode.
12 D155AX-6
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
Function of checking display of LCD (Liquid Function of checking service meter

Crystal Display) To check the service meter while the starting switch
While the ordinary screen is displayed, if the follow- is turned OFF, operate the numeral input switches
ing numeral input switch and function switch are as follows. At this time, only the service meter sec-
operated as follows, all the LCD (Liquid Crystal Dis- tion displays.
play) lights up in white. q Operation of switches (simultaneous): [4] + [1]
q Operation of switches (simultaneous): [4] + a Since there is some time lag in start of the
[F2] LCD, hold down the switches until the LCD dis-
a When finishing the operation of the switches, plays normally.
release [F2] first. a After the machine monitor is used continu-
a If there is a display error in the LCD, only that ously, blue points (points which do not go off)
part is indicated in black. may be seen on this screen. This phenome-
a The LCD panel sometimes has black points non does not indicate a failure or a defect.
(points which are not lighted) and bright points
(points which do not go off) for the reason of its
characteristics. If the number of the bright
points and black points does not exceed 10,
those points are not a failure or a defect.
a To return to the former screen, press the func-
tion switch.
14 D155AX-6
Function of changing maintenance password a Set a new password of 4 6 digits (If it

When changing the maintenance password used has only 3 or less digits or has 7 or more
for the maintenance setting function, follow these digits, it is not accepted).
procedures. q [F5]: Delete input numeral/Return to ordi-
nary screen
1. While the ordinary screen is displayed, perform q [F6]: Confirm input numeral
the following operation with the numeral input
switches.
q Operation of switches (While pressing [4],
perform the operation in order):
[4] + [5] o [5] o [5]
a This operation of the switches is not ac-
cepted until 10 minutes pass after the
starting switch is turned on.
4. After the "New Password" screen is displayed

again, input a new password again with the
numeral input switches and confirm it with the
function switch.
q [F5]: Delete input numeral/Return to ordi-
nary screen
q [F6]: Confirm input numeral
a If a password different from the password
2. After the "Password" screen is displayed, input input before is input, the message to input
the current password with the numeral input again is displayed.
switches and confirm it with the function
switch.
q [F5]: Delete input numeral/Return to ordi-
nary screen
q [F6]: Confirm input numeral
a Default password: [000000]
a If the input password is correct, the screen
changes to the next screen.
a If the input password is incorrect, the mes-
sage to input the password again is dis-
played.
5. If the screen to notify completion of setting is

displayed and then the ordinary screen is dis-
played, the password is changed successfully.
3. After the "New Password" screen is displayed,

input a new password with the numeral input
switches and confirm it with the function
switch.
D155AX-6 15
t Service mode a The items which can be selected in the

To change the operator mode to the service mode, service menu are as follows.
perform the following operation.
01 Monitoring
This operation is always required when you use the
service mode. Mechanical system "Abnormality
Record"
1. Check of display of screen and operation of 02 Abnormality Electrical system "Abnormality
switches Record Record"
While the ordinary screen is displayed, perform Air conditioner "Abnormality Record"/
the following operation with the numeral input Heater "Abnormality Record"
switches. 03 Maintenance Record
q Operation of switches (While pressing [4],
04 Maintenance Mode Change
perform the operation in order):
[4] + [1] o [2] o [3] 05 Phone Number Entry
a This operation of the switches is accepted Key-on Mode
only while the ordinary screen is dis- Setting of unit
played.
06 Default Setting of maintenance password
Setting of camera
Setting of ECO display
07 Adjustment
08 PM CLINIC
09 Cylinder Cut-Out
10 No Injection
11 Fuel Consumption
Terminal Status
12 KOMTRAX
GPS & Communication Status
Settings
Modem S/N
13 Service Message
2. Selection of service menu
When the "Service Menu" screen is displayed,
a Items with 2-digit codes are the menus dis-
the service mode is selected. Select a service
played on the Service menu screen. The items
menu you use with the function switches or
on their right are the menus on the next hierar-
numeral input switches.
chy.
q [F3]: Move to lower menu
q [F4]: Move to upper menu
q [F5]: Return to ordinary screen (operator
mode)
q [F6]: Confirm selection
a You may enter a 2-digit code with the
numeral input switches to select the menu
of that code and confirm it with [F6].
16 D155AX-6
Monitoring
The machine monitor can monitor the condition of
the machine in real time by receiving signals from
various switches, sensors, and actuators installed
to many parts of the machine and the information
from the controllers which are controlling switches,
etc.
1. Selecting menu
Select "01 Monitoring" on the "Service Menu"
screen.
3. Deciding monitoring items

After selecting monitoring items, execute moni-
toring with the function switch or numeral input
switch.
a Execution with function switch: Double-
click or hold down [F6] (about 2 seconds).
a Execution with numeral input switch: Input
[99999] and press [F6].
a When monitoring only 2 items, for exam-
ple, select them and confirm with [F6]. If
[F6] is pressed once more at this time,
monitoring is executed.
2. Selecting monitoring items
a If monitoring items are selected up to the
After the "Monitoring" screen is displayed,
limit number, monitoring is executed auto-
select items to be monitored with the function
matically.
switches or numeral input switches.
q [F1]: Move to next page (screen)
q [F2]: Move to previous page (screen)
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Delete input numeral/Return to ser-
vice menu screen
a Selection with function switches: Select an
item with [F3] or [F4] and confirm it with
[F6].
a Selection with numeral input switches:
Enter a 5-digit code, and the item of that
code is selected directly. Confirm that
item with [F6].
a If the color of the selected box changes
from yellow to red, selection of the item of
that box is confirmed.
a Up to 6 monitoring items can be selected
at a time. You may not able to set up to 6
items, however, depending on the display
form of those items.
D155AX-6 17
4. Executing monitoring 6. Changing machine setting mode

After the "Monitoring" screen is displayed, per- To change the setting of the "P/E Mode", "Fan
form the necessary operation of the machine Rev." mode, or "Working" mode during moni-
and check the monitoring information. toring, operate the corresponding switch under
a Monitoring information is indicated by the current condition, and the mode setting
value, ON/OFF, or special display. screen is displayed.
a The unit of display can be set to SI unit, While this screen is displayed, if the corre-
metric unit, or inch unit with the Default sponding switch is operated further, the corre-
function in the service mode. sponding mode is changed.
a After finishing changing the setting, press
[F6] to return to the monitoring information
screen.
a If the setting is changed during monitoring,
the new setting is held even after the
screen returns to the ordinary screen after
monitoring is finished.
5. Holding monitoring information

The monitoring information can be held and
holding is reset with the function switches.
q [F3]: Reset holding
q [F4]: Hold information (displayed data)
q [F5]: Return to monitoring selection menu
screen
18 D155AX-6
Monitoring items list
Code Monitoring item Unit (Initial setting: ISO) Component

Remarks
No. (Display on screen) ISO meter inch in charge
50300 S/T Lever 1 Potentio mV mV mV P/T

50301 S/T Lever 2 Potentio mV mV mV P/T
50400 Brake Pedal Potentio mV mV mV P/T
31619 Brake LH ECMV(F/B) mA mA mA P/T
31618 Brake RH ECMV(F/B) mA mA mA P/T
50600 HSS Solenoid LH(F/B) mA mA mA P/T
50601 HSS Solenoid RH(F/B) mA mA mA P/T
90600 S/T Clutch LH ECMV(F/B) mA mA mA P/T
90601 S/T Clutch RH ECMV(F/B) mA mA mA P/T
31628 S.S.P Solenoid mA mA mA P/T
32900 Pitch Angle P/T
60100 Pitch Angle Sensor mV mV mV P/T
60500 ENG Hold Relay mV mV mV P/T
60600 BR Hold Relay mV mV mV P/T
50000 Fuel Dial Throttle % % % P/T
03000 Fuel Dial Sensor mV mV mV P/T
BL (Left brake fill sw) ON OFF P/T
CL (Left clutch fill sw) ON OFF P/T
31521 S/T Fill Sw Input
CR (Right clutch fill sw) ON OFF P/T
BR (Right brake fill sw) ON OFF P/T
50200 T/M Lever 1 Potentio mV mV mV P/T
50201 T/M Lever 2 Potentio mV mV mV P/T
31622 T/M Clutch F ECMV(F/B) mA mA mA P/T
31616 T/M Clutch R ECMV(F/B) mA mA mA P/T
31602 T/M Clutch 1st ECMV(F/B) mA mA mA P/T
31603 T/M Clutch 2nd ECMV(F/B) mA mA mA P/T
31604 T/M Clutch 3rd ECMV(F/B) mA mA mA P/T
30100 T/C Oil Temperature C C F P/T
31400 T/M Out Speed r/min rpm rpm P/T
32601 T/C In Pressure MPa kg/cm psi P/T
32602 T/C In Pressure Sensor mV mV mV P/T
32603 T/C Out Pressure MPa kg/cm psi P/T
32604 T/C Out Pressure Sensor mV mV mV P/T
31642 L/U ECMV(F/B) mA mA mA P/T
90700 S/C ECMV(F/B) mA mA mA P/T
50900 T/M Lock Relay mV mV mV P/T
40001 Vehicle Speed km/h km/h MP/h P/T
60000 Traction W W W P/T
D155AX-6 19

Remarks
70200 T/M Out Speed Sensor mV mV mV P/T

70400 Back Alarm Relay mV mV mV P/T
31624 Fan Pump Solenoid(F/B) mA mA mA P/T
10000 Fan Speed r/min rpm rpm P/T
SUNC (Gear shift up sw) ON OFF P/T
SUNO (Gear shift up sw) ON OFF P/T
SDNC
ON OFF P/T
(Gear shift down sw)
40905 T/M Sw Input 1 SDNO

ON OFF P/T
(Gear shift down sw)
PNC
ON OFF P/T
(Parking brake lever sw)
PNO
ON OFF P/T
(Parking brake lever sw)
F (F clutch fill sw) ON OFF P/T
R (R clutch fill sw) ON OFF P/T
T/M Fill Sw
40906 1st (1st clutch fill sw) ON OFF P/T
Input 1
2nd (2nd clutch fill sw) ON OFF P/T
3rd (3rd clutch fill sw) ON OFF P/T
T/M Fill Sw L/U( Lock-up clutch fill sw) ON OFF P/T

31520
Input 2 S/C (Stator clutch fill sw) ON OFF P/T
Brly (Back Alarm relay) ON OFF P/T
Prly (Parking lock relay) ON OFF P/T
40909 T/M Output 1
Fres
ON OFF P/T
(Fan reverse solenoid)
70700 Hydraulic Pump Pressure 1 MPa kg/cm psi W/E
70701 Hydraulic Pressure Sensor 1 mV mV mV W/E
71001 Blade Raise EPC(F/B) mA mA mA W/E
71003 Blade Down EPC(F/B) mA mA mA W/E
71005 Blade Tilt LH-H EPC(F/B) mA mA mA W/E
71007 Blade Tilt LH-B EPC(F/B) mA mA mA W/E
90800 Blade Tilt RH-H EPC(F/B) mA mA mA W/E
90801 Blade Tilt RH-B EPC(F/B) mA mA mA W/E
71101 Ripper Raise EPC(F/B) mA mA mA W/E
71103 Ripper Down EPC(F/B) mA mA mA W/E
71105 Ripper Tilt In EPC(F/B) mA mA mA W/E
71107 Ripper Tilt Back EPC(F/B) mA mA mA W/E
73400 Blade Lift Lever A Potentio mV mV mV W/E
73401 Blade Lift Lever B Potentio mV mV mV W/E
73500 Blade Tilt Lever A Potentio mV mV mV W/E
20 D155AX-6

Remarks
73501 Blade Tilt Lever B Potentio mV mV mV W/E

73600 Ripper Tilt Lever A Potentio mV mV mV W/E
73601 Ripper Tilt Lever B Potentio mV mV mV W/E
73700 Ripper Lift Lever A Potentio mV mV mV W/E
73701 Ripper Lift Lever B Potentio mV mV mV W/E
01300 TVC Solenoid(F/B) mA mA mA W/E
90900 Quick Drop Solenoid(F/B) mA mA mA W/E
FLNC (Blade float sw) ON OFF W/E
FLNO (Blade float sw) ON OFF W/E
BPNC (Blade pitch sw) ON OFF W/E
70300 Blade Sw Input BPNO (Blade pitch sw) ON OFF W/E

WLNC
ON OFF W/E
(Work equipment lock sw)
WLNO
ON OFF W/E
(Work equipment lock sw)
20227 Monitor Assy P/N MON
20402 Monitor Serial No MON
20228 Monitor Prog P/N MON
20242 P/T Con Assy P/N P/T
20404 P/T Con Serial No P/T
20243 P/T Con Prog P/N P/T
20244 W/E Con Ass'y P/N W/E
20405 W/E Con Serial No W/E
20245 W/E Con Prog P/N W/E
04200 Fuel Level Sensor Volt V V V MON
04300 Battery Charge Volt V V V MON
04401 Hyd Oil Temperature C C F MON
04002 Hyd Temp Sens Volt V V V MON
18900 ECM Internal Temp C C F ENG
37200 Engine Oil Pressure kPa kg/cm psi ENG
00201 Machine ID ENG
20216 ECM Build Version ENG
20217 ECM Calibration Data Ver ENG
20400 ECM Serial No ENG
01002 Engine Speed r/min rpm rpm ENG
36700 Engine Torque Ratio % % % ENG
31701 Throttle Position % % % ENG
03001 Throttle Pos Sens Volt mV mV mV ENG
17500 Engine Power Mode ENG
D155AX-6 21

Remarks
36400 Rail Pressure MPa kg/cm psi ENG

36401 Rail Pressure Sens Volt V V V ENG
36200 Rail Press Command MPa kg/cm psi ENG
36300 Injection Timing Command CA CA CA ENG
04107 Coolant Temperature C C F ENG
01405 Coolant Temp Sens Volt V V V ENG
37400 Ambient Pressure kPa kg/cm psi ENG
37401 Ambient Press Sens Volt V V V ENG
Indication by abso-
36500 Charge Pressure-Abs kPa kg/cm psi ENG lute value (including
ambient pressure)
36501 Charge Press Sens Volt V V V ENG
03203 Battery Power Supply V V V ENG
37300 Fuel Rate l/h l/h gal/h ENG
31706 Final Throttle Position % % % ENG
18500 Charge Temperature C C F ENG
18501 Charge Temp Sens Volt V V V ENG
18600 Inject Fueling Command mg/st mg/st mg/st ENG
17201 PCV Close Timing CA CA CA ENG
18700 Engine Output Torque Nm kgm lhft ENG
37201 Eng Oil Press Sens Volt V V V ENG
14200 Fuel Temperature C C F ENG
14201 Fuel Temp Sens Volt V V V ENG
17903 EGR Inlet Pressure-A kPa kg/cm psi ENG
18001 EGR In Press Sens Volt mV mV mV ENG
18100 EGR Valve Position mm mm inch ENG
18101 EGR Valve Pos Sens Volt mV mV mV ENG
18200 BPS Valve Position mm mm inch ENG
18201 BPS Valve Pos Sens Volt mV mV mV ENG
R-sig ON OFF P/T
Acc ON OFF P/T
40912 P/T Sw Input Eng S ON OFF P/T
Eng L ON OFF P/T
Eng Sd ON OFF P/T
a Entry order of items in table

The items are entered in the order of display on the monitoring selection menu screen.
a Unit
The display unit can be set to ISO, meter, or inch freely (Set it with Unit in "Default" of the service menu).
"CA" in the display unit is an abbreviation for crankshaft angle.
"mg/st" in the display unit is an abbreviation for milligram/stroke.
a Components in charge
22 D155AX-6
MON : The machine monitor is in charge of detection of monitoring information.

ENG : The engine controller is in charge of detection of monitoring information.
P/T : The power train controller is in charge of detection of monitoring information.
W/E : The work equipment controller is in charge of detection of monitoring information.
D155AX-6 23
"Abnormality Record" (Mechanical system 3. Information displayed on "Abnormality Record"

"Abnormality Record") screen
The machine monitor classifies and records the On the "Mechanical Systems" screen, the fol-
abnormality which occurred in the past or which are lowing information is displayed.
occurring at present into the mechanical system (a): Occurrence order of abnormality from lat-
abnormality, electrical system abnormality, and air est one/Total number of records
conditioner abnormality or heater abnormality. (b): Failure code
To check the mechanical system "Abnormality (c): Contents of trouble
Record", perform the following procedures. (d): Number of occurrence time
(e): Service meter reading at first occurrence
1. Selecting menu (f): Service meter reach at last occurrence
Select "02 Abnormality Record" on the "Ser- q [F1]: Move to next page (screen) (if dis-
vice Menu" screen. played)
q [F2]: Move to previous page (screen) (if
displayed)
q [F5]: Return to "Abnormality Record" screen
a If no "Abnormality Record" is recorded,
"No Abnormality Record" is displayed.
a If the number of occurrence time is 1 (first
occurrence), the service meter reading at
the first occurrence and that at the last
occurrence are the same.
a If [E] is displayed on the left of a failure
code, the abnormality is still occurring or
resetting of it has not been confirmed.
a For all the failure codes that the machine
monitor can record, see the failure codes
2. Selecting sub menu table in "Abnormality Record (Electrical
After the "Abnormality Record" screen is dis- system Abnormality Record)".
played, select "01 Mechanical Systems" with
t he f u nc t i o n s wi t c h e s or nu m e r a l i np u t
switches.
q [F3]: Move to lower record
q [F4]: Move to upper record
q [F5]: Return to service menu screen
numeral input switches to select the
record of that code and confirm it with
[F6].
a The following figure shows the display of
the air conditioner specification. If the
heater specification is selected, "03
Heater Abnormality Record" is displayed. 4. Deleting "Abnormality Record"
The contents of the mechanical system
"Abnormality Record" cannot be deleted.
24 D155AX-6
"Abnormality Record" (Electrical system "Abnor- 3. Information displayed on "Abnormality Record"

mality Record") screen
The machine monitor classifies and records the On the "Electrical Systems" screen, the follow-
abnormality which occurred in the past or which are ing information is displayed.
occurring at present into the mechanical system (a):Occurrence order of abnormality from lat-
abnormality, electrical system abnormality, and air est one/Total number of records
conditioner abnormality or heater abnormality. (b):Failure code
To check the electrical system "Abnormality (c): Contents of trouble
Record", perform the following procedures. (d):Number of occurrence time
(e):Service meter reading at first occurrence
1. Selecting menu (f): Service meter reach at last occurrence
Select "02 Abnormality Record" on the "Ser- q [F1]: Move to next page (screen) (if dis-
vice Menu" screen. played)
q [F2]: Move to previous page (screen) (if
displayed)
q [F5]: Return to "Abnormality Record" screen
a If no "Abnormality Record" is recorded,
"No Abnormality Record" is displayed.
a If the number of occurrence time is 1 (first
occurrence), the service meter reading at
the first occurrence and that at the last
occurrence are the same.
a If [E] is displayed on the left of a failure
code, the abnormality is still occurring or
resetting of it has not been confirmed.
2. Selecting sub menu a For all the failure codes that the machine
After the "Abnormality Record" screen is dis- monitor can record, see the failure codes
played, select "02 Electrical Systems" with the table.
function switches or numeral input switches.
numeral input switches to select the
record of that code and confirm it with
[F6].
a The following figure shows the display of
the air conditioner specification. If the
heater specification is selected, "03
Heater Abnormality Record" is displayed.
4. Deleting "Abnormality Record"

1) While the "Electrical Systems" screen is
displayed, perform the following operation
with the numeral input switches.
q Operation of switches (While pressing
[4], perform the operation in order):
[4] + [1] o [2] o [3]
a Operate the switches similarly to the
procedure for changing the ordinary
display to the service mode.
D155AX-6 25
a The following figure shows the screen

displayed when the items are deleted
one by one (which is a little different
from the screen displayed when all
the items are deleted together).
2) Check that the screen is set in the delete

mode, and then delete the items one by
one or together with the function switches.
a If the screen is set in the delete mode,
[CLEAR] graphic mark is indicated at
[F2]. 4) If the screen to notify completion of dele-
q [F2]: Delete all items tion is displayed and then the "Electrical
q [F3]: Move to lower item Sys. Error Reset" (delete mode) screen is
q [F4]: Move to upper item displayed, the deletion of the "Abnormality
q [F5]: Return to "Abnormality Record" Record" is completed.
screen a After a while, the screen returns to
q [F6]: Delete selected item the "Electrical Sys. Error Reset"
a To delete items one by one: Select screen.
the item to be deleted with [F3] or [F4]
and press [F6].
a To delete all items together: Press
[F2], and all the items are deleted,
regardless of selection of the items.
a If [E] is displayed on the left of a fail-
ure code, the deleting operation is
accepted but the information is not
deleted.
3) After the "Electrical Sys. Error Reset"

screen is displayed, operate the function
switches.
q [F5]: Return to "Electrical Sys. Error
Reset" screen (Delete mode)
q [F6]: Execute deletion
26 D155AX-6
Failure codes table
Action Failure Alarm Component

Trouble (Displayed on screen) Category of history
code code buzzer in charge
E03 1500L0 Transmission clutch: Abnormal q P/T Electrical system
E03 15SAL1 Forward clutch: Fill high q P/T Electrical system
E03 15SALH Forward clutch: Fill Low q P/T Electrical system
E03 15SBL1 Reverse clutch: Fill high q P/T Electrical system
E03 15SBLH Reverse clutch: Fill Low q P/T Electrical system
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
E02 15SJL1 L/U : Fill high q P/T Electrical system
E02 15SJLH L/U : Fill low q P/T Electrical system
E04 2301L1 Right brake: Fill high q P/T Electrical system
E04 2301LH Right brake: Fill low q P/T Electrical system
E04 2302L1 Left brake: Fill high q P/T Electrical system
E04 2302LH Left brake: Fill low q P/T Electrical system
7RFAKA ECM HOLD RELAY: Disconnection P/T Electrical system
AA10NX Air Cleaner Clogging MON Mechanical system
AB00MA Battery Charge Abnormal MON Mechanical system
B@BAZG Eng Oil Press Low e ENG Mechanical system
B@BCNS Eng Water Overheat e ENG Mechanical system
B@BCZK Eng Water Level Low MON Mechanical system
B@CENS T/C Oil Overheat e P/T Mechanical system
B@HANS Hyd Oil Overheat e MON Mechanical system
E04 CA111 EMC Critical Internal Failure q ENG 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
E03 CA131 Throttle Sensor High Error q ENG Electrical system
E03 CA132 Throttle 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

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 CA234 Eng Overspeed 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 CA271 PCV1 Short Error q ENG Electrical system
E03 CA272 PCV1 Open Error q ENG Electrical system

E03 CA322 Inj #1 (L#1) Open/Short Error q ENG Electrical system
E04 CA342 Calibration Code Incompatibility q ENG Electrical system
E03 CA351 Injectors Drive Circuit Error q ENG Electrical system
E04 CA441 Battery Voltage Low Error q ENG Electrical system
E04 CA442 Battery Voltage 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
E02 CA553 Rail Press High Error q ENG Electrical system

E03 CA554 Rail Press Sensor In Range Error q ENG Electrical system
E02 CA559 Rail Press Low Error q ENG Electrical system
E03 CA689 Eng Ne Speed Sensor 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
E02 CA1228 EGR Valve Servo Error 1 q ENG Electrical system
28 D155AX-6

E03 CA1626 BP Valve Sol Current High Error q ENG Electrical system
E03 CA1627 BP Valve Sol Current Low Error q ENG Electrical system
E02 CA1628 Bypass Valve Servo Error 1 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
E03 CA1633 KOMNET Datalink Timeout 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
D110KA Battery relay: Disconnection P/T Electrical system
D110KB Battery Relay: Drive Short Circuit P/T Electrical system
E02 D130KA Neutral relay: Disconnection q P/T Electrical system
E02 D130KB Neutral relay: Short circuit q P/T Electrical system
E01 D161KA Back-up alarm relay: Disconnection P/T Electrical system
E01 D161KB Back-up alarm relay: Short circuit P/T Electrical system
D190KA ACC signal relay: Disconnection P/T Electrical system
D190KB ACC signal relay: Short circuit P/T Electrical system
E03 D5ZKKX Throttle Dial: Out of normal range q P/T Electrical system
E03 DAFRKR CAN Disconnection q MON Electrical system
E03 DB2RKR CAN Disconnection q ENG Electrical system

E04 DB90KK WE controller: Source voltage reduction q W/E Electrical system
E03 DB90KR PT controller: Can communication lost q P/T Electrical system
E01 DB90KT WE controller: Abnormality in controller W/E Electrical system
E04 DB99KQ WE controller: Type select signal q W/E Electrical system
E03 DB9RKR WE controller: Can communication lost q W/E Electrical system
E03 DBE0KK PT controller: Source voltage reduction q P/T Electrical system
D155AX-6 29

E01 DBE0KT PT controller: Abnormality in controller P/T Electrical system
E04 DBE9KQ PT controller: Type select signal q P/T Electrical system
E02 DD12KA Shift up Sw: Disconnection q P/T Electrical system
E02 D12KB Shift up Sw: Short circuit q P/T Electrical system
E02 D13KA Shift down Sw: Disconnection q P/T Electrical system
E02 DD13KB Shift down Sw: Short circuit q P/T Electrical system
E03 DD14KA Parking lever Sw: Disconnection q P/T Electrical system
E03 DD14KB Parking lever Sw: Short circuit q P/T Electrical system
E02 DDDDKA Back up brake Sw: Disconnection 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 DDN7KA WEQ Knob Sw(down): Disconnection q W/E Electrical system
E02 DDN7KB WEQ Knob Sw(down): Short circuit q W/E Electrical system
E01 DDN9KA WEQ Knob Sw(up): Disconnection W/E Electrical system
E01 DDN9KB WEQ Knob Sw(up): Short circuit W/E Electrical system
E03 DDNLKA Weq lock Sw: Disconnection q W/E Electrical system
E03 DDNLKB Weq lock Sw: Short circuit q W/E Electrical system
E02 DDTSL1 S/C: Fill high q P/T Electrical system
E02 DDTSLH S/C: Fill low q W/E Electrical system
E03 DFA4KX BL lever 1: Out of normal range q W/E Electrical system
E03 DFA4KZ BL lever: Disconnection or short circuit q W/E Electrical system
E03 DFA4L8 BL lever: Signal mismatch q W/E Electrical system
E03 DFA5KA BL lever 1: Disconnection q W/E Electrical system
E03 DFA5KB BL lever 1: Short circuit q W/E Electrical system
E03 DFA7KX BT lever 1: Out of normal range q W/E Electrical system

E03 DFA7KZ BT lever: Disconnection or short circuit q W/E Electrical system
E03 DFA7L8 BT lever: Signal mismatch q W/E Electrical system
E03 DFA8KA BT lever 1: Disconnection q W/E Electrical system
E03 DFA8KB BT lever 1: Short circuit q W/E Electrical system
E03 DFAAKX RL lever 1: Out of normal range q W/E Electrical system
E03 DFAAKZ RL lever: Disconnection or short circuit q W/E Electrical system
30 D155AX-6

E03 DFAAL8 RL lever: Signal mismatch q W/E Electrical system
E03 DFABKA RL lever 1: Disconnection q W/E Electrical system
E03 DFABKB RL lever 1: Short circuit q W/E Electrical system
E03 DFACKA RL lever 2: Disconnection q W/E Electrical system
E03 DFACKB RL lever 2: Short circuit q W/E Electrical system
E03 DFADKX RT lever 1: Out of normal range q W/E Electrical system
E03 DFADKZ RT lever: Disconnection or short circuit q W/E Electrical system
E03 DFADL8 RT lever: Signal mismatch q W/E Electrical system
E03 DFAEKA RT lever 1: Disconnection q W/E Electrical system
E03 DFAEKB RT lever 1: Short circuit q W/E Electrical system
E03 DFAFKA RT lever 2: Disconnection q W/E Electrical system
E03 DFAFKB RT lever 2: Short circuit q W/E Electrical system

E01 DGT1KA T/C oil temp sensor: Abnormal P/T Electrical system
E01 DGT1KX T/C oil temp sensor abnormal P/T Electrical system
DH21KA WEQ pressure sensor: Disconnection W/E Electrical system
DH21KB WEQ pressure sensor: Short circuit W/E Electrical system
E02 DHT5KA T/C in-pressure sensor: Disconnection q P/T Electrical system
E02 DHT5KB T/C in-pressure sensor: Short circuit q P/T Electrical system
E02 DHT7KA T/C out-pressure sensor: Disconnection 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
E03 DK30KA ST lever 1: Disconnection q P/T Electrical system
E03 DK30KB ST lever 1: Short circuit q P/T Electrical system
E04 DK30KX ST lever 1: Out of normal range q P/T Electrical system
E04 DK30KZ ST lever: Disconnection or short circuit q P/T Electrical system
E03 DK30L8 ST lever: Signal mismatch q P/T Electrical system
E03 DK40KA Brake potentiometer: Disconnection q P/T Electrical system

E03 DK40KB Brake potentiometer: Short circuit q P/T Electrical system
E04 DK55KX FR lever: Out of normal range q P/T Electrical system
E04 DK55KZ FR lever: Disconnection or short circuit q P/T Electrical system
E03 DK55L8 FR lever: Signal mismatch q P/T Electrical system
E03 DK56KA FR lever 1: Disconnection q P/T Electrical system
E03 DK56KB FR lever 1: Short circuit q P/T Electrical system
D155AX-6 31

E03 DKH1KA Pitch angle sensor: Disconnection q P/T Electrical system
E03 DKH1KB Pitch angle sensor: Short circuit q P/T Electrical system
E01 DLT3KA T/M out-speed sensor: Disconnection q P/T Electrical system
E01 DLT3KB T/M out-speed sensor: Abnormal q P/T Electrical system
E01 DW7BKA Fan rev EPC: Disconnection q P/T Electrical system
E01 DW7BKB Fan rev EPC: Short circuit P/T Electrical system
E03 DWN1KA Hss EPC1: Disconnection q P/T Electrical system
E03 DWN1KB Hss EPC1: Short circuit q P/T Electrical system
E03 DWN1KY Hss EPC1: Short circuit q P/T Electrical system

E04 DWN3KA Ssp solenoid: Disconnection q P/T Electrical system
E04 DWN3KB Ssp solenoid: Short circuit q P/T Electrical system
E04 DWN3KY SSP solenoid: Short circuit q P/T Electrical system
E01 DWN5KA Fan pump solenoid: Disconnection P/T Electrical system
E01 DWN5KB Fan pump solenoid: Short circuit W/E Electrical system
E01 DXA0KA TVC Sol.: Disconnection W/E Electrical system
E01 DXA0KB TVC Sol.: Short circuit W/E Electrical system
E01 DXA0KY TVC Sol.: Short circuit P/T Electrical system
E02 DXH1KA Lock-up ECMV: Disconnection q P/T Electrical system
E02 DXH1KB Lock-up ECMV: Short circuit q P/T Electrical system
E03 DXH1KY Lock-up ECMV: Short circuit q P/T Electrical system
E03 DXH4KA 1st clutch ECMV: Disconnection q P/T 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 DXH5KA 2nd clutch ECMV: Disconnection 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
E03 DXH7KA R clutch ECMV: Disconnection q P/T Electrical system
E03 DXH7KB R clutch ECMV: Short circuit q P/T Electrical system
E04 DXH7KY R clutch ECMV: Short circuit q P/T Electrical system
E03 DXH8KA F clutch ECMV: Disconnection q P/T Electrical system
E03 DXH8KB F clutch ECMV: Short circuit q P/T Electrical system
32 D155AX-6

E04 DXH8KY F clutch ECMV: Short circuit q P/T Electrical system
E04 DXHBKA Right brake ECMV: Disconnection q P/T Electrical system
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 DXHCKA Left brake ECMV: Disconnection 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 DXHRKA Blade up EPC: Disconnection q W/E Electrical system
E03 DXHRKB Blade up EPC: Short circuit q W/E Electrical system
E03 DXHRKY Blade up EPC: Short circuit q W/E Electrical system
E03 DXHSKA Blade down EPC: Disconnection q W/E 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 DXHTKA Blade left 1 EPC: Disconnection 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 DXHUKA Blade right 1 EPC: Disconnection 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 DXHWKA Ripper up EPC: Disconnection q W/E Electrical system
E03 DXHWKB Ripper up EPC: Short circuit q W/E Electrical system
E03 DXHWKY Ripper up EPC: Short circuit q W/E Electrical system
E03 DXHXKA Ripper down EPC: Disconnection 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 DXHYKA Ripper Tilt In EPC: Disconnection 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 DXJ4KA WEQ lock Sol.: Disconnection q W/E Electrical system
E03 DXJ4KB WEQ lock Sol.: Short circuit q W/E Electrical system
E03 DXJ8KA Blade left 2 EPC: Disconnection 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
E03 DXJ9KA Blade right 2 EPC: Disconnection q W/E Electrical system
D155AX-6 33

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
E01 DXJAKA Q-drop EPC: Disconnection W/E Electrical system
E01 DXJAKB Q-drop EPC: Short circuit W/E Electrical system
E01 DXJAKY Q-drop EPC: Short circuit W/E Electrical system
E02 DXJBKA S/C ECMV: Disconnection q P/T Electrical system
E02 DXJBKB S/C ECMV: Short circuit q P/T Electrical system
E02 DXJBKY S/C ECMV: Short circuit q P/T Electrical system

The items are entered in the order of their failure codes (incremental order).
a Action code
Attached: If the failure code is detected, the action code, failure code, and telephone No. (if regis-
tered) are displayed on the ordinary screen to notify the operator of the fault.
Not attached: Even if the failure code is detected, the machine monitor does not notify the operator of
the fault.
a Alarm buzzer
q: When occurrence of an error is notified to the operator, the buzzer sounds (The operator can stop
the buzzer with the alarm buzzer cancel switch).
e: Since the caution monitor is also turned ON, its function sounds the buzzer.
a Component in charge
MON: The machine monitor is in charge of detection of fault.
ENG: The engine controller is in charge of detection of fault.
P/T: The power train controller is in charge of detection of fault.
W/E: Work equipment controller is in charge of detection of fault.
a Category of record
Mechanical equipment system: Fault information is recorded in the "Mechanical Systems".
Electrical equipment system: Fault information is recorded in the "Electrical Systems" .
34 D155AX-6
"Abnormality Record" (Air conditioner "Abnor- 3. Information displayed on "Abnormality Record"

mality Record"/Heater "Abnormality Record") screen
The machine monitor classifies and records the On the air conditioner "Abnormality Record" or
abnormality which occurred in the past or which are heater "Abnormality Record" screen, the fol-
occurring at present into the mechanical system lowing information is displayed.
abnormality, electrical system abnormality, and air (a): System/Component name
conditioner abnormality or heater abnormality. (b): Number of occurrence time
To check the air conditioner "Abnormality Record" (c): Condition (Normal or abnormal)
or heater "Abnormality Record", perform the follow- q [F2]: Delete "Abnormality Record"
ing procedures. q [F5]: Return to "Abnormality Record" screen
a All the following figures show the air condi- a If [E] is displayed on the left of a condition,
tioner specification. the abnormality is still occurring or reset-
ting of it has not been confirmed.
1. Selecting menu a If "CAN Status" is displayed in Communi-
Select "02 Abnormality Record" on the Service cation condition, communication cannot
menu screen. be carried out normally. Accordingly, the
conditions of other items are turned OFF.
2. Selecting sub menu

After the "Abnormality Record" screen is dis- 4. Deleting "Abnormality Record"
played, select "03 Air-conditioning System" or While the "Abnormality Record" screen is dis-
"03 Heater Abnormality Record" with the func- played, press [F2], and the number of occur-
tion switches or numeral input switches. rence time of fault is deleted. If it is confirmed
q [F3]: Move to lower record at this time that the abnormality has been
q [F4]: Move to upper record reset, the display changes to Normal.
q [F6]: Confirm selection a Heater specification
a You may enter a 2-digit code with the In the heater specification, the display of "Air
numeral input switches to select the conditioner" is replaced with "Heater" and the
record of that code and confirm it with items which are not related to the heater are
[F6]. not displayed.
D155AX-6 35
Maintenance Record 01 Engine Oil Change

The machine monitor records the maintenance 02 Eng Oil Filter Change
information of the filters, oils, etc., which the opera-
03 Fuel Main Filter Change
tor can display and check by the following opera-
tions. When maintenance is carried out, if the data 41 Fuel Pre Filter Change
are reset in the operator mode, the number of the 04 Hyd Oil Filter Change
times of maintenance is recorded in this section. 06 Corrosion Resistor Change
07 Check and addition of damper case oil
1. Selecting menu
Select "03 Maintenance Record" on the "Ser- 08 Replacement interval of final drive case oil
vice Menu" screen. 10 Replacement of hydraulic oil
19 Replacement of power train oil
20 Replacement of power train oil filter
3. Items displayed on Maintenance Record screen

The following items are displayed.
(a): Maintenance items
(b): Number of times of change up to now
(c): Service meter reading (SMR) at previous
change
2. Selecting maintenance record item

After the "Maintenance Record" screen is dis-
played, select an item to be checked with the
numeral input switches to select the item
of that code.
a The following items can be selected in the

maintenance record.
36 D155AX-6
Maintenance Mode Change 00 Maintenance Mode On/Off

The operating condition for maintenance function in 01 Engine Oil Change Int
the operation mode can be set and changed with
02 Eng Oil Filter Change Int
this menu.
q Set function effective or ineffective 03 Fuel Main Filter Change Int
q Change set change interval (by items) 41 Fuel Pre Filter Change Int
q Initialize all set change intervals 04 Hyd Oil Filter Change Int
06 Replacement interval of corrosion resistor
1. Selecting menu
Select "04 Maintenance Mode Change" on the 07 Check and replacement interval of damper case oil
Service menu screen. 08 Replacement interval of final drive case oil
10 Replacement interval of hydraulic oil
19 Replacement interval of power train oil
20 Replacement interval of power train oil filter
99 Initialize all items
3. Contents of setting of ON/OFF of maintenance

mode
After selecting "00 Maintenance Mode On/Off",
if the screen is displayed, set ON or OFF with
the function switches.
q ON: Functions of all maintenance items
are set effective in operator mode
q OFF: Functions of all maintenance items
are set ineffective in operator mode
After the "Maintenance Mode On/Off" screen is
displayed, select an item to be monitored with
t he f u nc t i o n s wi t c h e s or nu m e r a l i np u t
q [F5]: Cancel selection and return to Main-
switches.
tenance mode screen
q [F6]: Confirm selection and return to
Maintenance mode screen
a Even if ON/OFF of each item has been
set, if the above setting is changed, it is
applied.
numeral input switches to select the item
of that code and confirm it with [F6].
4. Contents of setting of each maintenance item

After selecting each maintenance item, if the
screen is displayed, set the item with the func-
a The following items can be selected on tion switches.
the "Maintenance Mode On/Off" screen. q Default: Maintenance interval set in machine
monitor (Recommended by manufacturer
and not changeable).
D155AX-6 37
q Set: Maintenance interval which can be

set freely. Maintenance functions in oper-
ator mode operate on basis of this set time
(which is increased or decreased by 50
hours).
q ON: Maintenance function of this item is
set effective in operator mode.
q OFF: Maintenance function of this item is
set ineffective in operator mode.
q [F3]: Select Reduce set value (Upper) or
OFF (Lower).
q [F4]: Select Increase set value (Upper) or
ON (Lower).
q [F5]: Cancel setting before confirmation
and return to Maintenance Mode
Change screen.
q [F6]: Confirm setting of upper or lower line.
a After the setting of the upper and lower
lines is confirmed with [F6] and the screen
changes to the Maintenance Mode
Change screen with [F5], the setting is
effective.
5. Function of All Default Value

After selecting "99 All Default Value", if the
screen is displayed, set with the function
switches.
a If this operation is executed, the set val-
ues of all the maintenance items are set to
default values.
q [F5]: Return to Maintenance Mode Change
screen
q [F6]: Execute default setting
a A while after [F6] is pressed, the default
setting completion screen is displayed.
Then, if the "Maintenance Mode Change"
screen is displayed, default setting is com-
pleted.
a The default setting of the corrosion resis-
tor is "OFF".
38 D155AX-6
Phone Number Entry a If [F6] is pressed without inputting a digit,

The phone No. displayed when the action code/fail- there is not information of phone No.
ure code is displayed in the operator mode can be Accordingly, no phone No. is displayed in
input and changed according to the following pro- the operator mode.
cedure.
If a phone No. is not input with this function, no
phone No. is displayed in the operator mode.
1. Selecting menu
Select "05 Phone Number Entry" on the "Ser-
vice Menu" screen.
2. Registering and changing telephone No.

After the "Phone Number Entry" screen is dis-
played, register or change the phone No.
q [F2]: Delete all input No.
q [F3]: Move to left position (if not blank)
q [F4]: Move to right position (if not blank)
q [F5]: Delete input digit/Return to service
menu
q [F6]: Confirm input
a Up to 14 digits can be input from the left.

Input nothing in the surplus positions.
a If one of the input digits is wrong, move to
that digit (and its background changes to
orange) and overwrite it with the correct
digit.
D155AX-6 39
Default setting (Key-on Mode) 3. Selecting mode

Check or change various settings related to the After the "Key-on Mode" screen is displayed,
machine monitor and machine by default setting. select the mode to be set with the function
The function of Key-on Mode is used to set the ini- switches.
tial mode displayed on the machine monitor when q Mode at previous key-OFF: Final mode in
the starting switch is turned ON. previous operation is displayed when
starting switch is turned ON
1. Selecting menu q Default Value (ALL OFF): Default setting
Select "06 Default" on the "Service Menu" of all mode items (Power: E, other 3 items:
screen. OFF) is displayed when starting switch is
turned ON
q [F5]: Cancel selection and return to
default screen
q [F6]: Confirm selection and return to
default screen
a When the machine is delivered, Default
Value (All OFF).

After the "Default" screen is displayed, select
"01 Key-on Mode" with the function switches or
a Select this item similarly to an item on the
"Service Menu" screen.
a This function sets the following 4 mode
items (which are the items set with the
customize switch in the operator mode).
q Power: P/E
q Reverse slow mode: ON/OFF
q Work equipment fine control: ON/OFF
q Blade slow down: ON/OFF
40 D155AX-6
Default setting (Setting of unit)

Check or change various settings related to the
machine monitor and machine by default setting.
The unit selecting function is used to select the unit
of the data displayed for monitoring, etc.
1. Selecting menu
Select "06 Default" on the "Service Menu"
screen.

"02 Unit" with the function switches or numeral
input switches.
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
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
screen.
4. Displaying maintenance password screen

When the following operation is performed, the
password screen is displayed in the operator
mode.
q The ordinary screen is changed to the
maintenance mode (with [F5]) and then
the "Maintenance table" screen is
changed to the "Maintenance interval
reset" screen.
2. Selecting sub menu 5. Changing maintenance password

After the "Default" screen is displayed, select The password can be changed by operating
"03 Maintenance Password" with the function the switches specially in the operator mode.
switches or numeral input switches. a See "Function of changing maintenance
a Select this item similarly to an item on the password" in the operator mode.
Service menu screen. a Default password: [000000]
a If the password setting is changed from
"Enable" to "Disable", the password is
reset to the default.
a When "Enable" is set again, be sure to set
a new password.
a The maintenance password is different
from the engine start lock password.
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 [F5]: Cancel selection and return to Initial-
ization screen
42 D155AX-6
Default setting (Setting of camera) q [F3]: Move to left item

Check or change various settings related to the q [F4]: Move to right item
machine monitor and machine by default setting. q [F5]: Cancel setting before confirmation
The camera setting function is used to set default and return to Default screen
setting and removal of a camera. q [F6]: Confirm selection in each line
a After "Camera" screen is displayed, cam-
1. Selecting menu era 1 can be always set. When 2 or more
Select "06 Default" on the "Service Menu" cameras are connected, if camera 1 is set,
screen. the screen changes to setting of camera 2
automatically.
a After confirming the setting of each line
with [F6], return to the Default screen with
[F5], and the setting is effective.
a If a camera is connected but not set nor-
mally with this function, the graphic mark
of camera is not displayed at [F3] in the
operator mode. Accordingly, the image of
the camera cannot be used.
a If 2 or more cameras are connected, be
sure to set the use of them from camera 1
in order.
a The function of displaying 2 images simul-
taneously is effective when use of camera
2. Selecting sub menu 1 and camera 2 is set.
After the "Default" screen is displayed, select a When a camera is installed, check that the
"04 Camera" with the function switches or displayed image is not inverted horizon-
numeral input switches. tally in the operator mode.
3. Selecting camera setting

After the "Camera" screen is displayed, select
the setting with the function switches.
q OFF: Camera is not connected
q Original image: Image of connected cam-
era is displayed in original position (as in
mirror, used as back monitor)
q Reverse image: Image of connected cam-
era is displayed in reverse position (as
seen directly, used as front or side moni-
tor)
D155AX-6 43
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
screen.
a Display of ECO gauge (a)

"05 ECO Display" with the function switches or
3. Selecting display setting

After the "ECO Display" screen is displayed,
select the setting with the function switches.
q ON: Display ECO
q OFF: Do not display ECO
q [F3]: Move to left item
q [F4]: Move to right item
q [F5]: Cancel selection and return to default
screen
q [F6]: Confirm selection and return to default
screen
44 D155AX-6
Adjustment
The operator can adjust various items related to the
machine with the machine monitor.
When using an adjustment item, select it according
to the following procedure.
1. Selecting menu
Select "07 Adjustment" on the "Service Menu"
screen.
3. Displaying adjustment screen

After the "Adjustment" screen for the adjust-
ment ID is displayed, you can start adjustment.
a In the figure, adjustment ID [0002] is
selected and displayed as an example.
a "000", "00", and "0" on the left of the
adjustment ID must be filled but they are
not displayed on the adjustment screen.
a The functions given to function switches
[F3] [F6] depend on the adjustment item.
2. Selecting adjustment item
a For the method of operating each adjust-
After the "Adjustment" screen is displayed,
ment item, see the explanation of its
input the 4-digit adjustment ID of the adjust-
adjustment ID.
ment item to be used with the numeral input
switches.
q [F5]: Cancel adjustment and return to Ser-
vice menu screen
q [F6]: Confirm input adjustment ID and go
to Adjustment screen
a For the adjustment ID's and their adjust-
ment items, see the adjustment items
table.
a If the input adjustment ID is incorrect, the

message of "No ready Adjustment" is dis-
played and the ID input screen does not
change (Another ID can be input again
with the numeral input switches while this
screen is displayed).
D155AX-6 45
Adjustment items table

Adjustment
Adjustment item Remarks
ID
0002 Power train controller initialization
0004 Work equipment specification setting
0005 Brake pedal potentiometer initial correction
0007 Engine decelerator cutting Resetting auto-decelerating function
0009 Pitch angle sensor initial correction
0010 Fan 70% mode
0031 Work equipment controller initialization
0530 Stall mode Recommended mode of torque converter stall
0910 Load record check mode
1005 Fan 100% mode
1012 Steering lever neutral position adjustment
1013 Steering lever leftmost position adjustment
1014 Steering lever rightmost position adjustment
1015 Right brake oil pressure offset
1016 Left brake oil pressure offset
2021 Power train controller voltage check mode
2022 Work equipment controller voltage check mode
2222 HSS min. current setting mode
6001 R1 reverse slow set speed Fine adjustment of reverse slow mode
7842 Transmission clutch IP automatic initial correction
7843 Transmission clutch IP manual initial correction
7845 Transmission clutch IP learning display
8000 Blade lift lever neutral position adjustment
8001 Blade lift lever max. raising position adjustment
8002 Blade lift lever max. lowering position adjustment
8003 Blade tilt lever neutral position adjustment
8004 Blade tilt lever rightmost position adjustment
8005 Blade tilt lever leftmost position adjustment
8006 Ripper lift lever neutral position adjustment
8007 Ripper lift lever max. raising position adjustment
8008 Ripper lift lever max. lowering position adjustment
8009 Ripper tilt lever neutral position adjustment
8010 Ripper tilt lever max. IN position adjustment
8011 Ripper tilt lever max. BACK position adjustment
8020 Blade raising current correction Fine adjustment with blade fine control mode OFF
8021 Blade lowering current correction Fine adjustment with blade fine control mode OFF
8022 Blade raising current correction (Fine control mode) Fine adjustment with blade fine control mode ON
8023 Blade lowering current correction (Fine control mode) Fine adjustment with blade fine control mode ON
8024 Blade tilting left current correction
8025 Blade tilting right current correction
9995 Control brake release mode Control brake: Brake ECMV (Right and left)
9996 Sudden stop prevent valve operation mode
9997 High idle cut mode
9998 Max. gear speed setting mode
46 D155AX-6
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.
q Functions of function switches q Functions of function switches

[F3]: Unused [F3]: Increase specification value [CODE]
[F4]: Unused [F4]: Decrease specification value [CODE]
[F5]: Return to adjustment item selecting [F5]: Return to adjustment item selecting
screen (ID inputting screen) screen (ID inputting screen)
[F6]: Save setting [F6]: Save setting
q Operating method: q Operating method:

1) Press [F6] and check that the alarm 1) Press [F3] or [F4] to select the specifica-
buzzer sounds. tion value [CODE] of the work equipment
2) Check that the displayed specification concerned.
code [CODE] has changed from [5x5] to
CODE Type of work equipment
[555].
a If specification code [555] is not displayed, 0 Dual tiltdozer
the controller wiring harness or the con- 1 Single tiltdozer
troller unit may be defective. 2 Mechanical dozer
a Even if this adjustment code is turned off,
the setting is effective.
2) Press [F6] and check that the alarm buzz-
er sounds.
k If the specification of the work equip-
ment is different from the setting in the
controller, the work equipment may
move unexpectedly or an error may be
made. Accordingly, be sure to match
the controller to the work equipment.
the setting is effective.
D155AX-6 47
Adjustment ID: 0005 (Brake pedal potentiometer Adjustment ID: 0007

initial correction) (Engine decelerator cutting)
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.
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
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)
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).
the correction is effective.
D155AX-6 49
Adjustment ID: 0031 (Work equipment controller Adjustment ID: 0530

initialization) (Stall mode)
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
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,
[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]
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
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.

[F6]: Save adjustment value [F6]: Save adjustment value
q Operating method: q Operating method:

1) Check that the PCCS lever is in the neu- 1) Operate the PCCS lever to the left stroke
tral position of the steering direction and end of the steering direction and keep it in
keep it in that position. that position.
2) Press [F6] and check that the alarm 2) Press [F6] and check that the alarm
buzzer sounds. buzzer sounds.
a Even if the adjustment is carried out, the a Even if the adjustment is carried out, the
displayed value does not change. displayed value does not change.
a Even if this adjustment code is turned off, a Even if this adjustment code is turned off,
the adjustment is effective. the adjustment is effective.
a This adjustment code is used to make the a This adjustment code is used to make the
controller recognize the neutral position of controller recognize the leftmost position
the potentiometer. It is not used to adjust of the potentiometer. It is not used to
the steering force. adjust the steering force.
52 D155AX-6
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
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.
the adjustment is effective.
D155AX-6 53
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
screen (ID inputting screen) [F4]: Unused
[F6]: Save adjustment value [F5]: Return to adjustment item selecting
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
q Operating method q Operating method:

1) Increase or decrease the adjustment val- When this adjustment code is displayed, its
ue by pressing [F3] or [F4]. function is effective and the constant power
2) Press [F6] and check that the alarm buzz- supply voltage and switch power supply volt-
er sounds. age are displayed simultaneously.
a It is not necessary to operate the brake a After this adjustment code is turned OFF,
during adjustment. After finishing adjust- its function is ineffective.
ment, however, operate the brake and
actual brake performance.
a If the oil pressure has been adjusted, it is
displayed. It can be adjusted again within
the adjustment range, however.
54 D155AX-6
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.

q Information displayed on screen q Operating method

[WE CONTROLLER UNSWITCH POWER]: 1) Set the parking brake lever in the free
Constant power supply voltage position.
[WE CONTROLLER ACC POWER]: 2) Tilt the PCCS lever to a right or left posi-
Switch power supply voltage tion at which the current to be set is indi-
cated and hold it at that position.
q Operating method: q If the lever is tilted to the left, the cur-
When this adjustment code is displayed, its rent becomes negative.
function is effective and the constant power q If the lever is tilted to the right, the
supply voltage and switch power supply volt- current becomes positive.
age are displayed simultaneously. 3) Press [F6] and check that the alarm buzz-
a After this adjustment code is turned OFF, er sounds.
its function is ineffective. a The current (mA) varies in the range from
-350 (left end) to 350 (right end).
a As the set current is increased in the posi-
tive or negative direction, the turning
radius to start steering is reduced more
(the machine is steered more quickly).
a It is not necessary to steer the machine
ment, however, steer the machine and
actual steering feel.
a The following figure shows an example of
reducing the set current for the left steer-
ing to increase the turning radius.
D155AX-6 55
Adjustment ID: 6001 (R1 reverse slow set speed)
a Even if this adjustment code is turned off, the

adjustment is effective. q This adjustment code is used to adjust the
engine speed applied to travel at gear speed
R1 with the reverse slow mode ON.
a Use this adjustment code for work when nec-
essary.

[F3]: Increase adjustment value
[F4]: Decrease adjustment value
[F6]: Save adjustment value
q Information displayed on screen

The speed reduced from the high idle speed
(2,050 rpm) is displayed and the adjustment
value is increased or decreased by 50 rpm
(The value displayed on the screen is multi-
plied by 1/10).
a The default adjustment value is 300 rpm
(Displayed value: 30).
(Default setting: 2,050 300 = 1,850 rpm)
q Operating method
1) Increase or decrease the adjustment val-
ue by pressing [F3] or [F4].
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
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.
56 D155AX-6
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.

[F3]: Increase adjustment value [F3]: Increase adjustment value
[F4]: Decrease adjustment value [F4]: Decrease adjustment value
q Information displayed on screen q Information displayed on screen

The speed reduced from the high idle speed The speed reduced from the high idle speed
(2,050 rpm) is displayed and the adjustment (2,050 rpm) is displayed and the adjustment
value is increased or decreased by 50 rpm value is increased or decreased by 50 rpm
(The value displayed on the screen is multi- (The value displayed on the screen is multi-
plied by 1/10). plied by 1/10).
a The default adjustment value is 300 rpm a The default adjustment value is 300 rpm
(Displayed value: 30). (Displayed value: 30).
(Default setting: 2,050 300 = 1,850 rpm) (Default setting: 2,050 300 = 1,850 rpm)
q Operating method q Operating method

1) Increase or decrease the adjustment 1) Increase or decrease the adjustment val-
value by pressing [F3] or [F4]. ue by pressing [F3] or [F4].
2) Press [F6] and check that the alarm 2) Press [F6] and check that the alarm buzz-
buzzer 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 again is displayed. It can be adjusted again
within the adjustment range, however. within the adjustment range, however.
a It is not necessary to drive the machine a It is not necessary to drive the machine
during adjustment. After finishing adjust- during adjustment. After finishing adjust-
ment, however, drive the machine at R2 ment, however, drive the machine at R3
with the reverse slow mode ON and check with the reverse slow mode ON and check
that there is not a problem in the actual that there is not a problem in the actual
travel speed. travel speed.
D155AX-6 57
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.

[F3]: Unused [F3]: Increase adjustment value
[F4]: Unused [F4]: Decrease adjustment value
a If [F2] is pressed while [F1] is pressed, all
q Conditions for correction work the correction values are set to 0.
1) [ENGINE SPEED]: 1,700 1,950 rpm
2) [T/C TEMPERATURE]: 65 85 C q Functions of shift-up and shift-down switches
3) Parking brake lever: LOCK position You can select a clutch to be corrected manu-
a When using this adjustment code, keep ally with the shift-up and shift-down switches.
the ab ove c ond iti on s (I n pa rt ic ul ar,
increase the power train oil temperature q Conditions for correction work
sufficiently before starting adjustment). Same as the conditions for IP automatic cor-
rection (Adjustment ID: 7842).
q Operating method:
1) Start the engine and keep its speed in the q Operating method:
specified range of condition with the fuel 1) Start the engine and keep its speed in the
control dial. specified range of condition with the fuel
2) Press [F6] and start the correction work control dial.
and check that [1ST CLUTCH] is dis- 2) Select a clutch to be corrected manually
played newly on the screen. with the shift-up or shift-down switches.
3) If [END OF TEACHING] is displayed on 3) Increase or decrease the adjustment
the screen, press [F6]. If the alarm buzzer value by pressing [F3] or [F4].
sounds at this time, correction work is 4) Press [F6] and check that the alarm
completed. buzzer sounds.
a The machine does not move during the a The machine does not move during the
correction work. correction work.
the correction is effective. the correction is effective.
58 D155AX-6
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.

[F3]: Change display [F3]: Unused
[F4]: Change display [F4]: Unused

When this adjustment code is displayed, its 1) Check that the blade control lever is in the
function is effective and the correction informa- neutral position of the lifting direction and
tion is displayed. keep it in that position.
a After this adjustment code is turned OFF, 2) Press [F6] and check that the alarm
its function is ineffective. buzzer sounds.
a Even if the adjustment is carried out, the
displayed value does not change.
a This adjustment code is used to make the
controller recognize the neutral position of
the potentiometer. It is not used to adjust
the sensitivity of the blade control lever
(For adjustment of the sensitivity of the
blade control lever in the lifting direction,
carry out adjustment codes 8020 8023).
D155AX-6 59
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.


1) Operate the blade control lever to the rais- 1) Operate the blade control lever to the low-
ing stroke end of the lifting direction and ering stroke end of the lifting direction and
keep it in that position. keep it in that position.
controller recognize the maximum raising controller recognize the maximum lower-
position of the potentiometer. It is not ing position of the potentiometer. It is not
used to adjust the sensitivity of the blade used to adjust the sensitivity of the blade
control lever (For adjustment of the sensi- control lever (For adjustment of the sensi-
tivity of the blade control lever in the lifting tivity of the blade control lever in the lifting
direction, carry out adjustment codes direction, carry out adjustment codes
8020 8023). 8020 8023).
60 D155AX-6
Adjustment ID: 8003 (Blade tilt lever neutral posi- Adjustment ID: 8004 (Blade tilt lever rightmost
tion adjustment) position adjustment)
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


1) Check that the blade control lever is in the 1) Operate the blade control lever to the right
neutral position of the tilting direction and stroke end of the tilting direction and keep
keep it in that position. it in that position.
controller recognize the neutral position of controller recognize the rightmost position
the potentiometer. It is not used to adjust of the potentiometer. It is not used to
the sensitivity of the blade control lever adjust the sensitivity of the blade control
(For adjustment of the sensitivity of the lever (For adjustment of the sensitivity of
blade control lever in the tilting direction, the blade control lever in the tilting direc-
carry out adjustment codes 8024 and tion, carry out adjustment codes 8024 and
8025). 8025).
D155AX-6 61
Adjustment ID: 8005 (Blade tilt lever leftmost posi- Adjustment ID: 8006 (Ripper lift lever neutral posi-
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
a After the work equipment controller or blade a After the work equipment controller or ripper


1) Operate the blade control lever to the left 1) Check that the ripper control lever is in the
stroke end of the tilting direction and keep neutral position of the lifting direction and
it in that position. keep it in that position.
controller recognize the leftmost position controller recognize the neutral position of
of the potentiometer. It is not used to the potentiometer. It is not used to adjust
adjust the sensitivity of the blade control the sensitivity of the ripper control lever.
lever (For adjustment of the sensitivity of
the blade control lever in the tilting direc-
tion, carry out adjustment codes 8024 and
8025).
62 D155AX-6
Adjustment ID: 8007 (Ripper lift lever max. raising Adjustment ID: 8008 (Ripper lift lever max. lower-
position adjustment) ing position adjustment)
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


1) Operate the ripper control lever to the rais- 1) Operate the ripper control lever to the low-
ing stroke end of the lifting direction and ering stroke end of the lifting direction and
keep it in that position. keep it in that position.
controller recognize the maximum raising controller recognize the maximum lower-
position of the potentiometer. It is not ing position of the potentiometer. It is not
used to adjust the sensitivity of the ripper used to adjust the sensitivity of the ripper
D155AX-6 63
Adjustment ID: 8009 (Ripper tilt lever neutral posi- Adjustment ID: 8010 (Ripper tilt lever max. IN posi-
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
a After the work equipment controller or ripper a After the work equipment controller or ripper


1) Check that the ripper control lever is in the 1) Operate the ripper control lever to the IN
neutral position of the tilting direction and stroke end of the tilting direction and keep
keep it in that position. it in that position.
controller recognize the neutral position of controller recognize the maximum IN posi-
the potentiometer. It is not used to adjust tion of the potentiometer. It is not used to
the sensitivity of the ripper control lever. adjust the sensitivity of the ripper control
lever.
64 D155AX-6
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 [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
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
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.

[F3]: Increase adjustment value [Current offset] [F3]: Increase adjustment value [Current offset]
[F4]: Decrease adjustment value [Current offset] [F4]: Decrease adjustment value [Current offset]

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 adjusting adjustment. After finishing adjust-
ment, however, lower the blade and check ment, however, raise the blade and check
that there is not a problem in the actual that there is not a problem in the actual
operation feel (Check with the blade fine operation feel (Check with the blade fine
control mode OFF). control mode ON).
66 D155AX-6
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 necessary.
essary.
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
q Operating method
q Operating method 1) Increase or decrease the adjustment val-
1) Increase or decrease the adjustment value 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 buzzer 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 repeatedly, however.
edly, however. a It is not necessary to move the blade dur-
a It is not necessary to move the blade during adjustment. After finishing adjust-
ing adjustment. After finishing adjustment, 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.
D155AX-6 67
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,
[F3]: Increase adjustment value [Current offset] q Functions of function switches
[F4]: Decrease adjustment value [Current offset] [F3]: 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.
68 D155AX-6
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]

When this adjustment code is displayed, its 1) Increase or decrease the adjustment val-
function is effective and the sudden stop pre- ue by pressing [F3] or [F4].
vent solenoid valve and right and left brake 2) Press [F6] and check that the alarm buzz-
ECMV are kept stopped. er sounds.
a After this adjustment code is turned OFF, a When resetting the limitation of the high
its function is ineffective. idle speed, set the adjustment value to the
original high idle speed (2,050 rpm).
D155AX-6 69
Adjustment ID: 9998 (Max. gear speed setting mode)
q This adjustment code is used to limit the maxi-

mum transmission gear speed.
q The limited gear speed is applied in both auto-
matic gearshift mode and manual gearshift
mode.
a Use this adjustment code for work when nec-
essary.

[F3]: Increase adjustment value [MAX SHIFT]
[F4]: Decrease adjustment value [MAX SHIFT]
q Operating method
1) Increase or decrease the adjustment val-
ue by pressing [F3] or [F4].
er sounds.
a When resetting the limitation of the maxi-
mum gear speed, set the adjustment
value to the maximum gear speed (3RD).
70 D155AX-6
Pm Clinic q 2nd screen

The machine monitor can check the condition of the
machine without connecting testing tools to assist
the Pm Clinic and other periodic inspections.
1. Selecting menu
Select "08 PM CLINIC" on the Service menu
screen.
q [F1]: Change screen

q [F2]: Change screen
q [F4]: Hold (displayed data)
3. Holding displayed information

2. Information displayed on Pm Clinic screen The displayed information can be held and
The Pm Clinic function displays the following released with [F3] and [F4].
information on 2 pages.
q 1st screen
D155AX-6 71
Cylinder Cut-Out operation 3. Resetting disabled cylinder

The operator can perform Cylinder Cut-Out opera- When changing a cylinder to be disabled or
tion with the machine monitor. when reduced cylinder mode operation is fin-
Reduced cylinder mode operation means to run the ished, select a disabled cylinder to be reset
engine with 1 or more fuel injectors disabled electri- with the function switches.
cally to reduce the number of effective cylinders. a This operation may be performed while
This operation is used to find out a cylinder which the engine is running.
does not output power normally (combustion in it is a When [F6] is pressed, if background (a) of
abnormal). the selected cylinder No. becomes light
blue, the cylinder is reset.
1. Selecting menu a If the machine monitor rests a disabled
Select "09 Cylinder Cut-Out" on the "Service cylinder but the engine controller cannot
Menu" screen. reset that disabled cylinder, the back-
ground of the cylinder No. becomes red.
a The reduced cylinder mode operation is
not automatically reset after the screen
returns to the operator mode. Accord-
ingly, be sure to perform the resetting
operation after the reduced cylinder mode
operation is finished.
4. Function of holding displayed information

If [F4] is pressed during the reduced cylinder
mode operation, the displayed information is
newly held (c) (The real-time information is
kept displayed on the left side).
a While the information is held, if [F3] is
2. Selecting cylinder to be disabled pressed, the holding function is reset.
After the "Cylinder Cut-Out" screen is dis- a The holding function is effective, regard-
played, select a cylinder to be disabled with the less of setting of the reduced cylinder
function switches. mode operation.
q [F1]: Move selection mark (R) to left
q [F2]: Move selection mark (R) to right
q [F4]: Hold
a This operation may be performed while
the engine is running.
a When [F6] is pressed, if background (a) of
the selected cylinder No. becomes white,
the cylinder is disabled.
a If the machine monitor disables a cylinder
but the engine controller cannot disable
that cylinder, the background of the cylin-
der No. becomes yellow.
a One or more cylinders can be disabled.
[Reference]
q If a normally operating cylinder is disabled, the
following phenomena occur.
1) Lowering of engine speed
2) Increase of final injection rate command
(quantity)
q If the engine is running near the high idle, how-
ever, the engine speed may not lower for the
reason of engine control.
q In this case, lower the engine speed with the
fuel control dial and judge by increase of the
injection rate command.
72 D155AX-6
Display of No Injection a Limit the cranking time to 20 seconds to

If the engine is operated after long storage of the protect the starting motor.
machine, it may be worn or damaged because of
insufficient lubrication with oil. To prevent this, the
function to lubricate the engine before starting it by
cranking it without injecting fuel is installed.
Set the No Injection while the engine is stopped.
1. Selecting menu
Select "10 No Injection" on the "Service Menu"
screen.
4. Finishing no-injection cranking

After completing the no-injection cranking
operation, press [F6], and finish of no-injection
cranking is displayed and the screen returns to
the "Service Menu" screen automatically.
2. Displaying check screen

If the "No Injection" screen is displayed, the
machine monitor asks the operator if no-injec-
tion cranking should be performed. Answer
with the function switch.
q [F5]: Do not perform (Return to Service
menu screen)
q [F6]: Perform
a While the screen is changing to the follow-
ing screen, the screen of "Communication
between controllers is being checked" is 5. Prohibiting no-injection cranking
displayed. If the operator tries to perform the no-injection
cranking while the engine is running, the mes-
sage that the engine is running is displayed and
the no-injection cranking is not set effective.
a This function can be selected even while
the engine is running. If the no-injection
cranking is performed, however, the mes-
sage of "Engine is running" is displayed
on the screen.
3. Starting no-injection cranking

If no-injection cranking (Fuel injection in no cyl-
inders) becomes effective, that is displayed on
the screen. Under this condition, crank the
engine with the starting motor.
a While the screen is changing to the follow-
ing screen, the screen of "Setting is being
prepared" is displayed.
D155AX-6 73
Display of Fuel Consumption 3. Display and function during measurement

This function calculates the hourly fuel consump- Clock mark (a) flashes during measurement.
tion from the actual fuel consumption in a measur- a While the fuel consumption is being mea-
ing period and indicates it. sured, the operator can work with the
operator mode and other functions. Mea-
1. Selecting menu surement is not finished until this screen is
Select "11 Fuel Consumption" on the "Service displayed again and [F1] is pressed (Even
Menu" screen. if the starting switch is turned OFF, this
function is kept effective, although fuel
consumption is measured only while the
engine is running).
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
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.

After the "KOMTRAX Settings" screen is dis-
played, select "01 Terminal Status" with the
3. Contents of Terminal Status

On the "Terminal Status" screen, the following
items are displayed.
q Terminal Type: Model name of KOMTRAX
communication MODEM
q KOMTRAX communication: Executing con-
dition of KOMTRAX communication
q GMT time: Greenwich Meant Time (+ 9
hours in Japan)
D155AX-6 75
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

After the Display of "KOMTRAX Settings"
screen is displayed, select "02 GPS & Commu-
nication Status" with the function switches or
76 D155AX-6
Display of KOMTRAX Settings

The setting condition and operating condition of
KOMTRAX can be checked with KOMTRAX Set-
tings.
MODEM S/N is used to check the serial No. of the
KOMTRAX communication MODEM.
1. Selecting menu
Select "12 KOMTRAX Settings" on the "Ser-
vice Menu" screen.

After the Display of "KOMTRAX Settings"
screen is displayed, select "03 Modem S/N"
with the function switches or numeral input
switches.
3. Contents of display of MODEM S/N

The serial No. of KOMTRAX communication
MODEM is displayed.
q [F5]: Return to KOMTRAX Settings screen
D155AX-6 77
Display of Service Message q [F6]: Confirm and return input value

Special messages for the serviceman sent from the a This message is different from a message
KOMTRAX base station (a distributor, etc.) can be transmitted to the operator in the operator
checked with this function. mode.
If there is setting in a message, a return mail can be a Since this message is special for the ser-
sent by using numeral input switches. viceman, the message monitor is not dis-
played when it is received as in the
1. Operation to display menu operator mode.
Select "13 Service Message" on the "Service
Menu" screen.
2. Display of message (Read-only)

If there is a message, its contents are dis-
played. If there is not a message, "No mes-
sage" is displayed.
a This message is different from a message
transmitted to the operator in the operator
mode.
a Since this message is special for the ser-
viceman, the message monitor is not dis-
played when it is received as in the
operator mode.
3. Display of message (with return mail function)

If a box to enter a value with the numeral keys
is displayed under the message, enter a
proper number with the numeral input switches
and function switches and confirm it, and the
information is returned to the KOMTRAX base
station.
78 D155AX-6
D155AX-6 Bulldozer
2006 KOMATSU
All Rights Reserved
80 D155AX-6
SEN00682-01
D155AX-6

D155AX-6 80001 and up

Handling of power supply circuit of engine controller........................................................................... 2
Preparation work for troubleshooting of electrical system.................................................................... 3
Pm Clinic .............................................................................................................................................. 5
D155AX-6 1

Handling of power supply circuit
of engine controller 1
1. Before disconnecting or connecting a connec-
tor between the engine controller and engine,
be sure to turn the starting switch OFF.
2. If a T-adapter is inserted in or connected to a

connector between the engine controller and
engine for troubleshooting, do not start the
engine.
a You may turn the starting switch to the
OFF or ON position but must not turn it to
the START position.
2 D155AX-6
Preparation work for 2. Engine controller

troubleshooting of electrical 1) Open the left engine side cover and left
mudguard.
system 1 2) Remove the mounting bolts and cover (6).
a When carrying out troubleshooting of an elec-
tric circuit related to the machine monitor,
engine controller, power train controller, or work
equipment controller, expose the related con-
nectors according to the following procedure.
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}
4) Insert or connect troubleshooting T-adapt-

ers in or to connectors CM01, CM02, and
CM03 of machine monitor (5).
a AT11 is for the GPS antenna.
a If a camera is installed, CM05 is also
wired.
D155AX-6 3
3. Power train controller 2) Insert or connect troubleshooting T-adapt-

1) Remove the inside lower cover of the left ers in or to connectors WEC1, WEC2, and
console. WEC3 of work equipment controller (10).
a This cover is installed on the opposite a Since the connectors are fixed with
side of the work equipment controller. screws, loosen those screws before
2) Insert or connect troubleshooting T-adapt- disconnecting.
ers in or to connectors STC1, STC2, and a When returning the connectors, tight-
STC3 of power train controller (8). en the screws to the specified torque.
a Since the connectors are fixed with 3 Screw: 2.83 0.28 Nm
screws, loosen those screws before {0.288 0.028 kgm}
disconnecting.
a When returning the connectors, tight-
en the screws to the specified torque.
3 Screw: 2.83 0.28 Nm
{0.288 0.028 kgm}
4. Work equipment controller

1) Remove the inside lower cover (9) of the
left console.
a This cover is installed on the opposite
side of the work equipment controller.
4 D155AX-6
Pm Clinic 1
Machine model Serial No. Service meter
D155AX-6 h
User's name Date of execution Inspector
/ /
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
Fault history of mechanical system Fault history of electrical system

AA10NX times/1st time h/last h times/1st time h/last h
AB00MA times/1st time h/last h times/1st time h/last h
B@BAZG times/1st time h/last h times/1st time h/last h
B@BCNS times/1st time h/last h times/1st time h/last h
B@BCZK times/1st time h/last h times/1st time h/last h
B@CENS times/1st time h/last h times/1st time h/last h
B@HANS times/1st time h/last h times/1st time h/last h
CA234 times/1st time h/last h times/1st time h/last h
D155AX-6 5
Check positions/Method 1
6 D155AX-6
D155AX-6 7
8 D155AX-6
Pm Clinic check sheet
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
value ment result
machine
Low idle
Speed Adjust- rpm
Fan
ment: High idle 1,200 1,300 1,200 1,300

1005
Circuit MPa
High idle
pressure {kg/cm}
D155AX-6 9
3. Power train oil pressure

k Measure each transmission clutch pressure only while the engine is running at low speed
for safety.
Accepted
Rejected
Standard
value ment result
machine
0.05 0.49 0.05 0.49

Low idle
Inlet {0.5 5.0} {0.5 5.0}
Monitoring: 32601
pressure Max. 1.0 Max. 1.0
High idle
{Max. 10.0} {Max. 10.0}
0.05 0.29 0.05 0.29
Low idle
Outlet {0.5 3.0} {0.5 3.0}
Torque converter
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
value ment result
machine
2.81 3.11 Min. 2.62

Low idle
Main relief {28.7 31.7} {Min. 26.7}
Gear speed: P/N
pressure 3.04 3.33 Min. 2.84
High idle
{31.0 34.0} {Min. 29.0}
F clutch Gear speed: F3 2.45 2.75 Min. 2.26
Low idle
Transmission
pressure Brake: Applied {25.0 28.0} {Min. 23.0}

R clutch Gear speed: R3 MPa 2.65 2.94 Min. 2.45
Low idle
pressure Brake: Applied {kg/cm} {27.0 30.0} {Min. 25.0}
1st clutch Gear speed: F1 2.81 3.11 Min. 2.62
Low idle
2nd clutch Gear speed: F2 2.60 2.89 Min. 2.40
Low idle
3rd clutch Gear speed: F3 2.81 3.11 Min. 2.62
Low idle
Accepted
Rejected
Standard
value ment result
machine
2.46 3.04 2.16

Low idle
Right brake Gear speed: N {25.0 31.0} {22.0}
pressure Brake: Released 2.46 3.04 2.16
High idle
{25.0 31.0} {22.0}
Brake
MPa 2.46 3.04 2.16

Low idle
Left brake Gear speed: N {kg/cm} {25.0 31.0} {22.0}
pressure Brake: Released 2.46 3.04 2.16
High idle
{25.0 31.0} {22.0}
Brake
F2 stall, high idle Machine must not move.
performance
10 D155AX-6
4. Work equipment/HSS oil pressure
Accepted
Rejected
Standard
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
5. Work equipment speed
Accepted
Rejected
Standard
value ment result
machine
Blade raise High idle 3.0 4.0 3.0 4.0

equipment
Blade left tilt High idle 1.8 2.8 3.1

speed
Work
sec
Ripper lower High idle 1.5 2.5 3.5
Ripper tilt in High idle 4.5 5.5 6.2
6. Hydraulic drift of work equipment
Accepted
Rejected
Standard
value ment result
machine
Hydraulic oil
C
temperature
Hydraulic
Engine: Stopped
Hydraulic drift
drift
Blade lift: 15 minutes mm Max. 50 200

of blade lift
Ripper lift: 5 minutes
Hydraulic drift
mm Max. 50 70
of ripper lift
7. Final drive
Accepted
Rejected
Standard
value ment result
machine
There must not abnormally

FD Final drive Engine: Stopped
much metal dust.
D155AX-6 11
8. Repair record (Must be filled in)
Date Service meter Repair record Date Service meter Repair record
/ / h / / h
/ / h / / h
/ / h / / h
/ / h / / h
/ / h / / h
12 D155AX-6
Pm Clinic undercarriage check sheet
Machine model Serial No. Service meter User's name Date of execution Inspector
D155AX-6
1. Bushing temperature
Item Measurement condition Measurement result Accepted Rejected
Under- Bushing Measure just Left side of machine

carriage temperature after work. Right side of machine
Left side of machine
a Symbols to be entered in check drawing

H : Hot (You cannot keep touching, Very hot, Min. 50 C)
W : Warm (Lukewarm, warmer than link, Approx. 35 C)
C : Normal temperature: Same as link temperature
Right side of machine
a Symbols to be entered in check drawing

H : Hot (You cannot keep touching, Very hot, Min. 50 C)
W : Warm (Lukewarm, warmer than link, Approx. 35 C)
C : Normal temperature: Same as link temperature
D155AX-6 13
Accepted
Rejected
Clearance Measure-
Item Measurement condition Unit Pin No.
limit ment result
Left side of 1.4

machine (Each side)
Undercarriage
Opening of Measure
mm
track link dimension (a).
Right side of 1.4

machine (Each side)
Opening of track link (a)
14 D155AX-6
D155AX-6 Bulldozer
2006 KOMATSU
All Rights Reserved
16 D155AX-6
SEN00851-00
D155AX-6

D155AX-6 80001 and up
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
General information on troubleshooting 1

Points to remember when troubleshooting 1
k Stop the machine in a level ground, and check that the lock pin, blocks, and parking brake are
securely fitted.
k When carrying out the operation with two or more workers, keep strictly to the agreed signals,
and do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative () terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and function.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1. 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
Sequence of events in troubleshooting 1
D155AX-6 3
Check before troubleshooting 1
Item Criterion Remedy

1. Check of level and type of fuel Add fuel
2. Check of fuel for foreign matter Clean and drain
3. Check of hydraulic oil level Between H L Add oil
4. Check of damper case oil level Between H L Add oil
Lubricating
5. Check of power train oil level Between H L Add oil
oil/Coolant
6. Check of level and type of engine oil (in oil pan) Between H L Add oil
7. Check of coolant level (in sub tank) Between FULL - LOW Add coolant
8. Check of dust indicator for clogging Out of red range Clean or replace
9. Check of brake pedal stroke Adjust
Hydraulic/ 1. Check for abnormal noise/smell Repair

Mechanical 2. Check for oil leakage Repair
equipment 3. Bleeding air Bleed air
1. Check of battery terminals and wiring for loose-
Retighten or replace
ness and corrosion
2. Check of alternator terminals and wiring for
looseness and corrosion
3. Check of starting motor terminals and wiring for
looseness and corrosion
4. Check of battery voltage (with engine stopped) 20 30 V Charge or replace
5. Check of electrolyte level Between H L Add or replace
6. Check of wires for discoloration, burn, and
Electrical Repair or replace
removal of cover
equipment
7. Check for released wire clamp and drooping wire Repair
8. Check of wires for wetness (Check connectors
Dry
and terminals for wetness, in particular)
9. Check circuit breaker for turning OFF and fuse
Replace
for disconnection and corrosion
10. Check of alternator voltage After operating for several
Replace
(while engine speed is at middle or higher) minutes: 27.5 29.5 V
11. Check of battery relay for operating sound
Replace
(when starting switch is turned ON or OFF)
4 D155AX-6
Classification and procedures for troubleshooting 1

Classification for troubleshooting
Type Contents
Display of code Troubleshooting by failure code
E mode Troubleshooting for electrical system
H mode Troubleshooting for hydraulic and mechanical system
S mode Troubleshooting for engine
Procedure for troubleshooting

If a phenomenon looking like a trouble occurs in the machine, select a proper troubleshooting No. according
to the following procedure, and then go to the corresponding troubleshooting section.
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
Phenomena looking like troubles and troubleshooting Nos.
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
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
Connector pin Nos. and connection table 1

a The male and female mean the pin and jack respectively. The plug and receptacle mean the shapes of
the housing.
Total X type connector

num-
ber of Part No. of
Male (Housing: Receptacle) Female (Housing: Plug)
pins T-adapter
1 Part No.: 08055-00181 Part No.: 08055-00191 799-601-7010
2 799-601-7020
Part No.: 08055-00282 Part No.: 08055-00292
3 799-601-7030
Part No.: 08055-00381 Part No.: 08055-00391
4 799-601-7040
Part No.: 08055-00481 Part No.: 08055-00491

Part No. of terminal: 79A-222-3370 Part No. of terminal: 79A-222-3390
Wire size: 0.85 Wire size: 0.85

Grommet: Black Grommet: Black
Quantity: 20 pieces Quantity: 20 pieces
Part No. of terminal: 79A-222-3380 Part No. of terminal: 79A-222-3410

Grommet: Red Grommet: Red
8 D155AX-6
Total SWP type connector

num-
ber of Part No. of
pins T-adapter
6 799-601-7050
Part No.: 08055-10681 Part No.: 08055-10691
8 799-601-7060
Part No.: 08055-10881 Part No.: 08055-10891
12 799-601-7310
Part No.: 08055-11281 Part No.: 08055-11291
14 799-601-7070
Part No.: 08055-11481 Part No.: 08055-11491
D155AX-6 9
Total SWP type connector

num-
ber of Part No. of
pins T-adapter
16 799-601-7320
Part No.: 08055-11681 Part No.: 08055-11691

Part No. of terminal: Part No. of terminal:

Grommet: Black Grommet: Black
Part No. of terminal: Part No. of terminal:

Grommet: Red Grommet: Red
10 D155AX-6
Total M type connector

num-
ber of Part No. of
pins T-adapter
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080
2 799-601-7090
Part No.: 08056-00271 Part No.: 08056-00281
3 799-601-7110
Part No.: 08056-00371 Part No.: 08056-00381
4 799-601-7120
Part No.: 08056-00471 Part No.: 08056-00481
6 799-601-7130
Part No.: 08056-00671 Part No.: 08056-00681
8 799-601-7340
Part No.: 08056-00871 Part No.: 08056-00881
D155AX-6 11
Total S type connector

num-
ber of Part No. of
pins T-adapter
8 799-601-7140
Part No.: 08056-10871 Part No.: 08056-10881
10
799-601-7150
(White)
Part No.: 08056-11071 Part No.: 08056-11081
12
799-601-7350
(White)
Part No.: 08056-11271 Part No.: 08056-11281
16
799-601-7330
(White)
Part No.: 08056-11671 Part No.: 08056-11681
12 D155AX-6
Total S type connector

num-
ber of Part No. of
pins T-adapter
10

(Blue)
12
799-601-7160
(Blue)
Part No.: 08056-11272 Part No.: 08056-11282
16
799-601-7170
(Blue)
Part No.: 08056-11672 Part No.: 08056-11682
D155AX-6 13
Total MIC type connector

num-
ber of Part No. of
pins T-adapter
Part No. of body: 79A-222-2640 Part No. of body: 79A-222-2630

7
(Quantity: 5 pieces) (Quantity: 5 pieces)
11
5 799-601-2710

9 799-601-2950
Part No. of body:79A-222-2660 Part No. of body:79A-222-2650

13 799-601-2720

14 D155AX-6
Total MIC type connector

num-
ber of Part No. of
pins T-adapter
17 799-601-2730

21 799-601-2740


D155AX-6 15
Total AMP040 type connector

num-
ber of Part No. of
pins T-adapter
8 799-601-7180
Part No. of housing: 79A-222-3430

(Quantity: 5 pieces)
12 799-601-7190

16 799-601-7210

20 799-601-7220

a Part No. of terminal: 79A-222-3470 (Not related to number of poles)
16 D155AX-6
Total AMP070 type connector

num-
ber of Part No. of
pins T-adapter
10 799-601-7510
Part No.: 7821-92-7330
12 799-601-7520
Part No.: 7821-92-7340
14 799-601-7530
Part No.: 7821-92-7350
18 799-601-7540
Part No.: 7821-92-7360
20 799-601-7550
Part No.: 7821-92-7370
D155AX-6 17
Total L type connector

num-
ber of Part No. of
pins T-adapter
Total PA type connector

num-
ber of Part No. of
pins T-adapter
Total BENDIX (MS) type connector

num-
ber of Part No. of
pins T-adapter
10 799-601-3460
18 D155AX-6
Total KES 1 (For automobile) type connector

num-
ber of Part No. of
pins T-adapter.
Part No.: 08027-10210 (Natural color) Part No.: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
Part No.:08027-10310 Part No.:08027-10360
08027-10420 (Black) 08027-10470 (Black)
08027-10620 (Black) 08027-10670 (Black)
D155AX-6 19
Total KES 1 (For automobile) type connector

num-
ber of Part No. of
pins T-adapter
08027-10820 (Black) 08027-10870 (Black)
Total Connector for relay (Receptacle)

num-
ber of Part No. of
pins T-adapter
5 799-601-7360
6 799-601-7370
20 D155AX-6
Total F type connector

num-
ber of Part No. of
pins T-adapter
D155AX-6 21
[Pin No. is printed on connector (wire insertion side), too.]

Type HD30 Series connector
(shell
size Part No. of
Body (Plug) Body (Receptacle)
code) T-adapter
Pin (Male terminal) Pin (Female termial)
799-601-9210
Part No.: 08191-11201, 08191-11202, Part No.: 08191-14101, 08191-14102,

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (Female termial) Pin (Male terminal)
799-601-9210
Part No.: 08191-12201, 08191-12202, Part No.: 08191-13101, 08191-13102,

08191-12205, 08191-12206 08191-13105, 08191-13106
Pin (Male terminal) Pin (Female termial)
799-601-9220
Part No.: 08191-21201, 08191-12202, Part No.: 08191-24101, 08191-24102,

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
(2) Pin (Female termial) Pin (Male terminal)
799-601-9220
Part No.: 08191-22201, 08191-22202, Part No.: 08191-23101, 08191-23102,

08191-22205, 08191-22206 08191-23105, 08191-23106
22 D155AX-6

(shell
size Part No. of
code) T-adapter
Pin (Male terminal) Pin (Female terminal)
799-601-9230
18-20 Part No.:08191-31201, 08191-31202 Part No.:08191-34101, 08191-34102

(3) Pin (Female terminal) Pin (Male terminal)
799-601-9230
Part No.:08191-32201, 08191-32202 Part No.:08191-33101, 08191-33102

799-601-9240
18-21 Part No.:08191-41201, 08191-42202 Part No.:08191-44101, 08191-44102

799-601-9240
Part No.:08191-42201, 08191-42202 Part No.:08191-43101, 08191-43102
D155AX-6 23

(shell
size Part No. of
code) T-adapter
Pin (male terminal) Pin (Female terminal)
799-601-9250
24-9 Part No.:08191-51201, 08191-51202 Part No.:08191-54101, 08191-54102

799-601-9250
Part No.:08191-52201, 08191-52202 Part No.:08191-53101, 08191-53102

799-601-9260
Part No.: 08191-61201, 08191-62202, Part No.: 08191-64101, 08191-64102,

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260
Part No.: 08191-62201, 08191-62202, Part No.: 08191-63101, 08191-63102,

08191-62205, 08191-62206 08191-63105, 08191-63106
24 D155AX-6

(shell
size Part No. of
code) T-adapter
799-601-9270
Part No.: 08191-71201, 08191-71202, Part No.: 08191-74101, 08191-74102,

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270
Part No.: 08191-72201, 08191-72202, Part No.: 08191-73101, 08191-73102,

08191-72205, 08191-72206 08191-73105, 08191-73106
799-601-9280
Part No.: 08191-81201, 08191-81202 Part No.: 08191-84101, 08191-84102

08191-81203, 08191-81204 08191-84103, 08191-84104
24-23 08191-81205, 08191-80206 08191-84105, 08191-84106
799-601-9280
Part No.: 08191-82201, 08191-82202 Part No.: 08191-83101, 08191-83102

08191-82203, 08191-82204 08191-83103, 08191-83104
08191-82205, 08191-82206 08191-83105, 08191-83106
D155AX-6 25

(shell
size Part No. of
code) T-adapter.
799-601-9290
Part No.: 08191-91203, 08191-91204, Part No.: 08191-94103, 08191-94104,

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290
Part No.: 08191-92203, 08191-92204, Part No.: 08191-93103, 08191-93104,

08191-92205, 08191-92206 08191-93105, 08191-93106
26 D155AX-6

Total DT Series connector
num-
ber of Part No. of
pins T-adapter
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
4 799-601-9040
6 799-601-9050
D155AX-6 27

Total DT Series connector
num-
ber of Part No. of
pins T-adapter
Body color (Gray):

799-601-9060
Body color (Black):
799-601-9070
8
Body color (Green):
799-601-9080
Body color (Brown):
799-601-9090
Part No.: 08192-1820! (Normal type) Part No.: 08192-1810! (Normal type)
08192-2820! (Fine wire type) 08192-2810! (FIne wire type)
Body color (Gray):

799-601-9110
Body color (Black):
799-601-9120
12
Body color (Green):
799-601-9130
Body color (Brown):
799-601-9140
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

Total DTM Series connector
num-
ber of Part No. of
pins T-adapter
799-601-9010
2
Part No.: 08192-02200 Part No.: 08192-02100

Total DTHD Series connector
num-
ber of Part No. of
pins T-adapter
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

Total DRC26 Series connector
num-
ber of Part No. of
pins T-adapter
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
T-boxes and T-adapters table 1

a The part Nos. of the T-boxes, T-adapters, and other parts are shown on the leftmost column and the part
Nos. of the T-adapter kits are shown on the top line.
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
799-601-2600 T-box (for ECONO) 21 q q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3300 T-box (for ECONO) 24 q
799-601-3360 Plate for MS (24-pin) q
799-601-3370 Plate for MS (17-pin) q
799-601-3380 Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q q
799-601-3510 Adapter for BENDIX (MS) 5 MS-5S q q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4210 Adapter for DRC 50 DRC50 q
799-601-7010 Adapter for X (T-branch) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
D155AX-6 31
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
799-601-7070 Adapter for SWP 14 SW14P q q

799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-branch) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
32 D155AX-6
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

799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for DT and HD) 12 q q q
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410 Adapter for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 3 A3 q
799-601-9430 2 P q
799-601-9440 Adapter for engine (CRI-T2) 3 1,2,3 q
795-799-5520 Adapter for engine (HPI-T2) 2 S q
Adapter for engine (HPI-T2)
795-799-5530 2 C q
Adapter for engine (HPI-T2)
795-799-5540 2 A q
795-799-5460 Adapter for engine (HPI-T2) 3 q
799-601-4160 Adapter for engine (CRI-T3) 2 OIL q
799-601-4130 Adapter for engine (CRI-T3) 3 FCIN q
799-601-4140 Adapter for engine (CRI-T3) 3 FCIG q
799-601-4150 Adapter for engine (CRI-T3) 3 FCIB q
799-601-4180 Adapter for engine (CRI-T3) 3 FCIP3 q
799-601-4230 Adapter for engine (CRI-T3) 4 1,2,3,4 q
799-601-4260 Adapter for controller (ENG) 4 DTP4 q
799-601-4210 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4280 Box for controller (PUMP) 121 q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9370 Adapter for controller (HST) 26 HST26A q
D155AX-6 33
D155AX-6 Bulldozer
2006 KOMATSU
All Rights Reserved
34 D155AX-6
SEN00716-01
D155AX-6

D155AX-6 80001 and up
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
Failure code [15SGLH] Speed 3rd clutch: Fill low ............................................................................. 26

Failure code [15SJL1] L/U: Fill high .................................................................................................. 28
Failure code [15SJLH] L/U: Fill low ................................................................................................... 30
Failure code [2301L1] Right brake: Fill high ...................................................................................... 32
Failure code [2301LH] Right brake: Fill low ....................................................................................... 33
Failure code [2302L1] Left brake: Fill high ........................................................................................ 34
Failure code [2302LH] Left brake: Fill low ......................................................................................... 35
Failure code [7RFAKA] ECM HOLD RELAY: Disconnection ............................................................. 36
Failure code [AA10NX] Air Cleaner Clogging .................................................................................... 38
Failure code [AB00MA] Battery Charge Abnormal ............................................................................ 40
Failure code [B@BAZG] Eng Oil Press Low ..................................................................................... 42
Failure code [B@BCNS] Eng Water Overheat .................................................................................. 42
Failure code [B@BCZK] Eng Water Level Low ................................................................................. 43
Failure code [B@CENS] T/C Oil Overheat ........................................................................................ 43
Failure code [B@HANS] Hyd Oil Overheat ....................................................................................... 44
2 D155AX-6
Troubleshooting by failure and error codes, Part 1 1

Failure codes table 1
Action Alarm Component Category of
Failure code Trouble (Displayed on screen)
code buzzer in charge history
E03 1500L0 Transmission clutch: Abnormal q P/T Electrical system
E03 15SAL1 Forward clutch: Fill high q P/T Electrical system
E03 15SALH Forward clutch: Fill low q P/T Electrical system
E03 15SBL1 Reverse clutch: Fill high q P/T Electrical system
E03 15SBLH Reverse clutch: Fill low q P/T Electrical system
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
E02 15SJL1 L/U: Fill high q P/T Electrical system
E02 15SJLH L/U: Fill low q P/T Electrical system
E04 2301L1 Right brake: Fill high q P/T Electrical system
E04 2301LH Right brake: Fill low q P/T Electrical system
E04 2302L1 Left brake: Fill high q P/T Electrical system
E04 2302LH Left brake: Fill low q P/T Electrical system
7RFAKA ECM HOLD RELAY: Disconnection P/T Electrical system
AA10NX Air Cleaner Clogging MON Mechanical system
AB00MA Battery Charge Abnormal MON Mechanical system
B@BAZG Eng Oil Press Low e ENG Mechanical system
B@BCNS Eng Water Overheat e ENG Mechanical system
B@BCZK Eng Water Level Low MON Mechanical system
B@CENS T/C Oil Overheat e P/T Mechanical system
B@HANS Hyd Oil Overheat e MON Mechanical system
E04 CA111 EMC Critical Internal Failure q ENG 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
E03 CA131 Throttle Sensor High Error q ENG Electrical system
E03 CA132 Throttle 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
E01 CA154 Chg Air Temp Sensor Low Error ENG Electrical system
D155AX-6 3

E03 CA221 Ambient Press Sens High Error q ENG Electrical system
E03 CA222 Ambient Press Sens Low Error q ENG Electrical system
E00 CA234 Eng Overspeed ENG Mechanical 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
E04 CA342 Calibration Code Incompatibility q ENG Electrical system
E03 CA351 Injectors Drive Circuit Error q ENG Electrical system
E04 CA441 Battery Voltage Low Error q ENG Electrical system
E04 CA442 Battery Voltage 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
E02 CA553 Rail Press High Error q ENG Electrical system
E03 CA554 Rail Press Sensor In Range Error q ENG Electrical system
E02 CA559 Rail Press Low Error q ENG Electrical system
E03 CA689 Eng Ne Speed Sensor 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
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
4 D155AX-6

E03 CA1633 KOMNET Datalink Timeout 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 CA2272 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 CA2556 Grid Htr Relay Volt High Error ENG Electrical system
D110KA Battery relay: Disconnection P/T Electrical system
D110KB Battery Relay: Drive Short Circuit P/T Electrical system
E02 D130KA Neutral relay: Disconnection q P/T Electrical system
E02 D130KB Neutral relay: Short circuit q P/T Electrical system
E01 D161KA Back-up alarm relay: Disconnection P/T Electrical system
E01 D161KB Back-up alarm relay: Short circuit P/T Electrical system
D190KA ACC signal relay: Disconnection P/T Electrical system
D190KB ACC signal relay: Short circuit P/T Electrical system
E03 D5ZKKX Throttle Dial: Out of normal range q P/T Electrical system
E03 DAFRKR CAN Disconnection q MON Electrical system
E03 DB2RKR CAN Disconnection q ENG Electrical system
E03 DB90KR PT controller: Can communication lost q P/T Electrical system
E01 DB90KT WE controller: Abnormality in controller W/E Electrical system
E04 DB99KQ WE controller: Type select signal q W/E Electrical system
E03 DB9RKR WE controller: Can communication lost q W/E Electrical system
E01 DBE0KT PT controller: Abnormality in controller P/T Electrical system
E04 DBE9KQ PT controller: Type select signal q P/T Electrical system
E02 DD12KA Shift up Sw: Disconnection q P/T Electrical system
E02 DD12KB Shift up Sw: Short circuit q P/T Electrical system
E02 DD13KA Shift down Sw: Disconnection q P/T Electrical system
E02 DD13KB Shift down Sw: Short circuit q P/T Electrical system
E03 DD14KA Parking lever Sw: Disconnection q P/T Electrical system
E03 DD14KB Parking lever Sw: Short circuit q P/T Electrical system
D155AX-6 5

E02 DDDDKA Back up brake Sw: Disconnection 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 DDN7KA WEQ Knob Sw (down): Disconnection q W/E Electrical system
E02 DDN7KB WEQ Knob Sw (down): Short circuit q W/E Electrical system
E01 DDN9KA WEQ Knob Sw (up): Disconnection W/E Electrical system
E01 DDN9KB WEQ Knob Sw (up): Short circuit W/E Electrical system
E03 DDNLKA Weq lock Sw: Disconnection q W/E Electrical system
E03 DDNLKB Weq lock Sw: Short circuit q W/E Electrical system
E02 DDTSL1 S/C: Fill high q P/T Electrical system
E02 DDTSLH S/C: Fill low q P/T Electrical system
E03 DFA4KX BL lever 1: Out of normal range q W/E Electrical system
E03 DFA4KZ BL lever: Disconnection or short circuit q W/E Electrical system
E03 DFA4L8 BL lever: Signal mismatch q W/E Electrical system
E03 DFA7KX BT lever 1: Out of normal range q W/E Electrical system
E03 DFA7KZ BT lever: Disconnection or short circuit q W/E Electrical system
E03 DFA7L8 BT lever: Signal mismatch q W/E Electrical system
E03 DFAAKX RL lever 1: Out of normal range q W/E Electrical system
E03 DFAAKZ RL lever: Disconnection or short circuit q W/E Electrical system
E03 DFAAL8 RL lever: Signal mismatch q W/E Electrical system
E03 DFABKA RL lever 1: Disconnection q W/E Electrical system
E03 DFABKB RL lever 1: Short circuit q W/E Electrical system
E03 DFACKA RL lever 2: Disconnection q W/E Electrical system
E03 DFACKB RL lever 2: Short circuit q W/E Electrical system
E03 DFADKX RT lever 1: Out of normal range q W/E Electrical system
E03 DFADKZ RT lever: Disconnection or short circuit q W/E Electrical system
E03 DFADL8 RT lever: Signal mismatch q W/E Electrical system
E03 DFAEKA RT lever 1: Disconnection q W/E Electrical system
E03 DFAEKB RT lever 1: Short circuit q W/E Electrical system
E03 DFAFKA RT lever 2: Disconnection q W/E Electrical system
E03 DFAFKB RT lever 2: Short circuit q W/E Electrical system
E01 DGT1KA T/C oil temp sensor: Abnormal P/T Electrical system
E01 DGT1KX T/C oil temp sensor abnormal P/T Electrical system
6 D155AX-6

DH21KA WEQ pressure sensor: Disconnection W/E Electrical system
DH21KB WEQ pressure sensor: Short circuit W/E Electrical system
E02 DHT5KA T/C in-pressure sensor: Disconnection q P/T Electrical system
E02 DHT5KB T/C in-pressure sensor: Short circuit q P/T Electrical system
E02 DHT7KA T/C out-pressure sensor: Disconnection 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 ENG Electrical system
E04 DK30KX ST lever 1: Out of normal range q P/T Electrical system
E04 DK30KZ ST lever: Disconnection or short circuit q P/T Electrical system
E03 DK30L8 ST lever: Signal mismatch q P/T Electrical system
E03 DK40KA Brake potentiometer: Disconnection q P/T Electrical system
E03 DK40KB Brake potentiometer: Short circuit q P/T Electrical system
E04 DK55KX FR lever: Out of normal range q P/T Electrical system
E04 DK55KZ FR lever: Disconnection or short circuit q P/T Electrical system
E03 DK55L8 FR lever: Signal mismatch q P/T Electrical system
E03 DKH1KA Pitch angle sensor: Disconnection q P/T Electrical system
E03 DKH1KB Pitch angle sensor: Short circuit q P/T Electrical system
E01 DLT3KA T/M out-speed sensor: Disconnection P/T Electrical system
E01 DLT3KB T/M out-speed sensor: Abnormal P/T Electrical system
E01 DW7BKA Fan rev EPC: Disconnection P/T Electrical system
E01 DW7BKB Fan rev EPC: Short circuit P/T Electrical system
E04 DWN3KA Ssp solenoid: Disconnection q P/T Electrical system
E04 DWN3KB Ssp solenoid: Short circuit q P/T Electrical system
E04 DWN3KY Ssp solenoid: Short circuit q P/T Electrical system
E01 DWN5KA Fan pump solenoid: Disconnection P/T Electrical system
E01 DWN5KB Fan pump solenoid: Short circuit P/T Electrical system
E01 DXA0KA TVC Sol.: Disconnection W/E Electrical system
D155AX-6 7

E01 DXA0KB TVC Sol.: Short circuit W/E Electrical system
E01 DXA0KY TVC Sol.: Short circuit W/E Electrical system
E02 DXH1KA Lock-up ECMV: Disconnection q P/T Electrical system
E02 DXH1KB Lock-up ECMV: Short circuit q P/T Electrical system
E03 DXH1KY Lock-up ECMV: Short circuit q P/T Electrical system
E03 DXH4KA 1st clutch ECMV: Disconnection q P/T 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 DXH5KA 2nd clutch ECMV: Disconnection 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
E03 DXH7KA R clutch ECMV: Disconnection q P/T Electrical system
E03 DXH7KB R clutch ECMV: Short circuit q P/T Electrical system
E04 DXH7KY R clutch ECMV: Short circuit q P/T Electrical system
E03 DXH8KA F clutch ECMV: Disconnection q P/T Electrical system
E03 DXH8KB F clutch ECMV: Short circuit q P/T Electrical system
E04 DXH8KY F clutch ECMV: Short circuit q P/T Electrical system
E04 DXHBKA Right brake ECMV: Disconnection q P/T Electrical system
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 DXHCKA Left brake ECMV: Disconnection 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 DXHRKA Blade up EPC: Disconnection q W/E Electrical system
E03 DXHRKB Blade up EPC: Short circuit q W/E Electrical system
E03 DXHRKY Blade up EPC: Short circuit q W/E Electrical system
E03 DXHSKA Blade down EPC: Disconnection q W/E 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 DXHTKA Blade left 1 EPC: Disconnection 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 DXHUKA Blade right 1 EPC: Disconnection 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 DXHWKA Ripper up EPC: Disconnection q W/E Electrical system
E03 DXHWKB Ripper up EPC: Short circuit q W/E Electrical system
E03 DXHWKY Ripper up EPC: Short circuit q W/E Electrical system
8 D155AX-6

E03 DXHXKA Ripper down EPC: Disconnection 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 DXHYKA Ripper Tilt In EPC: Disconnection 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 DXJ4KA WEQ lock Sol.: Disconnection q W/E Electrical system
E03 DXJ4KB WEQ lock Sol.: Short circuit q W/E Electrical system
E03 DXJ8KA Blade left 2 EPC: Disconnection 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
E03 DXJ9KA Blade right 2 EPC: Disconnection q W/E Electrical system
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
E01 DXJAKA Q-drop EPC: Disconnection W/E Electrical system
E01 DXJAKB Q-drop EPC: Short circuit W/E Electrical system
E01 DXJAKY Q-drop EPC: Short circuit W/E Electrical system
E02 DXJBKA S/C ECMV: Disconnection q P/T Electrical system
E02 DXJBKB S/C ECMV: Short circuit q P/T Electrical system
E02 DXJBKY S/C ECMV: Short circuit q P/T Electrical system

The items are entered in the order of their failure codes (incremental order).
a Action code
Attached: If a failure code is detected, the action code, failure code, and telephone No. (if registered) are
displayed on the ordinary screen to notify the operator of the fault.
Not attached: Even if a failure code is detected, the machine monitor does not notify the operator of the
fault.
a Alarm buzzer
q: When occurrence of an error is notified to the operator, the buzzer sounds (The operator can stop
the buzzer with the alarm buzzer cancel switch).
e: Since the caution monitor is also turned ON, its function sounds the buzzer.
a Component in charge
MON:The machine monitor is in charge of detection of fault.
ENG: The engine controller is in charge of detection of fault.
P/T: The power train controller is in charge of detection of fault.
W/E: The work equipment controller is in charge of detection of fault.
a Category of history
Mechanical system: Fault information is recorded in the mechanical system fault history.
Electrical system: Fault information is recorded in the electrical system fault history.
D155AX-6 9
Before carrying out troubleshooting when failure code is displayed 1

Connection table of circuit breakers and fuse boxes
a This connection table shows the devices to which each power supply of the fuse box supplies power (An
accessory power supply is a device which supplies power while the starting switch is in the ON position
and an unswitched power supply is a device which supplies power while the starting switch is in the OFF
and ON positions).
a When carrying out troubleshooting related to the electrical system, you should check the circuit breakers
and fuses to see if the power is supplied normally.
Circuit breakers CB1 CB9

Circuit
Power circuit breaker Circuit
breaker Destination of power
(Type of power supply) breaker No.
capacity
CB9 20A Optional power supply
Power train controller
CB1 20A
Emergency power supply (For power train switch box)
CB105 Work equipment controller
CB2 20A
(Accessory power Emergency power supply (For work equipment switch box)
supply)
Air conditioner unit, blower motor, and compressor electromag-
CB3 20A
netic clutch
CB4 20A Headlamp, additional headlamp
CB5 20A Rear lamp, additional rear lamp, ripper point lamp
Starting switch
CB6 20A
Engine hold relay
CB30 Machine monitor
(Unswitched power
supply) CB7 20A Power train controller
Work equipment controller
CB8 30A Engine controller
CB105H
(Unswitched power Engine electrical intake air heater
supply)
Fuse box FS1

Power circuit breaker Fuel
Fuse No. Destination of power
(Type of power supply) capacity
CB30
(Unswitched power 1 20A Operator's cab power supply (To connection table of fuse box )
supply)
2 5A Backup alarm, backup alarm relay
CB105
(Accessory power 3 20A Operator's cab power supply (To connection table of fuse box )
supply) 4 20A Operator's cab power supply (To connection table of fuse box )
Starting switch (ACC) 5 5A Engine controller (Signal ACC)
10 D155AX-6
Fuse box FS2

CB30
(Unswitched power 1 5A Pedal brake solenoid valve
supply)
2 5A Parking brake solenoid valve
CB105 Engine electrical intake air heater

(Accessory power 3 20A Ripper pin puller solenoid valve
supply) Pneumatic suspension seat
4 5A Horn
Starting switch (ACC) 5 20A Optional power supply
D155AX-6 11
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
Fuse box
Power circuit fuse Fuel
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
Location of fuse box (In operator's cab)
D155AX-6 13
Information in troubleshooting table 1

a The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before carrying out troubleshooting, understand that information fully.
Action code Failure code
Display on Trouble Trouble name displayed in fault history of machine monitor
Display on machine
machine moni-
monitor
tor
Contents of
Contents of trouble detected by machine monitor or controller
trouble
Action of
Action taken by machine monitor or controller to protect system or devices when they detect
machine moni-
trouble
tor or controller
Problem that
Problem that appears on machine as result of action taken by machine monitor or controller
appears on
(shown above)
machine
Related infor-
Information related to detected trouble or troubleshooting
mation
Cause Standard value in normal state/Remarks on 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.
14 D155AX-6
Related circuit diagram
This drawing is a part of the electric circuit diagram related

to troubleshooting.
Connector No.: Indicates (Model Number of pins) and
(Color).
"Connector No. and pin No." from each branching/merg-
ing point: Shows the ends of branch or source of merging
within the parts of the same wiring harness.
Arrow (i o): Roughly shows the location on the machine.
D155AX-6 15
Failure code [1500L0] Transmission clutch: Abnormal 1

Action code Failure code Transmission clutch: Abnormal
Trouble
E03 1500L0 (Power train controller system)
Among failure codes related to transmission clutch, 2 or more of following failure codes occurred
similarly.
1) Either [DXH4KA] or [DXH4KB]
Contents of
Among failure codes related to transmission clutch, following combinations of failure codes
trouble
occurred similarly.
1) [15SAL1] and [15SBL1]
2) [15SALH] and [15SBLH]
3) 2 or all of [15SEL1], [15SFL1], and [15SGL1]
4) 2 or all of [15SELH], [15SFLH], and [15SGLH]
Action of
Limits operation of engine and transmission.
controller
Problem that Auto-shift-down function does not operate.
appears on Once machine is stopped, engine speed is limited to medium (half).
machine Once machine is stopped, travel is limited to specific gear speed.
Related
Method of reproducing failure code: Start engine + Travel.
information
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard If other failure codes are displayed, carry out troubleshooting for them.
value in normal [15SAL1], [15SALH], [15SBL1], [15SBLH], [15SEL1], [15SELH], [15SFL1], [15SFLH],
state [15SGL1], [15SGLH], [DXH4KA], [DXH4KB], [DXH5KA], [DXH5KB], [DXH6KA], [DXH6KB]
16 D155AX-6
Failure code [15SAL1] Forward clutch: Fill high 1

Action code Failure code Forward clutch: Fill high
Trouble
E03 15SAL1 (Power train controller system)
Contents of When output to transmission F clutch ECMV solenoid circuit is turned OFF, fill switch signal is
trouble turned ON.
Sets transmission in neutral when operator sets it in reverse position (Prevention of double engage-
Action of
ment).
controller
Problem that
Once machine is stopped, engine speed is limited to medium (half).
appears on
Once machine is stopped, travel is limited to F1.
machine
State of F clutch ECMV fill switch signal can be checked with monitoring function.
Related
(Code: 40906 T/M Fill Sw Input 1)
information
Method of reproducing failure code: Start engine + Set transmission in neutral.

a Prepare with starting switch OFF, then start engine and carry
out troubleshooting.
Defective F clutch ECMV fill PCCS lever
1 FFT (male) Resistance
switch (Internal short circuit) (Travel gear speed)
Between (1) chas- N Min. 1 Mz
sis ground F1, F2, F3 Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshoot-
Possible causes Ground fault in wiring har- ing without turning starting switch ON.
and standard 2 ness
value in normal (Contact with GND circuit) Wiring harness between STC2 (female) (35) Resis-
Min. 1 Mz
state FFT (female) (1) and chassis ground tance
Defective power train con- PCCS lever
3 STC2 Voltage
troller (Travel gear speed)
Between (35) chas- N 5 11 V
sis ground F1, F2, F3 Max. 1 V
If causes 1 3 are not detected in electrical system, hydraulic sys-
4 Defective hydraulic system
tem may be defective. Carry out related troubleshooting (H mode).
Circuit diagram related to transmission F clutch ECMV
D155AX-6 17
Failure code [15SALH] Forward clutch: Fill low 1

Action code Failure code Forward clutch: Fill low
Trouble
E03 15SALH (Power train controller system)
Contents of When output to transmission F clutch ECMV solenoid circuit is turned ON, fill switch signal is turned
trouble OFF.
Sets transmission in neutral when operator sets it in forward position (Prevention of double engage-
Action of
ment).
controller
Problem that
appears on
Once machine is stopped, travel is limited to R1.
machine
State of F clutch ECMV fill switch signal can be checked with monitoring function.
Related
information
Method of reproducing failure code: Start engine + Set transmission in forward position.

Defective F clutch ECMV fill PCCS lever
1 switch (Internal disconnec- FFT (male) Resistance
(Travel gear speed)
tion)
sis ground F1, F2, F3 Max. 1 z
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
Possible causes ing without turning starting switch ON.
ness (Disconnection in wiring
and standard 2
or defective contact in con- Wiring harness between STC2 (female) (35) Resis-
value in normal Max. 1 z
nector) FFT (female) (1) tance
state
3 STC2 Voltage
sis ground F1, F2, F3 Max. 1 V
18 D155AX-6
Failure code [15SBL1] Reverse clutch: Fill high 1

Action code Failure code Reverse clutch: Fill high
Trouble
E03 15SBL1 (Power train controller system)
Contents of When output to transmission R clutch ECMV solenoid circuit is turned OFF, fill switch signal is
trouble turned ON.
Sets transmission in neutral when operator sets it in forward position (Prevention of double engage-
Action of
ment).
controller
Problem that
appears on
machine
State of R clutch ECMV fill switch signal can be checked with monitoring function.
Related
information

Defective R clutch ECMV fill PCCS lever
1 FRT (male) Resistance
switch (Internal short circuit) (Travel gear speed)
sis ground R1, R2, R3 Max. 1 z
and standard 2 ness (Contact with GND cir-
value in normal cuit) Wiring harness between STC2 (female) (25) Resis-
Min. 1 Mz
state FRT (female) (1) and chassis ground tance
3 STC2 Voltage
sis ground R1, R2, R3 Max. 1 V
Circuit diagram related to transmission R clutch ECMV
D155AX-6 19
Failure code [15SBLH] Reverse clutch: Fill low 1

Action code Failure code Reverse clutch: Fill low
Trouble
E03 15SBLH (Power train controller system)
Contents of When output to transmission R clutch ECMV solenoid circuit is turned ON, fill switch signal is turned
trouble OFF.
Sets transmission in neutral when operator sets it in reverse position (Prevention of double engage-
Action of
ment).
controller
Problem that
appears on
machine
State of R clutch ECMV fill switch signal can be checked with monitoring function.
Related
information
Method of reproducing failure code: Start engine + Set transmission in reverse position.

Defective R clutch ECMV fill PCCS lever
1 switch (Internal disconnec- FRT (male) Resistance
(Travel gear speed)
tion)
sis ground R1, R2, R3 Max. 1 z
and standard 2
nector) FRT (female) (1) tance
state
3 STC2 Voltage
sis ground R1, R2, R3 Max. 1 V
20 D155AX-6
Failure code [15SEL1] Speed 1st clutch: Fill high 1

Action code Failure code Speed 1st clutch: Fill high
Trouble
E03 15SEL1 (Power train controller system)
Contents of When output to transmission 1st clutch ECMV solenoid circuit is turned OFF, fill switch signal is
trouble turned ON.
Action of
controller
Problem that
appears on
Once machine is stopped, travel is limited to F1 and R1.
machine
State of 1st clutch ECMV fill switch signal can be checked with monitoring function.
Related
information

a Prepare with starting switch OFF, then start engine, select
manual gearshift mode, and carry out troubleshooting.
Defective 1st clutch ECMV PCCS lever
F1T (male) Resistance
1 fill switch (Internal short cir- (Travel gear speed)
cuit) Other than F1, N, or
Between (1) chas- Min. 1 Mz
R1
sis ground
F1, R1 Max. 1 z
Min. 1 Mz
state F1T (female) (1) and chassis ground tance
PCCS lever
Defective power train con- STC3 Voltage
3 (Travel gear speed)
troller
Other than F1, N, or
Between (19) chas- 5 11 V
R1
sis ground
F1, R1 Max. 1 V
Circuit diagram related to transmission 1st clutch ECMV
D155AX-6 21
Failure code [15SELH] Speed 1st clutch: Fill low 1

Action code Failure code Speed 1st clutch: Fill low
Trouble
E03 15SELH (Power train controller system)
Contents of When output to transmission 1st clutch ECMV solenoid circuit is turned ON, fill switch signal is
trouble turned OFF.
Action of
controller
machine Once machine is stopped, travel is limited to F2 and R2.
State of 1st clutch ECMV fill switch signal can be checked with monitoring function.
Related (Code: 40906 T/M Fill Sw Input 1)
information Method of reproducing failure code: Start engine + Set transmission in F1 or R1 position (in manual
gearshift mode).

Defective 1st clutch ECMV PCCS lever
1 fill switch (Internal discon- (Travel gear speed)
nection) Other than F1, N, or
R1
sis ground
F1, R1 Max. 1 z
and standard 2
nector) F1T (female) (1) tance
state
PCCS lever
troller
R1
sis ground
F1, R1 Max. 1 V
22 D155AX-6
Failure code [15SFL1] Speed 2nd clutch: Fill high 1

Action code Failure code Speed 2nd clutch: Fill high
Trouble
E03 15SFL1 (Power train controller system)
Contents of When output to transmission 2nd clutch ECMV solenoid circuit is turned OFF, fill switch signal is
trouble turned ON.
Action of
controller
State of 2nd clutch ECMV fill switch signal can be checked with monitoring function.
Related
information

Defective 2nd clutch ECMV PCCS lever
R2
sis ground
F2, R2 Max. 1 z
Min. 1 Mz
PCCS lever
troller
R2
sis ground
F2, R2 Max. 1 V
Circuit diagram related to transmission 2nd clutch ECMV
D155AX-6 23
Failure code [15SFLH] Speed 2nd clutch: Fill low 1

Action code Failure code Speed 2nd clutch: Fill low
Trouble
E03 15SFLH (Power train controller system)
Contents of When output to transmission 2nd clutch ECMV solenoid circuit is turned ON, fill switch signal is
trouble turned OFF.
Action of
controller
Problem that
appears on
machine
State of 2nd clutch ECMV fill switch signal can be checked with monitoring function.
gearshift mode).

Defective 2nd clutch ECMV PCCS lever
R2
sis ground
F2, R2 Max. 1 z
and standard 2
state
PCCS lever
troller
R2
sis ground
F2, R2 Max. 1 V
24 D155AX-6
Failure code [15SGL1] Speed 3rd clutch: Fill high 1

Action code Failure code Speed 3rd clutch: Fill high
Trouble
E03 15SGL1 (Power train controller system)
Contents of When output to transmission 3rd clutch ECMV solenoid circuit is turned OFF, fill switch signal is
trouble turned ON.
Action of
controller
State of 3rd clutch ECMV fill switch signal can be checked with monitoring function.
Related
information

Defective 3rd clutch ECMV PCCS lever
R3
sis ground
F3, R3 Max. 1 z
Min. 1 Mz
PCCS lever
troller
R3
sis ground
F3, R3 Max. 1 V
Circuit diagram related to transmission 3rd clutch ECMV
D155AX-6 25
Failure code [15SGLH] Speed 3rd clutch: Fill low 1

Action code Failure code Speed 3rd clutch: Fill low
Trouble
E03 15SGLH (Power train controller system)
Contents of When output to transmission 3rd clutch ECMV solenoid circuit is turned ON, fill switch signal is
trouble turned OFF.
Action of
controller
Problem that
appears on
machine
State of 3rd clutch ECMV fill switch signal can be checked with monitoring function.
gearshift mode).

Defective 3rd clutch ECMV PCCS lever
R3
sis ground
F3, R3 Max. 1 z
and standard 2
state
PCCS lever
troller
R3
sis ground
F3, R3 Max. 1 V
If causes 1 - 3 are not detected in electrical system, hydraulic sys-
26 D155AX-6
Failure code [15SJL1] L/U: Fill high 1

Action code Failure code L/U: Fill high
Trouble
E02 15SJL1 (Power train controller system)
Contents of When output to torque converter lockup clutch ECMV solenoid circuit is turned OFF, fill switch sig-
trouble nal is turned ON.
Action of
None in particular.
controller
Problem that
appears on Engine may stall during travel.
machine
State of lockup clutch ECMV fill switch signal can be checked with monitoring function.
information Method of reproducing failure code: Start engine + Set transmission in forward position (in auto-
matic gearshift mode).

automatic gearshift mode, and carry out troubleshooting.
Defective lockup clutch PCCS lever
FLUC (male) Resistance
1 ECMV fill switch (Internal (Travel gear speed)
short circuit) N Min. 1 Mz
Between (1) chas-
sis ground Locked up at F1, F2,
Max. 1 z
or F3
Min. 1 Mz
state FLUC (female) (1) and chassis ground tance
PCCS lever
troller
N 5 11 V
Between (36) chas-
Max. 1 V
or F3
28 D155AX-6
Circuit diagram related to torque converter lockup clutch ECMV
D155AX-6 29
Failure code [15SJLH] L/U: Fill low 1

Action code Failure code L/U: Fill low
Trouble
E02 15SJLH (Power train controller system)
Contents of When output to torque converter lockup clutch ECMV solenoid circuit is turned ON, fill switch signal
trouble is turned OFF.
Action of
None in particular.
controller
Problem that
appears on Engine may stall during travel.
machine
State of lockup clutch ECMV fill switch signal can be checked with monitoring function.
information Method of reproducing failure code: Start engine + Set transmission in forward position (in auto-
matic gearshift mode).

Defective lockup clutch PCCS lever
FLUC (male) Resistance
1 ECMV fill switch (Internal dis- (Travel gear speed)
connection) N Min. 1 Mz
Between (1) chas-
Max. 1 z
or F3
and standard 2
nector) FLUC (female) (1) tance
state
PCCS lever
troller
N 5 11 V
Between (36) chas-
Max. 1 V
or F3
30 D155AX-6
D155AX-6 31
Failure code [2301L1] Right brake: Fill high 1

Action code Failure code Right brake: Fill high
Trouble
Contents of When output to steering case right brake ECMV solenoid circuit is turned OFF, fill switch signal is
trouble turned ON.
Action of
Limits operation of engine, transmission, and brake.
controller
Problem that Applies brake lightly during travel.
machine Once machine is stopped, machine cannot travel at all.
State of right brake ECMV fill switch signal can be checked with monitoring function.
Related (Code: 31521 S/T Fill Sw Input)
information Method of reproducing failure code: Start engine + Operate parking brake lever (Free) + Operate
brake pedal (Press).

a Prepare with starting switch OFF, then start engine, set parking
brake lever in Free position, and carry out troubleshooting.
Defective right brake ECMV
1 fill switch (Internal short cir- FBRR (male) Brake pedal Resistance
cuit) Between (1) chas- Released Max. 1 z
sis ground Pressed Min. 1 Mz
Min. 1 Mz
state FBRR (female) (1) and chassis ground tance
Defective power train con- STC2 Brake pedal Voltage
3
troller
Between (38) chas- Released Max. 1 V
sis ground Pressed 5 11V
Circuit diagram related to steering case right brake ECMV
32 D155AX-6
Failure code [2301LH] Right brake: Fill low 1

Action code Failure code Right brake: Fill low
Trouble
E04 2301LH (Power train controller system)
Contents of When output to steering case right brake ECMV solenoid circuit is turned ON, fill switch signal is
trouble turned OFF.
Action of
controller
State of right brake ECMV fill switch signal can be checked with monitoring function.

1 fill switch (Internal short cir- FBRR (male) Brake pedal Resistance
cuit) Between (1) chas- Released Max. 1 z
and standard 2
nector) FBRR (female) (1) tance
state
3
troller
sis ground Pressed 5 11 V
D155AX-6 33
Failure code [2302L1] Left brake: Fill high 1

Action code Failure code Left brake: Fill high
Trouble
Contents of When output to steering case left brake ECMV solenoid circuit is turned OFF, fill switch signal is
trouble turned ON.
Action of
controller
State of left brake ECMV fill switch signal can be checked with monitoring function.

Defective left brake ECMV fill FBRL (male) Brake pedal Resistance
1
switch (Internal short circuit)
Between (1) chas- Released Max. 1 z
Min. 1 Mz
state FBRL (female) (1) and chassis ground tance
3
troller
Circuit diagram related to steering case left brake ECMV
34 D155AX-6
Failure code [2302LH] Left brake: Fill low 1

Action code Failure code Left brake: Fill low
Trouble
E04 2302LH (Power train controller system)
Contents of When output to steering case left brake ECMV solenoid circuit is turned ON, fill switch signal is
trouble turned OFF.
Action of
controller
State of left brake ECMV fill switch signal can be checked with monitoring function.

Defective left brake ECMV fill FBRL (male) Brake pedal Resistance
1
switch (Internal short circuit)
Between (1) chas- Released Max. 1 z
and standard 2
nector) FBRL (female) (1) tance
state
3
troller
D155AX-6 35
Failure code [7RFAKA] ECM HOLD RELAY: Disconnection 1

Action code Failure code ECM HOLD RELAY: Disconnection
Trouble
7RFAKA (Power train controller system)
Contents of
When ground circuit of engine cut relay circuit is disconnected to turn output ON, no current flows.
trouble
Action of
None in particular.
controller
Problem that
appears on When engine cut mechanism is installed, engine cannot be cut (stopped).
machine
State of engine cut relay circuit signal can be checked with monitoring function.
(Code: 40912 P/T Sw Input)
Related
Method of reproducing failure code: Start engine.
information
This failure code detects abnormality on primary side (coil side) of engine cut relay but does not
detect abnormality on secondary side (contact side).

Defective engine cut relay ing without turning starting switch ON.
1
(Internal disconnection) ACT (male) Resistance
Between (1) (2) 200 400 z
Disconnection in wiring har- ing without turning starting switch ON.
ness (Disconnection in wiring Wiring harness between STC2 (female) (19) Resis-
2 Max. 1 z
or defective contact in con- ACT (female) (2) tance
Possible causes nector) Wiring harness between ACT (female) (1) Resis-
Max. 1 z
and standard terminal 270. tance
value in normal a Prepare with starting switch OFF, then carry out troubleshoot-
state ing without turning starting switch ON.
Short circuit in wiring har- Wiring harness between STC2 (female) (19) Resis-
Min. 1 Mz
3 ness (Contact with GND cir- ACT (female) (2) and chassis ground tance
cuit) Wiring harness between ACT (female) (1),
Resis-
(3) terminal 270, circuit branch end and Min. 1 Mz
tance
chassis ground.
a Prepare with starting switch OFF, then turn starting switch ON
Defective power train con- and carry out troubleshooting.
4
troller STC2 Voltage
Between (19) chassis ground 20 30 V
36 D155AX-6
Circuit diagram related to engine cut relay
D155AX-6 37
Failure code [AA10NX] Air Cleaner Clogging 1

Action code Failure code Air Cleaner Clogging
Trouble
AA10NX (Machine monitor system)
Contents of While engine was running, air cleaner clogging switch signal circuit detected clogging of air cleaner
trouble (opening of sensor contact).
Action of
None in particular.
machine monitor
Problem that
appears on If machine is used as it is, engine may be damaged.
machine
Related
information

Clogged air cleaner
1 a Air cleaner may be clogged. Check and clean or replace it.
(When system is normal)
Defective air cleaner clog- AF1 (male) Air cleaner Resistance
2 ging switch (Internal discon- Normal (Intake air
nection) Max. 1 z
resistance: *1)
Between (1) (2)
Clogged (Intake air
Min. 1 Mz
resistance: *2)
Possible causes
and standard
value in normal
state ness (Disconnection in wiring Wiring harness between CM02 (female) (4) Resis-
3 Max. 1 z
or defective contact in con- AF1 (female) (1) tance
nector) Wiring harness between CM01 (female) (7), Resis-
Max. 1 z
CM02 (female) (7) AF1 (female) (2) tance
CM02 Air cleaner Voltage
Defective power train con-
4 Normal (Intake air
troller Max. 1 V
resistance: *1)
Between (4) (7)
Clogged (Intake air
20 30 V
resistance: *2)
*1: Max. -3,430 Pa {-350 mmH2O}

*2: -7,470 490Pa {-762 50 mmH2O}
38 D155AX-6
Circuit diagram related to air cleaner clogging switch
D155AX-6 39
Failure code [AB00MA] Battery Charge Abnormal 1

Action code Failure code Battery Charge Abnormal
Trouble
AB00MA (Machine monitor system)
Contents of
While engine was running, alternator signal circuit detected that battery charge voltage was low.
trouble
Action of
Displays charge level monitor red on machine monitor.
machine monitor
Problem that
appears on If machine is used as it is, battery may not be charged.
machine
Battery voltage can be checked with monitoring function.
Related
(Code: 03203 Battery Power Supply)
information

Possible causes Defective charge by alterna-
1 CM01 Engine Voltage
and standard tor (When system is normal)
value in normal Between (11) chas- Above medium
27.5 29.5 V
state sis ground speed
If cause 1 is not detected, charge level monitor system may be
Defective charge level moni-
2 defective. Carry out "E-5 Caution item lights up while engine is
tor system
running" in E mode.
40 D155AX-6
Circuit diagram related to preheating/starting/charging of engine
D155AX-6 41
Failure code [B@BAZG] Eng Oil Press Low 1

Action code Failure code Eng Oil Press Low
Trouble
B@BAZG (Engine controller system)
Contents of While engine was running, engine oil pressure sensor signal circuit detected that engine oil pres-
trouble sure was abnormally low.
Action of
Displays engine oil pressure monitor red on machine monitor.
controller
Problem that
appears on If machine is used as it is, engine may be seized.
machine
Engine oil pressure sensor signal is input to engine controller and then transmitted to machine mon-
itor through communication system.
Related
Engine oil pressure can be checked with monitoring function.
information
(Code: 37200 Engine Oil Pressure)

Possible causes Low engine oil pressure
1 Check engine oil pressure. If it is low, remove cause.
and standard (When system is normal)
value in normal If cause 1 is not detected, engine oil pressure sensor may be
state Defective engine oil pressure
2 defective. Carry out troubleshooting for failure codes [CA135] and
sensor system
[CA141].
Failure code [B@BCNS] Eng Water Overheat 1

Action code Failure code Eng Water Overheat
Trouble
B@BCNS (Engine controller system)
Contents of While engine was running, engine coolant temperature sensor signal circuit detected that engine
trouble coolant was overheated.
Action of
Displays engine coolant temperature monitor red on machine monitor.
controller
Problem that
appears on If machine is used as it is, engine may be seized.
machine
Engine coolant temperature sensor signal is input to engine controller and then transmitted to
machine monitor through communication system.
Related
Engine coolant temperature can be checked with monitoring function.
information
(Code: 04107 Coolant Temperature)

Possible causes Overheated engine coolant Check engine coolant for overheating. If it is overheated, remove
1
and standard (When system is normal) cause.
value in normal If cause 1 is not detected, engine coolant temperature sensor may
state Defective engine coolant
2 be defective. Carry out troubleshooting for failure codes [CA144]
temperature sensor system
and [CA145].
42 D155AX-6
Failure code [B@BCZK] Eng Water Level Low 1

Action code Failure code Eng Water Level Low
Trouble
B@BCZK (Machine controller system)
Contents of While starting switch was ON (and engine was stopped) or engine was running, radiator coolant
trouble level switch signal circuit detected that radiator coolant level was low (sensor contact was open).
Action of
Displays radiator coolant level monitor red on machine monitor.
machine monitor
Problem that
appears on If machine is used as it is, engine may be overheated.
machine
Related
information

Possible causes Low coolant level Check radiator sub tank for lowering of coolant level. If coolant
1
and standard (When system is normal) level is low, add coolant.
value in normal If cause 1 is not detected, radiator coolant level monitor may be
state Defective radiator coolant
2 defective. Carry out "E-2 Caution item lights up while starting
level monitor system
switch is ON (and engine is stopped)" in E mode.
Failure code [B@CENS] T/C Oil Overheat 1

Action code Failure code T/C Oil Overheat
Trouble
B@CENS (Power train controller system)
Contents of While engine was running, torque converter oil temperature sensor signal circuit detected that
trouble power train oil was overheated.
Action of
Displays torque converter oil temperature monitor red on machine monitor.
controller
Problem that
appears on If machine is used as it is, power train components may be damaged.
machine
Torque converter oil temperature sensor signal is input to power train controller and then transmit-
ted to machine monitor through communication system.
Related
Power train oil temperature can be checked with monitoring function.
information
(Code: 30100 T/C Oil Temperature)

Possible causes Overheated power train oil Check power train oil for overheating. If it is overheated, remove
1
and standard (When system is normal) cause.
value in normal Defective torque converter If cause 1 is not detected, torque converter oil temperature sensor
state 2 oil temperature sensor sys- system may be defective. Carry out troubleshooting for failure
tem code [DGT1KA] or [DGT1KX].
D155AX-6 43
Failure code [B@HANS] Hyd Oil Overheat 1

Action code Failure code Hyd Oil Overheat
Trouble
B@HANS (Machine monitor system)
Contents of While engine was running, hydraulic oil temperature sensor signal circuit detected that hydraulic oil
trouble was overheated.
Action of
Displays hydraulic oil temperature monitor red on machine monitor.
controller
Problem that
appears on If machine is used as it is, work equipment and HSS circuit components may be damaged.
machine
Hydraulic oil temperature can be checked with monitoring function.
Related
(Code: 04401 Hyd Oil Temperature)
information

Overheated hydraulic oil Check hydraulic oil for overheating. If it is overheated, remove
Possible causes 1
(When system is normal) cause.
and standard
value in normal If cause 1 is not detected, hydraulic oil temperature gauge system
state Defective hydraulic oil tem- may be defective. Carry out troubleshooting for "E-10 Hydraulic oil
2
perature gauge system temperature gauge (Multi-gauge) does not indicated normally" in E
mode.
44 D155AX-6
D155AX-6 Bulldozer
2006 KOMATSU
All Rights Reserved
46 D155AX-6
SEN00717-01
D155AX-6

D155AX-6 80001 and up
codes, Part 2
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
D155AX-6 1
Failure code [CA221] Ambient Press Sens High Error....................................................................... 28

Failure code [CA222] Ambient Press Sens Low Error ....................................................................... 30
Failure code [CA227] Sens Supply 2 Volt High Error ......................................................................... 32
Failure code [CA234] Eng Overspeed................................................................................................ 34
Failure code [CA238] Ne Speed Sens Supply Volt Error.................................................................... 36
Failure code [CA263] Fuel Temp Sensor High Error .......................................................................... 38
Failure code [CA265] Fuel Temp Sensor Low Error........................................................................... 39
Failure code [CA271] PCV1 Short Error............................................................................................. 40
Failure code [CA272] PCV1 Open Error ............................................................................................ 41
Failure code [CA273] PCV2 Short Error............................................................................................. 42
Failure code [CA274] PCV2 Open Error ............................................................................................ 43
Failure code [CA322] Inj #1 (L#1) Open/Short Error .......................................................................... 44
Failure code [CA342] Calibration Code Incompatibility ...................................................................... 50
Failure code [CA351] Injectors Drive Circuit Error ............................................................................. 52
Failure code [CA352] Sens Supply 1 Volt Low Error.......................................................................... 54
Failure code [CA386] Sens Supply 1 Volt High Error ......................................................................... 56
Failure code [CA441] Battery Voltage Low Error................................................................................ 58
Failure code [CA442] Battery Voltage High Error ............................................................................... 58
Failure code [CA449] Rail Press Very High Error............................................................................... 59
Failure code [CA451] Rail Press Sensor High Error .......................................................................... 60
Failure code [CA452] Rail Press Sensor Low Error ........................................................................... 62
Failure code [CA553] Rail Press High Error....................................................................................... 62
Failure code [CA554] Rail Press Sensor In Range Error ................................................................... 63
Failure code [CA559] Rail Press Low Error........................................................................................ 64
Failure code [CA689] Eng Ne Speed Sensor Error ........................................................................... 68
2 D155AX-6

Failure code [CA111] EMC Critical Internal Failure 1
Action code Failure code EMC Critical Internal Failure
Trouble
E04 CA111 (Engine controller system)
Contents of
Trouble occurred in engine controller.
trouble
Action of
None in particular.
controller
Problem that
appears on Engine runs normally but may stop during operation or may not be able to start.
machine
Related Source voltage of engine controller can be checked with monitoring function.
information (Code: 03203 Battery Power Supply)

Defective circuit breaker If circuit breaker is turned OFF, circuit probably has ground fault.
1
(CB30 or CB8) (See cause 3.)
ing without turning starting switch ON.
Wiring harness between EGC3 (female) (3), Resis-
Max. 1 z
Disconnection in wiring har- (4) CB8 (2) tance
ness (Disconnection in wiring Wiring harness between CB8 (1) CB30 Resis-
2 Max. 1 z
or defective contact in con- (B30S) tance
nector) Wiring harness between CB30 (B30L) ter- Resis-
Max. 1 z
minal BRB tance
Max. 1 z
(2) chassis ground (GND20) tance
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 EGC3 (female) (3), Resis-
state Min. 1 Mz
(4) CB8 (2) and chassis ground tance
Wiring harness between CB8 (1) CB30
Ground fault in wiring har- Resis-
(B30S), circuit branch end and chassis Min. 1 Mz
3 ness (Contact with GND cir- tance
ground
cuit)
Wiring harness between CB30 (B30L) ter- Resis-
Min. 1 Mz
minal BRB and chassis ground tance
Wiring harness between EGC3 (female) (1),
Resis-
(2) chassis ground (GND20) and chassis Min. 1 Mz
tance
ground
and carry out troubleshooting.
4 Defective engine controller EGC3 Starting switch Voltage
Between (3), (4)
ON 20 30 V
(1), (2)
4 D155AX-6
Circuit diagram related to engine controller power supply
D155AX-6 5
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 1

Action code Failure code Eng Ne and Bkup Speed Sens Error
Trouble
Contents of
Trouble occurred in Ne speed sensor circuit and Bkup speed sensor circuit simultaneously.
trouble
Action of
None in particular.
controller
Problem that
Engine cannot be started (if engine has been stopped).
appears on
Engine stops (if engine has been running).
machine
Related
information

Defective Ne speed sensor Ne speed sensor system may be defective. Carry out trouble-
1
system shooting for code [CA689].
Defective Bkup speed sen- Bkup speed sensor system may be defective. Carry out trouble-
2
sor system shooting for code [CA778].
Possible causes Defective mount of Ne speed Check mount of Ne speed sensor directly for defect (defective
3
and standard sensor installation of sensor, internal trouble of flywheel, etc.)
value in normal Defective mount of Bkup Check mount of Bkup speed sensor directly for defect (defective
state 4
speed sensor installation of sensor, internal trouble of supply pump, etc.)
Defective connection (Wrong Check Ne speed sensor and Bkup speed sensor directly for defec-
5
connection) of sensor tive connection (wrong connection).
If causes 1 5 are not detected, engine controller may be defec-
6 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
6 D155AX-6
Failure code [CA122] Chg Air Press Sensor High Error 1

Action code Failure code Chg Air Press Sensor High Error
Trouble
Contents of
Signal voltage in charge pressure sensor circuit is abnormally high.
trouble
Action of
Fixes charge pressure (400 kPa {4.08 kg/cm2}) and continues operation.
controller
Problem that
appears on Acceleration performance of engine lowers or black smoke is produced more during acceleration.
machine
Related State of charge pressure sensor can be checked with monitoring function.
information (Code: 36500 Charge Pressure-Abs)

Defective sensor power sup- If code [CA187] or [CA227] is indicated, carry out troubleshooting
1
ply system for it first.
or start engine and carry out troubleshooting.
PIM Voltage
Defective charge pressure
2 Between (1) (2) Power supply 4.75 5.25 V
sensor (Internal trouble)
Pressure sensor voltage is measured with wiring harness con-
nected. Accordingly, if voltage is abnormal, check wiring harness
and controller, too, for another cause of trouble, and then judge.
Disconnection in wiring har- Wiring harness between EGC1 (female) Resis-
Max. 1 z
ness (Disconnection in wiring (37) PIM (female) (1) tance
3
or defective contact in con- Wiring harness between EGC1 (female) Resis-
nector) Max. 1 z
(47) PIM (female) (2) tance
Wiring harness between EGC1 (female) Resis-
Max. 1 z
(44) PIM (female) (3) tance
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
Min. 1 Mz
(44) PIM (female) (3) and chassis ground tance
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-
tance
(female) (44) PIM (female) (3)
Chassis ground between EGC1 (female)
Resis-
tance
(female) (44) PIM (female) (3)
6 Defective engine controller
EGC1 Voltage
Between (37) (47) Power supply 4.75 5.25 V
8 D155AX-6
Circuit diagram related to charge pressure sensor
D155AX-6 9
Failure code [CA123] Chg Air Press Sensor Low Error 1

Action code Failure code Chg Air Press Sensor Low Error
Trouble
Contents of
Signal voltage in charge pressure sensor circuit is abnormally low.
trouble
Action of Fixes charge pressure (400 kPa {4.08 kg/cm2}) and continues
controller operation.
Problem that
appears on Acceleration performance of engine lowers or black smoke is produced more during acceleration.
machine
Related State of charge pressure sensor can be checked with monitoring function.
information (Code: 36500 Charge Pressure-Abs)

and standard
value in normal Carry out troubleshooting for failure code [CA122].
state
10 D155AX-6
Failure code [CA131] Throttle Sensor High Error 1

Action code Failure code Throttle Sensor High Error
Trouble
Contents of
Signal voltage in decelerator pedal potentiometer circuit is abnormally high.
trouble
Action of
Sets throttle position with fuel control dial signal and continues operation.
controller
Problem that
appears on
machine
Related State of decelerator pedal optimum operation range signal can be checked with monitoring function.
information (Code: 03001 Throttle Pos Sens Volt)

Defective sensor power sup- If code [CA2185] or [CA2186] is indicated, carry out troubleshoot-
1
ply system ing for it first.
Defective fuel control dial DCL (male) Resistance

2
(Internal trouble) Between (B) (C) 1.5 2.5 kz
Between (A) (B) 0 3 kz
Between (A) (C) 0 3 kz
Disconnection in wiring har- Wiring harness between EGC2 (female) (9) Resis-
Max. 1 z
ness (Disconnection in wiring DCL (female) (A) tance
3
Possible causes or defective contact in con- Wiring harness between EGC2 (female) Resis-
nector) Max. 1 z
and standard (22) DCL (female) (B) tance
state Max. 1 z
(23) DCL (female) (C) tance
Wiring harness between EGC2 (female) (9) Resis-
DCL (female) (A) and chassis ground tance
Min. 1 Mz
(22) DCL (female) (B) and chassis ground tance
Min. 1 Mz
(23) DCL (female) (C) and chassis ground tance
5 Defective engine controller EGC2 Voltage
Between (9) (23) Signal 0.5 4.5 V
12 D155AX-6
Circuit diagram related to decelerator pedal potentiometer
D155AX-6 13
Failure code [CA132] Throttle Sensor Low Error 1

Action code Failure code Throttle Sensor Low Error
Trouble
Contents of
Signal voltage in decelerator pedal potentiometer circuit is abnormally low.
trouble
Action of
Sets throttle position with fuel control dial signal and continues operation.
controller
Problem that
appears on
machine
Related State of decelerator pedal optimum operation range signal can be checked with monitoring function.
information (Code: 03001 Throttle Pos Sens Volt)

and standard
state
14 D155AX-6
Failure code [CA135] Eng Oil Press Sensor High Error 1

Action code Failure code Eng Oil Press Sensor High Error
Trouble
Contents of
Signal voltage in engine oil pressure sensor circuit is abnormally high.
trouble
Action of
Sets engine oil pressure to default value (250 kPa {2.55 kg/cm2}) and continues operation.
controller
Problem that
appears on
machine
Related State of engine oil pressure sensor can be checked with monitoring function.
information (Code: 37201 Eng Oil Press Sens Volt)

1
POIL Voltage
Defective engine oil pressure
Sensor voltage is measured with wiring harness connected.
Accordingly, if voltage is abnormal, check wiring harness and con-
troller, too, for another cause of trouble, and then judge.
Max. 1 z
ness (Disconnection in wiring (37) POIL (female) (1) tance
3
nector) Max. 1 z
(47) POIL (female) (2) tance
Max. 1 z
(13) POIL (female) (3) tance
and standard
state (37) POIL (female) (1) and chassis ground tance
Min. 1 Mz
(47) POIL (female) (2) and chassis ground tance
Min. 1 Mz
(13) POIL (female) (3) and chassis ground tance
Resis-
(37) POIL (female) (1) and between EGC1 Min. 1 Mz
tance
Short circuit in wiring har- (female) (47) POIL (female) (2)
harness) Resis-
tance
(female) (13) POIL (female) (3)
Resis-
tance
(female) (13) POIL (female) (3)
EGC1 Voltage
16 D155AX-6
Circuit diagram related to engine oil pressure sensor
D155AX-6 17
Failure code [CA141] Eng Oil Press Sensor Low Error 1

Action code Failure code Eng Oil Press Sensor Low Error
Trouble
Contents of
Signal voltage in engine oil pressure sensor circuit is abnormally low.
trouble
Action of
Sets engine oil pressure to default value (250 kPa {2.55 kg/cm2}) and continues operation.
controller
Problem that
appears on
machine
Related State of engine oil pressure sensor can be checked with monitoring function.
information (Code: 37201 Eng Oil Press Sens Volt)

and standard
state
18 D155AX-6
Failure code [CA144] Coolant Temp Sens High Error 1

Action code Failure code Coolant Temp Sens High Error
Trouble
Contents of
Signal voltage in engine coolant temperature sensor circuit is abnormally high.
trouble
Action of
Fixes engine coolant temperature (90C) and continues operation.
controller
Problem that
appears on Startability of engine lowers at low temperature.
machine
Related State of engine coolant temperature sensor can be checked with monitoring function.
information (Code: 04105 Coolant Temp Sens Volt)

Defective engine coolant ing without turning starting switch ON.
1 temperature sensor (Internal
TWTR (male) Coolant temperature Resistance
trouble)
Between (A) (B) 10 100C 0.6 20 kz
ness (Disconnection in wiring Wiring harness between EGC1 (female) Resis-
2 Max. 1 z
Possible causes or defective contact in con- (15) TWTR (female) (A) tance
and standard nector) Wiring harness between EGC1 (female) Resis-
(38) TWTR (female) (B) tance
state
Ground fault in wiring har- ing without turning starting switch ON.
3 ness (Contact with GND cir- Wiring harness between EGC1 (female)
cuit) Resis-
(15) TWTR (female) (A) and chassis Min. 1 Mz
tance
ground
EGC1 (female) Coolant temperature Resistance
Between (15) (38) 10 100C 0.6 20 kz
20 D155AX-6
Circuit diagram related to engine coolant temperature sensor
D155AX-6 21
Failure code [CA145] Coolant Temp Sens Low Error 1

Action code Failure code Coolant Temp Sens Low Error
Trouble
Contents of
Signal voltage in engine coolant temperature sensor circuit is abnormally low.
trouble
Action of
Fixes engine coolant temperature (90C) and continues operation.
controller
Problem that
machine
Related State of engine coolant temperature sensor can be checked with monitoring function.
information (Code: 04105 Coolant Temp Sens Volt)

and standard
state
22 D155AX-6
Failure code [CA153] Chg Air Temp Sensor High Error 1

Action code Failure code Chg Air Temp Sensor High Error
Trouble
Contents of
Signal voltage in charge temperature sensor circuit is abnormally high.
trouble
Action of
Fixes charge temperature (intake air temperature) (70C) and continues operation.
controller
Problem that
machine
Related State of charge temperature sensor signal can be checked with monitoring function.
information (Code: 18501 Charge Temp Sens Volt)

Intake air
Defective charge tempera- TIM (male) Resistance
1 temperature
ture sensor (Internal trouble)
Between (A) (B) 10 100C 0.5 20 kz
Between (A) chas-
All range Min. 1 Mz
sis ground
Possible causes
and standard 2 Max. 1 z
or defective contact in con- (23) TIM (female) (A) tance
value in normal
nector) Wiring harness between EGC1 (female) Resis-
state Max. 1 z
(47) TIM (female) (B) tance
Min. 1 Mz
(23) TIM (female) (A) and chassis ground tance
4 Defective engine controller Intake air
EGC1 (female) Resistance
temperature
Between (23) (47) 10 100C 0.5 20 kz
24 D155AX-6
Circuit diagram related to charge temperature sensor
D155AX-6 25
Failure code [CA154] Chg Air Temp Sensor Low Error 1

Action code Failure code Chg Air Temp Sensor Low Error
Trouble
Contents of
Signal voltage in charge temperature sensor circuit is abnormally low.
trouble
Action of
Fixes charge temperature (intake air temperature) (70C) and continues operation.
controller
Problem that
machine
Related State of charge temperature sensor signal can be checked with monitoring function.
information (Code: 18501 Charge Temp Sens Volt)

and standard
state
Failure code [CA187] Sens Supply 2 Volt Low Error 1

Action code Failure code Sens Supply 2 Volt Low Error
Trouble
Contents of
Signal voltage in sensor power supply 2 (5 V) circuit is abnormally low.
trouble
Operates Bkup speed sensor with signals of Ne speed sensor.
Sets oil pressure sensor to default value (250 kPa {2.55 kg/cm2}) and continues operation.
Sets ambient pressure sensor to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.
Action of
Fixes charge pressure sensor value (400 kPa {4.08 kg/cm2}) and continues operation.
controller
Sets EGR inlet pressure sensor to default value (102 kPa {1.05 kg/cm2}) and continues operation.
Limits output of EGR valve lift sensor and closes EGR valve and bypass valve.
Limits output of bypass valve lift sensor and closes EGR valve and bypass valve.
Problem that
appears on Engine output drops.
machine
Related
information

and standard
state
26 D155AX-6
Failure code [CA221] Ambient Press Sens High Error 1

Action code Failure code Ambient Press Sens High Error
Trouble
Contents of
Signal voltage in ambient pressure sensor circuit is abnormally high.
trouble
Action of
Sets ambient pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.
controller
Problem that
machine
Related State of ambient pressure sensor signal can be checked with monitoring function.
information (Code: 37401 Ambient Press Sens Volt)

1
PAMB Voltage
Defective ambient pressure Between (1) (2) Power supply 4.75 5.25 V
2
sensor (Internal trouble) Between (3) (2) Signal
Max. 1 z
ness (Disconnection in wiring (37) PAMB (female) (1) tance
3
nector) Max. 1 z
(38) PAMB (female) (2) tance
Max. 1 z
PAMB (female) (3) tance
Possible causes
and standard
value in normal Wiring harness between EGC1 (female) (37) Resis-
state PAMB (female) (1) and chassis ground tance
cuit) Wiring harness between EGC1 (female) (38) Resis-
Min. 1 Mz
PAMB (female) (2) and chassis ground tance
Min. 1 Mz
PAMB (female) (3) and chassis ground tance
Resis-
(37) PAMB (female) (1) and between Min. 1 Mz
tance
Short circuit in wiring har- EGC1 (female) (38) - PAMB (female) (2)
harness) Resis-
tance
EGC1 (female) (3) PAMB (female) (3)
Resis-
tance
EGC1 (female) (3) PAMB (female) (3)
a repare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
6 Defective engine controller EGC1 Voltage
Between (33) (38) 4.75 5.25 V
Between (3) (38)
28 D155AX-6
Circuit diagram related to ambient pressure sensor
D155AX-6 29
Failure code [CA222] Ambient Press Sens Low Error 1

Action code Failure code Ambient Press Sens Low Error
Trouble
Contents of
Signal voltage in ambient pressure sensor circuit is abnormally low.
trouble
Action of
controller
Problem that
machine
Related State of ambient pressure sensor signal can be checked with monitoring function.
information (Code: 37401 Ambient Press Sens Volt)

and standard
state
30 D155AX-6
Failure code [CA227] Sens Supply 2 Volt High Error 1

Action code Failure code Sens Supply 2 Volt High Error
Trouble
Contents of
Signal voltage in sensor power supply 2 (5 V) circuit is abnormally high.
trouble
Operates Bkup speed sensor with signals of Ne speed sensor.
Sets oil pressure sensor to default value (250 kPa [2.55 kg/cm2}) and continues operation.
Action of
Fixes charge pressure sensor value (400 kPa [4.08 kg/cm2}) and continues operation.
controller
Sets EGR inlet pressure sensor to default value (102 kPa {1.05 kg/cm2}) and continues operation.
Limits output of EGR valve lift sensor and closes EGR valve and bypass valve.
Limits output of bypass valve lift sensor and closes EGR valve and bypass valve.
Problem that
machine
Related
information

1 Defective related system If another failure code is indicated, carry out troubleshooting for it.
Bkup speed sensor G connector
Oil pressure sensor POIL connector
Disconnect devices Ambient pressure
at right in order. If PAMB connector
Defective sensor (Internal sensor
2 "E" of failure code
trouble) Charge pressure
disappears when a PIM connector
sensor
device is discon-
nected, that device EGR inlet pressure
PEVA connector
has trouble in it. sensor
EGR valve lift sensor SEGR connector
Bypass valve lift sensor SBP connector
Possible causes ness (Disconnection in wiring Wiring harness between EGC1 (female) Resis-
3 Max. 1 z
and standard or defective contact in con- (37) each sensor (female) tance
value in normal nector) Wiring harness between EGC1 (female) Resis-
Max. 1 z
state (47) each sensor (female) tance
(37) each sensor (female) and chassis Min. 1 Mz
ground
cuit)
Resis-
(47) each sensor (female) and chassis Min. 1 Mz
tance
ground
Short circuit in wiring har- ing without turning starting switch ON.
harness) Resis-
(37) each sensor (female) and between Min. 1 Mz
tance
EGC1 (female) (47) each sensor (female)
EGC1 Voltage
Between (37) (47) 4.75 5.25 V
32 D155AX-6
Circuit diagram related to engine controller sensor power supply 2 (5 V)
D155AX-6 33
Failure code [CA234] Eng Overspeed 1

Action code Failure code Eng Overspeed
Trouble
CA234 (Engine controller system)
Contents of
Engine speed is above operating range.
trouble
Action of
Limits fuel injection rate until engine speed lowers to operating range.
controller
Problem that
appears on Engine speed fluctuates.
machine
Related Engine speed can be checked with monitoring function.
information (Code: 01002 Engine Speed)

Possible causes
and standard Way of use of machine may be improper. Teach proper way of use
2 Improper way of use
value in normal to operator.
state If causes 1 2 are not detected, engine controller may be defec-
out.)
34 D155AX-6
Failure code [CA238] Ne Speed Sens Supply Volt Error 1

Action code Failure code Ne Speed Sens Supply Volt Error
Trouble
Contents of
Trouble occurred in Ne speed sensor power supply (5 V) circuit.
trouble
Action of
Controls Ne speed sensor with signals of Bkup speed sensor.
controller
Problem that
Running engine stops (when Bkup speed sensor is also abnormal).
appears on
Stopped engine cannot be started (when Bkup speed sensor is also abnormal).
machine
Related
information

Disconnect devices
Defective Ne speed sensor at right in order. If
(Internal trouble) Engine Ne speed
disappears when a NE connector
sensor
device is discon-
nected, that device
has trouble in it.
2 Max. 1 z
or defective contact in con- (16) NE (female) (1) tance
Possible causes
Max. 1 z
and standard (48) NE (female) (2) tance
Ground fault in wiring har-
3 ness (Contact with GND cir- Min. 1 Mz
(16) NE (female) (1) and chassis ground tance
cuit)
Min. 1 Mz
harness) Resis-
(16) NE (female) (1) and between EGC1 Min. 1 Mz
tance
(female) (48) NE (female) (2)
EGC1 Voltage
Between (16) (48) 4.75 5.25 V
36 D155AX-6
Circuit diagram related to engine NE speed sensor
D155AX-6 37
Failure code [CA263] Fuel Temp Sensor High Error 1

Action code Failure code Fuel Temp Sensor High Error
Trouble
Contents of
Signal voltage in fuel temperature sensor circuit is abnormally high.
trouble
Action of
Fixes fuel temperature (90 C) and continues operation.
controller
Problem that
appears on
machine
Related State of fuel temperature sensor signal can be checked with monitoring function.
information (Code: 14201 Fuel Temp Sens Volt)

Defective fuel temperature ing without turning starting switch ON.
1
sensor (Internal trouble) TFUEL (male) Fuel temperature Resistance
Between (A) (B) 10 100C 0.6 20 kz
Possible causes 2 Max. 1 z
or defective contact in con- (30) TFUEL (female) (A) tance
and standard nector)
Max. 1 z
state (47) TFUEL (female) (B) tance
Min. 1 Mz
TFUEL (female) (A) and chassis ground tance
EGC1 (female) Fuel temperature Resistance
Between (30) (47) 10 100C 0.6 20 kz
Circuit diagram related to fuel temperature sensor
38 D155AX-6
Failure code [CA265] Fuel Temp Sensor Low Error 1

Action code Failure code Fuel Temp Sensor Low Error
Trouble
Contents of
Signal voltage in fuel temperature sensor circuit is abnormally low.
trouble
Action of
Fixes fuel temperature (90C) and continues operation.
controller
Problem that
appears on
machine
Related
information

and standard
state
D155AX-6 39
Failure code [CA271] PCV1 Short Error 1

Action code Failure code PCV1 Short Error
Trouble
Contents of
There is short circuit in PCV1 circuit of supply pump.
trouble
Action of
None in particular.
controller
Problem that
appears on
machine
Related
information

Defective supply pump PCV1 (male) Resistance
1
PCV1 (Internal short circuit) Between (1) (2) 2.3 5.3 z
Between (1), (2) chassis
Min. 1 Mz
ground
PCV1 (female) (1) and chassis ground tance
Possible causes cuit)
and standard Min. 1 Mz
value in normal
state a Prepare with starting switch OFF, then turn starting switch ON
Hot short (Short circuit with Wiring harness between EGC1 (female) (4)
3 Voltage Max. 1 V
24V circuit) in wiring harness PCV1 (female) (1) and chassis ground
Wiring harness between EGC1 (female) (5)
Voltage Max. 1 V
PCV1 (female) (2) and chassis ground
Between (4) (5) 2.3 5.3 z
Min. 1 Mz
ground
Circuit diagram related to supply pump PCV1
40 D155AX-6
Failure code [CA272] PCV1 Open Error 1

Action code Failure code PCV1 Open Error
Trouble
Contents of
There is disconnection in PCV1 circuit of supply pump.
trouble
Action of
None in particular.
controller
Problem that
appears on
machine
Related
information

1 PCV1 (Internal disconnec-
tion) Between (1) (2) 2.3 5.3 z
Min. 1 Mz
ground
ness (Disconnection in wiring Wiring harness between EGC1 (female) (4) Resis-
2 Max. 1 z
or defective contact in con- PCV1 (female) (1) tance
Possible causes nector) Wiring harness between EGC1 (female) (5) Resis-
and standard Max. 1 z
PCV1 (female) (2) tance
value in normal
state a Prepare with starting switch OFF, then carry out troubleshoot-
cuit)
Min. 1 Mz
Between (4) (5) 2.3 5.3 z
Min. 1 Mz
ground
D155AX-6 41
Failure code [CA273] PCV2 Short Error 1

Action code Failure code PCV2 Short Error
Trouble
Contents of
There is short circuit in PCV2 circuit of supply pump.
trouble
Action of
None in particular.
controller
Problem that
appears on
machine
Related
information

1
PCV2 (Internal short circuit) Between (1) (2) 2.3 5.3 z
Min. 1 Mz
ground
Possible causes cuit)
value in normal
Hot short (Short circuit with Wiring harness between EGC1 (female) (9)
3 Voltage Max. 1 V
24V circuit) in wiring harness PCV2 (female) (1) and chassis ground
Wiring harness between EGC1 (female) (10)
Voltage Max. 1 V
PCV2 (female) (2) and chassis ground
Between (9) (10) 2.3 5.3 z
Min. 1 Mz
ground
42 D155AX-6
Failure code [CA274] PCV2 Open Error 1

Action code Failure code PCV2 Open Error
Trouble
Contents of
There is disconnection in PCV2 circuit of supply pump.
trouble
Action of
None in particular.
controller
Problem that
appears on
machine
Related
information

1 PCV2 (Internal disconnec-
tion) Between (1) (2) 2.3 5.3 z
Min. 1 Mz
ground
ness (Disconnection in wiring Wiring harness between EGC1 (female) (9) Resis-
2 Max. 1 z
or defective contact in con- PCV2 (female) (1) tance
Possible causes nector) Wiring harness between EGC1 (female) Resis-
(10) PCV2 (female) (2) tance
value in normal
cuit)
Min. 1 Mz
Between (9) (10) 2.3 5.3 z
Min. 1 Mz
ground
D155AX-6 43
Failure code [CA322] Inj #1 (L#1) Open/Short Error 1

Action code Failure code Inj #1 (L#1) Open/Short Error
Trouble
Contents of
There is disconnection or short circuit in injector #1 circuit.
trouble
Action of
None in particular.
controller
Problem that
Output drops.
appears on
Rotation is unstable.
machine
Related
information

Defective injector #1 (Inter- CN1 (male) Resistance
1
nal trouble) Between (1) (2) 0.4 1.1 z
Min. 1 Mz
ground
2 Max. 1 z
or defective contact in con- (45) CN1 (female) (1) tance
(53) CN1 (female) (2) tance
value in normal
(45) CN1 (female) (1) and chassis ground tance
cuit)
Min. 1 Mz
Between (45) (53) 0.4 1.1 z
Min. 1 Mz
ground
Circuit diagram related to injector #1
44 D155AX-6

Trouble
Contents of
trouble
Action of
None in particular.
controller
Problem that
Output drops.
appears on
machine
Related
information

1
Min. 1 Mz
ground
2 Max. 1 z
value in normal
cuit)
Min. 1 Mz
Between (46) (60) 0.4 1.1 z
Min. 1 Mz
ground
D155AX-6 45

Trouble
Contents of
trouble
Action of
None in particular.
controller
Problem that
Output drops.
appears on
machine
Related
information

1
Min. 1 Mz
ground
2 Max. 1 z
value in normal
cuit)
Min. 1 Mz
Between (55) (52) 0.4 1.1 z
Min. 1 Mz
ground
46 D155AX-6

Trouble
Contents of
trouble
Action of
None in particular.
controller
Problem that
Output drops.
appears on
machine
Related
information

1
Min. 1 Mz
ground
2 Max. 1 z
value in normal
cuit)
Min. 1 Mz
Between (57) (59) 0.4 1.1 z
Min. 1 Mz
ground
D155AX-6 47

Trouble
Contents of
trouble
Action of
None in particular.
controller
Problem that
Output drops.
appears on
machine
Related
information

1
Min. 1 Mz
ground
2 Max. 1 z
value in normal
cuit)
Min. 1 Mz
Between (54) (51) 0.4 1.1 z
Min. 1 Mz
ground
48 D155AX-6

Trouble
Contents of
trouble
Action of
None in particular.
controller
Problem that
Output drops.
appears on
machine
Related
information

1
Min. 1 Mz
ground
2 Max. 1 z
value in normal
cuit)
Min. 1 Mz
Between (56) (58) 0.4 1.1 z
Min. 1 Mz
ground
D155AX-6 49
Failure code [CA342] Calibration Code Incompatibility 1

Action code Failure code Calibration Code Incompatibility
Trouble
Contents of
Incompatibility occurred in engine controller data.
trouble
Action of
None in particular.
controller
Problem that
appears on Engine continues operation normally, but it may stop during operation or may not be able to start.
machine
Related
information

and standard
state
50 D155AX-6
Failure code [CA351] Injectors Drive Circuit Error 1

Action code Failure code Injectors Drive Circuit Error
Trouble
Contents of
Trouble occurred in injector drive circuit.
trouble
Action of
Limits engine output and continues operation (Limits common rail pressure).
controller
Problem that
machine

If another failure code (failure code of trouble in injector system) is
1 Defective related system
indicated, carry out troubleshooting for it.
Defective circuit breaker If circuit breaker is turned OFF, circuit probably has ground fault
2
(CB30 or CB8) (See cause 4).
Max. 1 z
Disconnection in wiring har- (4) CB8 (2) tance
ness (Disconnection in wiring Wiring harness between CB8 (1) CB30 Resis-
3 Max. 1 z
or defective contact in con- (B30S) tance
nector) Wiring harness between CB30 (B30L) ter- Resis-
Max. 1 z
minal BRB tance
Possible causes Max. 1 z
and standard
Min. 1 Mz
(4) CB8 (2) and chassis ground tance
(B30S) or circuit branch end and chassis Min. 1 Mz
ground
cuit)
Min. 1 Mz
Wiring harness between EGC3 (female) (1),
Resis-
(2) chassis ground (GND20) and chassis Min. 1 Mz
tance
ground
EGC3 Voltage
Between (3), (4) (1), (2) 20 30 V
52 D155AX-6
Circuit diagram related to engine controller power supply
D155AX-6 53
Failure code [CA352] Sens Supply 1 Volt Low Error 1

Action code Failure code Sens Supply 1 Volt Low Error
Trouble
Contents of
Signal voltage in sensor power supply 1 (5 V) circuit of engine controller is abnormally low.
trouble
Action of
Limits common rail pressure sensor output and continues operation (Limits common rail pressure).
controller
Problem that
machine
Related
information

and standard
state
54 D155AX-6
Failure code [CA386] Sens Supply 1 Volt High Error 1

Action code Failure code Sens Supply 1 Volt High Error
Trouble
Contents of
Signal voltage in sensor power supply (5 V) circuit is abnormally high.
trouble
Action of
Limits common rail pressure sensor output and continues operation (Limits common rail pressure).
controller
Problem that
machine
Related
information

Disconnect devices
Defective sensor (Internal at right in order. If
trouble) Common rail pres-
disappears when a PFUEL connector
sure sensor
device is discon-
nected, that device
has trouble in it.
3 Max. 1 z
or defective contact in con- (33) PFUEL (female) (1) tance
and standard (47) PFUEL (female) (3) tance
(33) PFUEL (female) (1) and chassis Min. 1 Mz
ground
cuit)
Resis-
(47) PFUEL (female) (3) and chassis Min. 1 Mz
tance
ground
harness) Resis-
(33) PFUEL (female) (1) and between Min. 1 Mz
tance
EGC1 (female) (47) PFUEL (female) (3)
EGC1 Voltage
Between (33) (47) 4.75 5.25 z
56 D155AX-6
Circuit diagram related to engine controller sensor power supply 1 (5 V)
D155AX-6 57
Failure code [CA441] Battery Voltage Low Error 1

Action code Failure code Battery Voltage Low Error
Trouble
Contents of
Power supply circuit voltage of engine controller is abnormally low.
trouble
Action of
None in particular.
controller
Problem that
machine

and standard
state
Failure code [CA442] Battery Voltage High Error 1

Action code Failure code Battery Voltage High Error
Trouble
Contents of
Power supply circuit voltage of engine controller is abnormally low.
trouble
Action of
None in particular.
controller
Problem that
machine

and standard
state
58 D155AX-6
Failure code [CA449] Rail Press Very High Error 1

Action code Failure code Rail Press Very High Error
Trouble
Contents of
Common rail pressure sensor circuit detected abnormally high pressure (level 2).
trouble
Action of
controller
Problem that
machine
Related Common rail pressure can be checked with monitoring function.
information (Code: 36400 Rail Pressure)

and standard
state
D155AX-6 59
Failure code [CA451] Rail Press Sensor High Error 1

Action code Failure code Rail Press Sensor High Error
Trouble
Contents of
Signal voltage in common rail pressure sensor circuit is abnormally high.
trouble
Action of
controller
Problem that
machine
Related State of common rail pressure sensor signal can be checked with monitoring function.
information (Code: 36401 Rail Pressure Sens Volt)

1
PFUEL Voltage
Defective common rail pres- Between (1) (3) Power supply 4.75 5.25 V
2
sure sensor (Internal trouble) Between (2) (3) Signal 0.26 4.6 V
Max. 1 z
ness (Disconnection in wiring (33) PFUEL (female) (1) tance
3
nector) Max. 1 z
(25) PFUEL (female) (2) tance
Possible causes Wiring harness between EGC1 (female) Resis-
(47) PFUEL (female) (3) tance
value in normal
PFUEL (female) (1) and chassis ground tance
Min. 1 Mz
Min. 1 Mz
Resis-
tance
Short circuit in wiring har- EGC1 (female) (25) PFUEL (female) (2)
harness) Resis-
tance
Resis-
tance
60 D155AX-6
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
Circuit diagram related to common rail pressure sensor
D155AX-6 61
Failure code [CA452] Rail Press Sensor Low Error 1

Action code Failure code Rail Press Sensor Low Error
Trouble
Contents of
Signal voltage in common rail pressure sensor circuit is abnormally low.
trouble
Action of
controller
Problem that
machine

and standard
state
Failure code [CA553] Rail Press High Error 1

Action code Failure code Rail Press High Error
Trouble
Contents of
Common rail pressure sensor circuit detected abnormally high pressure (level 1).
trouble
Action of
None in particular.
controller
Problem that
machine

2 Use of improper fuel Check fuel used directly (for high viscosity).
Defective electrical system of Common rail pressure sensor may have electric trouble. Carry out
3
Possible causes common rail pressure sensor troubleshooting for failure code [CA451].
and standard Defective mechanical system
value in normal 4 of common rail pressure sen- Check mechanical system of common rail pressure sensor directly.
state sor
Check overflow valve directly for broken spring, worn seat, and
5 Defective overflow valve
stuck ball.
6 Clogging of overflow piping Check overflow piping directly for clogging.
7 Defective pressure limiter Check pressure limiter directly for mechanical defect.
62 D155AX-6
Failure code [CA554] Rail Press Sensor In Range Error 1

Action code Failure code Rail Press Sensor In Range Error
Trouble
Contents of
In-range error occurred in common rail pressure sensor circuit.
trouble
Action of
controller
Problem that
machine

and standard
value in normal Carry out troubleshooting for Failure code [CA451].
state
D155AX-6 63
Failure code [CA559] Rail Press Low Error 1

Action code Failure code Rail Press Low Error
Trouble
Contents of
Supply pump does not feed fuel (level 1).
trouble
Action of
Limits common rail pressure.
controller
Problem that
machine

2 Use of improper fuel Check fuel used directly for improper quality.
a For contents of troubleshooting, see Note 1. For check of pres-
sure in fuel low-pressure circuit, see Testing and adjusting,
Defective low-pressure cir- Testing fuel pressure.
3
cuit device
Pressure in fuel low-pressure Min. 0.15 MPa
circuit (high idle) {Min. 1.5 kg/cm2}
4 Clogging of filter/strainer a For contents of troubleshooting, see Note 2.
Defective electrical system of Supply pump PCV may have electric trouble. Carry out trouble-
5
supply pump PCV shooting for following codes; [CA271], [CA272], [CA273], [CA274].
Defective common rail pres- Common rail pressure sensor may be defective. Check wiring har-
6
sure sensor ness for damage.
Possible causes
and standard a For testing of leakage from pressure limiter, see Testing and
value in normal adjusting, Measuring fuel return rate and fuel leakage.
state 7 Defective pressure limiter Leakage from pressure limiter
(Operation equivalent to rated Max. 10 cc/min
operation (under stall load))
a For measuring of return (spill) limit from injector, see Testing
and adjusting, Measuring fuel return rate and fuel leakage.
Speed in rated operation
Return (Spill) limit from injector
(stall load)
8 Defective injector 1,600 rpm 960 cc/min

1,700 rpm 1,020 cc/min
1,800 rpm 1,080 cc/min
1,900 rpm 1,140 cc/min
2,000 rpm 1,200 cc/min
9 Defective supply pump If causes 1 8 are not detected, supply pump may be defective.
<How to use check sheet>

Carry out the above troubleshooting and take a record of the contents of the attached "Check sheet for rail
pressure low error".
64 D155AX-6
Note 1: Check the low-pressure circuit parts for the following items.
1) Fuel level
2) Clogging of fuel tank breather
3) Sticking and wear of feed pump and clogging of filter
4) Leakage through and clogging of low-pressure fuel piping
5) Defective operation of bypass valve and installation of wrong part (See Fig. 1)
6) Clogging of fuel filter
7) Fuel in oil pan (Fuel leakage inside head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
Overflow valve (1): Spring is seen through both holes.
Bypass valve (2): Spring is seen through hole on nut side.
Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
D155AX-6 65
Check sheet for rail pressure low error
Model D155AX-6 Work No.

Machine serial No. # Date of check / /
Engine SAA6D140E-5 Service meter h
Engine serial No. # Worker's name
A. Visual check Good NG

1 Fuel leakage to outside
2 Clogging of fuel tank breather
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)
Setting Reduced cylinder Checking condition ISO unit Good NG
No. 1 cylinder r/min
5 No. 2 cylinder r/min
Reduce No. 3 cylinder r/min
each
cylinder No. 4 cylinder r/min
66 D155AX-6

C. Check of fuel circuit pressure Checking condition Unit Good NG
Fuel low-pressure circuit MPa Min. 0.15
6 High idle
pressure {kg/cm2} {Min. 1.5}
D. Check of strainers and filters Good NG

7 Visual check of strainers
8 Visual check of gauze filter
9 Visual check of fuel filter
10 Visual check of bypass valve
E. Check of leakage and Standard value Measured

Checking condition Unit Good NG
return rate (Reference value) value
Leakage through pressure
11 Torque converter stal cc/min Max. 10
limiter
Torque converter stall
cc/min 960
1,600 rpm
cc/min 1,020
1,700 rpm
Torque converter stall Speed:
12 Return rate from injector cc/min 1,080
1,800 rpm Leakage
cc/min 1,140
1,900 rpm
cc/min 1,200
2,000 rpm
D155AX-6 67
Failure code [CA689] Eng Ne Speed Sensor Error 1

Action code Failure code Eng Ne Speed Sensor Error
Trouble
Contents of
Trouble occurred in engine Ne speed sensor circuit.
trouble
Action of
Operates with signals of Bkup speed sensor.
controller
Problem that
Running engine stops (when Bkup speed sensor is also abnormal).
appears on
Stopped engine cannot be started (when Bkup speed sensor is also abnormal).
machine
Related
information

Defective sensor power sup-
1 If code [CA238] is indicated, carry out troubleshooting for it first.
ply system
Max. 1 z
ness (Disconnection in wiring (16) NE (female) (1) tance
2
nector) Max. 1 z
(48) NE (female) (2) tance
Max. 1 z
(27) NE (female) (3) tance
Min. 1 Mz
Min. 1 Mz
and standard (27) NE (female) (3) and chassis ground tance
Resis-
tance
Short circuit in wiring har- (female) (48) NE (female) (2)
harness) Resis-
tance
Resis-
tance
Defective mount of sensor or Check Ne speed sensor directly for defective mount (defective
5 defective rotation sensing clearance) or check rotation sensing part (flywheel) directly for
part defect.
If causes 1 5 are not detected, engine Ne speed sensor may be
Defective engine Ne speed
6 defective. (Since trouble is in system, troubleshooting cannot be
sensor
carried out.)
out.)
68 D155AX-6
Circuit diagram related to engine Ne speed sensor
D155AX-6 69
D155AX-6 Bulldozer
2006 KOMATSU
All Rights Reserved
70 D155AX-6
SEN00718-01
D155AX-6

D155AX-6 80001 and up
codes, Part 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
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
2 D155AX-6

Failure code [CA731] Eng Bkup Speed Sens Phase Error 1
Action code Failure code Eng Bkup Speed Sens Phase Error
Trouble
Contents of
Engine Bkup sensor circuit detected phase error.
trouble
Action of
Controls with signals of engine Ne speed sensor.
controller
Problem that
Running engine stops (when Ne speed sensor is also abnormal).
appears on
Stopped engine cannot be started (when Ne speed sensor is also abnormal).
machine
Related
information

Possible causes
Defective engine Ne speed Engine Ne speed sensor may be defective. Carry out trouble-
and standard 1
sensor system shooting for failure code [CA689].
value in normal
state Defective engine Bkup Engine Bkup speed sensor may be defective. Carry out trouble-
2
speed sensor system shooting for failure code [CA778].
Failure code [CA757] All Continuous Data Lost Error 1

Action code Failure code All Continuous Data Lost Error
Trouble
Contents of
All data in engine controller are lost.
trouble
Action of
None in particular.
controller
Problem that
machine
Related
information

and standard
state
D155AX-6 3
Failure code [CA778] Eng Bkup Speed Sensor Error 1

Action code Failure code Eng Bkup Speed Sensor Error
Trouble
Contents of
Trouble occurred in engine Bkup speed sensor circuit.
trouble
Action of
Operates with signals of Ne speed sensor.
controller
Problem that
Running engine stops (when Ne speed sensor is also abnormal).
appears on
Stopped engine cannot be started (when Ne speed sensor is also abnormal).
machine
Related
information

1
Max. 1 z
ness (Disconnection in wiring (37) G (female) (1) tance
2
nector) Max. 1 z
(47) G (female) (2) tance
Max. 1 z
(26) G (female) (3) tance
(37) G (female) (1) and chassis ground tance
Min. 1 Mz
(47) G (female) (2) and chassis ground tance
Min. 1 Mz
and standard (26) G (female) (3) and chassis ground tance
Resis-
(37) G (female) (1) and between EGC1 Min. 1 Mz
tance
Short circuit in wiring har- (female) (47) G (female) (2)
harness) Resis-
tance
(female) (26) G (female) (3)
Resis-
tance
(female) (29) G (female) (3)
Defective mount of sensor or Check Bkup speed sensor directly for defective mount (defective
5 defective rotation sensing clearance) or check rotation sensing part (in supply pump) directly
part for defect.
If causes 1 5 are not detected, engine Bkup speed sensor may
Defective engine Bkup
6 be defective. (Since trouble is in system, troubleshooting cannot
speed sensor
be carried out.)
out.)
4 D155AX-6
Circuit diagram related to engine Bkup speed sensor
D155AX-6 5
Failure code [CA1228] EGR Valve Servo Error 1 1

Action code Failure code EGR Valve Servo Error 1
Trouble
Contents of
Trouble (level 1) occurred in EGR valve servo.
trouble
Action of
Performs open control.
controller
Problem that
appears on
machine
Related Operating condition of EGR valve can be checked with monitoring function.
information (Code: 18100 EGR Valve Position)

a For check of engine oil pressure, see Testing and adjusting,
Measuring engine oil pressure.
Engine Engine oil pressure
2 Low idle 0.08 MPa {0.8 kg/cm2 }
system (main circuit)
High idle 0.21 MPa {2.1 kg/cm2 }
Possible causes If engine oil pressure is abnormal, carry out troubleshooting for "S-
and standard 12 Oil pressure lowers" in S mode.
value in normal Defective oil pump for EGR
state 3 Check oil pump and relief valve for EGR valve circuit directly.
valve
Defective oil feed piping for
4 Check oil feed piping for EGR valve circuit directly.
EGR valve
Defective oil return piping for
5 Check oil return piping for EGR valve circuit directly.
EGR valve
6 Defective EGR valve Check mechanical section of EGR valve directly.
out.)
6 D155AX-6
Failure code [CA1625] EGR Valve Servo Error 2 1

Action code Failure code EGR Valve Servo Error 2
Trouble
Contents of
Trouble (level 2) occurred in EGR valve servo.
trouble
Action of Limits engine output and continues operation.
controller Closes EGR valve and bypass valve.
Problem that
machine
Related Operating condition of EGR valve can be checked with monitoring function.
information (Code: 18100 EGR Valve Position)

and standard
state
D155AX-6 7
Failure code [CA1626] BP Valve Sol Current High Error 1

Action code Failure code BP Valve Sol Current High Error
Trouble
Contents of
There is short circuit in drive circuit of bypass valve solenoid.
trouble
Problem that
machine
Related
information

Defective bypass valve sole- ing without turning starting switch ON.
1
noid (Internal trouble) BP (male) Resistance
Between (1) (2) 10 21 z
2 Max. 1 z
or defective contact in con- (31) BP (female) (1) tance
Max. 1 z
(11) BP (female) (2) tance
and standard Ground fault in wiring har-
state (31) BP (female) (1) and chassis ground tance
cuit)
Min. 1 Mz
(11) BP (female) (2) and chassis ground tance
Hot short (Short circuit with Wiring harness between EGC1 (female)
4 Voltage Max. 1 V
24V circuit) in wiring harness (31) - BP (female) (1) and chassis ground
Voltage Max. 1 V
(11) BP (female) (2) and chassis ground
Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Between (31) (11) 10 21 z
8 D155AX-6
Circuit diagram related to bypass valve solenoid & lift sensor
D155AX-6 9
Failure code [CA1627] BP Valve Sol Current Low Error 1

Action code Failure code BP Valve Sol Current Low Error
Trouble
Contents of
There is disconnection in drive circuit of bypass valve solenoid.
trouble
Problem that
machine
Related
information

and standard
state
10 D155AX-6
Failure code [CA1628] Bypass Valve Servo Error 1 1

Action code Failure code Bypass Valve Servo Error 1
Trouble
Contents of
Trouble (level 1) occurred in bypass valve servo.
trouble
Action of
Performs open control.
controller
Problem that
appears on
machine
Related Operating condition of bypass valve can be checked with monitoring function.
information (Code: 18200 BPS Valve Position)

a For check of engine oil pressure, see Testing and adjusting,
Measuring engine oil pressure.
Engine Engine oil pressure
2 Low idle 0.08 MPa {0.8 kg/cm2 }
system (main circuit)
High idle 0.21 MPa {2.1 kg/cm2 }
Possible causes If engine oil pressure is abnormal, carry out troubleshooting for "S
and standard 12 Oil pressure lowers" in S mode.
value in normal Defective oil pump for
state 3 Check oil pump and relief valve for bypass valve circuit directly.
bypass valve
Defective oil feed piping for
4 Check oil feed piping for bypass valve circuit directly.
bypass valve
Defective oil return piping for
5 Check oil return piping for bypass valve circuit directly.
bypass valve
6 Defective bypass valve Check mechanical section of bypass valve directly.
out.)
D155AX-6 11
Failure code [CA1619] Bypass Valve Servo Error 2 1

Action code Failure code Bypass Valve Servo Error 2
Trouble
Contents of
Trouble (level 2) occurred in bypass valve servo.
trouble
Problem that
machine
Related Operating condition of bypass valve can be checked with monitoring function.
information (Code: 18200 BPS Valve Position)

and standard
state
12 D155AX-6
Failure code [CA1631] BP Valve Pos Sens High Error 1

Action code Failure code BP Valve Pos Sens High Error
Trouble
Contents of
Signal voltage in bypass valve lift sensor circuit is abnormally high.
trouble
Problem that
machine
Related State of bypass valve lift sensor signal can be checked with monitoring function.
information (Code: 18201 BPS Valve Pos Sens Volt)

1
SBP Voltage
Defective bypass valve lift
Max. 1 z
ness (Disconnection in wiring (37) SBP (female) (1) tance
3
nector) Max. 1 z
(38) SBP (female) (2) tance
(29) SBP (female) (3), (4) tance
and standard
value in normal
state
Min. 1 Mz
Ground fault in wiring har- (37) SBP (female) (1) and chassis ground tance
4 ness (Contact with GND cir- Wiring harness between EGC1 (female) Resis-
cuit) Min. 1 Mz
(38) SBP (female) (2) and chassis ground tance
Resis-
(29) SBP (female) (3), (4) and chassis Min. 1 Mz
tance
ground
Resis-
(37) SBP (female) (1) and between EGC1 Min. 1 Mz
tance
Short circuit in wiring har- (female) (38) SBP (female) (2)
harness) Resis-
tance
(female) (29) SBP (female) (3), (4)
Resis-
tance
(female) (29) SBP (female) (3), (4)
14 D155AX-6

Possible causes Prepare with starting switch OFF, then turn starting switch ON or
and standard start engine and carry out troubleshooting.
value in normal 6 Defective engine controller
state EGC1 Voltage
Between (37) (38) 4.75 5.25 V
Circuit diagram related to bypass valve solenoid & lift sensor
D155AX-6 15
Failure code [CA1632] BP Valve Pos Sens Low Error 1

Action code Failure code BP Valve Pos Sens Low Error
Trouble
Contents of
Signal voltage in bypass valve lift sensor circuit is abnormally low.
trouble
Problem that
machine
Related State of bypass valve lift sensor signal can be checked with monitoring function.
information (Code: 18201 BPS Valve Pos Sens Volt)

and standard
state
16 D155AX-6
Failure code [CA1633] KOMNET Datalink Timeout Error 1

Action code Failure code KOMNET Datalink Timeout Error
Trouble
Contents of Trouble occurred in KOMNET (CAN) communication circuit between engine controller and machine
trouble monitor, power train controller, and work equipment controller.
Action of
Operates in default mode or maintains condition when abnormality occurs.
controller
Problem that
appears on
machine
Related
information

Disconnection in wiring har- Wiring harness between CM02 (female) (8),
Resis-
ness (Disconnection in wiring (9) EGC2 (female) (46), STC2 (female) Max. 1 z
1 tance
or defective contact in con- (32) or WEC2 (female) (32)
nector) Wiring harness between CM02 (female)
Resis-
(10) EGC2 (female) (47), STC2 (female) Max. 1 z
tance
(22) or WEC2 (female) (22)
Wiring harness between CM02 (female) (8),
(9) EGC2 (female) (46), STC2 (female)
Resis-
(32), WEC2 (female) (32), ACCN (female) Min. 1 Mz
Ground fault in wiring har- tance
(17), SRV (male) (3) or CA1 (female) (A)
and chassis ground
cuit)
Wiring harness between CM02 (female)
Resis-
Possible causes (22), WEC2 (female) (22), ACCN (female) Min. 1 Mz
tance
and standard (18), SRV (male) (10) or CA1 (female) (B)
value in normal and chassis ground
(32), WEC2 (female) (32), ACCN (female) Voltage Max. 1 V
Hot short (Contact with GND (17), SRV (male) (3) or CA1 (female) (A)
3
circuit) in wiring harness and chassis ground
(18), SRV (male) (10) or CA1 (female) (B)
and chassis ground
Prepare with starting switch OFF, then carry out troubleshooting
Defective CAN terminal without turning starting switch ON.
4 resistance (Internal discon-
CA1 (male) Resistance
nection or short circuit)
Between (A) (B) Approx. 120 z
out.)
18 D155AX-6
Circuit diagram related to CAN communication
D155AX-6 19
Failure code [CA1642] EGR Inlet Press Sens Low Error 1

Action code Failure code EGR Inlet Press Sens Low Error
Trouble
Contents of
Signal voltage in EGR inlet pressure sensor circuit is abnormally low.
trouble
Action of Sets EGR inlet pressure to default value (102 kPa {1.04 kg/cm2}) and continues operation.
controller Limits engine output and continues operation.
Problem that
machine
Related State of EGR valve inlet pressure sensor signal can be checked with monitoring function.
information (Code: 18001 EGR In Press Sens Volt)

and standard
state
20 D155AX-6
Failure code [CA1653] EGR Inlet Press Sens High Error 1

Action code Failure code EGR Inlet Press Sens High Error
Trouble
Contents of
Signal voltage in EGR inlet pressure sensor circuit is abnormally high.
trouble
Action of Sets EGR inlet pressure to default value (102 kPa {1.04 kg/cm2}) and continues operation.
controller Limits engine output and continues operation.
Problem that
machine
Related State of EGR valve inlet pressure sensor signal can be checked with monitoring function.
information (Code: 18001 EGR In Press Sens Volt)

1
PEVA Voltage
Defective EGR inlet pressure
Max. 1 z
ness (Disconnection in wiring (37) PEVA (female) (1) tance
3
nector) Max. 1 z
(47) PEVA (female) (2) tance
Max. 1 z
(20) PEVA (female) (3) tance
Possible causes
and standard
value in normal Wiring harness between EGC1 (female) (37) Resis-
state PEVA (female) (1) and chassis ground tance
Min. 1 Mz
PEVA (female) (2) and chassis ground tance
Min. 1 Mz
PEVA (female) (3) and chassis ground tance
Resis-
(37) PEVA (female) (1) and between Min. 1 Mz
tance
Short circuit in wiring har- EGC1 (female) (47) PEVA (female) (2)
harness) Resis-
tance
EGC1 (female) (20) PEVA (female) (3)
Resis-
tance
EGC1 (female) (20) PEVA (female) (3)
EGC1 Voltage
Between (37) (47) 4.75 5.25 V
22 D155AX-6
Circuit diagram related to EGR inlet pressure sensor
D155AX-6 23
Failure code [CA2185] Throt Sens Sup Volt High Error 1

Action code Failure code Throt Sens Sup Volt High Error
Trouble
Contents of
Signal voltage in throttle sensor power supply (5 V) circuit is abnormally high.
trouble
Action of
Sets throttle position with signal of fuel control dial and continues operation.
controller
Problem that
appears on
machine
Related
information

Disconnect devices
Defective fuel control dial at right in order. If
(Internal trouble) Decelerator pedal
disappears when a DCL connector
potentiometer
device is discon-
nected, that device
has trouble in it.
2 Max. 1 z
or defective contact in con- (22) DCL (female) (B) tance
Possible causes
Max. 1 z
and standard (23) DCL (female) (C) tance
(22) DCL (female) (B) and chassis ground tance
cuit)
Min. 1 Mz
(23) DCL (female) (C) and chassis ground tance
harness) Resis-
(22) DCL (female) (B) and between EGC2 Min. 1 Mz
tance
(female) (23) DCL (female) (C)
EGC2 Voltage
Between (22) (23) 4.75 5.25 V
24 D155AX-6
Circuit diagram related to throttle sensor power supply of engine controller
D155AX-6 25
Failure code [CA2186] Throt Sens Sup Volt Low Error 1

Action code Failure code Throt Sens Sup Volt Low Error
Trouble
Contents of
Signal voltage in throttle sensor power supply (5 V) circuit of engine controller is abnormally low.
trouble
Action of
Sets throttle position with signal of fuel control dial and continues operation.
controller
Problem that
appears on
machine
Related
information

and standard
state
Failure code [CA2249] Rail Press Very Low Error 1

Action code Failure code Rail Press Very Low Error
Trouble
Contents of
Very low pressure error (level 2) occurred in supply pump.
trouble
Action of
Limits common rail pressure.
controller
Problem that
machine
Related
information

and standard
state
26 D155AX-6
Failure code [CA2271] EGR Valve Pos Sens High Error 1

Action code Failure code EGR Valve Pos Sens High Error
Trouble
Contents of
Signal voltage in EGR valve lift sensor circuit is abnormally high.
trouble
Problem that
machine
Related State of EGR valve lift sensor signal can be checked with monitoring function.
information (Code: 18101 EGR Valve Pos Sens Volt)

1
ply for it first.
SEGR Voltage
Defective EGR valve lift sen-
sor (Internal trouble)

Max. 1 z
ness (Disconnection in wiring (37) SEGR (female) (1) tance
3
nector) Max. 1 z
(47) SEGR (female) (2) tance
Max. 1 z
(19) SEGR (female) (3), (4) tance
value in normal Wiring harness between EGC1 (female)
state Resis-
(37) SEGR (female) (1) and chassis Min. 1 Mz
ground tance
4 ness (Contact with GND cir- Wiring harness between EGC1 (female)
cuit) Resis-
(47) SEGR (female) (2) and chassis Min. 1 Mz
ground tance

Resis-
(19) SEGR (female) (3), (4) and chassis Min. 1 Mz
tance
ground
Resis-
(37) SEGR (female) (1) and between Min. 1 Mz
tance
EGC1 (female) (47) SEGR (female) (2)
Short circuit in wiring har- Wiring harness between EGC1 (female)
5 ness (with another wiring (37) SEGR (female) (1) and between Resis-
harness) Min. 1 Mz
EGC1 (female) (19) SEGR (female) (3), tance
(4)
(47) SEGR (female) (2) and between Resis-
Min. 1 Mz
EGC1 (female) (19) SEGR (female) (3), tance
(4)
28 D155AX-6

and standard or start engine and carry out troubleshooting.
value in normal 6 Defective engine controller
state EGC1 Voltage
Between (37) (47) 4.75 5.25 V
Circuit diagram related to EGR valve solenoid & lift sensor
D155AX-6 29
Failure code [CA2272] EGR Valve Pos Sens Low Error 1

Action code Failure code EGR Valve Pos Sens Low Error
Trouble
Contents of
Signal voltage in EGR valve lift sensor circuit is abnormally low.
trouble
Problem that
machine
Related State of EGR valve lift sensor signal can be checked with monitoring function.
information (Code: 18101 EGR Valve Pos Sens Volt)

and standard
state
30 D155AX-6
Failure code [CA2351] EGR Valve Sol Current High Error 1

Action code Failure code EGR Valve Sol Current High Error
Trouble
Contents of
There is short circuit in EGR valve solenoid drive circuit.
trouble
Problem that
machine
Related
information

Defective EGR valve sole- ing without turning starting switch ON.
1
noid (Internal trouble) EGR (male) Resistance
Between (1) (2) 10 21 z
2 Max. 1 z
or defective contact in con- (22) EGR (female) (1) tance
Max. 1 z
(11) EGR (female) (2) tance
Possible causes Wiring harness between EGC1 (female)

and standard (22) EGR (female) (1) and chassis Min. 1 Mz
value in normal ground
cuit)
state Wiring harness between EGC1 (female)
Resis-
(11) EGR (female) (2) and chassis Min. 1 Mz
tance
ground
Hot short (Short circuit with (22) EGR (female) (1) and chassis Voltage Max. 1 V
4
24V circuit) in wiring harness ground
(11) EGR (female) (2) and chassis Voltage Max. 1 V
ground
Between (22) (11) 10 21 z
32 D155AX-6
Circuit diagram related to EGR valve solenoid & lift sensor
D155AX-6 33
Failure code [CA2352] EGR Valve Sol Current Low Error 1

Action code Failure code EGR Valve Sol Current Low Error
Trouble
Contents of
There is disconnection in EGR valve solenoid drive circuit.
trouble
Problem that
machine
Related
information

and standard
value in normal Carry out troubleshooting failure code [CA2351].
state
34 D155AX-6
Failure code [CA2555] Grid Htr Relay Volt Low Error 1

Action code Failure code Grid Htr Relay Volt Low Error
Trouble
Contents of
There is disconnection in intake air heater relay circuit.
trouble
Action of
None in particular.
controller
Problem that
appears on Engine does not start easily at low temperature.
machine
Related Engine coolant temperature can be checked with monitoring function.
information (Code: 04107 Coolant Temperature)

and standard
value in normal Carry out troubleshooting failure code [CA2556].
state
D155AX-6 35
Failure code [CA2556] Grid Htr Relay Volt High Error 1

Action code Failure code Grid Htr Relay Volt High Error
Trouble
Contents of
There is short circuit in intake air heater relay.
trouble
Action of
None in particular.
controller
Problem that
appears on Engine does not start easily at low temperature.
machine
Engine controller has automatic preheating function, which is turned ON when engine coolant tem-
Related perature is below -5 C (for up to 30 seconds).
information Engine coolant temperature can be checked with monitoring function.

Defective intake air heater ing without turning starting switch ON.
1
relay (Internal trouble) PHR (male) Resistance
Between (1) (2) 200 400 z
2 Max. 1 z
Possible causes or defective contact in con- (40) PHR (female) (1) tance
and standard nector) Wiring harness between PHR (female) (2) Resis-
Max. 1 z
value in normal chassis ground (GND03) tance
Min. 1 Mz
(40) PHR (female) (1) and chassis ground tance
4 Defective engine controller EGC2 Coolant temperature Voltage
Between (40) chas- -5 C or higher Max. 1 V
sis ground Below -5 C 20 30 V
36 D155AX-6
Circuit diagram related to preheating/starting/charging of engine
D155AX-6 37
Failure code [D110KA] Battery relay: Disconnection 1

Action code Failure code Battery relay: Disconnection
Trouble
D110KA (Power train controller system)
Contents of
Turns signal to battery relay holding circuit, no current flows.
trouble
Action of
Turns signal to battery relay holding circuit OFF.
controller
Problem that
appears on Problem may occur in writing data into ROM (non-volatile memory) of each controller.
machine
tate of battery relay holding circuit signal can be checked with monitoring function.
Related
(Code: 60600 BR Hold Relay)
information
Method of reproducing failure code: Turn starting switch ON o OFF.

Defective battery relay (Inter- ing without turning starting switch ON.
1
nal disconnection) Battery relay Continuity
Between terminals SW BRE There is continuity
2 Max. 1 z
or defective contact in con- terminal SW tance
Possible causes nector)
and standard Wiring harness between terminal BRE and Resis-
Max. 1 z
value in normal chassis ground tance
Hot short (Short circuit with
3
24V circuit) in wiring harness Wiring harness between STC3 (female) (4)
terminal SW, terminal 260, terminal AL/R Voltage Max. 1 V
or circuit branch end and chassis ground
4 STC3 Starting switch Voltage
troller
Between (4) chas-
OFF Max. 1 V
sis ground
38 D155AX-6
Circuit diagram related to driving of battery relay
D155AX-6 39
Failure code [D110KB] Battery Relay: Drive Short Circuit 1

Action code Failure code Battery Relay: Drive Short Circuit
Trouble
D110KB (Power train controller system)
Contents of
When signal was output to battery relay circuit, abnormal current flowed.
trouble
Action of
Turns signal to battery relay holding circuit OFF.
controller
Problem that
appears on Problem may occur in writing data into ROM (non-volatile memory) of each controller.
machine
State of battery relay holding circuit signal can be checked with monitoring function.
Related
(Code: 60600 BR Hold Relay)
information
Method of reproducing failure code: Turn starting switch ON o OFF.

Defective battery relay (Inter- Battery relay Continuity/Resistance
1
nal short circuit) Between terminals SW BRE There is continuity
Between terminal SW chassis
Min. 1 Mz
ground
Possible causes
and standard a Prepare with starting switch OFF, then carry out troubleshoot-
value in normal Ground fault in wiring har- ing without turning starting switch ON.
state 2 ness (Contact with GND cir- Wiring harness between STC3 (female) (4)
cuit) Resis-
terminal SW, terminal 260 or RSD Min. 1 Mz
tance
(female) (1) and chassis ground
3 STC3 Starting switch Voltage
troller
Between (4) chas-
ON 20 30 V
sis ground
40 D155AX-6
Circuit diagram related to driving of battery relay
D155AX-6 41
Failure code [D130KA] Neutral relay: Disconnection 1

Action code Failure code Neutral relay: Disconnection
Trouble
E02 D130KA (Power train controller system)
Contents of
When ground circuit of neutral safety relay circuit is disconnected, no current flows.
trouble
Action of
Turns output of neutral safety relay circuit OFF.
controller
Problem that
appears on Engine cannot be started.
machine
State of neutral safety relay circuit signal can be checked with monitoring function.
(Code: 59099 T/M Lock Relay)
Related
Method of reproducing failure code: Turn starting switch ON + Operate parking brake lever (Free).
information
This failure code detects abnormality on primary side (coil side) of neutral safety relay but does not

1 Defective fuse (FS2-5) If fuse is broken, circuit probably has ground fault (See cause 4).
Defective neutral safety relay ing without turning starting switch ON.
2
(Internal disconnection) NSF (male) Resistance
Between (1) (2) 300 600 z
3 Max. 1 z
or defective contact in con- NSF (female) (2) tance
Possible causes nector) Wiring harness between NSF (female) (1) Resis-
Max. 1 z
and standard FS21 (5) tance
Ground fault in wiring har- Wiring harness between STC2 (female) (8) Resis-
Min. 1 Mz
4 ness (Contact with GND cir- NSF (female) (2) and chassis ground tance
cuit) Wiring harness between NSF (female) (1)
Resis-
FS21 (5) or circuit branch end and chassis Min. 1 Mz
tance
ground
Defective power train con- STC2 Parking brake lever Voltage
5
troller
Between (8) chas- Lock Max. 1 V
sis ground Free 20 30 V
42 D155AX-6
Circuit diagram related to neutral safety relay
D155AX-6 43
Failure code [D130KB] Neutral relay: Short circuit 1

Action code Failure code Neutral relay: Short circuit
Trouble
E02 D130KB (Power train controller system)
Contents of
When ground circuit of neutral safety relay was disconnected, abnormal current flowed.
trouble
Action of
Turns output of neutral safety relay circuit OFF.
controller
Problem that
appears on Engine cannot be started.
machine
State of neutral safety relay circuit signal can be checked with monitoring function.
(Code: 59099 T/M Lock Relay)
Related
information
This failure code detects abnormality on primary side (coil side) of neutral safety relay but does not

Defective neutral safety relay ing without turning starting switch ON.
1
(Internal short circuit) NSF (male) Resistance
Between (1) (2) 300 600 z
and standard Hot short (Short circuit with and carry out troubleshooting.
2
value in normal 24V circuit) in wiring harness Wiring harness between STC2 (female) (8)
state Voltage Max. 1 V
NSF (female) (2) and chassis ground
Defective power train con- STC2 Parking brake lever Voltage
3
troller
Between (8) chas- Lock Max. 1 V
sis ground Free 20 30 V
44 D155AX-6
Circuit diagram related to neutral safety relay
D155AX-6 45
Failure code [D161KA] Back-up alarm relay: Disconnection 1

Action code Failure code Back-up alarm relay: Disconnection
Trouble
E01 D161KA (Power train controller system)
Contents of
When ground circuit of back-up alarm relay circuit is disconnected, no current flows.
trouble
Action of
Turns output of back-up alarm relay circuit OFF.
controller
Problem that
appears on Back-up alarm does not sound
machine
State of back-up alarm relay circuit signal can be checked with monitoring function.
(Code: 70400 Back Alarm Relay)
Related
Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (R: Reverse).
information
This failure code detects abnormality on primary side (coil side) of back-up alarm relay but does not

Defective back-up alarm ing without turning starting switch ON.
2
relay (Internal disconnection) BKA (male) Resistance
Between (1) (2) 300 600 z
3 Max. 1 z
or defective contact in con- BKA (female) (2) tance
nector) Wiring harness between BKA (female) (1) Resis-
FS12 (2) tance
and standard
Ground fault in wiring har- Wiring harness between STC2 (female) (18)
Resis-
4 ness (Contact with GND cir- BKA (female) (2) or circuit branch end and Min. 1 Mz
tance
cuit) chassis ground
Wiring harness between BKA (female) (1), Resis-
Min. 1 Mz
(3) FS12 (2) and chassis ground tance
5 STC2 Voltage
troller (Directional)
sis ground R (Reverse) Max. 1 V
46 D155AX-6
Circuit diagram related to back-up alarm relay
D155AX-6 47
Failure code [D161KB] Back-up alarm relay: Short circuit 1

Action code Failure code Back-up alarm relay: Short circuit
Trouble
E01 D161KB (Power train controller system)
Contents of
When ground circuit of back-up alarm relay was disconnected, abnormal current flowed.
trouble
Action of
Turns output of back-up alarm relay circuit OFF.
controller
Problem that
appears on Back-up alarm does not sound.
machine
State of back-up alarm relay circuit signal can be checked with monitoring function.
(Code: 70400 Back Alarm Relay)
Related
Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (R: Reverse)
information
This failure code detects abnormality on primary side (coil side) of back-up alarm relay but does not

Defective back-up alarm ing without turning starting switch ON.
1
relay (Internal short circuit) BKA (male) Resistance
Between (1) (2) 300 600 z
Possible causes and carry out troubleshooting.
and standard 2
value in normal BKA (female) (2) or circuit branch end and Voltage Max. 1 V
state chassis ground
3 STC2 Voltage
troller (Directional)
sis ground R (Reverse) Max. 1 V
48 D155AX-6
Circuit diagram related to back-up alarm relay
D155AX-6 49
Failure code [D190KA] ACC signal relay: Disconnection 1

Action code Failure code ACC signal relay: Disconnection
Trouble
D190KA (Power train controller system)
Contents of
When ground circuit of ACC signal drive relay circuit is disconnected, no current flows.
trouble
Action of
Turns signal to ACC signal drive relay circuit OFF.
controller
Problem that
Turbo-timer function does not operate (if turbo-timer is installed).
appears on
Machine is not affected particularly (if turbo-timer is not installed).
machine
State of ACC signal drive relay circuit signal can be checked with monitoring function.
(Code: 60500 ENG Hold Relay)
Related
Method of reproducing failure code: Turn starting switch ON o OFF (if turbo-timer is installed).
information
This failure code detects abnormality on primary side (coil side) of ACC signal drive relay but does
not detect abnormality on secondary side (contact side).

Defective ACC signal drive ing without turning starting switch ON.
1
relay (Internal disconnection) EHL (male) Resistance
Between (1) (2) 200 400 z
or defective contact in con- EHL (female) (2) tance
value in normal Wiring harness between EHL (female) (1) Resis-
Max. 1 z
state branch point (J) tance
Hot short (Short circuit with and carry out troubleshooting.
3
Voltage Max. 1 V
EHL (female) (2) and chassis ground
Defective power train con- ing without turning starting switch ON.
4
troller STC2 (female) Resistance
Between (9) chassis ground 200 400 z
50 D155AX-6
Circuit diagram related to ACC signal drive relay
D155AX-6 51
Failure code [D190KB] ACC signal relay: Short circuit 1

Action code Failure code ACC signal relay: Short circuit
Trouble
D190KB (Power train controller system)
Contents of
When ground circuit of ACC signal drive relay was disconnected, abnormal current flowed.
trouble
Action of
Turns output of ACC signal drive relay circuit OFF.
controller
Problem that
Turbo-timer function does not operate (if turbo-timer is installed).
appears on
Machine is not affected particularly (if turbo-timer is not installed).
machine
State of ACC signal drive relay circuit signal can be checked with monitoring function.
(Code: 60500 ENG Hold Relay)
Related
Method of reproducing failure code: Turn starting switch ON o OFF (if turbo-timer is installed).
information
This failure code detects abnormality on primary side (coil side) of ACC signal drive relay but does
not detect abnormality on secondary side (contact side).

Defective ACC signal drive ing without turning starting switch ON.
1
relay (Short circuit) EHL (male) Resistance
Between (1) (2) 200 400 z
Possible causes
and standard Ground fault in wiring har- ing without turning starting switch ON.
value in normal 2 ness (Contact with GND cir-
state cuit) Wiring harness between STC2 (female) (9) Resis-
1 Mz
EHL (female) (2) and chassis ground tance
3
Between (9) chassis ground 200 400 z
52 D155AX-6
Circuit diagram related to ACC signal drive relay
D155AX-6 53
Failure code [D5ZKKX] Throttle Dial: Out of normal range 1

Action code Failure code Throttle Dial: Out of normal range
Trouble
E03 D5ZKKX (Power train controller system)
Contents of
Signal voltage of fuel control dial is below 0.30 V or above 4.55 V.
trouble
Action of Continues control with decelerator pedal potentiometer signal.
controller Limits operation of engine and transmission.
Problem that
appears on
machine
State of fuel control dial can be checked with monitoring function.
Related
(Code: 03000 Fuel Dial Sensor)
information
Method of reproducing failure code: Turn starting switch ON.

Defective sensor 5V power If failure code [DBE7KK] is also displayed, carry out troubleshoot-
1
supply system ing for it first.
Defective fuel control dial DIAL (male) Resistance
2 (Internal disconnection or
Between (1) (3) 4.0 6.0 kz
short circuit)
Between (1) (2) 0.25 7.0 kz
Between (2) (3) 0.25 7.0 kz
or defective contact in con- DIAL (female) (1) tance
and standard
nector) Wiring harness between STC1 (female) (1) Resis-
state DIAL (female) (2) tance
cuit) Wiring harness between STC1 (female) (1) Resis-
Min. 1 Mz
DIAL (female) (2) and chassis ground tance
Hot short (Contact with GND and carry out troubleshooting.
5
circuit) in wiring harness Wiring harness between STC1 (female) (1)
Voltage Max. 1 V
DIAL (female) (2) and chassis ground
6
Between (1) (21) 0.30 4.33 V
54 D155AX-6
Circuit diagram related to fuel control dial
D155AX-6 55
Failure code [DAFRKR] CAN Disconnection (Monitor) 1

Action code Failure code CAN Disconnection (Monitor)
Trouble
E03 DAFRKR (Machine monitor system)
Contents of Machine monitor cannot recognize engine controller, power train controller, or work equipment con-
trouble troller in CAN communication circuit.
Action of
controller
Problem that System may not operate normally.
Related
information

Resis-
1 tance
Resis-
tance
Resis-
and chassis ground
cuit)
Resis-
Possible causes tance
and standard and chassis ground
value in normal
Hot short (Short circuit with (17), SRV (male) (3) or CA1 (female) (A)
3
24V circuit) in wiring harness and chassis ground
and chassis ground
Defective CAN terminal ing without turning starting switch ON.
If causes 1 4 are not detected, machine monitor, engine control-
Defective machine monitor ler, power train controller or work equipment controller may be
5
or controller defective. (Since trouble is in system, troubleshooting cannot be
carried out.)
56 D155AX-6
D155AX-6 57
Failure code [DB2RKR] CAN Disconnection (Engine controller) 1

Action code Failure code CAN Disconnection (Engine controller)
Trouble
E03 DB2RKR (Power train controller system)
Contents of
Power train controller cannot recognize engine controller in CAN communication circuit.
trouble
Action of
controller
Related
information

Resis-
1 tance
Resis-
tance
Resis-
and chassis ground
cuit)
Resis-
Possible causes (22), WEC2 (female) (22), ACCN (female) Min. 1 Mz
tance
and standard (18), SRV (male) (10) or CA1 (female) (B)
value in normal and chassis ground
3
and chassis ground
If causes 1 4 are not detected, engine controller or power train
Defective engine controller
5 controller may be defective. (Since trouble is in system, trouble-
or power train controller
shooting cannot be carried out.)
58 D155AX-6
D155AX-6 59
Failure code [DB90KK] WE controller: Source voltage reduction 1

Action code Failure code WE controller: Source voltage reduction
Trouble
E04 DB90KK (Work equipment controller system)
Contents of
Source voltage of work equipment controller is below 17 V.
trouble
Action of
controller
Machine monitor may not display normally.
Problem that
Relays and solenoids may not be driven and system may not operate normally.
appears on
machine
Once machine is stopped, it cannot travel at all.
Related Source voltage of work equipment controller can be checked with adjusting function. (Code: 2022)
information Method of reproducing failure code: Turn starting switch ON.

1
(CB2, CB7, CB30 or CB105) (See cause 3).
Wiring harness between WEC3 (female) (1), Resis-
Max. 1 z
(11) CB7 (2) tance
Wiring harness between CB7 (1) CB30 Resis-
Max. 1 z
(B30S) tance
Disconnection in wiring har- minal BRB Max. 1 z
tance
2
or defective contact in con- Wiring harness between WEC3 (female) (2), Resis-
Max. 1 z
nector) (12), (22) CB2 (2) tance
Max. 1 z
(B105S) tance
Wiring harness between CB105 (B105L) Resis-
Max. 1 z
terminal BRC tance
Possible causes Wiring harness between WEC3 (female)
and standard Resis-
(21), (31), (32), (33) chassis ground Max. 1 z
value in normal tance
(GND11)
state
Wiring harness between WEC3 (female) (1),
Resis-
(11) CB7 (2) or circuit branch end and Min. 1 Mz
tance
chassis ground
Resis-
tance
ground
cuit)
Wiring harness between WEC3 (female) (2),
Resis-
(12), (22) CB2 (2) or WEPW (female) (A) Min. 1 Mz
tance
and chassis ground
Resis-
tance
ground
Min. 1 Mz
terminal BRC and chassis ground tance
60 D155AX-6

Possible causes
WEC3 Starting switch Voltage
and standard
value in normal Defective work equipment Between (1), (11)
4 OFF 20 30 V
state controller (21), (31), (32), (33)
Between (2), (12),
20 30 V
(22) (21), (31), (32), ON
(33)
Circuit diagram related to work equipment controller power supply
D155AX-6 61
Failure code [DB90KR] PT controller: Can communication lost 1

Action code Failure code PT controller: Can communication lost
Trouble
E03 DB90KR (Power train controller system)
Contents of Power train controller cannot recognize machine monitor, engine controller or work equipment con-
Action of
controller
Related
information

Resis-
1 tance
Resis-
tance
Resis-
and chassis ground
cuit)
Resis-
value in normal
3
and chassis ground
5
carried out.)
62 D155AX-6
D155AX-6 63
D155AX-6 Bulldozer
2006 KOMATSU
All Rights Reserved
64 D155AX-6
SEN00719-01
D155AX-6

D155AX-6 80001 and up
codes, Part 4
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 [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
D155AX-6 1
Failure code [DD13KB] Shift down Sw: Short circuit.......................................................................... 28

Failure code [DD14KA] Parking lever Sw: Disconnection .................................................................. 30
Failure code [DD14KB] Parking lever Sw: Short circuit...................................................................... 32
Failure code [DDDDKA] Back up brake Sw: Disconnection............................................................... 34
Failure code [DDDDKB] Back up brake Sw: Short circuit .................................................................. 36
Failure code [DDDDKX] Back up brake Sw: Signal mismatch ........................................................... 38
Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection ........................................................ 40
Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit ............................................................ 42
Failure code [DDN9KA] WEQ Knob Sw (up): Disconnection ............................................................. 44
Failure code [DDN9KB] WEQ Knob Sw (up): Short circuit................................................................. 46
Failure code [DDNLKA] Weq lock Sw: Disconnection........................................................................ 48
Failure code [DDNLKB] Weq lock Sw: Short circuit ........................................................................... 50
Failure code [DDTSL1] S/C: Fill high ................................................................................................. 52
Failure code [DDTSLH] S/C: Fill low .................................................................................................. 54
2 D155AX-6

Failure code [DB90KT] WE controller: Abnormality in controller 1
Action code Failure code WE controller: Abnormality in controller
Trouble
E01 DB90KT (Work equipment controller system)
Contents of
Information in ROM (non-volatile memory) of work equipment controller is abnormal.
trouble
Action of
Sets internal adjustment values to default values.
controller
Problem that
Operating feel of work equipment may become bad.
appears on
machine Adjusting function of machine monitor may not operate normally.
Related
information

Turn Adjustment function in service mode ON and perform opera-
tion of reproducing trouble. If "E" of failure code disappears at this
Possible causes Defective adjustment of work
1 time, system is normal.
and standard equipment controller
Adjustment code: 0031
value in normal
(Initialization of work equipment controller)
state
Troubleshooting cannot be carried out since defect is in work
Defective work equipment
2 equipment controller. (If there is not any visible trouble in machine,
controller
controller may be used as it is.)
D155AX-6 3

Trouble
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.
Related
information

Disconnect devices
Defective work equipment at right in order. If
1 pump oil pressure sensor "E" of failure code Work equipment
(Internal trouble) disappears when a pump oil pressure Connector HHP
device is discon- sensor
nected, that device
has trouble in it.
cuit) Wiring harness between WEC3 (female) Resis-
state Min. 1 Mz
(34) HHP (female) (B) and chassis ground tance
3
24V circuit) in wiring harness Wiring harness between WEC3 (female)
Voltage Max. 1 V
(34) HHP (female) (B) and chassis ground
4 WEC1, WEC3 Voltage
controller
Between WEC3 (34)
4.5 5.5 V
WEC1 (21)
4 D155AX-6
Circuit diagram related to work equipment controller 5V sensor power supply
D155AX-6 5

Trouble
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.
Related
information

a Prepare with starting switch OFF, then turn starting switch
ON and carry out troubleshooting.
Disconnect devices
Defective blade control lever at right in order.If "E" Blade control lever Connector WLV1
1 or ripper control lever (Inter- of failure code disap-
nal trouble) pears when a device
is disconnected, that Ripper control
device has trouble in Connector WLV2
lever
it.
a Prepare with starting switch OFF, then carry out trouble-
shooting without turning starting switch ON.
Wiring harness between WEC1 (female)
(22) WLV1 (female) (4), (8) and chassis Min. 1 Mz
Possible causes 2 ness (Contact with GND cir- tance
ground [Blade control lever system]
and standard cuit)
value in normal Wiring harness between WEC1 (female)
Resis-
state (22) WLV2 (female) (4), (8) and chassis Min. 1 Mz
tance
ground [Ripper control lever system]
Hot short (Short circuit with (22) WLV1 (female) (4), (8) and chassis Voltage Max. 1 V
3
24V circuit) in wiring harness ground [Blade control lever system]
(22) WLV2 (female) (4), (8) and chassis Voltage Max. 1 V
ground [Ripper control lever system]
Defective work equipment ON and carry out troubleshooting.
4
controller WEC1 Voltage
Between WEC1(22) (21) 4.5 5.5 V
6 D155AX-6
Circuit diagram related to work equipment controller 5V sensor power supply
D155AX-6 7
Failure code [DB99KQ] WE controller: Type select signal 1

Action code Failure code WE controller: Type select signal
Trouble
E04 DB99KQ (Work equipment controller system)
Contents of Specification setting in work equipment controller does not match to specification setting signal
trouble (Work equipment controller cannot be recognized).
Action of Turns all outputs of work equipment controller OFF.
Problem that Machine does not move at all.
machine Once machine is stopped, it cannot travel at all.
Related
information

Turn Adjustment function in service mode ON and perform
operation of reproducing trouble. If "E" of failure code disap-
Defective adjustment of work
1 pears at this time, system is normal.
equipment controller
Adjustment code: 0031
(Initialization of work equipment controller)
Possible causes Disconnection in wiring har- a Prepare with starting switch OFF, then carry out trouble-
and standard ness (Disconnection in wiring shooting without turning starting switch ON.
value in normal 2
or defective contact in con- Wiring harness between WEC3 (female) Resis-
state nector) Max. 1 z
3 WEC3 Voltage
controller
Wiring harness between (30) chassis
Max. 1 V
ground
Circuit diagram related to work equipment controller type select power supply
8 D155AX-6
Failure code [DB9RKR] WE controller: Can communication lost 1

Action code Failure code WE controller: Can communication lost
Trouble
E03 DB9RKR (Work equipment controller system)
Contents of Work equipment controller cannot recognize machine monitor, engine controller or power train con-
Action of
controller
Related
information

Resis-
1 tance
Resis-
tance
Resis-
(17), SRV(male) (3) or CA1 (female) (A) and
chassis ground
cuit)
Resis-
value in normal
3
and chassis ground
5
carried out.)
10 D155AX-6
D155AX-6 11
Failure code [DBE0KK] PT controller: Source voltage reduction 1

Action code Failure code PT controller: Source voltage reduction
Trouble
E03 DBE0KK (Power train controller system)
Contents of
Source voltage of work equipment controller is below 17 V.
trouble
Action of
controller
Machine monitor may not display normally.
Problem that
Relays and solenoids may not be driven and system may not operate normally.
appears on
machine Once machine is stopped, engine speed is limited to medium (half).
Related Source voltage of power train controller can be checked with adjusting function. (Code: 2121)
information Method of reproducing failure code: Turn starting switch ON.

1
(CB1, CB7, CB30 or CB105) (See cause 3).
Wiring harness between STC3 (female) (1), Resis-
Max. 1 z
(11) CB7 (2) tance
Max. 1 z
(B30S) tance
Disconnection in wiring har- minal BRB Max. 1 z
tance
2
or defective contact in con- Wiring harness between STC3 (female) (2), Resis-
Max. 1 z
nector) (12), (22) CB1 (2) tance
Max. 1 z
(B105S) tance
Max. 1 z
terminal BRC tance
Possible causes Wiring harness between STC3 (female)
and standard Resis-
(21), (31), (32), (33) chassis ground Max. 1 z
(GND11)
state
Wiring harness between STC3 (female) (1),
Resis-
(11) CB7 (2) or circuit branch end and Min. 1 Mz
tance
chassis ground
Resis-
tance
ground
cuit)
Wiring harness between STC3 (female) (2),
Resis-
(12), (22) CB1 (2) or PL1 (female) (68) Min. 1 Mz
tance
and chassis ground
Resis-
tance
ground
Min. 1 Mz
terminal BRC and chassis ground tance
12 D155AX-6

Possible causes
STC3 Starting switch Voltage
and standard
value in normal Defective power train con- Between (1), (11)
4 OFF 20 30 V
state troller (21), (31), (32), (33)
Between (2), (12),
(22) (21), (31), (32), ON 20 30 V
(33)
Circuit diagram related to power train controller power supply
D155AX-6 13
Failure code [DBE0KT] PT controller: Abnormality in controller 1

Action code Failure code PT controller: Abnormality in controller
Trouble
E01 DBE0KT (Power train controller system)
Contents of
Information in ROM (non-volatile memory) of power train controller is abnormal.
trouble
Action of
Sets internal adjustment values to default values.
controller
Problem that
Shifting feel of transmission may become bad.
appears on
machine Adjusting function may not operate normally.
Related
information

Possible causes Defective adjustment of tion of reproducing trouble. If "E" of failure code disappears at this
1
and standard power train controller time, system is normal.
value in normal Adjustment code: 0002 (Initialization of power train controller)
state
Troubleshooting cannot be carried out since defect is in power train
2 controller. (If there is not any visible trouble in machine, controller
troller
may be used as it is.)
14 D155AX-6

Trouble
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.
Related
information

Disconnect devices Pitch angle sensor Connector PT1
Defective pitch angle sensor at right in order. If
1 or torque converter pressure "E" of failure code Torque converter
Connector TIP
sensor (Internal trouble) disappears when a inlet pressure sensor
device is discon-
nected, that device Torque converter out-
Connector TOP
has trouble in it. let pressure sensor

and standard Wiring harness between STC1 (female) (16)
value in normal Resis-
PT1 (female) (C) [Pitch angle sensor sys- Min. 1 Mz
state tance
Ground fault in wiring har- tem]
2 ness (Contact with GND cir- Wiring harness between STC1 (female) (16)
cuit) Resis-
PIT (female) (B) [Torque converter inlet Min. 1 Mz
tance
pressure sensor system]
Wiring harness between STC1 (female) (16)
Resis-
TOP (female) (B) [Torque converter outlet Min. 1 Mz
tance
pressure sensor system]
3
Between (16) (21) 20 30 V
16 D155AX-6
Circuit diagram related to power train controller 24V sensor power supply
D155AX-6 17

Trouble
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.
Related
information

Disconnect devices Brake pedal
Defective brake pedal poten- at right in order. If Connector BRK
potentiometer
1 tiometer, fuel control dial or "E" of failure code
PCCS lever (Internal trouble) disappears when a
Fuel control dial Connector DIAL
device is discon-
nected, that device
PCCS lever Connector TLV1
has trouble in it.
Resis-
BRK (female) (C) and chassis ground Min. 1 Mz
tance
Ground fault in wiring har- [Brake pedal potentiometer system]
2 ness (Contact with GND cir- Wiring harness between STC1 (female) (22)
cuit) Resis-
DIAL (female) (1) and chassis ground Min. 1 Mz
[Fuel control dial system]
and standard
value in normal Wiring harness between STC1 (female) (22)
Resis-
state TLV1 (female) (4), (5) and chassis ground Min. 1 Mz
tance
[PCCS lever system]
BRK (female) (C) and chassis ground Voltage Max. 1 V
[Brake pedal potentiometer system]
3
DIAL (female) (1) and chassis ground Voltage Max. 1 V
[Fuel control dial system]
TLV1 (female) (4), (5) and chassis ground Voltage Max. 1 V
[PCCS lever system]
4
Between (22) (21) 4.5 5.5 V
18 D155AX-6
Circuit diagram related to power train controller 5V sensor power supply
D155AX-6 19
Failure code [DBE9KQ] PT controller: Type select signal 1

Action code Failure code PT controller: Type select signal
Trouble
E04 DBE9KQ (Power train controller system)
Contents of Specification setting in power train controller does not match to specification setting signal
trouble (Power train controller cannot be recognized).
Action of Turns all outputs of power train controller OFF.
Problem that Machine does not move at all.
Related
information

Defective adjustment of tion of reproducing trouble. If "E" of failure code disappears at this
1
power train controller time, system is normal.
Adjustment code: 0002 (Initialization of power train controller)
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
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
Failure code [DD12KA] Shift up Sw: Disconnection 1

Action code Failure code Shift up Sw: Disconnection
Trouble
E02 DD12KA (Power train controller system)
Contents of
Signals of 2 systems of shift-up switch circuit are turned OFF (opened) simultaneously.
trouble
Action of
Recognizes that shift-up switch is not pressed.
controller
Problem that
Transmission gear cannot be shifted up.
appears on
machine Auto shift-down function does not operate.
"NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error.
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.

Shift-up switch
SFTU (male)
Defective shift-up switch OFF (Released) ON (Pressed)
1
(Internal disconnection) Resistance between
Max. 1 z Min. 1 Mz
(3) (2)
Resistance between
Min. 1 Mz Max. 1 z
(1) (2)
Disconnection in wiring har- Wiring harness between STC3 (female) (9) Resis-
Max. 1 z
ness (Disconnection in wiring SFTU (female) (1) tance
2
nector) Max. 1 z
Possible causes SFTU (female) (2) tance
and standard Wiring harness between STC1 (female) (12) Resis-
SFTU (female) (3) tance
state
Hot short (Short circuit with Wiring harness between STC3 (female) (9)
3 Voltage Max. 1 V
24V circuit) in wiring harness SFTU (female) (1) and chassis ground
Voltage Max. 1 V
SFTU (female) (3) and chassis ground
Shift-up switch
STC1 ,STC3
OFF (Released) ON (Pressed)
4 Voltage between
troller
STC1 (12) STC1 Max. 1 V 5 11 V
(4)
Voltage between
5 11 V Max. 1 V
STC3 (9) STC1 (4)
22 D155AX-6
Circuit diagram related to shift-up switch & shift-down switch
D155AX-6 23
Failure code [DD12KB] Shift up Sw: Short circuit 1

Action code Failure code Shift up Sw: Short circuit
Trouble
E02 DD12KB (Power train controller system)
Contents of
Signals of 2 systems of shift-up switch circuit are turned ON (closed) simultaneously.
trouble
Action of
Recognizes that shift-up switch is not pressed.
controller
Problem that
Transmission gear cannot be shifted up.
appears on
Related State of shift-up switch signal can be checked with monitoring function.
Method of reproducing failure code: Turn starting switch ON + Operate shift-up switch.

Shift-up switch
SFTU (male)
Defective shift-up switch OFF (Released) ON (Pressed)
1
(Internal short circuit) Resistance between
Max. 1 z Min. 1 Mz
(3) (2)
Resistance between
Min. 1 Mz Max. 1 z
(1) (2)
value in normal Wiring harness between STC3 (female) (9) Resis-
state SFTU (female) (1) and chassis ground tance
cuit)
Wiring harness between STC1 (female) (12) Resis-
Min. 1 Mz
SFTU (female) (3) and chassis ground tance
Shift-up switch
STC1 ,STC3
Defective power train con- OFF (Released) ON (Pressed)
3
troller Voltage between
Max. 1 V 5 11 V
STC1 (12) STC1 (4)
Voltage between
5 11 V Max. 1 V
STC3 (9) STC1 (4)
24 D155AX-6
D155AX-6 25
Failure code [DD13KA] Shift down Sw: Disconnection 1

Action code Failure code Shift down Sw: Disconnection
Trouble
Contents of
Signals of 2 systems of shift-down switch circuit are turned OFF (opened) simultaneously.
trouble
Action of
Recognizes that shift-down switch is not pressed.
controller
Problem that
Transmission gear cannot be shifted down.
appears on
Related State of shift-down switch signal can be checked with monitoring function.
Method of reproducing failure code: Turn starting switch ON + Operate shift-down switch.

Shift-down switch
SFTD (female)
Defective shift-down switch OFF (Released) ON (Pressed)
1
Max. 1 z Min. 1 Mz
(3) (2)
Resistance between
Min. 1 Mz Max. 1 z
(1) (2)
Max. 1 z
ness (Disconnection in wiring SFTD (female) (1) tance
2
Possible causes nector) Max. 1 z
SFTD (female) (2) tance
and standard
Max. 1 z
state SFTD (female) (3) tance
3 Voltage Max. 1 V
24V circuit) in wiring harness SFTD (female) (1) and chassis ground
Voltage Max. 1 V
SFTD (female) (3) and chassis ground
Shift-down switch
STC1
4
Max. 1 V 5 11 V
(24) - (4)
Voltage between
5 11 V Max. 1 V
(18) (4)
26 D155AX-6
D155AX-6 27
Failure code [DD13KB] Shift down Sw: Short circuit 1

Action code Failure code Shift down Sw: Short circuit
Trouble
Contents of
Signals of 2 systems of shift-down switch circuit are turned ON (closed) simultaneously.
trouble
Action of
Recognizes that shift-down switch is not pressed.
controller
Problem that
Transmission gear cannot be shifted down.
appears on
Related State of shift-down switch signal can be checked with monitoring function.
Method of reproducing failure code: Turn starting switch ON + Operate shift-down switch.

Shift-down switch
SFTD (female)
Defective shift-down switch OFF (Released) ON (Pressed)
1
Max. 1 z Min. 1 Mz
(3) (2)
Resistance between
Min. 1 Mz Max. 1 z
(1) (2)
state SFTD (female) (1) and chassis ground tance
cuit)
Min. 1 Mz
SFTD (female) (3) and chassis ground tance
Shift-down switch
STC1
3
Max. 1 V 5 11 V
(24) (4)
Voltage between
5 11 V Max. 1 V
(18) (4)
28 D155AX-6
D155AX-6 29
Failure code [DD14KA] Parking lever Sw: Disconnection 1

Action code Failure code Parking lever Sw: Disconnection
Trouble
Contents of
Signals of 2 systems of parking brake lever switch circuit are turned OFF (opened) simultaneously.
trouble
Action of Recognizes that parking brake lever is in FREE position.
Problem that
appears on
Related State of parking brake lever switch signal can be checked with monitoring function.
Method of reproducing failure code: Turn starting switch ON + Operate parking brake lever.

Parking brake lever
Defective parking brake lever PKSW (male)
FREE position LOCK position
2 switch (Internal disconnec-
tion) Resistance between
Max. 1 z Min. 1 Mz
(A) (B)
Resistance between
Min. 1 Mz Max. 1 z
(A) (C)
Disconnection in wiring har- Wiring harness between FS22 (2) PKSW Resis-
Max. 1 z
ness (Disconnection in wiring (female) (A) tance
3
nector) Max. 1 z
PKSW (female) (B) tance
Possible causes
Max. 1 z
value in normal PKSW (female) (C) tance
Wiring harness between FS22 (2) PKSW Resis-
Min. 1 Mz
Ground fault in wiring har- (female) (A) and chassis ground tance
4 ness (Contact with GND cir- Wiring harness between STC1 (female) (23) Resis-
cuit) Min. 1 Mz
PKSW (female) (B) and chassis ground tance
Resis-
PKSW (female) (C), PKS (female) (1) or Min. 1 Mz
tance
PKD (female) (1) and chassis ground
Parking brake lever
STC1
Defective power train con- FREE position LOCK position
5
troller Voltage between (23)
20 30 V Max. 1 V
chassis ground
Voltage between (17)
Max. 1 V 20 30 V
chassis ground
30 D155AX-6
Circuit diagram related to parking brake lever switch and solenoid valve
D155AX-6 31
Failure code [DD14KB] Parking lever Sw: Short circuit 1

Action code Failure code Parking lever Sw: Short circuit
Trouble
Contents of
Signals of 2 systems of parking brake lever switch circuit are turned ON (closed) simultaneously.
trouble
Action of Recognizes that parking brake lever is in FREE position.
Problem that
appears on
Related State of parking brake lever switch signal can be checked with monitoring function.
Method of reproducing failure code: Turn starting switch ON + Operate parking brake lever.

Parking brake lever
PKSW (male)
Defective parking brake lever FREE position LOCK position
1
switch (Internal short circuit) Resistance between
Max. 1 z Min. 1 Mz
(A) (B)
Resistance between
Min. 1 Mz Max. 1 z
(A) (C)
value in normal Hot short (Short circuit with Voltage Max. 1 V
2 PKSW (female) (B) and chassis ground
state 24V circuit) in wiring harness
PKSW (female) (C), PKS (female) (1) or Voltage Max. 1 V
PKD (female) (1) and chassis ground
Parking brake lever
STC1
Defective power train con- FREE position LOCK position
3
20 30 V Max. 1 V
chassis ground
Voltage between (17)
Max. 1 V 20 30 V
chassis ground
32 D155AX-6
Circuit diagram related to parking brake lever switch and solenoid valve
D155AX-6 33
Failure code [DDDDKA] Back up brake Sw: Disconnection 1

Action code Failure code Back up brake Sw: Disconnection
Trouble
E02 DDDDKA (Power train controller system)
Contents of
Signals of 2 systems of brake pedal switch circuit are turned OFF (opened) simultaneously.
trouble
Action of Recognizes that brake pedal is not pressed.
Problem that
appears on
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.

Brake pedal
BKSW (male)
Defective brake pedal switch Released Pressed
2
Max. 1 z Min. 1 Mz
(A) (B)
Resistance between
Min. 1 Mz Max. 1 z
(A) (C)
Disconnection in wiring har- Wiring harness between FS22 (1) BKSW Resis-
Max. 1 z
ness (Disconnection in wiring (female) (A) tance
3
nector) Max. 1 z
BKSW (female) (B) tance
Possible causes
Max. 1 z
value in normal BKSW (female) (C) tance
Wiring harness between FS22 (1) BKSW Resis-
Min. 1 Mz
Ground fault in wiring har- (female) (A) and chassis ground tance
4 ness (Contact with GND cir- Wiring harness between STC1 (female) (11) Resis-
cuit) Min. 1 Mz
BKSW (female) (B) and chassis ground tance
Resis-
BKSW (female) (C), PBS (female) (1) or Min. 1 Mz
tance
PBD (female) (1) and chassis ground
Brake pedal
STC1
Defective power train con- Released Pressed
5
20 30 V Max. 1 V
chassis ground
Voltage between (5)
Max. 1 V 20 30 V
chassis ground
34 D155AX-6
Circuit diagram related to brake pedal switch and solenoid valve
D155AX-6 35
Failure code [DDDDKB] Back up brake Sw: Short circuit 1

Action code Failure code Back up brake Sw: Short circuit
Trouble
E02 DDDDKB (Power train controller system)
Contents of
Signals of 2 systems of brake pedal switch circuit are turned ON (closed) simultaneously.
trouble
Action of Recognizes that brake pedal is not pressed.
Problem that
appears on
Related State of brake pedal switch signal can be checked with monitoring function.

Brake pedal
BKSW (male)
Defective brake pedal switch Released Pressed
1
Max. 1 z Min. 1 Mz
(A) (B)
Resistance between
Min. 1 Mz Max. 1 z
(A) (C)
value in normal Hot short (Short circuit with Voltage Max. 1 V
2 BKSW (female) (B) and chassis ground
state 24V circuit) in wiring harness
BKSW (female) (C), PBS (female) (1), or Voltage Max. 1 V
PBD (female) (1) and chassis ground
Brake pedal
STC1
Defective power train con- Released Pressed
3
20 30 V Max. 1 V
chassis ground
Voltage between (5)
Max. 1 V 20 30 V
chassis ground
36 D155AX-6
Circuit diagram related to brake pedal switch and solenoid valve
D155AX-6 37
Failure code [DDDDKX] Back up brake Sw: Signal mismatch 1

Action code Failure code Back up brake Sw: Signal mismatch
Trouble
E02 DDDDKX (Power train controller system)
Contents of
Brake pedal potentiometer signal does not match to brake pedal switch signal.
trouble
Action of
None in particular.
controller
Problem that
appears on Backup brake may not operate.
machine
State of brake pedal potentiometer signal can be checked with monitoring function.
Related
(Code: 50400 Brake Pedal Potentio)
information

Defective brake pedal switch If failure code [DDDDKA] or [DDDDKB] is also displayed, carry out
1
system troubleshooting for it first.
Possible causes
and standard Adjust brake pedal and perform operation of reproducing trouble.
value in normal 2 Defective brake pedal switch If "E" of failure code disappears at this time, system is normal.
state Testing and adjusting item: Adjusting brake pedal
If causes 1 2 are not detected, power train controller may be
troller
carried out.)
38 D155AX-6
Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection 1

Action code Failure code WEQ Knob Sw (down): Disconnection
Trouble
E02 DDN7KA (Work equipment controller system)
Contents of
Signals of 2 systems of blade pitch switch circuit are turned OFF (opened) simultaneously.
trouble
Action of
Recognizes that blade pitch switch is not pressed.
controller
Problem that
appears on Blade pitch function does not operate.
machine
Related State of blade pitch switch signal can be checked with monitoring function.
information (Code: 70300 Blade Sw Input)
Method of reproducing failure code: Turn starting switch ON + Operate blade pitch switch.

Blade pitch switch
BNSL (female)
Defective blade pitch switch OFF (Released) ON (Pressed)
1
Max. 1 z Min. 1 Mz
(3) (2)
Resistance between
Min. 1 Mz Max. 1 z
(1) (2)
Disconnection in wiring har- Wiring harness between WEC2 (female) Resis-
Max. 1 z
ness (Disconnection in wiring (16) BNSL (female) (1) tance
2
or defective contact in con- Wiring harness between WEC1 (female) (4) Resis-
nector) Max. 1 z
BNSL (female) (2) tance
Possible causes
and standard Wiring harness between WEC2 (female) (6) Resis-
Max. 1 z
value in normal BNSL (female) (3) tance
3 (16) BNSL (female) (1) and chassis Voltage Max. 1 V
24V circuit) in wiring harness
ground
Wiring harness between WEC2 (female) (6)
Voltage Max. 1 V
BNSL (female) (3) and chassis ground
Blade pitch switch
WEC1, WEC2
4 Voltage between
controller Max. 1 V 5 11 V
WEC2 (6) WEC1 (4)
Voltage between
WEC2 (16) 5 11 V Max. 1 V
WEC1 (4)
40 D155AX-6
Circuit diagram related to blade float switch and blade pitch switch
D155AX-6 41
Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit 1

Action code Failure code WEQ Knob Sw (down): Short circuit
Trouble
E02 DDN7KB (Work equipment controller system)
Contents of
Signals of 2 systems of blade pitch switch circuit are turned ON (closed) simultaneously.
trouble
Action of
Recognizes that blade pitch switch is not pressed.
controller
Problem that
appears on Blade pitch function does not operate.
machine
Related State of blade pitch switch signal can be checked with monitoring function.
Method of reproducing failure code: Turn starting switch ON + Operate blade pitch switch.

Blade pitch switch
BNSL (female)
Defective blade pitch switch OFF (Released) ON (Pressed)
1
Max. 1 z Min. 1 Mz
(3) (2)
Resistance between
Min. 1 Mz Max. 1 z
(1) (2)
Possible causes
and standard Ground fault in wiring har- Wiring harness between WEC2 (female)
Resis-
value in normal 2 ness (Contact with GND cir- (16) BNSL (female) (1) and chassis Min. 1 Mz
tance
state cuit) ground
Wiring harness between WEC2 (female) (6) Resis-
Min. 1 Mz
BNSL (female) (3) and chassis ground tance
Blade pitch switch
WEC1, WEC2
3 Voltage between
controller Max. 1 V 5 11 V
WEC2 (6) WEC1 (4)
Voltage between
WEC2 (16) 5 11 V Max. 1 V
WEC1 (4)
42 D155AX-6
D155AX-6 43
Failure code [DDN9KA] WEQ Knob Sw (up): Disconnection 1

Action code Failure code WEQ Knob Sw (up): Disconnection
Trouble
E01 DDN9KA (Work equipment controller system)
Contents of
Signals of 2 systems of blade float switch circuit are turned OFF (opened) simultaneously.
trouble
Action of
Recognizes that blade float switch is not pressed.
controller
Problem that
appears on Blade float function does not operate.
machine
Related State of blade float switch signal can be checked with monitoring function.
Method of reproducing failure code: Turn starting switch ON + Operate blade float switch.

Blade float switch
BNSU (male)
Defective blade float switch OFF (Released) ON (Pressed)
1
Max. 1 z Min. 1 Mz
(3) (2)
Resistance between
Min. 1 Mz Max. 1 z
(1) (2)
Max. 1 z
ness (Disconnection in wiring (36) BNSU (female) (1) tance
2
nector) Max. 1 z
BNSU (female) (2) tance
Possible causes Wiring harness between WEC2 (female) Resis-

Max. 1 z
and standard (26) BNSU (female) (3) tance
value in normal a Prepare with starting switch OFF, then turn starting switch ON
state and carry out troubleshooting.
Hot short (Short circuit with (36) BNSU (female) (1) and chassis Voltage Max. 1 V
3
(26) BNSU (female) (3) and chassis Voltage Max. 1 V
ground
Blade float switch
WEC1, WEC2
Defective work equipment Voltage between
4
controller WEC2 (26) Max. 1 V 5 11 V
WEC1 (4)
Voltage between
WEC2 (36) 5 11 V Max. 1 V
WEC1 (4)
44 D155AX-6
D155AX-6 45
Failure code [DDN9KB] WEQ Knob Sw (up): Short circuit 1

Action code Failure code WEQ Knob Sw (up): Short circuit
Trouble
E01 DDN9KB (Work equipment controller system)
Contents of
Signals of 2 systems of blade float switch circuit are turned ON (closed) simultaneously.
trouble
Action of
Recognizes that blade float switch is not pressed.
controller
Problem that
appears on Blade float function does not operate.
machine
Method of reproducing failure code: Turn starting switch ON + Operate blade float switch.

Blade float switch
BNSU (male)
Defective blade float switch OFF (Released) ON (Pressed)
1
Max. 1 z Min. 1 Mz
(3) (2)
Resistance between
Min. 1 Mz Max. 1 z
(1) (2)
Possible causes Wiring harness between WEC2 (female)

and standard (36) BNSU (female) (1) and chassis Min. 1 Mz
value in normal ground
cuit)
state Wiring harness between WEC2 (female)
Resis-
(26) BNSU (female) (3) and chassis Min. 1 Mz
tance
ground
Blade float switch
WEC1, WEC2
3
WEC1 (4)
Voltage between
WEC2 (36) 5 11 V Max. 1 V
WEC1 (4)
46 D155AX-6
D155AX-6 47
Failure code [DDNLKA] Weq lock Sw: Disconnection 1

Action code Failure code Weq lock Sw: Disconnection
Trouble
E03 DDNLKA (Work equipment controller system)
Contents of Signals of 2 systems of work equipment lock lever switch circuit are turned OFF (opened) simulta-
trouble neously.
Action of Recognizes that work equipment lock lever is in FREE position.
Problem that
appears on
Method of reproducing failure code: Turn starting switch ON + Operate work equipment lock lever.

Work equipment lock lever
Defective work equipment WELK (male)
1 lock lever switch (Internal
disconnection) Resistance between
Max. 1 z Min. 1 Mz
(B) (A)
Resistance between
Min. 1 Mz Max. 1 z
(C) (A)
Max. 1 z
ness (Disconnection in wiring (10) WELK (female) (A) tance
2
nector) Max. 1 z
WELK (female) (B) tance
Possible causes Wiring harness between WEC2 (female) Resis-
(15) WELK (female) (C) tance
value in normal
state
Wiring harness between WEC2 (female) (5)
Hot short (Short circuit with Voltage Max. 1 V
3 WELK (female) (B) and chassis ground
(15) WELK (female) (C) and chassis Voltage Max. 1 V
ground
WEC1, WEC2
4
WEC1 (10)
Voltage between
WEC2 (15) 5 11 V Max. 1 V
WEC1 (10)
48 D155AX-6
Circuit diagram related to work equipment lock lever switch
D155AX-6 49
Failure code [DDNLKB] Weq lock Sw: Short circuit 1

Action code Failure code Weq lock Sw: Short circuit
Trouble
E03 DDNLKB (Work equipment controller system)
Contents of Signals of 2 systems of work equipment lock lever switch circuit are turned ON (closed) simulta-
trouble neously.
Action of Recognizes that work equipment lock lever is in FREE position.
Problem that
appears on
Method of reproducing failure code: Turn starting switch ON + Operate work equipment lock lever.

Defective work equipment WELK (male)
1 lock lever switch (Internal
short circuit) Resistance between
Max. 1 z Min. 1 Mz
(B) (A)
Resistance between
Min. 1 Mz Max. 1 z
(C) (A)
Possible causes Ground fault in wiring har- Wiring harness between WEC2 (female) (5) Resis-
2 ness (Contact with GND cir- WELK (female) (B) and chassis ground tance
value in normal cuit) Wiring harness between WEC2 (female)
state Resis-
(15) WELK (female) (C) and chassis Min. 1 Mz
tance
ground
WEC1, WEC2
3
WEC1 (10)
Voltage between
WEC2 (15) 5 11 V Max. 1 V
WEC1 (10)
50 D155AX-6
Circuit diagram related to work equipment lock lever switch
D155AX-6 51
Failure code [DDTSL1] S/C: Fill high 1

Action code Failure code S/C: Fill high
Trouble
E02 DDTSL1 (Power train controller system)
Contents of When signal is not output to solenoid circuit of torque converter stator clutch ECMV, fill switch signal
trouble is turned ON.
Action of
None in particular.
controller
Problem that
appears on Travel torque may not be obtained sufficiently.
machine
State of fill switch signal of stator clutch ECMV can be checked with monitoring function.
Related
information
Method of reproducing failure code: Start engine + Set travel lever in N (Neutral).

Defective fill switch of stator PCCS lever
FSTC (male) Resistance
1 clutch ECMV (Internal short (Travel gear speed)
circuit) N Max. 1 z
Between (1) chas-
Min. 1 Mz
or F3
Min. 1 Mz
state FSTC (female) (1) and chassis ground tance
PCCS lever
troller
N Max. 1 V
Between (26) chas-
5 11 V
or F3
52 D155AX-6
Circuit diagram related to torque converter stator clutch ECMV
D155AX-6 53
Failure code [DDTSLH] S/C: Fill low 1

Action code Failure code S/C: Fill low
Trouble
E02 DDTSLH (Power train controller system)
Contents of When signal is output to solenoid circuit of torque converter stator clutch ECMV, fill switch signal is
trouble turned OFF.
Action of
None in particular.
controller
Problem that
appears on Travel torque may not be obtained sufficiently.
machine
State of fill switch signal of stator clutch ECMV can be checked with monitoring function.
information Method of reproducing failure code: Start engine + Set travel lever in F (Forward) (Automatic gear-
shift mode).

Defective fill switch of stator PCCS lever
FSTC (male) Resistance
1 clutch ECMV (Internal dis- (Travel gear speed)
connection) N Max. 1 z
Between (1) chas-
Min. 1 Mz
or F3
and standard 2
nector) FSTC (female) (1) tance
state
PCCS lever
troller
N Max. 1 V
Between (26) chas-
5 11 V
or F3
54 D155AX-6
D155AX-6 55
D155AX-6 Bulldozer
2006 KOMATSU
All Rights Reserved
56 D155AX-6
SEN00720-01
D155AX-6

D155AX-6 80001 and
upAction code
codes, Part 5
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
Failure code [DFA9KB] BT lever 2: Short circuit ................................................................................ 22

Failure code [DFAAKX] RL lever 1: Out of normal range ................................................................... 24
Failure code [DFAAKZ] RL lever: Disconnection or short circuit ........................................................ 24
Failure code [DFAAL8] RL lever: Signal mismatch ............................................................................ 25
Failure code [DFABKA] RL lever 1: Disconnection ............................................................................ 26
Failure code [DFABKB] RL lever 1: Short circuit ................................................................................ 28
Failure code [DFACKA] RL lever 2: Disconnection ............................................................................ 30
Failure code [DFACKB] RL lever 2: Short circuit................................................................................ 32
Failure code [DFADKX] RL lever 1: Out of normal range................................................................... 34
Failure code [DFADKZ] RL lever: Disconnection or short circuit........................................................ 34
Failure code [DFADL8] RL lever: Signal mismatch ............................................................................ 35
Failure code [DFAEKA] RL lever 1: Disconnection ............................................................................ 36
Failure code [DFAEKB] RL lever 1: Short circuit ................................................................................ 38
Failure code [DFAFKA] RL lever 2: Disconnection............................................................................. 40
Failure code [DFAFKB] RL lever 2: Short circuit ................................................................................ 42
Failure code [DGT1KA] T/C oil temp sensor: Abnormal..................................................................... 44
Failure code [DGT1KX] T/C oil temp sensor: Abnormal..................................................................... 46
Failure code [DH21KA] Weq pressure sensor: Disconnection ........................................................... 48
Failure code [DH21KB] Weq pressure sensor: Short circuit .............................................................. 50
Failure code [DHT5KA] T/C in-pressure sensor: Disconnection ........................................................ 52
Failure code [DHT5KB] T/C in-pressure sensor: Short circuit............................................................ 54
Failure code [DHT7KA] T/C out-pressure sensor: Disconnection ...................................................... 56
Failure code [DHT7KB] T/C out-pressure sensor: Short circuit.......................................................... 58
Failure code [DK10KX] Fuel control Dial: Out of normal range.......................................................... 60
2 D155AX-6

Failure code [DFA4KX] BL lever 1: Out of normal range 1
Action code Failure code BL lever 1: Out of normal range
Trouble
E03 DFA4KX (Work equipment controller system)
Contents of In blade control lever lift potentiometer 1 and 2 systems, either of failure codes [DFA5KA] and
trouble [DFA5KB] and either of failure codes [DFA6KA] and [DFA6KB] occurred simultaneously.
Action of
controller
Problem that
appears on
machine
State of blade control lever lift potentiometer signal can be checked with monitoring function.
(Code: 73400 Blade Lift Lever A Potentio)
Related
(Code: 73401 Blade Lift Lever B Potentio)
information
Method of reproducing failure code: Turn starting switch ON + Operate blade control lever
(in lifting direction).

and standard
value in normal Carry out troubleshooting for failure codes [DFA5KA], [DFA5KB], [DFA6KA], and [DFA6KB].
state
Failure code [DFA4KZ] BL lever: Disconnection or short circuit 1

Action code Failure code BL lever: Disconnection or short circuit
Trouble
E03 DFA4KZ (Work equipment controller system)
In blade control lever lift potentiometer 1 and 2 systems, when starting switch is turned ON, only
Contents of
either side is abnormal and then either of failure codes [DFA5KA] and [DFA5KB] and either of fail-
trouble
ure codes [DFA6KA] and [DFA6KB] occurred simultaneously.
Action of
controller
Problem that
appears on
machine
Related
information

and standard
state
D155AX-6 3
Failure code [DFA4L8] BL lever: Signal mismatch 1

Action code Failure code BL lever: Signal mismatch
Trouble
E03 DFA4L8 (Work equipment controller system)
Contents of In blade control lever lift potentiometer 1 and 2 systems, total of both signal voltages is below 4.41 V
trouble or above 5.59 V.
Action of Continues control with signal of normal one of blade control lever lift potentiometer 1 and 2 systems.
Problem that
appears on
machine
Related
information

and standard
state
4 D155AX-6
Failure code [DFA5KA] BL lever 1: Disconnection 1

Action code Failure code BL lever 1: Disconnection
Trouble
E03 DFA5KA (Work equipment controller system)
Contents of
Signal voltage of blade control lever lift potentiometer 1 system is below 0.5 V.
trouble
Action of Continues control with signal of blade control lever lift potentiometer 2 system.
Problem that
appears on
machine
State of blade control lever lift potentiometer 1 signal can be checked with monitoring function.
Related (Code: 73400 Blade Lift Lever A Potentio)
information Method of reproducing failure code: Turn starting switch ON + Operate blade control lever

Defective sensor 5V power If failure code [DB97KK] is also displayed, carry out troubleshoot-
1
Defective blade control lever WLV1 (male) Blade control lever Resistance
2 lift potentiometer 1 (Internal
Between (4) (1) 3.2 kz 20 %
disconnection)
Between (4) (3) Neutral 1.6 kz 20 %
Between (3) (1) 1.6 kz 20 %
Possible causes
and standard
value in normal ness (Disconnection in wiring Wiring harness between WEC1 (female) Resis-
3 Max. 1 z
state or defective contact in con- (22) WLV1 (female) (4) tance
nector) Wiring harness between WEC1 (female) (2) Resis-
Max. 1 z
WLV1 (female) (3) tance
cuit) Wiring harness between WEC1 (female) (2) Resis-
Min. 1 Mz
WLV1 (female) (3) and chassis ground tance
Defective work equipment and carry out troubleshooting.
5
Between (2) (21) 0.5 4.5 V
6 D155AX-6
Circuit diagram related to blade control lever potentiometer
D155AX-6 7
Failure code [DFA5KB] BL lever 1: Short circuit 1

Action code Failure code BL lever 1: Short circuit
Trouble
E03 DFA5KB (Work equipment controller system)
Contents of
Signal voltage of blade control lever lift potentiometer 1 system is above 4.5 V.
trouble
Problem that
appears on
machine
Related (Code: 73400 Blade Lift Lever A Potentio)

1
Between (4) (1) 3.2 kz 20 %
short circuit)
Possible causes Between (4) (3) Neutral 1.6 kz 20 %
and standard
value in normal Between (3) (1) 1.6 kz 20 %
3
24V circuit) in wiring harness Wiring harness between WEC1 (female) (2)
Voltage Max. 1 V
WLV1 (female) (3) and chassis ground
4
Between (2) (21) 0.5 4.5 V
8 D155AX-6
D155AX-6 9
Failure code [DFA6KA] BL lever 2: Disconnection 1

Action code Failure code BL lever 2: Disconnection
Trouble
Contents of
Signal voltage of blade control lever lift potentiometer 2 system is below 0.5 V.
trouble
Problem that
appears on
machine
Related (Code: 73401 Blade Lift Lever B Potentio)

1
Between (4) (1) 3.2 kz 20 %
disconnection)
Between (2) (1) 1.6 kz 20 %
Possible causes Disconnection in wiring har- ing without turning starting switch ON.
and standard ness (Disconnection in wiring Wiring harness between WEC1 (female) Resis-
value in normal 3 Max. 1 z
or defective contact in con- (22) WLV1 (female) (4) tance
state nector) Wiring harness between WEC1 (female) Resis-
Max. 1 z
(19) WLV1 (female) (2) tance
4 ness (Contact with GND cir- Wiring harness between WEC1 (female)
cuit) Resis-
(19) WLV1 (female) (2) and chassis Min. 1 Mz
tance
ground
5
Between (19) (21) 0.5 4.5 V
10 D155AX-6
D155AX-6 11
Failure code [DFA6KB] BL lever 2: Short circuit 1

Action code Failure code BL lever 2: Short circuit
Trouble
Contents of
Signal voltage of blade control lever lift potentiometer 2 system is above 4.5 V.
trouble
Problem that
appears on
machine
Related (Code: 73401 Blade Lift Lever B Potentio)

1
Between (4) (1) 3.2 kz 20 %
short circuit)
and standard Between (2) (1) 1.6 kz 20 %
value in normal
state
3
(19) WLV1 (female) (2) and chassis Voltage Max. 1 V
ground
4
Between (19) (21) 0.5 4.5 V
12 D155AX-6
D155AX-6 13
Failure code [DFA7KX] BT lever 1: Out of normal range 1

Action code Failure code BT lever 1: Out of normal range
Trouble
E03 DFA7KX (Work equipment controller system)
Contents of In blade control lever tilt potentiometer 1 and 2 systems, either of failure codes [DFA8KA] and
trouble [DFA8KB] and either of failure codes [DFA9KA] and [DFA9KB] occurred simultaneously.
Action of
controller
Problem that
appears on
machine
State of blade control lever tilt potentiometer signal can be checked with monitoring function.
(Code: 73500 Blade Tilt Lever A Potentio)
Related
(Code: 73501 Blade Tilt Lever B Potentio)
information
(in tilting direction).

and standard
state
Failure code [DFA7KZ] BT lever: Disconnection or short circuit 1

Action code Failure code BT lever: Disconnection or short circuit
Trouble
E03 DFA7KZ (Work equipment controller system)
In blade control lever tilt potentiometer 1 and 2 systems, when starting switch is turned ON, only
Contents of
either side is abnormal and then either of failure codes [DFA8KA] and [DFA8KB] and either of fail-
trouble
ure codes [DFA9KA] and [DFA9KB] occurred simultaneously.
Action of
controller
Problem that
appears on
machine
Related
information

and standard
state
14 D155AX-6
Failure code [DFA7L8] BT lever: Signal mismatch 1

Action code Failure code BT lever: Signal mismatch
Trouble
E03 DFA7L8 (Work equipment controller system)
Contents of In blade control lever tilt potentiometer 1 and 2 systems, total of both signal voltages is below 4.41 V
Action of Continues control with signal of normal one of blade control lever tilt potentiometer 1 and 2 systems.
Problem that
appears on
machine
Related
information

and standard
state
D155AX-6 15
Failure code [DFA8KA] BT lever 1: Disconnection 1

Action code Failure code BT lever 1: Disconnection
Trouble
Contents of
Signal voltage of blade control lever tilt potentiometer 1 system is below 0.5 V.
trouble
Action of Continues control with signal of blade control lever tilt potentiometer 2 system.
controller Limits operation of engine and transmission
Problem that
appears on
machine
State of blade control lever tilt potentiometer 1 signal can be checked with monitoring function.
Related (Code: 73500 Blade Tilt Lever A Potentio)

1
2 tilt potentiometer 1 (Internal
Between (8) (5) 3.2 kz 20 %
disconnection)
Between (7) (5) 1.6 kz 20 %
Max. 1 z
cuit) Resis-
tance
ground
5
Between (13) (21) 0.5 4.5 V
16 D155AX-6
D155AX-6 17
Failure code [DFA8KB] BT lever 1: Short circuit 1

Action code Failure code BT lever 1: Short circuit
Trouble
Contents of
Signal voltage of blade control lever tilt potentiometer 1 system is above 4.5 V.
trouble
Problem that
appears on
machine
Related (Code: 73500 Blade Tilt Lever A Potentio)

1
Between (8) (5) 3.2 kz 20 %
short circuit)
value in normal
state
3
ground
4
Between (13) (21) 0.5 4.5 V
18 D155AX-6
D155AX-6 19
Failure code [DFA9KA] BT lever 2: Disconnection 1

Action code Failure code BT lever 2: Disconnection
Trouble
Contents of
Signal voltage of blade control lever tilt potentiometer 2 system is below 0.5 V.
trouble
Problem that
appears on
machine
Related (Code: 73501 Blade Tilt Lever B Potentio)

1
Between (8) (5) 3.2 kz 20 %
disconnection)
Between (6) (5) 1.6 kz 20 %
Possible causes
and standard
3 Max. 1 z
Max. 1 z
Min. 1 Mz
5
Between (7) (21) 0.5 4.5 V
20 D155AX-6
D155AX-6 21
Failure code [DFA9KB] BT lever 2: Short circuit 1

Action code Failure code BT lever 2: Short circuit
Trouble
Contents of
Signal voltage of blade control lever tilt potentiometer 2 system is above 4.5 V.
trouble
Problem that
appears on
machine
Related (Code: 73501 Blade Tilt Lever B Potentio)

1
Between (8) (5) 3.2 kz 20 %
short circuit)
and standard
3
Voltage Max. 1 V
4
Between (7) (21) 0.5 4.5 V
22 D155AX-6
D155AX-6 23
Failure code [DFAAKX] RL lever 1: Out of normal range 1

Action code Failure code RL lever 1: Out of normal range
Trouble
E03 DFAAKX (Work equipment controller system)
Contents of In ripper control lever lift potentiometer 1 and 2 systems, either of failure codes [DFABKA] and
trouble [DFABKB] and either of failure codes [DFACKA] and [DFACKB] occurred simultaneously.
Action of
controller
Problem that
appears on
machine
State of ripper control lever lift potentiometer signal can be checked with monitoring function.
(Code: 73700 Ripper Lift Lever A Potentio)
Related
(Code: 73701 Ripper Lift Lever B Potentio)
information
Method of reproducing failure code: Turn starting switch ON + Operate ripper control lever

and standard
value in normal Carry out troubleshooting for failure codes [DFABKA], [DFABKB], [DFACKA], and [DFACKB].
state
Failure code [DFAAKZ] RL lever: Disconnection or short circuit 1

Action code Failure code RL lever: Disconnection or short circuit
Trouble
E03 DFAAKZ (Work equipment controller system)
In ripper control lever lift potentiometer 1 and 2 systems, when starting switch is turned ON, only
Contents of
either side is abnormal and then either of failure codes [DFABKA] and [DFABKB] and either of fail-
trouble
ure codes [DFACKA] and [DFACKB] occurred simultaneously.
Action of
controller
Problem that
appears on
machine
Related
information

and standard
state
24 D155AX-6
Failure code [DFAAL8] RL lever: Signal mismatch 1

Action code Failure code RL lever: Signal mismatch
Trouble
E03 DFAAL8 (Work equipment controller system)
Contents of In ripper control lever lift potentiometer 1 and 2 systems, total of both signal voltages is below 4.41
trouble V or above 5.59 V.
Continues control with signal of normal one of ripper control lever lift potentiometer 1 and 2 sys-
Action of
tems.
controller
Problem that
appears on
machine
Related
information

and standard
state
D155AX-6 25
Failure code [DFABKA] RL lever 1: Disconnection 1

Action code Failure code RL lever 1: Disconnection
Trouble
E03 DFABKA (Work equipment controller system)
Contents of
Signal voltage of ripper control lever lift potentiometer 1 system is below 0.5 V.
trouble
Action of Continues control with signal of ripper control lever lift potentiometer 2 system.
Problem that
appears on
machine
State of ripper control lever lift potentiometer 1 signal can be checked with monitoring function.
Related (Code: 73700 Ripper Lift Lever A Potentio)
information Method of reproducing failure code: Turn starting switch ON + Operate ripper control lever

1
Defective ripper control lever WLV2 (male) Ripper control lever Resistance
Between (8) (5) 3.2 kz 20 %
disconnection)
Between (7) (5) 1.6 kz 20 %
Max. 1 z
cuit) Resis-
tance
ground
5
Between (14) (21) 0.5 4.5 V
26 D155AX-6
Circuit diagram related to ripper control lever potentiometer
D155AX-6 27
Failure code [DFABKB] RL lever 1: Short circuit 1

Action code Failure code RL lever 1: Short circuit
Trouble
E03 DFABKB (Work equipment controller system)
Contents of
Signal voltage of ripper control lever lift potentiometer 1 system is above 4.5 V.
trouble
Problem that
appears on
machine
Related (Code: 73700 Ripper Lift Lever A Potentio)

1
Between (8) (5) 3.2 kz 20 %
short circuit)
value in normal
state
3
24V circuit) in wiring harness Wiring harness between WEC1 (female) Resis-
tance
ground
4
Between (14) (21) 0.5 4.5 V
28 D155AX-6
D155AX-6 29
Failure code [DFACKA] RL lever 2: Disconnection 1

Trouble
E03 DFACKA (Work equipment controller system)
Contents of
Signal voltage of ripper control lever lift potentiometer 2 system is below 0.5 V.
trouble
Problem that
appears on
machine
Related (Code: 73701 Ripper Lift Lever B Potentio)

1
Between (8) (5) 3.2 kz 20 %
disconnection)
Between (6) (5) 1.6 kz 20 %
Possible causes
and standard
3 Max. 1 z
Max. 1 z
Min. 1 Mz
5
Between (8) (21) 0.5 4.5 V
30 D155AX-6
D155AX-6 31
Failure code [DFACKB] RL lever 2: Short circuit 1

Trouble
E03 DFACKB (Work equipment controller system)
Contents of
Signal voltage of ripper control lever lift potentiometer 2 system is above 4.5 V.
trouble
Problem that
appears on
machine
tate of ripper control lever lift potentiometer 2 signal can be checked with monitoring function.
Related (Code: 73701 Ripper Lift Lever B Potentio)

1
Between (8) (5) 3.2 kz 20 %
short circuit)
and standard
3
Voltage Max. 1 V
4
Between (8) (21) 0.5 4.5 V
32 D155AX-6
D155AX-6 33
Failure code [DFADKX] RL lever 1: Out of normal range 1

Action code Failure code RL lever 1: Out of normal range
Trouble
E03 DFADKX (Work equipment controller system)
Contents of In ripper control lever tilt potentiometer 1 and 2 systems, either of failure codes [DFAEKA] and
trouble [DFAEKB] and either of failure codes [DFAFKA] and [DFAFKB] occurred simultaneously.
Action of
controller
Problem that
appears on
machine
State of ripper control lever tilt potentiometer signal can be checked with monitoring function.
(Code: 73600 Ripper Tilt Lever A Potentio)
Related
(Code: 73601 Ripper Tilt Lever B Potentio)
information

and standard
value in normal Carry out troubleshooting for failure codes [DFAEKA], [DFAEKB], [DFAFKA], and [DFAFKB].
state
Failure code [DFADKZ] RL lever: Disconnection or short circuit 1

Action code Failure code RL lever: Disconnection or short circuit
Trouble
E03 DFADKZ (Work equipment controller system)
In ripper control lever tilt potentiometer 1 and 2 systems, when starting switch is turned ON, only
Contents of
either side is abnormal and then either of failure codes [DFAEKA] and [DFAEKB] and either of fail-
trouble
ure codes [DFAFKA] and [DFAFKB] occurred simultaneously.
Action of
controller
Problem that
appears on
machine
Related
information

and standard
state
34 D155AX-6
Failure code [DFADL8] RL lever: Signal mismatch 1

Action code Failure code RL lever: Signal mismatch
Trouble
E03 DFADL8 (Work equipment controller system)
Contents of In ripper control lever tilt potentiometer 1 and 2 systems, total of both signal voltages is
trouble below 4.41 V or above 5.59 V.
Continues control with signal of normal one of ripper control lever tilt potentiometer 1 and 2 sys-
Action of
tems.
controller
Problem that
appears on
machine
Related
information

and standard
state
D155AX-6 35
Failure code [DFAEKA] RL lever 1: Disconnection 1

Trouble
E03 DFAEKA (Work equipment controller system)
Contents of
Signal voltage of ripper control lever tilt potentiometer 1 system is below 0.5 V.
trouble
Action of Continues control with signal of ripper control lever tilt potentiometer 2 system.
Problem that
appears on
machine
State of ripper control lever tilt potentiometer 1 signal can be checked with monitoring function.
Related (Code: 73600 Ripper Tilt Lever A Potentio)

1
Between (4) (1) 3.2 kz 20 %
disconnection)
Between (3) (1) 1.6 kz 20 %
Possible causes
and standard
3 Max. 1 z
Max. 1 z
Min. 1 Mz
5
Between (3) (21) 0.5 4.5 V
36 D155AX-6
D155AX-6 37
Failure code [DFAEKB] RL lever 1: Short circuit 1

Trouble
E03 DFAEKB (Work equipment controller system)
Contents of
Signal voltage of ripper control lever tilt potentiometer 1 system is above 4.5 V.
trouble
Problem that
appears on
machine
Related (Code: 73600 Ripper Tilt Lever A Potentio)

1
Between (4) (1) 3.2 kz 20 %
short circuit)
and standard
3
Voltage Max. 1 V
4
Between (3) (21) 0.5 4.5 V
38 D155AX-6
D155AX-6 39
Failure code [DFAFKA] RL lever 2: Disconnection 1

Trouble
E03 DFAFKA (Work equipment controller system)
Contents of
Signal voltage of ripper control lever tilt potentiometer 2 system is below 0.5 V.
trouble
Problem that
appears on
machine
Related (Code: 73601 Ripper Tilt Lever B Potentio)

1
Between (4) (1) 3.2 kz 20 %
disconnection)
Between (2) (1) 1.6 kz 20 %
Max. 1 z
cuit) Resis-
tance
ground
5
Between (20) (21) 0.5 4.5 V
40 D155AX-6
D155AX-6 41
Failure code [DFAFKB] RL lever 2: Short circuit 1

Trouble
E03 DFAFKB (Work equipment controller system)
Contents of
Signal voltage of ripper control lever tilt potentiometer 2 system is above 4.5 V.
trouble
Problem that
appears on
machine
Related (Code: 73601 Ripper Tilt Lever B Potentio)

1
Between (4) (1) 3.2 kz 20 %
short circuit)
value in normal
state
3
ground
4
Between (20) (21) 0.5 4.5 V
42 D155AX-6
D155AX-6 43
Failure code [DGT1KA] T/C oil temp sensor: Abnormal 1

Action code Failure code T/C oil temp sensor: Abnormal
Trouble
E01 DGT1KA (Power train controller system)
Contents of
Torque converter oil temperature sensor signal is out of normal range.
trouble
Action of
None in particular.
controller
Problem that
appears on Power train oil temperature gauge may not indicate normally.
machine
Torque converter oil temperature can be checked with monitoring function.
Related
information
Method of reproducing failure code: Turn starting switch ON or start engine.

Defective torque converter ing without turning starting switch ON.
oil temperature sensor (Inter- TCT (male) Resistance
1
nal short circuit or disconnec-
tion) Between (1) (2) 1 50 kz
Between (1) chassis ground Min. 1 Mz
2 Max. 1 V
or defective contact in con- TCT (female) (1) tance
Possible causes Max. 1 V
TCT (female) (2) tance
and standard
state 3 ness (Contact with GND cir-
Min. 1 Mz
TCT (female) (1) and chassis ground tance
4
Voltage Max. 1 V
TCT (female) (1) and chassis ground
Defective power train con- STC1 (female) Resistance
5
troller
Between (9) (21) 1 50 kz
44 D155AX-6
Circuit diagram related to torque converter oil temperature sensor
D155AX-6 45
Failure code [DGT1KX] T/C oil temp sensor: Abnormal 1

Action code Failure code T/C oil temp sensor: Abnormal
Trouble
E01 DGT1KX (Power train controller system)
Contents of
Torque converter oil temperature sensor signal is out of normal range.
trouble
Action of
None in particular.
controller
Problem that
appears on Power train oil temperature gauge may not indicate normally.
machine
Torque converter oil temperature can be checked with monitoring function.
Related
information
Method of reproducing failure code: Turn starting switch ON or start engine.

Defective torque converter ing without turning starting switch ON.
oil temperature sensor (Inter- TCT (male) Resistance
1
nal short circuit or disconnec-
tion) Between (1) (2) 1 50 kz
2 Max. 1 z
or defective contact in con- TCT (female) (1) tance
TCT (female) (2) tance
and standard
state 3 ness (Contact with GND cir-
Min. 1 Mz
TCT (female) (1) and chassis ground tance
4
Voltage Max. 1 V
TCT (female) (1) and chassis ground
5
troller
Between (9) (21) 1 50 kz
46 D155AX-6
Circuit diagram related to torque converter oil temperature sensor
D155AX-6 47
Failure code [DH21KA] Weq pressure sensor: Disconnection 1

Action code Failure code Weq pressure sensor: Disconnection
Trouble
DH21KA (Work equipment controller system)
Contents of
Signal voltage of work equipment pump oil pressure sensor is below 0.5 V.
trouble
Action of
None in particular.
controller
Problem that
appears on Oil pressure of work equipment pump cannot be monitored.
machine
State of work equipment pump oil pressure sensor can be checked with monitoring function.
Related
(Code: 70701 Hydraulic Pressure Sensor 1)
information

1
or start engine and carry out troubleshooting in each case.
HHP Voltage
Defective work equipment oil
Between (B) (A) Power supply 4.5 5.5 V
2 pressure sensor (Internal
trouble) Between (C) (A) Signal 0.5 6.0 V
value in normal
state Max. 1 z
ness (Disconnection in wiring (21) HHP (female) (A) tance
3
or defective contact in con- Wiring harness between WEC3 (female) Resis-
nector) Max. 1 z
(34) HHP (female) (B) tance
Wiring harness between WEC1 (female) (1) Resis-
Max. 1 z
HHP (female) (C) tance
Min. 1 Mz
HHP (female) (C) and chassis ground tance
If causes 1 4 are not detected, work equipment controller may be
controller
carried out.)
48 D155AX-6
Circuit diagram related to work equipment oil pressure sensor
D155AX-6 49
Failure code [DH21KB] Weq pressure sensor: Short circuit 1

Action code Failure code Weq pressure sensor: Short circuit
Trouble
DH21KB (Work equipment controller system)
Contents of
Signal voltage of work equipment pump oil pressure sensor is below 6.0 V.
trouble
Action of
None in particular.
controller
Problem that
appears on Oil pressure of work equipment pump cannot be monitored.
machine
State of work equipment pump oil pressure sensor can be checked with monitoring function.
Related
(Code: 70701 Hydraulic Pressure Sensor 1)
information

1
HHP Voltage
Defective work equipment oil
Between (B) (A) Power supply 4.5 5.5 V
2 pressure sensor (Internal
Possible causes trouble) Between (C) (A) Signal 0.5 6.0 V
and standard
value in normal
state
3
Voltage Max. 1 V
HHP (female) (C) and chassis ground
If causes 1 3 are not detected, work equipment controller may be
controller
carried out.)
50 D155AX-6
Circuit diagram related to work equipment oil pressure sensor
D155AX-6 51
Failure code [DHT5KA] T/C in-pressure sensor: Disconnection 1

Action code Failure code T/C in-pressure sensor: Disconnection
Trouble
E02 DHT5KA (Power train controller system)
Contents of
Signal voltage of torque converter inlet pressure sensor is below 0.5 V.
trouble
Action of
controller
Problem that Torque converter inlet pressure cannot be monitored.
State of torque converter inlet pressure sensor can be checked with monitoring function.
Related
(Code: 32602 T/C In Pressure Sensor)
information

Defective sensor 24 V power If failure code [DBE6KK] is also displayed, carry out troubleshoot-
1
TIP Voltage
Defective torque converter
Between (B) (A) Power supply 20 30 V
2 inlet pressure sensor (Inter-
nal trouble) Between (C) (A) Signal 0.5 6.0 V
Possible causes
and standard Disconnection in wiring har- Wiring harness between STC1 (female) (21) Resis-
Max. 1 z
value in normal ness (Disconnection in wiring TIP (female) (A) tance
3
state or defective contact in con- Wiring harness between STC1 (female) (16) Resis-
nector) Max. 1 z
TIP (female) (B) tance
Max. 1 z
TIP (female) (C) tance
Ground fault in wiring har- Wiring harness between STC1 (female) (16)
Resis-
4 ness (Contact with GND cir- TIP (female) (B) or circuit branch end and Min. 1 Mz
tance
Min. 1 Mz
TIP (female) (C) and chassis ground tance
troller
carried out.)
52 D155AX-6
Circuit diagram related to torque converter inlet pressure sensor
D155AX-6 53
Failure code [DHT5KB] T/C in-pressure sensor: Short circuit 1

Action code Failure code T/C in-pressure sensor: Short circuit
Trouble
E02 DHT5KB (Power train controller system)
Contents of
Signal voltage of torque converter inlet pressure sensor is above 6.0 V.
trouble
Action of
controller
Problem that Torque converter inlet pressure cannot be monitored.
State of torque converter inlet pressure sensor can be checked with monitoring function.
Related
(Code: 32602 T/C In Pressure Sensor)
information

1
TIP Voltage
2 inlet pressure sensor (Inter-
Possible causes Sensor voltage is measured with wiring harness connected.
and standard Accordingly, if voltage is abnormal, check wiring harness and con-
value in normal troller, too, for another cause of trouble, and then judge.
3 TIP (female) (A) or circuit branch end and Voltage Max. 1 V
chassis ground
Voltage Max. 1 V
TIP (female) (C) and chassis ground
troller
carried out.)
54 D155AX-6
Circuit diagram related to torque converter inlet pressure sensor
D155AX-6 55
Failure code [DHT7KA] T/C out-pressure sensor: Disconnection 1

Action code Failure code T/C out-pressure sensor: Disconnection
Trouble
E02 DHT7KA (Power train controller system)
Contents of
Signal voltage of torque converter outlet pressure sensor is below 0.5 V.
trouble
Action of
controller
Problem that Torque converter outlet pressure cannot be monitored.
State of torque converter outlet pressure sensor can be checked with monitoring function.
Related
(Code: 32604 T/C Out Pressure Sensor)
information

1
TOP Voltage
2 outlet pressure sensor (Inter-
Disconnection in wiring har- Max. 1 z
value in normal TOP (female) (A) tance
state 3
nector) Max. 1 z
TOP (female) (B) tance
Max. 1 z
TOP (female) (C) tance
TOP (female) (B) or circuit branch end tance
cuit)
Min. 1 Mz
TOP (female) (C) and chassis ground tance
troller
carried out.)
56 D155AX-6
Circuit diagram related to torque converter outlet pressure sensor
D155AX-6 57
Failure code [DHT7KB] T/C out-pressure sensor: Short circuit 1

Action code Failure code T/C out-pressure sensor: Short circuit
Trouble
E02 DHT7KB (Power train controller system)
Contents of
Signal voltage of torque converter outlet pressure sensor is above 6.0 V.
trouble
Action of
controller
Problem that Torque converter outlet pressure cannot be monitored.
State of torque converter outlet pressure sensor can be checked with monitoring function.
Related
(Code: 32604 T/C Out Pressure Sensor)
information

1
TOP Voltage
2 outlet pressure sensor (Inter-
Possible causes Sensor voltage is measured with wiring harness connected.
and standard Accordingly, if voltage is abnormal, check wiring harness and con-
value in normal troller, too, for another cause of trouble, and then judge.
state
3 Voltage Max. 1 V
24V circuit) in wiring harness TOP (female) (A) or circuit branch end
Voltage Max. 1 V
TOP (female) (C) and chassis ground
troller
carried out.)
58 D155AX-6
Circuit diagram related to torque converter outlet pressure sensor
D155AX-6 59
Failure code [DK10KX] Fuel control Dial: Out of normal range 1

Action code Failure code Fuel control Dial: Out of normal range
Trouble
E03 DK10KX (Power train controller system)
Contents of
Signal voltage of fuel control dial is out of normal range.
trouble
Action of Continues control with signal of decelerator pedal potentiometer.
Problem that
appears on
machine
State of fuel control dial signal can be checked with monitoring function.
Related
(Code: 03000 Fuel Dial Sensor)
information

1
Defective fuel control dial DIAL (male) Resistance
Between (1) (3) 4.0 6.0 kz
short circuit)
Between (1) (2) 0.25 7.0 kz
Between (2) (3) 0.25 7.0 kz
Max. 1 z
ness (Disconnection in wiring DIAL (female) (1) tance
3
nector) Max. 1 z
DIAL (female) (2) tance
Max. 1 z
DIAL (female) (3) tance
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
Min. 1 Mz
DIAL (female) (2) and chassis ground tance
DIAL (female) (1) or circuit branch end Voltage Max. 1 V
Hot short (Short circuit with and chassis ground
5
Voltage Max. 1 V
DIAL (female) (2) and chassis ground
DIAL (female) (3) or circuit branch end Voltage Max. 1 V
and chassis ground
6
troller
Between (22) (21) 4.6 5.4 V
Between (1) (21) 0.5 4.5 V
60 D155AX-6
Circuit diagram related to fuel control dial
D155AX-6 61
D155AX-6 Bulldozer
2006 KOMATSU
All Rights Reserved
62 D155AX-6
SEN00721-01
D155AX-6

D155AX-6 80001 and up
codes, Part 6
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
Failure code [DK56KB] FR lever 1: Short circuit ................................................................................ 22

Failure code [DK57KA] FR lever 2: Disconnection............................................................................. 24
Failure code [DK57KB] FR lever 2: Short circuit ................................................................................ 26
Failure code [DKH1KA] Pitch angle sensor: Disconnection ............................................................... 28
Failure code [DKH1KB] Pitch angle sensor: Short circuit................................................................... 30
Failure code [DLT3KA] T/M out-speed sensor: Disconnection........................................................... 32
Failure code [DLT3KB] T/M out-speed sensor: Abnormal .................................................................. 33
Failure code [DW7BKA] Fan rev EPC: Disconnection ....................................................................... 34
Failure code [DW7BKB] Fan rev EPC: Short circuit........................................................................... 35
Failure code [DWN1KA] Hss EPC1: Disconnection ........................................................................... 36
Failure code [DWN1KB] Hss EPC1: Short circuit............................................................................... 37
Failure code [DWN1KY] Hss EPC1: Short circuit............................................................................... 38
Failure code [DWN2KA] Hss EPC2: Disconnection ........................................................................... 39
Failure code [DWN2KB] Hss EPC2: Short circuit............................................................................... 40
Failure code [DWN2KY] Hss EPC2: Short circuit............................................................................... 41
Failure code [DWN3KA] Ssp solenoid: Disconnection ....................................................................... 42
Failure code [DWN3KB] Ssp solenoid: Short circuit........................................................................... 44
Failure code [DWN3KY] Ssp solenoid: Short circuit........................................................................... 46
Failure code [DWN5KA] Fan pump solenoid: Disconnection ............................................................. 48
Failure code [DWN5KB] Fan pump solenoid: Short circuit................................................................. 49
Failure code [DXA0KA] TVC Sol.: Disconnection .............................................................................. 50
Failure code [DXA0KB] TVC Sol.: Short circuit .................................................................................. 51
Failure code [DXA0KY] TVC Sol.: Short circuit ................................................................................. 52
Failure code [DXH1KA] Lock-up ECMV: Disconnection..................................................................... 54
Failure code [DXH1KB] Lock-up ECMV: Short circuit ........................................................................ 56
Failure code [DXH1KY] Lock-up ECMV: Short circuit ........................................................................ 58
Failure code [DXH4KA] 1st clutch ECMV: Disconnection .................................................................. 60
2 D155AX-6

Failure code [DK30KA] ST lever 1: Disconnection 1
Action code Failure code ST lever1: Disconnection
Trouble
E03 DK30KA (Power train controller system)
Contents of
Signal voltage of PCCS lever steering potentiometer 1 system is below 0.5 V.
trouble
Action of Continues control with signal of PCCS lever steering potentiometer 2 system.
Problem that
appears on
machine
State of PCCS lever steering potentiometer 1 signal can be checked with monitoring function.
Related (Code: 50300 S/T Lever 1 Potentio)
information Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (in steering
direction).

1
Defective PCCS lever steer- TLV1 (male) PCCS lever Resistance
2 ing potentiometer 1 (Internal
Between (5) (8) 3.2 kz 20%
disconnection)
Between (5) (7) Neutral 1.6 kz 20%
Between (7) (8) 1.6 kz 20%
Possible causes
and standard
value in normal ness (Disconnection in wiring Wiring harness between STC1 (female) (22) Resis-
3 Max. 1 z
state or defective contact in con- TLV1 (female) (5) tance
Max. 1 z
TLV1 (female) (7) tance
Min. 1 Mz
TLV1 (female) (7) and chassis ground tance
5
Between (2) (21) 0.5 4.5 V
4 D155AX-6
Circuit diagram related to PCCS lever potentiometer
D155AX-6 5
Failure code [DK30KB] ST lever 1: Short circuit 1

Action code Failure code ST lever1: Short circuit
Trouble
E03 DK30KB (Power train controller system)
Contents of
Signal voltage of PCCS lever steering potentiometer 1 system is above 4.5 V.
trouble
Problem that
appears on
machine
direction).

1
Between (5) (8) 3.2 kz 20%
short circuit)
Possible causes Between (5) (7) Neutral 1.6 kz 20%
and standard
value in normal Between (7) (8) 1.6 kz 20%
3
Voltage Max. 1 V
TLV1 (female) (7) and chassis ground
4
Between (2) (21) 0.5 4.5 V
6 D155AX-6
D155AX-6 7
Failure code [DK30KX] ST lever 1: Out of normal range 1

Action code Failure code ST lever 1: Out of normal range
Trouble
Contents of In PCCS lever steering potentiometer 1 and 2 systems, either of failure codes [DK30KA] and
trouble [DK30KB] and either of failure codes [DK31KA] and [DK31KB] occurred simultaneously.
Action of
controller
Problem that
appears on
machine
State of PCCS lever steering potentiometer signal can be checked with monitoring function.
(Code: 50300 S/T Lever 1 Potentio)
Related
information
Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (in steering
direction).

and standard
value in normal Carry out troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
state
Failure code [DK30KZ] RL lever: Disconnection or short circuit 1

Action code Failure code ST lever: Disconnection or short circuit
Trouble
E04 DK30KZ (Power train controller system)
In PCCS lever steering potentiometer 1 and 2 systems, when starting switch is turned ON, only
Contents of
either side is abnormal and then either of failure codes [DK30KA] and [DK30KB] and either of fail-
trouble
ure codes [DK31KA] and [DK31KB] occurred simultaneously.
Action of
controller
Problem that
appears on
machine
Related
information
direction).

and standard
state
8 D155AX-6
Failure code [DK30L8] ST lever: Signal mismatch 1

Action code Failure code ST lever: Signal mismatch
Trouble
E03 DK30L8 (Power train controller system)
Contents of In PCCS lever steering potentiometer 1 and 2 systems, total of both signal voltages is below 4.41 V
Action of Continues control with signal of normal one of PCCS lever steering potentiometer 1 and 2 systems.
Problem that
appears on
machine
Related
information
direction).

and standard
state
D155AX-6 9
Failure code [DK31KA] ST lever 2: Disconnection 1

Action code Failure code ST lever 2: Disconnection
Trouble
Contents of
Signal voltage of PCCS lever steering potentiometer 2 system is below 0.5 V.
trouble
Problem that
appears on
machine
direction).

1
Between (5) (8) 3.2 kz 20%
disconnection)
Between (6) (8) 1.6 kz 20%
Possible causes
and standard
3 Max. 1 z
Max. 1 z
Min. 1 Mz
5
Between (19) (21) 0.5 4.5 V
10 D155AX-6
D155AX-6 11
Failure code [DK31KB] ST lever 2: Short circuit 1

Action code Failure code ST lever 2: Short circuit
Trouble
Contents of
Signal voltage of PCCS lever steering potentiometer 2 system is above 4.5 V.
trouble
Problem that
appears on
machine
direction).

1
Between (5) (8) 3.2 kz 20%
short circuit)
and standard
3
Voltage Max. 1 V
4
Between (19) (21) 0.5 4.5 V
12 D155AX-6
D155AX-6 13
Failure code [DK40KA] Brake potentiometer: Disconnection 1

Action code Failure code Brake potentiometer: Disconnection
Trouble
Contents of
Signal voltage of brake pedal potentiometer is below 0.5 V.
trouble
Action of
Cannot recognize brake pedal position.
controller
Problem that
appears on Auto shift-down function may not operate normally.
machine
Related
information

1
Defective brake pedal poten- BRK (male) Resistance
2 tiometer (Internal disconnec-
Between (A) (C) 4.0 6.0 kz
tion)
Between (A) (B) 0.25 7.0 kz
Between (B) (C) 0.25 7.0 kz
Max. 1 z
Possible causes ness (Disconnection in wiring BRK (female) (A) tance
and standard 3
value in normal nector) Max. 1 z
BRK (female) (B) tance
state
Max. 1 z
BRK (female) (C) tance
Ground fault in wiring har- Wiring harness between STC1 (female) (3) Resis-
Min. 1 Mz
4 ness (Contact with GND cir- BRK (female) (B) and chassis ground tance
cuit) Wiring harness between STC1 (female) (22)
Resis-
BRK (female) (C) or circuit branch end Min. 1 Mz
tance
and chassis ground
5
Between (3) (21) 0.5 4.5 V
14 D155AX-6
Circuit diagram related to brake pedal potentiometer
D155AX-6 15
Failure code [DK40KB] Brake potentiometer: Short circuit 1

Action code Failure code Brake potentiometer: Short circuit
Trouble
Contents of
Signal voltage of brake pedal potentiometer is above 4.5 V.
trouble
Action of
Cannot recognize brake pedal position.
controller
Problem that
appears on Auto shift-down function may not operate normally.
machine
Related
information

1
Defective brake pedal poten- BRK (male) Resistance
2 tiometer (Internal short cir-
Between (A) (C) 4.0 6.0 kz
cuit)
Between (A) (B) 0.25 7.0 kz
Possible causes Between (B) (C) 0.25 7.0 kz
and standard a Prepare with starting switch OFF, then turn starting switch ON
value in normal and carry out troubleshooting.
state
Hot short (Short circuit with Voltage Max. 1 V
3 BRK (female) (B) and chassis ground
BRK (female) (C) or circuit branch end Voltage Max. 1 V
and chassis ground
4
Between (3) (21) 0.5 4.5 V
16 D155AX-6
Circuit diagram related to brake pedal potentiometer
D155AX-6 17
Failure code [DK55KX] FR lever: Out of normal range 1

Action code Failure code FR lever 1: Out of normal range
Trouble
Contents of In PCCS lever F-R potentiometer 1 and 2 systems, either of failure codes [DK56KA] and [DK56KB]
trouble and either of failure codes [DK57KA] and [DK57KB] occurred simultaneously.
Action of
controller
Problem that
appears on
machine
State of PCCS lever F-R potentiometer signal can be checked with monitoring function.
(Code: 50200 T/M Lever 1 Potentio)
Related
information
Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (in F-R direc-
tion).

and standard
state
Failure code [DK55KZ] FR lever: Disconnection or short circuit 1

Action code Failure code FR lever: Disconnection or short circuit
Trouble
E04 DK55KZ (Power train controller system)
In PCCS lever F-R potentiometer 1 and 2 systems, when starting switch is turned ON, only either
Contents of
side is abnormal and then either of failure codes [DK56KA] and [DK56KB] and either of failure
trouble
codes [DK57KA] and [DK57KB] occurred simultaneously.
Action of
controller
Problem that
appears on
machine
Related
information
tion).

and standard
state
18 D155AX-6
Failure code [DK55L8] FR lever: Signal mismatch 1

Action code Failure code FR lever: Signal mismatch
Trouble
E03 DK55L8 (Power train controller system)
Contents of In PCCS lever F-R potentiometer 1 and 2 systems, total of both signal voltages is below 4.41 V or
trouble above 5.59 V.
Action of Continues control with signal of normal one of PCCS lever F-R potentiometer 1 and 2 systems.
Problem that
appears on
machine
Related
information
tion).

and standard
state
D155AX-6 19
Failure code [DK56KA] FR lever 1: Disconnection 1

Action code Failure code FR lever 1: Disconnection
Trouble
Contents of
Signal voltage of PCCS lever F-R potentiometer 1 system is below 0.5 V.
trouble
Action of Continues control with signal of PCCS lever F-R potentiometer 2 system.
Problem that
appears on
machine
State of PCCS lever F-R potentiometer 1 signal can be checked with monitoring function.
Related (Code: 50200 T/M Lever 1 Potentio)
information Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (in F-R direc-
tion).

1
Defective PCCS lever F-R TLV1 (male) PCCS lever Resistance
2 potentiometer 1 (Internal dis-
Between (4) (1) 3.2 kz 20%
connection)
Between (3) (1) 1.6 kz 20%
Possible causes
and standard
3 Max. 1 z
Max. 1 z
Min. 1 Mz
5
Between (13) (21) 0.5 4.5 V
20 D155AX-6
D155AX-6 21
Failure code [DK56KB] FR lever 1: Short circuit 1

Action code Failure code FR lever 1: Short circuit
Trouble
Contents of
Signal voltage of PCCS lever F-R potentiometer 1 system is above 4.5 V.
trouble
Problem that
appears on
machine
tion).

1
2 potentiometer 1 (Internal
Between (4) (1) 3.2 kz 20%
short circuit)
and standard
3
Voltage Max. 1 V
4
Between (13) (21) 0.5 4.5 V
22 D155AX-6
D155AX-6 23
Failure code [DK57KA] FR lever 2: Disconnection 1

Action code Failure code FR lever 2: Disconnection
Trouble
Contents of
Signal voltage of PCCS lever F-R potentiometer 2 system is below 0.5 V.
trouble
Problem that
appears on
machine
tion).

1
2 potentiometer 2 (Internal dis-
Between (4) (1) 3.2 kz 20%
connection)
Between (2) (1) 1.6 kz 20%
Possible causes
and standard
3 Max. 1 z
Max. 1 z
Min. 1 Mz
5
Between (7) (21) 0.5 4.5 V
24 D155AX-6
D155AX-6 25
Failure code [DK57KB] FR lever 2: Short circuit 1

Action code Failure code FR lever 2: Short circuit
Trouble
Contents of
Signal voltage of PCCS lever F-R potentiometer 2 system is above 4.5 V.
trouble
Problem that
appears on
machine
tion).

1
2 potentiometer 2 (Internal
Between (4) (1) 3.2 kz 20%
short circuit)
and standard
3
Voltage Max. 1 V
4
Between (7) (21) 0.5 4.5 V
26 D155AX-6
D155AX-6 27
Failure code [DKH1KA] Pitch angle sensor: Disconnection 1

Action code Failure code Pitch angle sensor: Disconnection
Trouble
E03 DKH1KA (Power train controller system)
Contents of
Signal voltage of pitch angle sensor is below 0.5 V.
trouble
Action of Cannot sense pitch angle of machine.
Problem that Gearshift shock is made on slope or steering shock is made on level ground.
State of pitch angle sensor signal can be checked with monitoring function.
Related
(Code: 60100 Pitch Angle Sensor)
information

1
PT1 Voltage
Defective pitch angle sensor Between (C) (A) Power supply 20 30 V
2
(Internal trouble) Between (B) (A) Signal 0.15 4.85 V
value in normal
state Max. 1 z
ness (Disconnection in wiring PT1 (female) (A) tance
3
nector) Max. 1 z
PT1 (female) (B) tance
Max. 1 z
PT1 (female) (C) tance
Min. 1 Mz
PT1 (female) (B) and chassis ground tance
troller
carried out.)
28 D155AX-6
Circuit diagram related to pitch angle sensor
D155AX-6 29
Failure code [DKH1KB] Pitch angle sensor: Short circuit 1

Action code Failure code Pitch angle sensor: Short circuit
Trouble
E03 DKH1KB (Power train controller system)
Contents of
Signal voltage of pitch angle sensor is above 4.85 V.
trouble
Action of Cannot sense pitch angle of machine.
Problem that Gearshift shock is made on slope or steering shock is made on level ground.
State of pitch angle sensor signal can be checked with monitoring function.
Related
(Code: 60100 Pitch Angle Sensor)
information

1
PT1 Voltage
Defective pitch angle sensor Between (C) (A) Power supply 20 30 V
2
Possible causes (Internal trouble) Between (B) (A) Signal 0.15 4.85 V
and standard
value in normal
state
3
Voltage Max. 1 V
PT1 (female) (B) and chassis ground
troller
carried out.)
30 D155AX-6
Circuit diagram related to pitch angle sensor
D155AX-6 31
Failure code [DLT3KA] T/M out-speed sensor: Disconnection 1

Action code Failure code T/M out-speed sensor: Disconnection
Trouble
E01 DLT3KA (Power train controller system)
Contents of
No signal is input from transmission bevel speed sensor.
trouble
Action of
Recognizes that transmission bevel speed is 0 rpm.
controller
Problem that
Transmission bevel speed cannot be monitored.
appears on
Traction force cannot be calculated.
machine
Transmission bevel speed can be checked with monitoring function.
Related (Code: 31400 T/M Out Speed)
information Method of reproducing failure code: Turn starting switch ON + Drive machine (actually or with no
load).

Defective transmission bevel
1 speed sensor (Internal dis- BVRV (male) Resistance
connection or short circuit) Between (1) (2) 500 1,000 z
Possible causes
and standard ness (Disconnection in wiring Wiring harness between STC2 (female) (30) Resis-
3 Max. 1 z
value in normal or defective contact in con- BVRV (female) (1) tance
state nector) Wiring harness between STC2 (female) (29) Resis-
Max. 1 z
BVRV (female) (2) tance
Min. 1 Mz
BVRV (female) (1) and chassis ground tance
troller
carried out.)
Circuit diagram related to transmission bevel speed sensor
32 D155AX-6
Failure code [DLT3KB] T/M out-speed sensor: Abnormal 1

Action code Failure code T/M out-speed sensor: Abnormal
Trouble
E01 DLT3KB (Power train controller system)
Contents of
No signal is input from transmission bevel speed sensor.
trouble
Action of
Recognizes that transmission bevel speed is 0 rpm.
controller
Problem that
Transmission bevel speed cannot be monitored.
appears on
Traction force cannot be calculated.
machine
Transmission bevel speed can be checked with monitoring function.
Related (Code: 31400 T/M Out Speed)
information Method of reproducing failure code: Turn starting switch ON + Drive machine (actually or with no
load).

Defective transmission bevel
1 speed sensor (Internal dis- BVRV (male) Resistance
connection or short circuit) Between (1) (2) 500 1,000 z
Possible causes
and standard ness (Disconnection in wiring Wiring harness between STC2 (female) (30) Resis-
2 Max. 1 z
value in normal or defective contact in con- BVRV (female) (1) tance
state nector) Wiring harness between STC2 (female) (29) Resis-
Max. 1 z
BVRV (female) (2) tance
Min. 1 Mz
BVRV (female) (1) and chassis ground tance
troller
carried out.)
Circuit diagram related to transmission bevel speed sensor
D155AX-6 33
Failure code [DW7BKA] Fan rev EPC: Disconnection 1

Action code Failure code Fan rev EPC: Disconnection
Trouble
E01 DW7BKA (Power train controller system)
Contents of
When signal is output to fan reverse solenoid circuit, no current flows.
trouble
Action of
Turns signal to fan reverse solenoid circuit OFF.
controller
Problem that
appears on Fan reverse function cannot be used.
machine
Operating condition of fan reverse solenoid can be checked with monitoring function.
Related
(Code: 40909 T/M Output 1)
information
Method of reproducing failure code: Turn starting switch ON + Select fan reverse mode.

Defective fan reverse sole- ing without turning starting switch ON.
1
noid (Internal disconnection) FAR (male) Resistance
Between (1) (2) 34 44 z
Possible causes ness (Disconnection in wiring Wiring harness between STC3 (female) (18) Resis-
or defective contact in con- FAR (female) (1) tance
value in normal nector) Wiring harness between STC3 (female) (13) Resis-
state Max. 1 z
FAR (female) (2) tance
3
Voltage Max. 1 V
FAR (female) (1) and chassis ground
troller
carried out.)
Circuit diagram related to fan reverse solenoid
34 D155AX-6
Failure code [DW7BKB] Fan rev EPC: Short circuit 1

Action code Failure code Fan rev EPC: Short circuit
Trouble
E01 DW7BKB (Power train controller system)
Contents of
When signal was output to fan reverse solenoid circuit, abnormal current flowed.
trouble
Action of
Turns signal to fan reverse solenoid circuit OFF.
controller
Problem that
appears on Fan reverse function cannot be used.
machine
Operating condition of fan reverse solenoid can be checked with monitoring function.
Related
(Code: 40909 T/M Output 1)
information
Method of reproducing failure code: Turn starting switch ON + Select fan reverse mode.

Defective fan reverse sole- FAR (male) Resistance
1
noid (Internal short circuit)
Between (1) (2) 34 44 z
value in normal Min. 1 Mz
FAR (female) (1) and chassis ground tance
state
3 ness (with another wiring Wiring harness between STC3 (female) (18)
harness) Resis-
FAR (female) (1) and between STC3 Min. 1 Mz
tance
(female) (13) FAR (female) (2)
troller
carried out.)
Circuit diagram related to fan reverse solenoid
D155AX-6 35
Failure code [DWN1KA] Hss EPC1: Disconnection 1

Action code Failure code Hss EPC1: Disconnection
Trouble
E03 DWN1KA (Power train controller system)
Contents of
When signal is output to HSS left EPC solenoid circuit, no current flows.
trouble
Action of Turns signal to HSS left EPC solenoid circuit OFF.
Problem that
appears on
machine
Output to HSS left EPC solenoid can be checked with monitoring function.
Related
(Code: 50600 HSS Solenoid LH (F/B))
information
Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (Left steering)

Defective HSS left EPC sole- ing without turning starting switch ON.
1
noid (Internal disconnection) HSL (male) Resistance
Between (1) (2) 4.5 14.5 z
2 Max. 1 z
and standard or defective contact in con- HSL (female) (1) tance
Max. 1 z
state HSL (female) (2) tance
3
HSL (female) (2) or circuit branch end and Voltage Max. 1 V
chassis ground
troller
carried out.)
Circuit diagram related to HSS left EPC solenoid
36 D155AX-6
Failure code [DWN1KB] Hss EPC1: Short circuit 1

Action code Failure code Hss EPC1: Short circuit
Trouble
E03 DWN1KB (Power train controller system)
Contents of
When signal is output to HSS left EPC solenoid circuit, abnormal current flowed.
trouble
Problem that
appears on
machine
Related
information
Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (Left steering).

Defective HSS left EPC sole- HSL (male) Resistance
1
Between (1) (2) 4.5 14.5 z
HSL (female) (1) and chassis ground tance
state
harness) Resis-
HSL (female) (1) and between STC3 Min. 1 Mz
tance
(female) (3) HSL (female) (2)
troller
carried out.)
D155AX-6 37
Failure code [DWN1KY] Hss EPC1: Short circuit 1

Trouble
E03 DWN1KY (Power train controller system)
Contents of
When signal is output to HSS left EPC solenoid circuit, abnormal current flowed.
trouble
Problem that
appears on
machine
Related
information
Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (Left steering).

Defective HSS left EPC sole- HSL (male) Resistance
1
Between (1) (2) 4.5 14.5 z
Possible causes Hot short (Short circuit with and carry out troubleshooting.
and standard 2
value in normal Voltage Max. 1 V
HSL (female) (1) and chassis ground
state
harness) Resis-
HSL (female) (1) and between STC3 Min. 1 Mz
tance
(female) (3) HSL (female) (2)
troller
carried out.)
38 D155AX-6
Failure code [DWN2KA] Hss EPC2: Disconnection 1

Action code Failure code Hss EPC2: Disconnection
Trouble
Contents of
When signal is output to HSS right EPC solenoid circuit, no current flows.
trouble
Action of Turns signal to HSS right EPC solenoid circuit OFF.
Problem that
appears on
machine
Output to HSS right EPC solenoid can be checked with monitoring function.
Related
(Code: 50601 HSS Solenoid RH (F/B))
information
Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (Right steering).

Defective HSS right EPC ing without turning starting switch ON.
1 solenoid (Internal disconnec-
HSR (male) Resistance
tion)
Between (1) (2) 4.5 14.5 z
2 Max. 1 z
and standard or defective contact in con- HSR (female) (1) tance
Max. 1 z
state HSR (female) (2) tance
3
HSR (female) (2) or circuit branch end and Voltage Max. 1 V
chassis ground
troller
carried out.)
Circuit diagram related to HSS right EPC solenoid
D155AX-6 39
Failure code [DWN2KB] Hss EPC2: Short circuit 1

Trouble
Contents of
When signal is output to HSS right EPC solenoid circuit, abnormal current flowed.
trouble
Problem that
appears on
machine
Related
information

Defective HSS right EPC
1 solenoid (Internal short cir- HSR (male) Resistance
cuit) Between (1) (2) 4.5 14.5 z
HSR (female) (1) and chassis ground tance
state
harness) Resis-
HSR (female) (1) and between STC3 Min. 1 Mz
tance
(female) (3) HSR (female) (2)
troller
carried out.)
40 D155AX-6
Failure code [DWN2KY] Hss EPC2: Short circuit 1

Trouble
Contents of
When signal is output to HSS right EPC solenoid circuit, abnormal current flowed.
trouble
Problem that
appears on
machine
Related
information

Defective HSS right EPC
1 solenoid (Internal short cir- HSR (male) Resistance
cuit) Between (1) (2) 4.5 14.5 z
and standard 2
HSR (female) (1) and chassis ground
state
harness) Resis-
HSR (female) (1) and between STC3 Min. 1 Mz
tance
(female) (3) HSR (female) (2)
troller
carried out.)
D155AX-6 41
Failure code [DWN3KA] Ssp solenoid: Disconnection 1

Action code Failure code Ssp solenoid: Disconnection
Trouble
Contents of
When signal is output to sudden stop prevent solenoid circuit, no current flows.
trouble
Action of
controller
Problem that Brake is applied lightly during travel.
Output to sudden stop prevent solenoid can be checked with monitoring function.
Related
(Code: 31628 SSP Solenoid)
information

Defective sudden stop pre- ing without turning starting switch ON.
1 vent solenoid (Internal dis-
SSP (male) Resistance
connection)
Between (1) (2) 3.5 12.5 z
or defective contact in con- SSP (female) (1) tance
Max. 1 z
state SSP (female) (2) tance
3
Voltage Max. 1 V
SSP (female) (1) and chassis ground
4
Between (7) (23) 3.5 12.5 z
42 D155AX-6
Circuit diagram related to sudden stop prevent solenoid
D155AX-6 43
Failure code [DWN3KB] Ssp solenoid: Short circuit 1

Action code Failure code Ssp solenoid: Short circuit
Trouble
Contents of
When signal was output to sudden stop prevent solenoid circuit, abnormal current flowed.
trouble
Action of
controller
Related
information

Defective sudden stop pre-
1 vent solenoid (Internal short SSP (male) Resistance
circuit) Between (1) (2) 3.5 12.5 z
Possible causes cuit) Wiring harness between STC3 (female) (7) Resis-
Min. 1 Mz
and standard SSP (female) (1) and chassis ground tance
Short circuit in wiring har-
harness) Resis-
SSP (female) (1) and between STC3 Min. 1 Mz
tance
(female) (23) SSP (female) (2)
4
troller
Between (7) (23) 3.5 12.5 z
44 D155AX-6
D155AX-6 45
Failure code [DWN3KY] Ssp solenoid: Short circuit 1

Action code Failure code Ssp solenoid: Short circuit
Trouble
Contents of
When signal was output to sudden stop prevent solenoid circuit, abnormal current flowed.
trouble
Action of
controller
Related
information

Defective sudden stop pre-
1 vent solenoid (Internal short SSP (male) Resistance
2
Possible causes 24V circuit) in wiring harness Wiring harness between STC3 (female) (7)
Voltage Max. 1 V
and standard SSP (female) (1) and chassis ground
harness) Resis-
SSP (female) (1) and between STC3 Min. 1 Mz
tance
(female) (23) SSP (female) (2)
4
troller
Between (7) (23) 3.5 12.5 z
46 D155AX-6
D155AX-6 47
Failure code [DWN5KA] Fan pump solenoid: Disconnection 1

Action code Failure code Fan pump solenoid: Disconnection
Trouble
Contents of
When signal is output to fan pump EPC solenoid circuit, no current flows.
trouble
Action of
Turns signal to fan pump EPC solenoid circuit OFF.
controller
Problem that
appears on Fan speed is kept at maximum.
machine
Output to fan pump EPC solenoid can be checked with monitoring function.
Related
(Code: 31624 Fan pump Solenoid (F/B))
information

Defective fan pump EPC ing without turning starting switch ON.
FAC (male) Resistance
tion)
Between (1) (2) 2 12 z
2 Max. 1 z
and standard or defective contact in con- FAC (female) (1) tance
Max. 1 z
state FAC (female) (2) tance
3
FAC (female) (2) or circuit branch end and Voltage Max. 1 V
chassis ground
troller
carried out.)
Circuit diagram related to fan control solenoid
48 D155AX-6
Failure code [DWN5KB] Fan pump solenoid: Short circuit 1

Action code Failure code Fan pump solenoid: Short circuit
Trouble
Contents of
When signal was output to fan pump EPC solenoid circuit, abnormal current flowed.
trouble
Action of
Turns signal to fan pump EPC solenoid circuit OFF.
controller
Problem that
appears on Fan speed is kept at maximum.
machine
Output to fan pump EPC solenoid can be checked with monitoring function.
Related
(Code: 31624 Fan pump Solenoid (F/B))
information

Defective fan pump EPC
1 solenoid (Internal short cir- FAC (male) Resistance
cuit) Between (1) (2) 2 12 z
FAC (female) (1) and chassis ground tance
state
harness) Resis-
FAC (female) (1) and between STC3 Min. 1 Mz
tance
(female) (23) FAC (female) (2)
troller
carried out.)
Circuit diagram related to fan control solenoid
D155AX-6 49
Failure code [DXA0KA] TVC Sol.: Disconnection 1

Action code Failure code TVC Sol.: Disconnection
Trouble
E01 DXA0KA (Work equipment controller system)
Contents of
When signal is output to work equipment-HSS pump TVC solenoid circuit, no current flows.
trouble
Action of
Turns signal to work equipment-HSS pump TVC solenoid circuit OFF.
controller
Problem that
appears on If engine is loaded while running at low speed, it stops.
machine
Output to work equipment-HSS pump TVC solenoid can be checked with monitoring function.
Related
(Code: 01300 TVC Solenoid (F/B))
information

Defective work equipment- ing without turning starting switch ON.
1 HSS pump TVC solenoid
TVC (male) Resistance
(Internal disconnection)
Between (1) (2) 2 12 z
ness (Disconnection in wiring Wiring harness between WEC3 (female) (7) Resis-
or defective contact in con- TVC (female) (1) tance
value in normal Wiring harness between WEC3 (female) (3) Resis-
Max. 1 z
state TVC (female) (2) tance
3
Voltage Max. 1 V
TVC (female) (1) and chassis ground
Defective work equipment ing without turning starting switch ON.
4
controller WEC3 (female) Resistance
Between (7) (3) 2 12 z
Circuit diagram related to work equipment-HSS pump TVC solenoid
50 D155AX-6
Failure code [DXA0KB] TVC Sol.: Short circuit 1

Action code Failure code TVC Sol.: Short circuit
Trouble
E01 DXA0KB (Work equipment controller system)
Contents of When signal was output to work equipment-HSS pump TVC solenoid circuit, abnormal current
trouble flowed.
Action of
controller
Problem that
appears on If engine is loaded while running at low speed, it stops.
machine
Related
information

Defective work equipment-
1 HSS pump TVC solenoid TVC (male) Resistance
(Internal disconnection) Between (1) (2) 2 12 z
Possible causes cuit) Wiring harness between WEC3 (female) (7) Resis-
Min. 1 Mz
and standard TVC (female) (1) and chassis ground tance
3 ness (with another wiring Wiring harness between WEC3 (female) (7)
harness) Resis-
TVC (female) (1) and between WEC3 Min. 1 Mz
tance
(female) (3) TVC (female) (2)
Defective work equipment WEC3 (female) Resistance
4
controller
Between (7) (3) 2 12 z
D155AX-6 51
Failure code [DXA0KY] TVC Sol.: Short circuit 1

Action code Failure code TVC Sol.: Short circuit
Trouble
E01 DXA0KY (Work equipment controller system)
Contents of When signal was output to work equipment-HSS pump TVC solenoid circuit, abnormal current
trouble flowed.
Action of
controller
Problem that
appears on Work equipment speed may be lowered.
machine
Related
information

Defective work equipment-
1 HSS pump TVC solenoid TVC (male) Resistance
(Internal disconnection) Between (1) (2) 2 12 z
2
Possible causes 24V circuit) in wiring harness Wiring harness between WEC3 (female) (7)
Voltage Max. 1 V
and standard TVC (female) (1) and chassis ground
3 ness (with another wiring Wiring harness between WEC3 (female) (7)
harness) Resis-
TVC (female) (1) and between WEC3 Min. 1 Mz
tance
(female) (3) TVC (female) (2)
4
controller
Between (7) (3) 2 12 z
52 D155AX-6
Failure code [DXH1KA] Lock-up ECMV: Disconnection 1

Action code Failure code Lock-up ECMV: Disconnection
Trouble
E02 DXH1KA (Power train controller system)
Contents of
When signal is output to torque converter lockup clutch ECMV solenoid circuit, no current flows.
trouble
Action of
Turns signal to torque converter lockup clutch ECMV solenoid circuit OFF.
controller
Problem that
appears on Torque converter lockup function does not operate.
machine
Output to torque converter lockup clutch ECMV solenoid can be checked with monitoring function.
Related
(Code: 31642 L/U ECMV (F/B))
information
Method of reproducing failure code: Start engine + Drive forward (in auto gearshift mode).

Defective lockup clutch ing without turning starting switch ON.
1 ECMV solenoid (Internal dis-
SLUC (male) Resistance
connection)
Between (1) (2) 3.5 12.5 z
or defective contact in con- SLUC (female) (1) tance
Max. 1 z
state SLUC (female) (2) tance
3
Voltage Max. 1 V
SLUC (female) (1) and chassis ground
4
Between (17) (13) 3.5 12.5 z
54 D155AX-6
D155AX-6 55
Failure code [DXH1KB] Lock-up ECMV: Short circuit 1

Action code Failure code Lock-up ECMV: Short circuit
Trouble
E02 DXH1KB (Power train controller system)
Contents of When signal was output to torque converter lockup clutch ECMV solenoid circuit, abnormal current
trouble flowed.
Action of
controller
Problem that
appears on Torque converter lockup function does not operate.
machine
Output to torque converter lockup clutch ECMV solenoid can be checked with monitoring function.
Related
(Code: 31642 L/U ECMV (F/B))
information
Method of reproducing failure code: Start engine + Drive forward (in auto gearshift mode).

Defective lockup clutch
1 ECMV solenoid (Internal SLUC (male) Resistance
short circuit) Between (1) (2) 3.5 12.5 z
Min. 1 Mz
and standard SLUC (female) (1) and chassis ground tance
harness) Resis-
SLUC (female) (1) and between STC3 Min. 1 Mz
tance
(female) (13) SLUC (female) (2)
4
troller
Between (17) (13) 3.5 12.5 z
56 D155AX-6
D155AX-6 57
Failure code [DXH1KY] Lock-up ECMV: Short circuit 1

Action code Failure code Lock-up ECMV: Short circuit
Trouble
E03 DXH1KY (Power train controller system)
Contents of When signal was output to torque converter lockup clutch ECMV solenoid circuit, abnormal current
trouble flowed.
Action of
controller
Problem that
Torque converter lockup function operates constantly.
appears on
Engine may stall during travel.
machine
Output to lockup clutch ECMV solenoid can be checked with monitoring function.
Related (Code: 31642 L/U ECMV (F/B))
information Method of reproducing failure code: Start engine + Drive in auto gearshift mode (while lockup is in
operation).

Defective lockup clutch
1 ECMV solenoid (Internal SLUC (male) Resistance
short circuit) Between (1) (2) 3.5 12.5 z
2
Voltage Max. 1 V
and standard SLUC (female) (1) and chassis ground
harness) Resis-
SLUC (female) (1) and between STC3 Min. 1 Mz
tance
(female) (13) SLUC (female) (2)
4
troller
Between (17) (13) 3.5 12.5 z
58 D155AX-6
D155AX-6 59
Failure code [DXH4KA] 1st clutch ECMV: Disconnection 1

Action code Failure code 1st clutch ECMV: Disconnection
Trouble
Contents of
When signal is output to transmission 1st clutch ECMV solenoid circuit, no current flows.
trouble
Action of Turns signal to transmission 1st clutch ECMV solenoid circuit OFF.
Problem that Auto shift-down function does not operate.
Output to 1st clutch ECMV solenoid can be checked with monitoring function.
Related
(Code: 31602 T/M Clutch 1st ECMV (F/B))
information
Method of reproducing failure code: Start engine + Set gear to F1 or R1.

Defective 1st clutch ECMV ing without turning starting switch ON.
1
solenoid S1T (male) Resistance
Between (1) (2) 3.5 12.5 z
2 Max. 1 z
and standard or defective contact in con- S1T (female) (1) tance
Max. 1 z
state S1T (female) (2) tance
3
S1T (female) (2) or circuit branch end and Voltage Max. 1 V
chassis ground
troller
carried out.)
60 D155AX-6
D155AX-6 Bulldozer
2006 KOMATSU
All Rights Reserved
62 D155AX-6
SEN00722-01
D155AX-6

D155AX-6 80001 and up
codes, Part 7
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
Failure code [DXH8KY] F clutch ECMV: Short circuit ........................................................................ 16

Failure code [DXHBKA] Right brake ECMV: Disconnection............................................................... 18
Failure code [DXHBKB] Right brake ECMV: Short circuit .................................................................. 20
Failure code [DXHBKY] Right brake ECMV: Short circuit .................................................................. 22
Failure code [DXHCKA] Left brake ECMV: Disconnection................................................................. 24
Failure code [DXHCKB] Left brake ECMV: Short circuit .................................................................... 26
Failure code [DXHCKY] Left brake ECMV: Short circuit .................................................................... 28
Failure code [DXHRKA] Blade up EPC: Disconnection ..................................................................... 30
Failure code [DXHRKB] Blade up EPC: Short circuit ......................................................................... 31
Failure code [DXHRKY] Blade up EPC: Short circuit ......................................................................... 32
Failure code [DXHSKA] Blade down EPC: Disconnection ................................................................. 33
Failure code [DXHSKB] Blade down EPC: Short circuit..................................................................... 34
Failure code [DXHSKY] Blade down EPC: Short circuit..................................................................... 35
Failure code [DXHTKA] Blade left 1 EPC: Disconnection .................................................................. 36
Failure code [DXHTKB] Blade left 1 EPC: Short circuit...................................................................... 37
Failure code [DXHTKY] Blade left 1 EPC: Short circuit...................................................................... 38
Failure code [DXHUKA] Blade right 1 EPC: Disconnection ............................................................... 39
Failure code [DXHUKB] Blade right 1 EPC: Short circuit ................................................................... 40
Failure code [DXHUKY] Blade right 1 EPC: Short circuit ................................................................... 41
Failure code [DXHWKA] Ripper up EPC: Disconnection ................................................................... 42
Failure code [DXHWKB] Ripper up EPC: Short circuit....................................................................... 43
Failure code [DXHWKY] Ripper up EPC: Short circuit....................................................................... 44
Failure code [DXHXKA] Ripper down EPC: Disconnection................................................................ 45
Failure code [DXHXKB] Ripper down EPC: Short circuit ................................................................... 46
Failure code [DXHXKY] Ripper down EPC: Short circuit ................................................................... 47
Failure code [DXHYKA] Ripper Tilt In EPC: Disconnection................................................................ 48
Failure code [DXHYKB] Ripper Tilt In EPC: Short circuit ................................................................... 49
Failure code [DXHYKY] Ripper Tilt In EPC: Short circuit ................................................................... 50
Failure code [DXHZKA] Ripper Tilt Back EPC: Disconnection........................................................... 51
Failure code [DXHZKB] Ripper Tilt Back EPC: Short circuit .............................................................. 52
Failure code [DXHZKY] Ripper Tilt Back EPC: Short circuit .............................................................. 53
Failure code [DXJ4KA] Weq lock Sol.: Disconnection ....................................................................... 54
Failure code [DXJ4KB] Weq lock Sol.: Short circuit ........................................................................... 55
2 D155AX-6

Failure code [DXH4KB] 1st clutch ECMV: Short circuit 1
Action code Failure code 1st clutch ECMV: Short circuit
Trouble
Contents of
When signal was output to transmission 1st clutch ECMV solenoid circuit, abnormal current flowed.
trouble
Related
information

Defective 1st clutch ECMV
1 solenoid (Internal short cir- S1T (male) Resistance
cuit) Between (1) (2) 3.5 12.5 z
S1T (female) (1) and chassis ground tance
state
harness) Resis-
S1T (female) (1) and between STC3 Min. 1 Mz
tance
(female) (23) S1T (female) (2)
troller
carried out.)
D155AX-6 3
Failure code [DXH4KY] 1st clutch ECMV: Short circuit 1

Action code Failure code 1st clutch ECMV: Short circuit
Trouble
Contents of
When signal was output to transmission 1st clutch ECMV solenoid circuit, abnormal current flowed.
trouble
Related
information

Defective 1st clutch ECMV
cuit) Between (1) (2) 3.5 12.5 z
and standard 2
S1T (female) (1) and chassis ground
state
harness) Resis-
tance
troller
carried out.)
4 D155AX-6
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection 1

Action code Failure code 2nd clutch ECMV: Disconnection
Trouble
Contents of
When signal is output to transmission 2nd clutch ECMV solenoid circuit, no current flows.
trouble
Action of Turns signal to transmission 2nd clutch ECMV solenoid circuit OFF.
Output to 2nd clutch ECMV solenoid can be checked with monitoring function.
Related
(Code: 31603 T/M Clutch 2nd ECMV (F/B))
information

Defective 2nd clutch ECMV ing without turning starting switch ON.
S2T (male) Resistance
tion)
Between (1) (2) 3.5 12.5 z
2 Max. 1 z
and standard or defective contact in con- S2T (female) (1) tance
Max. 1 z
state S2T (female) (2) tance
3
chassis ground
troller
carried out.)
D155AX-6 5
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit 1

Action code Failure code 2nd clutch ECMV: Short circuit
Trouble
Contents of
When signal was output to transmission 2nd clutch ECMV solenoid circuit, abnormal current flowed.
trouble
Related
information

Defective 2nd clutch ECMV
cuit) Between (1) (2) 3.5 12.5 z
state
harness) Resis-
tance
troller
carried out.)
6 D155AX-6
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit 1

Action code Failure code 2nd clutch ECMV: Short circuit
Trouble
Contents of
When signal was output to transmission 2nd clutch ECMV solenoid circuit, abnormal current flowed.
trouble
Related
information

Defective 2nd clutch ECMV
cuit) Between (1) (2) 3.5 12.5 z
and standard 2
state
harness) Resis-
tance
troller
carried out.)
D155AX-6 7
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection 1

Action code Failure code 3rd clutch ECMV: Disconnection
Trouble
Contents of
When signal is output to transmission 3rd clutch ECMV solenoid circuit, no current flows.
trouble
Action of Turns signal to transmission 3rd clutch ECMV solenoid circuit OFF.
Problem that
appears on
machine
Output to 3rd clutch ECMV solenoid can be checked with monitoring function.
Related
(Code: 31604 T/M Clutch 3rd ECMV (F/B))
information

Defective 3rd clutch ECMV
1 solenoid (Internal disconnec- S3T (male) Resistance
tion) Between (1) (2) 3.5 12.5 z
or defective contact in con- S3T (female) (1) tance
value in normal nector)
state Wiring harness between STC3 (female) (23) Resis-
Max. 1 z
S3T (female) (2) tance
3
chassis ground
troller
carried out.)
8 D155AX-6
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit 1

Action code Failure code 3rd clutch ECMV: Short circuit
Trouble
Contents of
When signal was output to transmission 3rd clutch ECMV solenoid circuit, abnormal current flowed.
trouble
Problem that
appears on
machine
Related
information

cuit) Between (1) (2) 3.5 12.5 z
state
harness) Resis-
tance
troller
carried out.)
D155AX-6 9
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit 1

Action code Failure code 3rd clutch ECMV: Short circuit
Trouble
Contents of
When signal was output to transmission 3rd clutch ECMV solenoid circuit, abnormal current flowed.
trouble
Problem that
appears on
machine
Related
information

cuit) Between (1) (2) 3.5 12.5 z
and standard 2
state
harness) Resis-
tance
troller
carried out.)
10 D155AX-6
Failure code [DXH7KA] R clutch ECMV: Disconnection 1

Action code Failure code R clutch ECMV: Disconnection
Trouble
Contents of
When signal is output to transmission R clutch ECMV solenoid circuit, no current flows.
trouble
Action of Turns signal to transmission R clutch ECMV solenoid circuit OFF.
Problem that
appears on
machine
Output to R clutch ECMV solenoid can be checked with monitoring function.
Related
(Code: 31616 T/M Clutch R ECMV (F/B))
information
Method of reproducing failure code: Start engine + Set gear to R (Reverse).

Defective R clutch ECMV ing without turning starting switch ON.
SRT (male) Resistance
tion)
Between (1) (2) 3.5 12.5 z
2 Max. 1 z
and standard or defective contact in con- SRT (female) (1) tance
Max. 1 z
state SRT (female) (2) tance
3
SRT (female) (2) or circuit branch end and Voltage Max. 1 V
chassis ground
troller
carried out.)
D155AX-6 11
Failure code [DXH7KB] R clutch ECMV: Short circuit 1

Action code Failure code R clutch ECMV: Short circuit
Trouble
Contents of
When signal was output to transmission R clutch ECMV solenoid circuit, abnormal current flowed.
trouble
Problem that
appears on
machine
Related
information

Defective R clutch ECMV
1 solenoid (Internal short cir- SRT (male) Resistance
cuit) Between (1) (2) 3.5 12.5 z
SRT (female) (1) and chassis ground tance
state
harness) Resis-
SRT (female) (1) and between STC3 Min. 1 Mz
tance
(female) (13) SRT (female) (2)
If causes 1 - 3 are not detected, power train controller may be
troller
carried out.)
12 D155AX-6
Failure code [DXH7KY] R clutch ECMV: Short circuit 1

Action code Failure code R clutch ECMV: Short circuit
Trouble
Contents of
When signal was output to transmission R clutch ECMV solenoid circuit, abnormal current flowed.
trouble
Problem that
appears on
machine
Related
information

Defective R clutch ECMV
1 solenoid (Internal short cir- SRT (male) Resistance
cuit) Between (1) (2) 3.5 12.5 z
and standard 2
SRT (female) (1) and chassis ground
state
harness) Resis-
SRT (female) (1) and between STC3 Min. 1 Mz
tance
(female) (13) SRT (female) (2)
troller
carried out.)
D155AX-6 13
Failure code [DXH8KA] F clutch ECMV: Disconnection 1

Action code Failure code F clutch ECMV: Disconnection
Trouble
Contents of
When signal is output to transmission F clutch ECMV solenoid circuit, no current flows.
trouble
Action of Turns signal to transmission F clutch ECMV solenoid circuit OFF.
Problem that
appears on
machine
Output to F clutch ECMV solenoid can be checked with monitoring function.
Related
(Code: 31622 T/M Clutch F ECMV (F/B))
information
Method of reproducing failure code: Start engine + Set gear to F (Forward).

Defective F clutch ECMV ing without turning starting switch ON.
SFT (male) Resistance
tion)
Between (1) (2) 3.5 12.5 z
2 Max. 1 z
and standard or defective contact in con- SFT (female) (1) tance
Max. 1 z
state SFT (female) (2) tance
3
SFT (female) (2) or circuit branch end and Voltage Max. 1 V
chassis ground
troller
carried out.)
14 D155AX-6
Failure code [DXH8KB] F clutch ECMV: Short circuit 1

Action code Failure code F clutch ECMV: Short circuit
Trouble
Contents of
When signal was output to transmission F clutch ECMV solenoid circuit, abnormal current flowed.
trouble
Problem that
appears on
machine
Related
information

Defective F clutch ECMV
1 solenoid (Internal short cir- SFT (male) Resistance
cuit) Between (1) (2) 3.5 12.5 z
SFT (female) (1) and chassis ground tance
state
harness) Resis-
SFT (female) (1) and between STC3 Min. 1 Mz
tance
(female) (13) SFT (female) (2)
troller
carried out.)
D155AX-6 15
Failure code [DXH8KY] F clutch ECMV: Short circuit 1

Action code Failure code F clutch ECMV: Short circuit
Trouble
Contents of
When signal was output to transmission F clutch ECMV solenoid circuit, abnormal current flowed.
trouble
Problem that
appears on
machine
Related
information

Defective F clutch ECMV
1 solenoid (Internal short cir- SFT (male) Resistance
cuit) Between (1) (2) 3.5 12.5 z
and standard 2
SFT (female) (1) and chassis ground
state
harness) Resis-
SFT (female) (1) and between STC3 Min. 1 Mz
tance
(female) (13) SFT (female) (2)
troller
carried out.)
16 D155AX-6
Failure code [DXHBKA] Right brake ECMV: Disconnection 1

Action code Failure code Right brake ECMV: Disconnection
Trouble
E04 DXHBKA (Power train controller system)
Contents of
When signal is output to steering case right brake ECMV solenoid circuit, no current flows.
trouble
Action of Turns signal to steering case right brake ECMV solenoid circuit OFF.
Output to right brake ECMV solenoid can be checked with monitoring function.
Related
(Code: 31618 Brake RH ECMV (F/B))
information

Defective right brake ECMV ing without turning starting switch ON.
SBRR (male) Resistance
tion)
Between (1) (2) 3.5 12.5 z
or defective contact in con- SBRR (female) (1) tance
Max. 1 z
state SBRR (female) (2) tance
3
Voltage Max. 1 V
SBRR (female) (1) and chassis ground
4
Between (15) (3) 3.5 12.5 z
18 D155AX-6
D155AX-6 19
Failure code [DXHBKB] Right brake ECMV: Short circuit 1

Action code Failure code Right brake ECMV: Short circuit
Trouble
E04 DXHBKB (Power train controller system)
Contents of When signal was output to steering case right brake ECMV solenoid circuit, abnormal current
trouble flowed.
Related
information

1 solenoid (Internal short cir- SBRR (male) Resistance
cuit) Between (1) (2) 3.5 12.5 z
Min. 1 Mz
and standard SBRR (female) (1) and chassis ground tance
harness) Resis-
SBRR (female) (1) and between STC3 Min. 1 Mz
tance
(female) (3) SBRR (female) (2)
4
troller
Between (15) (3) 3.5 12.5 z
20 D155AX-6
D155AX-6 21
Failure code [DXHBKY] Right brake ECMV: Short circuit 1

Action code Failure code Right brake ECMV: Short circuit
Trouble
E04 DXHBKY (Power train controller system)
Contents of When signal was output to steering case right brake ECMV solenoid circuit, abnormal current
trouble flowed.
Related
information

1 solenoid (Internal short cir- SBRR (male) Resistance
cuit) Between (1) (2) 3.5 12.5 z
2
Voltage Max. 1 V
and standard SBRR (female) (1) and chassis ground
harness) Resis-
SBRR (female) (1) and between STC3 Min. 1 Mz
tance
(female) (3) SBRR (female) (2)
4
troller
Between (15) (3) 3.5 12.5 z
22 D155AX-6
D155AX-6 23
Failure code [DXHCKA] Left brake ECMV: Disconnection 1

Action code Failure code Left brake ECMV: Disconnection
Trouble
E04 DXHCKA (Power train controller system)
Contents of
When signal is output to steering case left brake ECMV solenoid circuit, no current flows.
trouble
Action of Turns signal to steering case left brake ECMV solenoid circuit OFF.
Output to left brake ECMV solenoid can be checked with monitoring function.
Related
(Code: 31619 Brake LH ECMV (F/B))
information

Defective left brake ECMV ing without turning starting switch ON.
SBRL (male) Resistance
tion)
Between (1) (2) 3.5 12.5 z
or defective contact in con- SBRL (female) (1) tance
Max. 1 z
state SBRL (female) (2) tance
3
Voltage Max. 1 V
SBRL (female) (1) and chassis ground
4
Between (5) (3) 3.5 12.5 z
24 D155AX-6
D155AX-6 25
Failure code [DXHCKB] Left brake ECMV: Short circuit 1

Action code Failure code Left brake ECMV: Short circuit
Trouble
E04 DXHCKB (Power train controller system)
Contents of
When signal was output to steering case left brake ECMV solenoid circuit, abnormal current flowed.
trouble
Related
information

Defective left brake ECMV
1 solenoid (Internal short cir- SBRL (male) Resistance
cuit) Between (1) (2) 3.5 12.5 z
Min. 1 Mz
and standard SBRL (female) (1) and chassis ground tance
harness) Resis-
SBRL (female) (1) and between STC3 Min. 1 Mz
tance
(female) (3) SBRL (female) (2)
4
troller
Between (5) (3) 3.5 12.5 z
26 D155AX-6
D155AX-6 27
Failure code [DXHCKY] Left brake ECMV: Short circuit 1

Action code Failure code Left brake ECMV: Short circuit
Trouble
E04 DXHCKY (Power train controller system)
Contents of
When signal was output to steering case left brake ECMV solenoid circuit, abnormal current flowed.
trouble
Related
information

Defective left brake ECMV
1 solenoid (Internal short cir- SBRL (male) Resistance
cuit) Between (1) (2) 3.5 12.5 z
2
Voltage Max. 1 V
and standard SBRL (female) (1) and chassis ground
harness) Resis-
SBRL (female) (1) and between STC3 Min. 1 Mz
tance
(female) (3) SBRL (female) (2)
4
troller
Between (5) (3) 3.5 12.5 z
28 D155AX-6
D155AX-6 29
Failure code [DXHRKA] Blade up EPC: Disconnection 1

Action code Failure code Blade up EPC: Disconnection
Trouble
E03 DXHRKA (Work equipment controller system)
Contents of
When signal is output to blade lift-up EPC solenoid circuit, no current flows.
trouble
Action of Turns signal to blade lift-up EPC solenoid circuit OFF.
Problem that Blade cannot be lifted up.
machine Once machine is stopped, travel is limited to R1.
Output to blade lift-up EPC solenoid can be checked with monitoring function.
Related
(Code: 71001 Blade Raise EPC (F/B))
information
Method of reproducing failure code: Turn starting switch ON + Operate blade control lever (Raise).

Defective blade lift-up EPC ing without turning starting switch ON.
WEP1 (male) Resistance
tion)
Between (1) (2) 4.5 14.5 z
and standard Disconnection in wiring har-
value in normal ness (Disconnection in wiring Wiring harness between WEC3 (female) (6) Resis-
2 Max. 1 z
state or defective contact in con- WEP1 (female) (1) tance
nector) Wiring harness between WEC3 (female) Resis-
Max. 1 z
(13) WEP1 (female) (2) tance
3
Between (6) (13) 4.5 14.5 z
Circuit diagram related to blade lift-up EPC solenoid
30 D155AX-6
Failure code [DXHRKB] Blade up EPC: Short circuit 1

Action code Failure code Blade up EPC: Short circuit
Trouble
E03 DXHRKB (Work equipment controller system)
Contents of
When signal was output to blade lift-up EPC solenoid circuit, abnormal current flowed.
trouble
Related
information

Defective blade lift-up EPC
1 solenoid (Internal short cir- WEP1 (male) Resistance
cuit) Between (1) (2) 4.5 14.5 z
Possible causes
state cuit) Wiring harness between WEC3 (female) (6) Resis-
Min. 1 Mz
WEP1 (female) (1) and chassis ground tance
3
controller
Between (6) (13) 4.5 14.5 z
D155AX-6 31
Failure code [DXHRKY] Blade up EPC: Short circuit 1

Action code Failure code Blade up EPC: Short circuit
Trouble
E03 DXHRKY (Work equipment controller system)
Contents of
When signal was output to blade lift-up EPC solenoid circuit, abnormal current flowed.
trouble
Related
information

Defective blade lift-up EPC
cuit) Between (1) (2) 4.5 14.5 z
Possible causes
and standard
value in normal 2
state 24V circuit) in wiring harness Wiring harness between WEC3 (female) (6)
Voltage Max. 1 V
WEP1 (female) (1) and chassis ground
3
controller
Between (6) - (13) 4.5 14.5 z
Between (6) - chassis ground Min. 1 Mz
32 D155AX-6
Failure code [DXHSKA] Blade down EPC: Disconnection 1

Action code Failure code Blade down EPC: Disconnection
Trouble
E03 DXHSKA (Work equipment controller system)
Contents of
When signal is output to blade lift-down EPC solenoid circuit, no current flows.
trouble
Action of Turns signal to blade lift-down EPC solenoid circuit OFF.
Problem that Blade cannot be lifted down.
Output to blade lift-down EPC solenoid can be checked with monitoring function.
Related
(Code: 71003 Blade Down EPC (F/B))
information
Method of reproducing failure code: Turn starting switch ON + Operate blade control lever (Lower).

Defective blade lift-down ing without turning starting switch ON.
1 EPC solenoid (Internal dis-
connection)
Between (1) (2) 4.5 14.5 z
2 Max. 1 z
state or defective contact in con- (16) WEP2 (female) (1) tance
Max. 1 z
3
Between (16) (13) 4.5 14.5 z
Circuit diagram related to blade lift-down EPC solenoid
D155AX-6 33
Failure code [DXHSKB] Blade down EPC: Short circuit 1

Action code Failure code Blade down EPC: Short circuit
Trouble
E03 DXHSKB (Work equipment controller system)
Contents of
When signal was output to blade lift-down EPC solenoid circuit, abnormal current flowed.
trouble
Related
information

Defective blade lift-down
1 EPC solenoid (Internal short WEP2 (male) Resistance
value in normal 2 ness (Contact with GND cir- Wiring harness between WEC3 (female)
state cuit) Resis-
(16) WEP2 (female) (1) and chassis Min. 1 Mz
tance
ground
3
controller
Between (16) (13) 4.5 14.5 z
34 D155AX-6
Failure code [DXHSKY] Blade down EPC: Short circuit 1

Action code Failure code Blade down EPC: Short circuit
Trouble
E03 DXHSKY (Work equipment controller system)
Contents of
When signal was output to blade lift-down EPC solenoid circuit, abnormal current flowed.
trouble
Related
information

Defective blade lift-down
and standard and carry out troubleshooting.
value in normal Hot short (Short circuit with
2
state 24V circuit) in wiring harness Wiring harness between WEC3 (female)
(16) WEP2 (female) (1) and chassis Voltage Max. 1 V
ground
3
controller
Between (16) (13) 4.5 14.5 z
D155AX-6 35
Failure code [DXHTKA] Blade left 1 EPC: Disconnection 1

Action code Failure code Blade left 1 EPC: Disconnection
Trouble
E03 DXHTKA (Work equipment controller system)
Contents of
When signal is output to blade tilt right head EPC solenoid circuit, no current flows.
trouble
Action of Turns signal to blade tilt right head EPC solenoid circuit OFF.
Problem that Blade tilt cylinder or pitch right cylinder cannot be retracted.
Output to blade tilt right head EPC solenoid can be checked with monitoring function.
Related (Code: 90800 Blade Tilt RH-H EPC (F/B))
information Method of reproducing failure code: Turn starting switch ON + Operate blade control lever (Pitch
back).

Defective blade tilt right head ing without turning starting switch ON.
connection)
Between (1) (2) 2 12 z
2 Max. 1 z
Max. 1 z
3
Between (26) (23) 2 12 z
Circuit diagram related to blade tilt right head EPC solenoid
36 D155AX-6
Failure code [DXHTKB] Blade left 1 EPC: Short circuit 1

Action code Failure code Blade left 1 EPC: Short circuit
Trouble
E03 DXHTKB (Work equipment controller system)
Contents of
When signal was output to blade tilt right head EPC solenoid circuit, abnormal current flowed.
trouble
back).

Defective blade tilt right head
circuit) Between (1) (2) 2 12 z
state cuit) Resis-
tance
ground
3
controller
Between (26) (23) 2 12 z
D155AX-6 37
Failure code [DXHTKY] Blade left 1 EPC: Short circuit 1

Trouble
E03 DXHTKY (Work equipment controller system)
Contents of
When signal was output to blade tilt right head EPC solenoid circuit, abnormal current flowed.
trouble
back).

Defective blade tilt right head
2
ground
3
controller
Between (26) (23) 2 12 z
38 D155AX-6
Failure code [DXHUKA] Blade right 1 EPC: Disconnection 1

Action code Failure code Blade right 1 EPC: Disconnection
Trouble
E03 DXHUKA (Work equipment controller system)
Contents of
When signal is output to blade tilt right bottom EPC solenoid circuit, no current flows.
trouble
Action of Turns signal to blade tilt right bottom EPC solenoid circuit OFF.
Output to blade tilt right bottom EPC solenoid can be checked with monitoring function.
Related (Code: 90801 Blade Tilt RH-B EPC (F/B))
forward).

Defective blade tilt right bot- ing without turning starting switch ON.
1 tom EPC solenoid (Internal
disconnection)
Between (1) (2) 2 12 z
2 Max. 1 z
Max. 1 z
3
Between (36) (23) 2 12 z
Circuit diagram related to blade tilt right bottom EPC solenoid
D155AX-6 39
Failure code [DXHUKB] Blade right 1 EPC: Short circuit 1

Action code Failure code Blade right 1 EPC: Short circuit
Trouble
E03 DXHUKB (Work equipment controller system)
Contents of
When signal was output to blade tilt right bottom EPC solenoid circuit, abnormal current flowed.
trouble
forward).

Defective blade tilt right bot-
1 tom EPC solenoid (Internal WEP6 (male) Resistance
short circuit) Between (1) (2) 2 12 z
state cuit) Resis-
tance
ground
3
controller
Between (36) (23) 2 12 z
40 D155AX-6
Failure code [DXHUKY] Blade right 1 EPC: Short circuit 1

Trouble
E03 DXHUKY (Work equipment controller system)
Contents of
When signal was output to blade tilt right bottom EPC solenoid circuit, abnormal current flowed.
trouble
forward).

Defective blade tilt right bot-
2
ground
3
controller
Between (36) (23) 2 12 z
D155AX-6 41
Failure code [DXHWKA] Ripper up EPC: Disconnection 1

Action code Failure code Ripper up EPC: Disconnection
Trouble
E03 DXHWKA (Work equipment controller system)
Contents of
When signal is output to ripper lift-up EPC solenoid circuit, no current flows.
trouble
Action of Turns signal to ripper lift-up EPC solenoid circuit OFF.
Problem that Ripper cannot be lifted up.
Output to ripper lift-up EPC solenoid can be checked with monitoring function.
Related
(Code: 71101 Ripper Raise EPC (F/B))
information
Method of reproducing failure code: Turn starting switch ON + Operate ripper control lever (Raise).

Defective ripper lift-up EPC ing without turning starting switch ON.
tion)
Between (1) (2) 2 12 z
2 Max. 1 z
state or defective contact in con- WEP7 (female) (1) tance
Max. 1 z
3
Between (5) (23) 2 12 z
Circuit diagram related to ripper lift-up EPC solenoid
42 D155AX-6
Failure code [DXHWKB] Ripper up EPC: Short circuit 1

Action code Failure code Ripper up EPC: Short circuit
Trouble
E03 DXHWKB (Work equipment controller system)
Contents of
When signal was output to ripper lift-up EPC solenoid circuit, abnormal current flowed.
trouble
Related
information

Defective ripper lift-up EPC
Possible causes
state cuit) Wiring harness between WEC3 (female) (5) Resis-
Min. 1 Mz
WEP7 (female) (1) and chassis ground tance
3
controller
Between (5) (23) 2 12 z
D155AX-6 43
Failure code [DXHWKY] Ripper up EPC: Short circuit 1

Action code Failure code Ripper up EPC: Short circuit
Trouble
E03 DXHWKY (Work equipment controller system)
Contents of
When signal was output to ripper lift-up EPC solenoid circuit, abnormal current flowed.
trouble
Related
information

Defective ripper lift-up EPC
Possible causes
and standard
value in normal 2
state 24V circuit) in wiring harness Wiring harness between WEC3 (female) (5)
Voltage Max. 1 V
WEP7 (female) (1) and chassis ground
3
controller
Between (5) (23) 2 12 z
44 D155AX-6
Failure code [DXHXKA] Ripper down EPC: Disconnection 1

Action code Failure code Ripper down EPC: Disconnection
Trouble
E03 DXHXKA (Work equipment controller system)
Contents of
When signal is output to ripper lift-down EPC solenoid circuit, no current flows.
trouble
Action of Turns signal to ripper lift-down EPC solenoid circuit OFF.
Problem that Ripper cannot be lifted down.
Output to ripper lift-down EPC solenoid can be checked with monitoring function.
Related
(Code: 71103 Ripper Down EPC (F/B))
information
Method of reproducing failure code: Turn starting switch ON + Operate ripper control lever (Lower).

Defective ripper lift-down ing without turning starting switch ON.
connection)
Between (1) (2) 2 12 z
2 Max. 1 z
Max. 1 z
3
Between (15) (23) 2 12 z
Circuit diagram related to ripper lift-down EPC solenoid
D155AX-6 45
Failure code [DXHXKB] Ripper down EPC: Short circuit 1

Action code Failure code Ripper down EPC: Short circuit
Trouble
E03 DXHXKB (Work equipment controller system)
Contents of
When signal was output to ripper lift-down EPC solenoid circuit, abnormal current flowed.
trouble
Related
information

Defective ripper lift-down
state cuit) Resis-
tance
ground
3
controller
Between (15) (23) 2 12 z
46 D155AX-6
Failure code [DXHXKY] Ripper down EPC: Short circuit 1

Action code Failure code Ripper down EPC: Short circuit
Trouble
E03 DXHXKY (Work equipment controller system)
Contents of
When signal was output to ripper lift-down EPC solenoid circuit, abnormal current flowed.
trouble
Related
information

Defective ripper lift-down
2
ground
3
controller
Between (15) (23) 2 12 z
D155AX-6 47
Failure code [DXHYKA] Ripper Tilt In EPC: Disconnection 1

Action code Failure code Ripper Tilt In EPC: Disconnection
Trouble
E03 DXHYKA (Work equipment controller system)
Contents of
When signal is output to ripper tilt-in EPC solenoid circuit, no current flows.
trouble
Action of Turns signal to ripper tilt-in EPC solenoid circuit OFF.
Problem that Ripper cannot be tilted in.
Output to ripper tilt-in EPC solenoid can be checked with monitoring function.
Related
(Code: 71105 Ripper Tilt In EPC (F/B))
information
Method of reproducing failure code: Turn starting switch ON + Operate ripper control lever (Tilt in).

Defective ripper tilt-in EPC ing without turning starting switch ON.
tion)
Between (1) (2) 2 12 z
2 Max. 1 z
Max. 1 z
3
Between (25) (23) 2 12 z
Circuit diagram related to ripper tilt-in EPC solenoid
48 D155AX-6
Failure code [DXHYKB] Ripper Tilt In EPC: Short circuit 1

Action code Failure code Ripper Tilt In EPC: Short circuit
Trouble
E03 DXHYKB (Work equipment controller system)
Contents of
When signal was output to ripper tilt-in EPC solenoid circuit, abnormal current flowed.
trouble
Related
information

Defective ripper tilt-in EPC
state cuit) Resis-
tance
ground
3
controller
Between (25) (23) 2 12 z
D155AX-6 49
Failure code [DXHYKY] Ripper Tilt In EPC: Short circuit 1

Action code Failure code Ripper Tilt In EPC: Short circuit
Trouble
E03 DXHYKY (Work equipment controller system)
Contents of
When signal was output to ripper tilt-in EPC solenoid circuit, abnormal current flowed.
trouble
Related
information

Defective ripper tilt-in EPC
2
ground
3
controller
Between (25) (23) 2 12 z
50 D155AX-6
Failure code [DXHZKA] Ripper Tilt Back EPC: Disconnection 1

Action code Failure code Ripper Tilt Back EPC: Disconnection
Trouble
E03 DXHZKA (Work equipment controller system)
Contents of
When signal is output to ripper tilt-back EPC solenoid circuit, no current flows.
trouble
Action of Turns signal to ripper tilt-back EPC solenoid circuit OFF.
Problem that Ripper cannot be tilted back.
Output to ripper tilt-back EPC solenoid can be checked with monitoring function.
Related (Code: 71107 Ripper Tilt Back EPC (F/B))
information Method of reproducing failure code: Turn starting switch ON + Operate ripper control lever (Tilt
back).

Defective ripper tilt-back ing without turning starting switch ON.
WEPA (male) Resistance
connection)
Between (1) (2) 2 12 z
2 Max. 1 z
state or defective contact in con- (35) WEPA (female) (1) tance
Max. 1 z
(23) WEPA (female) (2) tance
3
Between (35) (23) 2 12 z
Circuit diagram related to ripper tilt-back EPC solenoid
D155AX-6 51
Failure code [DXHZKB] Ripper Tilt Back EPC: Short circuit 1

Action code Failure code Ripper Tilt Back EPC: Short circuit
Trouble
E03 DXHZKB (Work equipment controller system)
Contents of
When signal was output to ripper tilt-back EPC solenoid circuit, abnormal current flowed.
trouble
back).

Defective ripper tilt-back
1 EPC solenoid (Internal short WEPA (male) Resistance
state cuit) Resis-
(35) WEPA (female) (1) and chassis Min. 1 Mz
tance
ground
3
controller
Between (35) (23) 2 12 z
52 D155AX-6
Failure code [DXHZKY] Ripper Tilt Back EPC: Short circuit 1

Action code Failure code Ripper Tilt Back EPC: Short circuit
Trouble
E03 DXHZKY (Work equipment controller system)
Contents of
When signal was output to ripper tilt-back EPC solenoid circuit, abnormal current flowed.
trouble
back).

Defective ripper tilt-back
1 EPC solenoid (Internal short WEPA (male) Resistance
2
(35) WEPA (female) (1) and chassis Voltage Max. 1 V
ground
3
controller
Between (35) (23) 2 12 z
D155AX-6 53
Failure code [DXJ4KA] Weq lock Sol.: Disconnection 1

Action code Failure code Weq lock Sol.: Disconnection
Trouble
E03 DXJ4KA (Work equipment controller system)
Contents of
When signal is output to work equipment lock solenoid circuit, no current flows.
trouble
Action of
Turns signal to work equipment lock solenoid circuit OFF.
controller
Problem that
appears on Blade and ripper cannot be operated.
machine
Related Method of reproducing failure code: Turn starting switch ON + Operate work equipment lock lever
information (Free).

1 lock solenoid (Internal dis-
WLK (male) Resistance
connection)
Between (1) (2) 20 60 z
2 Max. 1 z
state or defective contact in con- WLK (female) (1) tance
Max. 1 z
WLK (female) (2) tance
3
Between (8) (3) 20 60 z
Circuit diagram related to work equipment lock solenoid
54 D155AX-6
Failure code [DXJ4KB] Weq lock Sol.: Short circuit 1

Action code Failure code Weq lock Sol.: Short circuit
Trouble
E03 DXJ4KB (Work equipment controller system)
Contents of
When signal was output to work equipment lock solenoid circuit, abnormal current flowed.
trouble
Action of
Turns signal to work equipment lock solenoid circuit OFF.
controller
Problem that
appears on Blade and ripper cannot be operated.
machine
Related Method of reproducing failure code: Turn starting switch ON + Operate work equipment lock lever
information (Free).

1 lock solenoid (Internal short WLK (male) Resistance
Possible causes 2 ness (Contact with GND cir-
WLK (female) (1) and chassis ground tance
value in normal
3
Voltage Max. 1 V
WLK (female) (1) and chassis ground
4
controller
Between (8) (3) 20 60 z
Circuit diagram related to work equipment lock solenoid
D155AX-6 55
D155AX-6 Bulldozer
2006 KOMATSU
All Rights Reserved
56 D155AX-6
SEN00723-01
D155AX-6

D155AX-6 80001 and up
codes, Part 8
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

Failure code [DXJ8KA] Blade left 2 EPC: Disconnection 1
Action code Failure code Blade left 2 EPC: Disconnection
Trouble
Contents of
When signal is output to blade tilt left bottom EPC solenoid circuit, no current flows.
trouble
Action of Turns signal to blade tilt left bottom EPC solenoid circuit OFF.
Problem that Blade tilt cylinder or pitch left cylinder cannot be extended.
Output to blade tilt left bottom EPC solenoid can be checked with monitoring function.
Related (Code: 71007 Blade Tilt LH-B EPC (F/B))
forward).

Defective blade tilt left bot- ing without turning starting switch ON.
1 tom EPC solenoid (Internal
disconnection)
Between (1) (2) 2 12 z
2 Max. 1 z
Max. 1 z
3
Between (38) (13) 2 12 z
Circuit diagram related to blade tilt left bottom EPC solenoid
2 D155AX-6
Failure code [DXJ8KB] Blade left 2 EPC: Short circuit 1

Trouble
Contents of
When signal was output to blade tilt left bottom EPC solenoid circuit, abnormal current flowed.
trouble
forward).

Defective blade tilt left bot-
state cuit) Resis-
tance
ground
3
controller
Between (38) (13) 2 12 z
D155AX-6 3
Failure code [DXJ8KY] Blade left 2 EPC: Short circuit 1

Trouble
E03 DXJ8KY (Work equipment controller system)
Contents of
When signal was output to blade tilt left bottom EPC solenoid circuit, abnormal current flowed.
trouble
forward).

Defective blade tilt left bot-
2
ground
3
controller
Between (38) (13) 2 12 z
4 D155AX-6
Failure code [DXJ9KA] Blade right 2 EPC: Disconnection 1

Action code Failure code Blade right 2 EPC: Disconnection
Trouble
Contents of
When signal is output to blade tilt left head EPC solenoid circuit, no current flows.
trouble
Action of Turns signal to blade tilt left head EPC solenoid circuit OFF.
Problem that Blade tilt cylinder or pitch left cylinder cannot be retracted.
Output to blade tilt left head EPC solenoid can be checked with monitoring function.
Related (Code: 71005 Blade Tilt LH-H EPC (F/B))
back).

Defective blade tilt left head ing without turning starting switch ON.
connection)
Between (1) (2) 2 12 z
2 Max. 1 z
Max. 1 z
3
Between (28) (13) 2 12 z
Circuit diagram related to blade tilt left head EPC solenoid
D155AX-6 5
Failure code [DXJ9KB] Blade right 2 EPC: Short circuit 1

Trouble
Contents of
When signal was output to blade tilt left head EPC solenoid circuit, abnormal current flowed.
trouble
back).

Defective blade tilt left head
1 EPC solenoid (Internal dis- WEP3 (male) Resistance
connection) Between (1) (2) 2 12 z
state cuit) Resis-
tance
ground
3
controller
Between (28) (13) 2 12 z
6 D155AX-6
Failure code [DXJ9KY] Blade right 2 EPC: Short circuit 1

Trouble
E03 DXJ9KY (Work equipment controller system)
Contents of
When signal was output to blade tilt left head EPC solenoid circuit, abnormal current flowed.
trouble
back).

Defective blade tilt left head
value in normal Hot short in wiring harness
2 Wiring harness between WEC3 (female)
state (Contact with GND circuit)
ground
3
controller
Between (28) (13) 2 12 z
D155AX-6 7
Failure code [DXJAKA] Q-drop EPC: Disconnection 1

Action code Failure code Q-drop EPC: Disconnection
Trouble
E01 DXJAKA (Work equipment controller system)
Contents of
When signal is output to blade quick drop EPC solenoid circuit, no current flows.
trouble
Action of
Turns signal to blade quick drop EPC solenoid circuit OFF.
controller
Problem that
appears on Blade quick drop function does not operate.
machine
Output to blade quick drop EPC solenoid can be checked with monitoring function.
Related
(Code: 90900 Quick Drop Solenoid (F/B))
information

Defective blade quick drop ing without turning starting switch ON.
QDP (male) Resistance
connection)
Between (1) (2) 4.5 14.5 z
2 Max. 1 z
state or defective contact in con- (37) QDP (female) (1) tance
Max. 1 z
QDP (female) (2) tance
3
Between (37) (3) 4.5 14.5 z
8 D155AX-6
Circuit diagram related to blade quick drop EPC solenoid
D155AX-6 9
Failure code [DXJAKB] Q-drop EPC: Short circuit 1

Action code Failure code Q-drop EPC: Short circuit
Trouble
E01 DXJAKB (Work equipment controller system)
Contents of
When signal was output to blade quick drop EPC solenoid circuit, abnormal current flowed.
trouble
Action of
controller
Problem that
machine
Related
information

Defective blade quick drop
1 EPC solenoid (Internal short QDP (male) Resistance
Possible causes
state cuit) Wiring harness between WEC3 (female) Resis-
Min. 1 Mz
(37) QDP (female) (1) and chassis ground tance
3
controller
Between (37) (3) 4.5 14.5 z
10 D155AX-6
D155AX-6 11
Failure code [DXJAKY] Q-drop EPC: Short circuit 1

Action code Failure code Q-drop EPC: Short circuit
Trouble
E01 DXJAKY (Work equipment controller system)
Contents of
When signal was output to blade quick drop EPC solenoid circuit, abnormal current flowed.
trouble
Action of
controller
Problem that
machine
Related
information

Defective blade quick drop
1 EPC solenoid (Internal short QDP (male) Resistance
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
(37) QDP (female) (1) and chassis ground
3
controller
Between (37) (3) 4.5 14.5 z
12 D155AX-6
D155AX-6 13
Failure code [DXJBKA] S/C ECMV: Disconnection 1

Action code Failure code S/C ECMV: Disconnection
Trouble
E02 DXJBKA (Power train controller system)
Contents of
When signal is output to torque converter stator clutch ECMV solenoid circuit, no current flows.
trouble
Action of
Turns signal to torque converter stator clutch ECMV solenoid circuit OFF.
controller
Problem that
appears on Sufficient torque may not be obtained during travel.
machine
Output to torque converter stator clutch ECMV solenoid can be checked with monitoring function.
Related
(Code: 90700 S/C ECMV (F/B))
information

Defective stator clutch ECMV ing without turning starting switch ON.
SSTC (male) Resistance
tion)
Between (1) (2) 5 25 z
or defective contact in con- SSTC (female) (1) tance
Max. 1 z
state SSTC (female) (2) tance
3
Voltage Max. 1 V
SSTC (female) (1) and chassis ground
4
Between (38) (13) 5 25 z
14 D155AX-6
D155AX-6 15
Failure code [DXJBKB] S/C ECMV: Short circuit 1

Action code Failure code S/C ECMV: Short circuit
Trouble
E02 DXJBKB (Power train controller system)
Contents of When signal was output to torque converter stator clutch ECMV solenoid circuit, abnormal current
trouble flowed.
Action of
controller
Problem that
machine
Related
information

Defective stator clutch ECMV
1 solenoid (Internal short cir- SSTC (male) Resistance
Min. 1 Mz
and standard SSTC (female) (1) and chassis ground tance
harness) Resis-
SSTC (female) (1) and between STC3 Min. 1 Mz
tance
(female) (13) SSTC (female) (2)
4
troller
Between (38) (13) 5 25 z
16 D155AX-6
D155AX-6 17
Failure code [DXJBKY] S/C ECMV: Short circuit 1

Action code Failure code S/C ECMV: Short circuit
Trouble
E02 DXJBKY (Power train controller system)
Contents of When signal was output to torque converter stator clutch ECMV solenoid circuit, abnormal current
trouble flowed.
Action of
controller
Problem that
machine
Related
information

Defective stator clutch ECMV
1 solenoid (Internal short cir- SSTC (male) Resistance
2
Voltage Max. 1 V
and standard SSTC (female) (1) and chassis ground
harness) Resis-
SSTC (female) (1) and between STC3 Min. 1 Mz
tance
(female) (13) SSTC (female) (2)
4
troller
Between (38) (13) 5 25 z
18 D155AX-6
D155AX-6 19
D155AX-6 Bulldozer
2006 KOMATSU
All Rights Reserved
20 D155AX-6
SEN00807-01
D155AX-6

D155AX-6 80001 and up
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
E-12 Machine monitor does not display some items.......................................................................... 29

E-13 Function switch does not work................................................................................................... 29
E-14 Operation mode does not change ............................................................................................. 30
E-15 Gearshift mode does not change............................................................................................... 30
E-16 Customize function does not operate normally.......................................................................... 31
E-17 Customize memory function does not normally......................................................................... 31
E-18 Float mode does not change ..................................................................................................... 32
E-19 Alarm buzzer cannot be stopped ............................................................................................... 32
E-20 Air conditioner does not operate normally (including air conditioner fault history)..................... 33
E-21 When starting switch is turned OFF, service meter is not displayed.......................................... 46
E-22 Machine monitor cannot be set in service mode ....................................................................... 46
E-23 Ripper pin puller cylinder does not operate ............................................................................... 48
E-24 Backup alarm does not sound or does not stop ........................................................................ 50
E-25 Headlamp, rear lamp, and ripper point lamp do not light up...................................................... 52
E-26 Windshield wiper and window washer do not operate............................................................... 56
E-27 KOMTRAX system does not operate normally .......................................................................... 72
2 D155AX-6
Troubleshooting of electrical system (E-mode) 1

Before carrying out troubleshooting for electrical system 1
Connection table of circuit breakers and fuse boxes
a This connection table shows the devices to which each power supply of the fuse box supplies power (An
accessory power supply is a device which supplies power while the starting switch is in the ON position
and an unswitched power supply is a device which supplies power while the starting switch is in the OFF
and ON positions).
a When carrying out troubleshooting related to the electrical system, you should check the circuit breakers
and fuses to see if the power is supplied normally.
Circuit breakers CB1 CB9

Circuit
Power circuit breaker Circuit
breaker Destination of power
(Type of power supply) breaker No.
capacity
CB9 20A Optional power supply
Power train controller
CB1 20A
Emergency power supply (For power train switch box)
CB105 Work equipment controller
CB2 20A
(Accessory power Emergency power supply (For work equipment switch box)
supply)
Air conditioner unit, blower motor, and compressor electromag-
CB3 20A
netic clutch
CB4 20A Headlamp, additional headlamp
CB5 20A Rear lamp, additional rear lamp, ripper point lamp
Starting switch
CB6 20A
Engine hold relay
CB30 Machine monitor
(Unswitched power
supply) CB7 20A Power train controller
Work equipment controller
CB8 30A Engine controller
CB105H
(Unswitched power Engine electrical intake air heater
supply)
Fuse box FS1

CB30
(Unswitched power 1 20A Operator's cab power supply (To connection table of fuse box )
supply)
2 5A Backup alarm, backup alarm relay
CB105
(Accessory power 3 20A Operator's cab power supply (To connection table of fuse box )
supply)
4 20A Operator's cab power supply (To connection table of fuse box )
Starting switch (ACC) 5 5A Engine controller (Signal ACC)
D155AX-6 3
Fuse box FS2

CB30
(Unswitched power 1 5A Pedal brake solenoid valve
supply)
2 5A Parking brake solenoid valve
CB105 Engine electrical intake air heater

(Accessory power 3 20A Ripper pin puller solenoid valve
supply) Pneumatic suspension seat
4 5A Horn
Starting switch (ACC) 5 20A Optional power supply
4 D155AX-6
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
Fuse box
Power circuit fuse Fuel
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
Location of fuse box (In operator's cab)
6 D155AX-6

a The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before carrying out troubleshooting, understand that information fully.
Trouble Trouble which occurred in the machine

Related
information
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.
Related circuit diagram
This drawing is a part of the electric circuit diagram related to troubleshooting.

Connector No.: Indicates (Model Number of pins) and (Color).
"Connector No. and pin No." from each branching/merging point:
Shows the ends of branch or source of merging within the parts of the
same wiring harness.
Arrow (io): Roughly shows the location on the machine.
D155AX-6 7
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.

1 Low charge level of battery Electrolyte specific gravity
Battery voltage (2 pieces)
(1 piece)
Min. 24 V Min. 1.26
Defective circuit breaker If circuit breaker is turned OFF, circuit probably has ground fault.
2
(CB30, CB6, or CB7) (See cause 6.)
Machine monitor connector may be connected wrongly. Check it
Wrong connection of connec-
3 directly (Connection between connectors CM01 and CM02 and
tor
between connectors CM03 and CM04).
Defective starting switch and carry out troubleshooting.
4
(Internal disconnection) Starting switch Resistance
Between 250 270 ON Max. 1 z
Possible causes
value in normal ing without turning starting switch ON.
state Wiring harness between battery () chas- Resis-
Max. 1 z
sis ground tance
Wiring harness between battery (+) termi- Resis-
Max. 1 z
nal BRB CB30 (B30L) tance
Wiring harness between CB30 (B30S) Resis-
Max. 1 z
Disconnection in wiring har- CB7 (1) tance
ness (Disconnection in wiring Wiring harness between CB7 (2) CM01 Resis-
5 Max. 1 z
or defective contact in con- (female) (1), (2) tance
Max. 1 z
Wiring harness between CB30 (B30S) Resis-
Max. 1 z
CB6 (1) tance
Wiring harness between CB6 (2) terminal Resis-
Max. 1 z
250 tance
Wiring harness between terminal 270 Resis-
Max. 1 z
CM01 (female) (14) tance
8 D155AX-6

Wiring harness between battery (+) termi- Resis-
Min. 1 Mz
nal BRB CB30 (B30L) and chassis ground tance
Wiring harness between CB30 (B30S)
Resis-
CB7 (1) or circuit branch end and chassis Min. 1 Mz
tance
ground
Wiring harness between CB7 (2) CM01
Resis-
Ground fault in wiring har- (female) (1), (2) or circuit branch end and Min. 1 Mz
tance
6 ness (Contact with GND cir- chassis ground
cuit) Wiring harness between CB30 (B30S)
Possible causes Resis-
CB6 (1) or circuit branch end and chassis Min. 1 Mz
and standard tance
ground
value in normal
state Wiring harness between CB6 (2) terminal
Resis-
250 or circuit branch end and chassis Min. 1 Mz
tance
ground
Wiring harness between terminal 270
Resis-
CM01 (female) (14) or circuit branch end Min. 1 Mz
tance
and chassis ground
a Prepare with starting switch OFF, then hold starting switch OFF
and ON and carry out troubleshooting in each case.
CM01 Starting switch Voltage
7 Defective machine monitor Between (1), (2)
OFF 20 30 V
(3) , (4)
Between (14)
ON 20 30 V
(3), (4)
Circuit diagram related to machine monitor power supply
D155AX-6 9
E-2 When starting switch turned ON (before startingengine), basic

check item lights up 1
Trouble When starting switch turned ON (before starting engine), basic check item lights up.
Related
Basic check item is only lowering of radiator coolant level.
information

Lowering of radiator coolant
Coolant level in radiator sub tank may be low. Check it and add
1 level (When system is nor-
coolant if necessary.
mal)
Defective radiator coolant Sub tank coolant
WLV (male) Resistance
2 level switch (Internal discon- level
nection) Between FULL
Max. 1 z
Between (1) (2) LOW
Possible causes Below LOW Min. 1 Mz

value in normal Disconnection in wiring har- ing without turning starting switch ON.
state ness (Disconnection in wiring Wiring harness between CM02 (female) (3) Resis-
3 Max. 1 z
or defective contact in con- WLV (female) (1) tance
Max. 1 z
CM02 (female) (7) WLV (female) (2) tance
Sub tank coolant
CM02 Voltage
4 Defective machine monitor level
Between FULL
Between (3) Max. 1 V
LOW
chassis ground
Below LOW 20 30 V
Circuit diagram related to radiator coolant level switch
10 D155AX-6
E-3 Engine does not start (Engine does not turn) 1

Trouble Engine does not start (Engine does not turn).
Related Engine starting circuit has following 2 start lock mechanisms.

1) Start lock with password of machine monitor
information 2) Start lock with parking brake lever and work equipment lock lever

1 Low charge level of battery Electrolyte specific gravity
Battery voltage (2 pieces)
(1 piece)
Min. 24 V Min. 1.26
a Prepare with starting switch OFF, then keep starting switch
OFF and turn it to START and carry out troubleshooting in each
case.
Defective starting switch
2 Starting switch Resistance
OFF Min. 1 Mz
Between 250 280
START Max. 1 z
a Prepare with starting switch OFF, then turn starting switch to
START and carry out troubleshooting.
Defective neutral safety relay
3 Replace neutral safety relay (Right No.) with another
(Internal trouble)
relay. If engine starts at this time, neutral safety relay is NSF
defective.
a Prepare with starting switch OFF, then turn starting switch to
START and carry out troubleshooting.
Starting motor Voltage
Between B
Battery power supply 20 30 V
chassis ground
Defective starting motor
4 Between ST (2)
(Internal defect) Starting signal 20 30 V
chassis ground
Possible causes
and standard Between ST (2)
Generation signal Max. 1 V
value in normal chassis ground
state
If battery power supply, starting signal, and generation signal are
normal but starting motor does not turn, starting motor is defective.
Defective alternator (Internal
5 Alternator Voltage
short circuit)
Between R
Generation signal Max. 1 V
chassis ground
Disconnection in wiring har-
ness (Disconnection in wiring Wiring harness between terminal 280 NSF Resis-
6 Max. 1 z
or defective contact in con- (female) (3) tance
nector)
Wiring harness between NSF (female) (5) Resis-
Max. 1 z
PRE ST (female) (1) tance
Ground fault in wiring har- Wiring harness between terminal 280 NSF
Resis-
7 ness (Contact with GND cir- (female) (3) or circuit branch end and chas- Min. 1 Mz
tance
cuit) sis ground
Wiring harness between NSF (female) (5) Resis-
Min. 1 Mz
PRE ST (female) (1) and chassis ground tance
8
24V circuit) in wiring harness Wiring harness between terminal R ST
(female) (2) or circuit branch end and chas- Voltage Max. 1 V
sis ground
12 D155AX-6
Circuit diagram related to preheating/starting of engine and charge of battery
D155AX-6 13
E-4 Preheater does not operate 1

Trouble (1) When starting switch is turned to HEAT position, preheating monitor does not light up.
Preheater monitor lights up when starting switch is turned to HEAT.
Related
If engine coolant temperature is below -5 C, automatic warm-up system operates and preheating
information
monitor lights up for up to 40 seconds.

OFF and turn it to HEAT and carry out troubleshooting in each
case.
1 Starting switch Resistance
OFF Min. 1 Mz
Between 250 255
HEAT Max. 1 z
Possible causes
and standard Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
ness (Disconnection in wiring ing without turning starting switch ON.
value in normal 2
state or defective contact in con- Wiring harness between CM01 (female) Resis-
nector) Max. 1 z
(16) terminal 255 tance
OFF and turn it to HEAT and carry out troubleshooting in each
case.
3 Defective machine monitor CM01 Starting switch Voltage
Between (16) OFF Max. 1 V
chassis ground HEAT 20 30 V
14 D155AX-6
(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)).

1
(CB105H) (See cause 5).
a Prepare with starting switch OFF (with wiring harness con-
nected), then turn starting switch to HEAT and carry out trou-
bleshooting.
Defective heater relay (Inter- Heater relay Starting switch Voltage
2
nal disconnection) Between HT
20 30 V
chassis ground
HEAT
Between HT/B
20 30 V
chassis ground
a Prepare with starting switch OFF (with wiring harness con-
nected), then turn starting switch to HEAT and carry out trou-
bleshooting in each case.
Defective intake air heater RH1 Starting switc Voltage
3
(Internal disconnection) Between terminal
HEAT 20 30 V
chassis ground
If voltage is normal but heater mounting part does not become
Possible causes warm, intake air heater is defective.
state
Wiring harness between terminal 255 ter- Resis-
Max. 1 z
Disconnection in wiring har- minal HT tance
ness (Disconnection in wiring Wiring harness between terminal BRC Resis-
4 Max. 1 z
or defective contact in con- CB105H (B105HS) tance
nector) Wiring harness between CB105H (B105HL) Resis-
Max. 1 z
terminal HT/A tance
Wiring harness between terminal HT/B Resis-
Max. 1 z
terminal RHT tance
Wiring harness between terminal 255 ter-
Resis-
minal HT or CM01 (female) (16) or circuit Min. 1 Mz
tance
Ground fault in wiring har- branch end and chassis ground
5 ness (Contact with GND cir- Wiring harness between terminal BRC Resis-
Min. 1 Mz
cuit) CB105H (B105HS) and chassis ground tance
Wiring harness between CB105H (B105HL) Resis-
Min. 1 Mz
terminal HT/A and chassis ground tance
Wiring harness between terminal HT/B Resis-
Min. 1 Mz
terminal RHT and chassis ground tance
D155AX-6 15
16 D155AX-6
E-5 Precaution item lights up while engine is running 1

Trouble Precaution item lights up while engine is running.
Check item is only charge level monitor.
Related
State of generation signal of alternator can be checked with monitoring function.
information
(Code: 04300 Battery Charge Volt)

Defective generation by out troubleshooting.
1 alternator (when system is Alternator Engine speed Voltage
normal) Between R
Medium or higher 20 30 V
chassis ground
ness (Disconnection in wiring ing without turning starting switch ON.
2
Possible causes or defective contact in con- Wiring harness between CM01 (female) (11) Resis-
nector) Max. 1 z
and standard terminal R tance
3 ness (Contact with GND cir- Wiring harness between CM01 (female) (11)
cuit) Resis-
terminal R or circuit branch end and chas- Min. 1 Mz
tance
sis ground
4 Defective machine monitor CM01 Engine Voltage
Between (11)
Medium or higher 20 30 V
chassis ground
18 D155AX-6
D155AX-6 19
E-6 Emergency stop item lights up while engine is running 1

Trouble (1) Engine coolant temperature monitor lights up.
Signals of engine coolant temperature sensor are input to engine controller and then transmitted to
Related machine monitor through communication system.

Overheating of engine cool- Engine coolant may be overheated. If it is overheated, remove
1
ant (when system is normal) cause.
Possible causes
and standard If cause 1 is not detected, engine coolant temperature sensor sys-
Defective engine coolant
value in normal 2 tem may be defective. Carry out troubleshooting for failure codes
temperature sensor system
state [CA144] and [CA145].
If causes 1 and 2 are not detected, machine monitor may be defec-
3 Defective machine monitor tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
Trouble (2) Engine oil pressure monitor lights up.

Signals of engine oil pressure sensor are input to engine controller and then transmitted to machine
Related monitor through communication system.
information Engine oil pressure can be checked with monitoring function.
(Code: 37200 Engine Oil Pressure)

Lowering of engine oil pres-
1 sure (when system is nor- Engine oil pressure may be low. If it is low, remove cause.
Possible causes mal)
and standard If cause 1 is not detected, engine oil pressure sensor system may
value in normal Defective engine oil pressure
2 be defective. Carry out troubleshooting for failure codes [CA135]
state sensor system
and [CA141].
out.)
Trouble (3) Power train oil temperature monitor lights up.

Signals of torque converter oil temperature sensor are input to power train controller and then trans-
Related mitted to machine monitor through communication system.
information Power train oil temperature can be checked with monitoring function.

Overheating of power train Power train oil may be overheated. If it is overheated, remove
1
oil (when system is normal) cause.
Possible causes
and standard If cause 1 is not detected, power train oil temperature sensor sys-
Defective power train oil tem-
value in normal 2 tem may be defective. Carry out troubleshooting for failure codes
perature sensor system
state [DGT1KA] and [DGT1KX].
out.)
20 D155AX-6
Trouble (4) Hydraulic oil temperature monitor lights up.

Related Hydraulic oil temperature can be checked with monitoring function.
information (Code: 04401 Hyd Oil Temperature)

Possible causes Overheating of hydraulic oil Hydraulic oil may be overheated. If it is overheated, remove
1
and standard (when system is normal) cause.
value in normal If cause 1 is not detected, hydraulic oil temperature gauge system
state Defective hydraulic oil tem-
2 may be defective. Carry out troubleshooting for E-10 Hydraulic oil
perature gauge system
temperature gauge (Multi-gauge) does not display normally.
D155AX-6 21
E-7 Engine coolant temperature gauge does not indicate normally 1

(1) While engine coolant temperature is rising normally, temperature gauge does not rise from white
Trouble range (C).
(2) While engine coolant temperature is stabilized normally, temperature gauge rises to red range (H).

Possible causes
Defective engine coolant Engine coolant temperature sensor system may be defective.
and standard 1
temperature sensor system Carry out troubleshooting for failure codes [CA144] and [CA145].
value in normal
state If cause 1 is not detected, machine monitor may be defective.
2 Defective machine monitor
(Since trouble is in system, troubleshooting cannot be carried out.)
(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.

a Turn starting switch ON or start engine and carry out trouble-
shooting.
Engine coolant tem- Coolant temperature Color of monitor light
Possible causes perature gauge level (a)
and standard 105 C 6
value in normal 1 Defective machine monitor Red
102 C 5
state
100 C 4
85 C 3 Blue
60 C 2
30 C 1 White
Engine coolant temperature gauge and coolant temperature monitor
22 D155AX-6
E-8 Fuel level gauge does not indicate normally 1

(1) While fuel is added, fuel level gauge does not rise from red range (E).
Trouble
(2) While fuel level is low, fuel level gauge does not lower from green range top (F)
Related Signal voltage of fuel level sensor can be checked with monitoring function.
nformation (Code: 04200 Fuel Level Sensor Volt)

Defective fuel level sensor
1 (Internal disconnection or FLV (male) Fuel level Resistance
short circuit) FULL Approx. 4 z
Between (1) (2)
EMPTY Approx. 85 z
ness (Disconnection in wiring Wiring harness between CM01 (female) (9) Resis-
2 Max. 1 z
or defective contact in con- FLV (female) (1) tance
Possible causes
nector) Wiring harness between CM01 (female) Resis-
value in normal (12) FLV (female) (2) tance
cuit) Wiring harness between CM01 (female) (9) Resis-
Min. 1 Mz
FLV (female) (1) and chassis ground tance
4
24V circuit) in wiring harness Wiring harness between CM01 (female) (9)
Voltage Max. 1 V
FLV (female) (1) and chassis ground
If causes 1 4 are not detected, machine monitor may be defec-
out.)
Circuit diagram related to fuel level sensor
D155AX-6 23
(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)

shooting.
Reading of fuel level Color of monitor light
Quantity of fuel
Possible causes gauge (a)
and standard 565 l 6
value in normal 1 Defective machine monitor 425 l 5
state
310 l 4 Blue
220 l 3
150 l 2
75 l 1 Red
Fuel level gauge and fuel level monitor
24 D155AX-6
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.

Possible causes Power train oil temperature sensor system may be defective.
Defective power train oil tem-
and standard 1 Carry out troubleshooting for failure codes [DGT1KA] and
perature sensor system
value in normal [DGT1KX].
state If cause 1 is not detected, machine monitor may be defective.
(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.

shooting.
Power train oil tem- Power train oil tem- Color of monitor light
Possible causes perature perature gauge level (a)
and standard 130 C 6
value in normal 1 Defective machine monitor Red
120 C 5
state
118 C 4
80 C 3 Blue
50 C 2
0 C 1 White
Power train oil temperature gauge and power train oil temperature monitor
D155AX-6 25
E-10 Hydraulic temperature gauge (multi-gauge) does not indicate

normally 1
(1) While hydraulic oil temperature is rising normally, temperature gauge does not rise from white
Trouble range (C).
(2) While hydraulic oil temperature is stabilized normally, temperature gauge rises to red range (H).
Related Hydraulic temperature can be checked with monitoring function.

Defective hydraulic oil tem- ing without turning starting switch ON.
perature sensor system HDT (male) Resistance
1
(Internal disconnection or
short circuit) Between (1) (2) 3.5 90 kz
ness (Disconnection in wiring Wiring harness between CM01 (female) (8) Resis-
2 Max. 1 z
or defective contact in con- HDT (female) (1) tance
Possible causes
nector) Wiring harness between CM01 (female) Resis-
value in normal (12) HDT (female) (2) tance
cuit) Wiring harness between CM01 (female) (8) Resis-
Min. 1 Mz
HDT (female) (1) and chassis ground tance
4
24V circuit) in wiring harness Wiring harness between CM01 (female) (8)
Voltage Max. 1 V
HDT (female) (1) and chassis ground
out.)
26 D155AX-6
Circuit diagram related to hydraulic oil temperature sensor
D155AX-6 27
(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.

shooting.
Reading of hydraulic
Hydraulic oil temper- Color of monitor light
oil temperature
Possible causes ature (a)
gauge
and standard
value in normal 110 C 6
1 Defective machine monitor Red
state 100 C 5
98 C 4
70 C 3 Blue
20 C 2
0 C 1 White
Hydraulic oil temperature gauge and hydraulic oil temperature monitor
28 D155AX-6
E-11 Contents of display by machine monitor are different from

applicable machine 1
Trouble Contents of display by machine monitor are different from applicable machine.
Related
information

and standard
value in normal Machine monitor may be defective. (Since trouble is in system,
state troubleshooting cannot be carried out.)
E-12 Machine monitor does not display some items 1

Trouble Machine monitor does not display some items.
The LCD panel sometimes has black points (points which are not lighted) and bright points (points
Related
which do not go off) for the reason of its characteristics. If the number of the bright points and black
information
points does not exceed 10, those points are not a failure or a defect.

a Turn starting switch ON and carry out troubleshooting.
Possible causes
Defective machine monitor When following switches are operated, if all LCD panel is lighted
and standard 1
(LCD panel) up (all surface becomes white), LCD panel is normal.
value in normal
state Operation of switches: [4] + [F2] (Press simultaneously)
Defective machine monitor If cause 1 is not detected, machine monitor may be defective.
2
(body) (Since trouble is in system, troubleshooting cannot be carried out.)
E-13 Function switch does not work 1

Trouble Function switch does not work.
Related
information

and standard
D155AX-6 29
E-14 Operation mode does not change 1

Trouble (1) When operation mode switch is operated, display of operation mode monitor does not change.
Related
information

and standard
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)

Possible causes
Machine monitor may be defective. (Since trouble is in system,
and standard 1 Defective machine monitor
troubleshooting cannot be carried out.)
value in normal
state Engine controller may be defective. (Since trouble is in system,
E-15 Gearshift mode does not change 1

Trouble (1) When gearshift mode switch is operated, display of speed mode section does not change.
Related
information

and standard
Trouble (2) When gearshift mode is changed, gearshift setting of power train is not changed.
Related
information

Possible causes
value in normal
state Defective power train con- Power train controller may be defective. (Since trouble is in sys-
2
troller tem, troubleshooting cannot be carried out.)
30 D155AX-6
E-16 Customize function does not operate normally 1

Trouble (1) When customize switch is operated, customize screen is not displayed.
Related
information

and standard
Trouble (2) When setting is changed on customize screen, setting of machine is not changed.
Related
information

Possible causes 1 Defective machine monitor
and standard
value in normal Defective engine controller,
Engine controller, power train controller, or pump controller may be
state defective power train control-
ler, or defective pump con-
carried out.)
troller
E-17 Customize memory function does not normally 1

Trouble (1) When customize memory switch is operated, customize memory screen is not displayed.
Related
information

and standard
Trouble (2) When selection is changed on customize memory screen, setting of machine is not changed.
Related
information

Possible causes 1 Defective machine monitor
and standard
value in normal Defective engine controller,
Engine controller, power train controller, or pump controller may be
state defective power train control-
ler, or defective pump con-
carried out.)
troller
D155AX-6 31
E-18 Float mode does not change 1

Trouble (1) When float mode switch is operated, float mode monitor does not light up or go off.
Related
information

and standard
Trouble (2) When float mode is changed, setting of machine is not changed.
Related
information

Possible causes
value in normal
state Pump controller may be defective. (Since trouble is in system,
2 Defective pump controller
E-19 Alarm buzzer cannot be stopped 1

Trouble Alarm buzzer cannot be stopped.
Related
information

and standard
32 D155AX-6
E-20 Air conditioner does not operate normally

(including air conditioner fault history) 1
Trouble (1) When air conditioner switch is operated, air conditioner control screen is not displayed.
Related
information

and standard
Trouble (2) When air conditioner switch is operated, air conditioner does not operate at all.
Related
information

1
(CB3) (See cause 4).
If fuse in unit is broken, circuit in unit probably has ground fault
2 Defective fuse in unit
(See cause 4).
ness (Disconnection in wiring Wiring harness between CB3 (2) fuse in Resis-
3 Max. 1 z
or defective contact in con- unit - ACW (wiring side) (6) tance
nector)
Wiring harness between ACW (wiring side) Resis-
Max. 1 z
Possible causes
value in normal Ground fault in wiring har- ing without turning starting switch ON.
state 4 ness (Contact with GND cir- Wiring harness between CB3 (2) fuse in
cuit) Resis-
unit ACW (wiring side) (6) or circuit branch Min. 1 Mz
tance
end and chassis ground
Defective air conditioner con- ACW (wiring side) Voltage
5
troller Between (6) (16) 20 30 V
If above voltage is normal, air conditioner controller may be defec-
tive.
out.)
D155AX-6 33
Trouble (3) Air does not come out (Air flow is insufficient).
Related
information

ing without turning starting switch ON (coil side).
AC03 (male) Resistance
Between (1) (3) 140 340 z
Defective blower relay
1 a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting (contact side).
AC03 Air conditioner switch Voltage
Between (4)
Air blow position 20 30 V
chassis ground
Defective power transistor
2 Fan switch If air flow changes according to
(Internal defect)
Operate between Low and operation of fan switch, power
Medium and High. transistor (PTR) is normal.
3 Defective blower motor MB (wiring side) Air conditioner switch Voltage
Possible causes
and standard (Internal defect) Between (1) (2) Air blow position 20 30 V
value in normal If above voltage is normal and blower motor does not revolve,
state blower motor (MB) is defective.
Wiring harness between CB3 (2) fuse in Resis-
Max. 1 z
unit - AC03 (female) (1) tance
Wiring harness between AC03 (female) (3) Resis-
Max. 1 z
ACW (wiring side) (36) tance
Wiring harness between CB3 (2) AC03 Resis-
Max. 1 z
Disconnection in wiring har- (female) (4) tance
ness (Disconnection in wiring Wiring harness between AC03 (female) (5) Resis-
4 Max. 1 z
or defective contact in con- MB (wiring side) (1) tance
nector) Wiring harness between MB (wiring side) (2) Resis-
Max. 1 z
PTR (wiring side) (3) tance
Wiring harness between PTR (wiring side) Resis-
Max. 1 z
Max. 1 z
(2) ACW (wiring side) (8) tance
Max. 1 z
34 D155AX-6

Min. 1 Mz
ACW (wiring side) (36) and chassis ground tance
Ground fault in wiring har- Wiring harness between AC03 (female) (5) Resis-
Min. 1 Mz
5 ness (Contact with GND cir- MB (wiring side) (1) and chassis ground tance
Possible causes cuit) Wiring harness between MB (wiring side) (2) Resis-
PTR (wiring side) (3) and chassis ground tance
value in normal
Wiring harness between PTR (wiring side)
state Resis-
(2) ACW (wiring side) (8) and chassis Min. 1 Mz
tance
ground
If causes 1 5 are not detected, air conditioner controller may be
Defective air conditioner con-
troller
carried out.)
If causes 1 5 are not detected, air conditioner system may be
Defective air conditioner sys-
7 defective. See Machine Component Volume, Shop Manual, Trou-
tem
bleshooting, Air conditioner, Troubleshooting.
D155AX-6 35
Trouble (4) Air is not cooled (Cooling performance is insufficient).

Related
information

ing without turning starting switch ON (coil side).
Between (1) (3) 140 340 z
Defective compressor relay
1 a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting (contact side).
AC04 Air conditioner switch Voltage
Between (2)
Cooling position 20 30 V
chassis ground
Internal air sensor may be defective. Carry out troubleshooting for
2 Defective internal air sensor
"Abnormality in internal air sensor".
Defective high and low pres- High and low pressure switches may be defective. Carry out trou-
3
sure switches bleshooting for "Abnormality in refrigerant".
Defective compressor clutch
4 Compressor clutch may be defective. Check it directly.
(Internal defect)
Defective compressor (Inter-
5 Compressor may be defective. Check it directly.
nal defect)
value in normal
state Wiring harness between CB3 (2) fuse in Resis-
Max. 1 z
Disconnection in wiring har- unit AC04 (female) (1) tance
6 Max. 1 z
or defective contact in con- ACW (wiring side) (35) tance
nector) Wiring harness between CB3 (2) AC04 Resis-
Max. 1 z
(female) (4) tance
Max. 1 z
A/C (female) (1) tance
ACW (wiring side) (35) and chassis ground tance
cuit)
Min. 1 Mz
A/C (female) (1) and chassis ground tance
troller
carried out.)
If causes 1 7 are not detected, air conditioner system may be
Defective air conditioner sys-
9 defective. See Machine Component Volume, Shop Manual, Trou-
tem
bleshooting, "Air conditioner", Troubleshooting.
36 D155AX-6
(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.

1 Max. 1 z
or defective contact in con- CM02 (female) (8), (9) tance
nector) Wiring harness between AC02 (female) (2) Resis-
Max. 1 z
CM02 (female) (10) tance
Wiring harness between AC02 (female) (1)
CM02 (female) (8), (9), EGC2 (female)
Resis-
(46), STC2 (female) (32), WEC2 (female) Max. 1 z
(32), CA1 (female) (A), or SRV (female) (3)
and chassis ground
cuit)
CM02 (female) (10), EGC2 (female) (47),
Resis-
STC2 (female) (22), WEC2 (female) (22), Max. 1 z
tance
CA1 (female) (B), or SRV (female) (10) and
chassis ground
Possible causes
and standard
value in normal
state Wiring harness between AC02 (female) (1)
CM02 (female) (8), (9), EGC2 (female)
Resis-
(46), STC2 (female) (32), WEC2 (female) Min. 1 Mz
tance
Hot short (Short circuit with (32), CA1 (female) (A), or SRV (female) (3)
3
24V circuit) in wiring harness and chassis ground
CM02 (female) (10), EGC2 (female) (47),
Resis-
STC2 (female) (22), WEC2 (female) (22), Min. 1 Mz
tance
CA1 (female) (B), or SRV (female) (10) and
chassis ground
4 resistance (Internal short cir-
cuit or disconnection)
troller
carried out.)
out.)
D155AX-6 37
Trouble (6) Air conditioner fault history: Setting condition "Abnormality"

If setting of air conditioner controller model is different from setting of machine monitor model,
"Abnormality" is displayed.
Related
information
out normally. Accordingly, this condition is not displayed.
Method of reproducing fault history: Turn starting switch ON.

Possible causes
Defective air conditioner con- Air conditioner controller may be defective. (Since trouble is in
and standard 1
troller system, troubleshooting cannot be carried out.)
value in normal
state Machine monitor may be defective. (Since trouble is in system,
Trouble (7) Air conditioner fault history: Internal air sensor "Abnormality"
Related
information
Method of reproducing fault history: Turn starting switch ON + Turn air conditioner (A/C) switch ON.

Defective internal air sensor ing without turning starting switch ON.
THI (device side) Resistance
short circuit)
Between (1) (2) 300 z 430 kz
ness (Disconnection in wiring Wiring harness between ACW (wiring side) Resis-
2 Max. 1 z
or defective contact in con- (11) THI (wiring side) (2) tance
nector) Wiring harness between ACW (wiring side) Resis-
(27) THI (wiring side) (1) tance
and standard
value in normal
state Short circuit in wiring har-
3 Wiring harness between ACW (wiring side)
ness (with GND circuit) Resis-
(11) THI (wiring side) (2) and chassis Min. 1 Mz
tance
ground
4
24V circuit) in wiring harness Wiring harness between ACW (wiring side)
(11) THI (wiring side) (2) and chassis Voltage Max. 1 V
ground
troller
carried out.)
38 D155AX-6
Trouble (8) Air conditioner fault history: External air sensor "Unused"
External air sensor is not used in air conditioner system of this machine.
Related
information

and standard
value in normal Since external air sensor is not used in air conditioner system of
1 Normal display
state this machine, above display is normal.
Trouble (9) Air conditioner fault history: Air flow sensor "Abnormality"
Related
information

Defective air flow sensor ing without turning starting switch ON.
THF (device side) Resistance
short circuit)
Between (1) (2) 100 z 115 kz
2 Max. 1 z
or defective contact in con- (12) THF (wiring side) (2) tance
(27) THF (wiring side) (1) tance
and standard
value in normal
state Short circuit in wiring har-
3 Wiring harness between ACW (wiring side)
ness (with GND circuit) Resis-
(12) THF (wiring side) (2) and chassis Min. 1 Mz
tance
ground
4
24V circuit) in wiring harness Wiring harness between ACW (wiring side)
(12) THF (wiring side) (2) and chassis Voltage Max. 1 V
ground
troller
carried out.)
D155AX-6 39
Trouble (10) Air conditioner fault history: Daylight sensor "Abnormality"

Related
information

Defective daylight sensor
1 Daylight sensor may be defective.
(Internal defect)
2 Max. 1 z
or defective contact in con- (3) SLS (female) (1) tance
Max. 1 z
(15) SLS (female) (2) tance
Possible causes Ground fault in wiring har- Wiring harness between ACW (wiring side)
and standard Resis-
3 ness (Contact with GND cir- (3) SLS (female) (1) or circuit branch end Min. 1 Mz
state
Wiring harness between ACW (wiring side) Resis-
Min. 1 Mz
(15) SLS (female) (2) and chassis ground tance
Wiring harness between ACW (wiring side)
4 (3) SLS (female) (1) or circuit branch end Voltage Max. 1 V
and chassis ground
Wiring harness between ACW (wiring side)
Voltage Max. 1 V
(15) SLS (female) (2) and chassis ground
troller
carried out.)
40 D155AX-6
Trouble (11) Air conditioner fault history: Air outlet damper "Abnormality"
Related
information

Defective air outlet servomo-
1 Air outlet servomotor may be defective.
tor (Internal defect)
Wiring harness between MV1 (wiring side) Resis-
Max. 1 z
Disconnection in wiring har- Wiring harness between MV1 (wiring side) Resis-
Max. 1 z
ness (Disconnection in wiring (3) ACW (wiring side) (27) tance
2
or defective contact in con- Wiring harness between MV1 (wiring side) Resis-
nector) Max. 1 z
Max. 1 z
Max. 1 z
Wiring harness between MV1 (wiring side)
Resis-
(1) ACW (wiring side) (3) or circuit branch Min. 1 Mz
tance
Possible causes Ground fault in wiring har- Resis-
and standard 3 ness (Contact with GND cir- tance
ground
value in normal cuit)
state Wiring harness between MV1 (wiring side)
Resis-
(6) - ACW (wiring side) (24) and chassis Min. 1 Mz
tance
ground
Resis-
tance
ground
(1) ACW (wiring side) (3) or circuit branch Voltage Max. 1 V
Hot short (Short circuit with (5) ACW (wiring side) (9) and chassis Voltage Max. 1 V
4
(6) ACW (wiring side) (24) and chassis Voltage Max. 1 V
ground
Wiring harness between MV1(wiring side)
ground
troller
carried out.)
D155AX-6 41
Trouble (12) Air conditioner fault history: A/M damper "Abnormality"

Related
information

Defective air mix servomotor
1 Air mix servomotor may be defective.
(Internal defect)
Wiring harness between MAM (wiring side) Resis-
Max. 1 z
Disconnection in wiring har- Wiring harness between MAM (wiring side) Resis-
Max. 1 z
ness (Disconnection in wiring (3) ACW (wiring side) (3) tance
2
or defective contact in con- Wiring harness between MAM(wiring side) Resis-
nector) Max. 1 z
(5) ACW(wiring side) (2) tance
Wiring harness between MAM(wiring side) Resis-
Max. 1 z
Wiring harness between MAM (wiring side) Resis-
Max. 1 z
Wiring harness between MAM(wiring side)
Resis-
(3) ACW (wiring side) (3) or circuit branch Min. 1 Mz
tance
Wiring harness between MAM (wiring side)
Possible causes Ground fault in wiring har- Resis-
and standard 3 ness (Contact with GND cir- tance
ground
value in normal cuit)
state Wiring harness between MAM (wiring side)
Resis-
tance
ground
Resis-
tance
ground
(3) ACW (wiring side) (3) or circuit branch Voltage Max. 1 V
Hot short (Short circuit with (5) ACW (wiring side) (2) and chassis Voltage Max. 1 V
4
ground
ground
troller
carried out.)
42 D155AX-6
Trouble (13) Air conditioner fault history: Refrigerant "Abnormality"

Related
information

Insufficient refrigerant (gas)
1 Refrigerant (gas) may be insufficient. Check it directly.
(when system is normal)
Defective high and low pres- ing without turning starting switch ON.
2 sure switches (Internal dis-
connection)
Possible causes Between (1) (2) Max. 1 z
state Disconnection in wiring har-
3 Max. 1 z
or defective contact in con- (4) AC05 (female) (1) tance
nector) Wiring harness between AC05 (female) (2) Resis-
Max. 1 z
chassis ground (GND12) tance
troller
carried out.)
D155AX-6 43
Circuit diagram related to air conditioner
44 D155AX-6
D155AX-6 45
E-21 When starting switch is turned OFF, service meter is not

displayed 1
Trouble When starting switch is turned OFF, service meter is not displayed.
While starting switch is at OFF position, if following switches are operated, service meter is dis-
Related
played at top center of screen.
information
Operation of switches: [4] + [1] (Press simultaneously)

When starting switch is turned ON, if machine monitor displays
Possible causes
Defective backup power sup- nothing, backup power supply system may be defective. In this
and standard 1
ply system case, carry out troubleshooting for "E-1 When starting switch
value in normal
turned ON, machine monitor displays nothing".
state
If cause 1 is not detected, machine monitor may be defective.
E-22 Machine monitor cannot be set in service mode 1

Trouble Machine monitor cannot be set in service mode.
Related If following switches are operated, machine monitor is set in service mode.
information Operation of switches: [4] + [1] o [2] o [3] (While pressing [4], press other switches in order)

and standard
46 D155AX-6
E-23 Ripper pin puller cylinder does not operate 1

(1) When pin puller switch is pulled out, cylinder is not retracted.
Trouble
(2) When pin puller switch is pushed in, cylinder is not extended.
Related
information

1 Defective fuse(FS2-3) If fuse is broken, circuit probably has ground fault (See cause 5).
2 Defective pin puller switch PLSW (male) Pin puller switch Resistance
Pulled out Max. 1 z
Between (1) (2)
Pushed in Min. 1 Mz
3 Defective pin puller solenoid PPL (male) Resistance
Between (1) (2) 10 80 z
Disconnection in wiring har- Wiring harness between FS22 (3) PLSW Resis-
ness (Disconnection in wiring (female) (1) tance
and standard 4
value in normal or defective contact in con- Wiring harness between PLSW (female) (2) Resis-
nector) Max. 1 z
state PPL (female) (1) tance
Wiring harness between PLSW (female) (2) Resis-
Max. 1 z
Ground fault in wiring har- Wiring harness between FS22 (3) PLSW
Resis-
5 ness (Contact with GND cir- (female) (1) or circuit branch end and chas- Min. 1 Mz
tance
cuit) sis ground
Wiring harness between PLSW (female) (2) Resis-
Min. 1 Mz
PPL (female) (1) and chassis ground tance
Wiring harness between FS22 (3) PLSW
6 (female) (1) or circuit branch end and chas- Voltage Max. 1 V
sis ground
Wiring harness between PLSW (female) (2)
Voltage Max. 1 V
PPL (female) (1) and chassis ground
48 D155AX-6
Circuit diagram related to ripper pin puller switch and solenoid
D155AX-6 49
E-24 Backup alarm does not sound or does not stop 1

Trouble Backup alarm does not sound or does not stop.
Related
information

Defective backup alarm relay
1 (Internal disconnection or Replace backup alarm relay (Right No.) with
short circuit) another relay. If backup alarm operates nor-
BKA
mally at this time, backup alarm relay is
defective.
Disconnection in wiring har- Wiring harness between BKA (female) (3) Resis-
Max. 1 z
ness (Disconnection in wiring branch point (F) tance
2
or defective contact in con- Wiring harness between BKA (female) (5) Resis-
Possible causes nector) Max. 1 z
BKAL (female) (1) tance
and standard
value in normal Wiring harness between BKAL (female) (2) Resis-
Max. 1 z
state chassis ground (GND03) tance
3 ness (Contact with GND cir- Wiring harness between BKA (female) (5)
cuit) Resis-
BKAL (female) (1) or circuit branch end and Min. 1 Mz
tance
chassis ground
4
24V circuit) in wiring harness Wiring harness between BKA (female) (5)
BKAL (female) (1) or circuit branch end and Voltage Max. 1 V
chassis ground
Defective backup alarm
5 If causes 1 4 are not detected, backup alarm may be defective.
(Internal trouble)
50 D155AX-6
Circuit diagram related to backup alarm
D155AX-6 51
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.

1
Defective headlamp (Broken Headlamp bulb and ground wire may be defective. Check them
2
bulb, default grounding) directly.
FLSW (male) Headlamp switch Resistance
Defective headlamp switch
3 Between (5) (4) Moon mark Max. 1 z
Between (5) (4)
Neutral Min. 1 Mz
Between (5) (6)
Between (5) (6) Sun mark Max. 1 z
Defective left headlamp relay
4 (Internal disconnection or Replace left headlamp relay (Right No.) with
short circuit) another relay. If left headlamp becomes
LMFL
normal at this time, left headlamp relay is
defective.
Defective right headlamp
5 relay (Internal disconnection Replace right headlamp relay (Right No.)
Possible causes or short circuit) with another relay. If right headlamp
LMFR
and standard becomes normal at this time, right head-
value in normal lamp relay is defective.
Defective assembled-type ing without turning starting switch ON.
6 diode LMD1 or LMD2 (Inter-
LMD1 (male), LMD2 (male) Continuity
nal disconnection)
Between (2) (1) There is continuity
Max. 1 z
FLSW (female) (5) tance
Wiring harness between FLSW (female) (4) Resis-
Max. 1 z
LMD1 (female) (2) tance
Wiring harness between LMD1 (female) (1),
Resis-
Disconnection in wiring har- LMD2 (female) (1) LMFL (female) (1), Max. 1 z
tance
ness (Disconnection in wiring LMFR (female) (1)
7
or defective contact in con- Wiring harness between LMFL (female) (2),
nector) Resis-
LMFR (female) (2) chassis ground Max. 1 z
tance
(GND03)
Wiring harness between CB4 (2) LMFL Resis-
Max. 1 z
(female) (3), LMFR (female) (3) tance
Wiring harness between LMFL (female) (5) Resis-
Max. 1 z
LHDL (female) (1) tance
Wiring harness between LMFR (female) (5) Resis-
Max. 1 z
LHDR (female) (1) tance
52 D155AX-6

Resis-
FLSW (female) (5) or circuit branch end and Min. 1 Mz
tance
chassis ground
Wiring harness between FLSW (female) (4),
Resis-
(3) LMD1 (female) (2) or CM01 (female) Min. 1 Mz
(13) and chassis ground
value in normal Wiring harness between LMD1 (female) (1),
8 ness (Contact with GND cir- Resis-
state LMD2 (female) (1) LMFL (female) (1), Min. 1 Mz
cuit) tance
LMFR (female) (1) and chassis ground
Wiring harness between CB4 (2) LMFL
Resis-
(female) (3), LMFR (female) (3) and chassis Min. 1 Mz
tance
ground
Wiring harness between LMFL (female) (5) Resis-
Min. 1 Mz
LHDL (female) (1) and chassis ground tance
Wiring harness between LMFR (female) (5) Resis-
Min. 1 Mz
LHDR (female) (1) and chassis ground tance
D155AX-6 53
Trouble (2) Rear lamp and ripper point lamp do not light up.
Related
information

1
Defective rear lamp (Broken Rear lamp bulb and ground wire may be defective. Check them
2
bulb, default grounding) directly.
Defective ripper point lamp
(Broken bulb, default ground- Ripper point lamp bulb and ground wire may be defective. Check
3
ing) them directly.

Defective rear lamp switch RLSW (male) Rear lamp switch Resistance
4
OFF Min. 1 Mz
Between (5) (6)
ON Max. 1 z
Defective rear lamp relay and carry out troubleshooting.
5 (Internal disconnection or Replace rear lamp relay (Right No.) with
short circuit) another relay. If rear lamp becomes normal LMRE
at this time, rear lamp relay is defective.
Possible causes and carry out troubleshooting.
and standard Defective ripper point lamp
value in normal 6 relay (Internal disconnection Replace ripper point lamp relay (Right No.)
or short circuit) with another relay. If ripper point lamp
state LMRP
becomes normal at this time, ripper point
lamp relay is defective.
Max. 1 z
RLSW (female) (5) tance
Wiring harness between RLSW (female) (6) Resis-
Max. 1 z
LMRE (female) (1), LMRP (female) (1) tance
Wiring harness between LMRE (female) (2),
Resis-
LMRP (female) (2) chassis ground Max. 1 z
Disconnection in wiring har- tance
(GND03)
7 Wiring harness between CB5 (2) LMRE Resis-
or defective contact in con- Max. 1 z
(female) (3), LMRP (female) (3) tance
nector)
Wiring harness between LMRE (female) (5) Resis-
Max. 1 z
LREL (female) (1), LRER (female) (1) tance
Wiring harness between LREL (female) (2) Resis-
Max. 1 z
Wiring harness between LRER (female) (2) Resis-
Max. 1 z
Wiring harness between LMRP (female) (5) Resis-
Max. 1 z
LRP1 (female) (1) tance
54 D155AX-6

Resis-
RLSW (female) (5) or circuit branch end and Min. 1 Mz
tance
chassis ground
Wiring harness between RLSW (female) (6),
Possible causes Resis-
(1) LMRE (female) (1), LMRP (female) (1) Min. 1 Mz
and standard Ground fault in wiring har- tance
and chassis ground
state cuit) Wiring harness between CB5 (2) LMRE
Resis-
(female) (3), LMRP (female) (3) and chassis Min. 1 Mz
tance
ground
Wiring harness between LMRE (female) (5)
Resis-
LREL (female) (1), LRER (female) (1) and Min. 1 Mz
tance
chassis ground
Wiring harness between LMRP (female) (5) Resis-
Min. 1 Mz
LRP1 (female) (1) and chassis ground tance
Circuit diagram related to headlamp, rear lamp, and ripper point lamp
D155AX-6 55
E-26 Windshield wiper and window washer do not operate 1

Trouble (1) No windshield wipers and window washers do not operate.
Related
information

Defective fuse
1 If fuse is broken, circuit probably has ground fault (See cause 3).
(FS1 4 or -4)
ness (Disconnection in wiring Wiring harness between FS12 (4) fuse Resis-
2 Max. 1 z
Possible causes or defective contact in con- (B3) tance
value in normal Wiring harness between fuse (4) CN11 Resis-
Max. 1 z
state (female) (5) tance
Wiring harness between FS12 (4) fuse Min. 1 Mz
(B3) and chassis ground
cuit)
Wiring harness between fuse (4) CN11 Resis-
Min. 1 Mz
(female) (5) and chassis ground tance
56 D155AX-6
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.

1 Defective fuse ( -5) If fuse is broken, circuit probably has ground fault (See cause 7).
Defective front wiper motor CN23 Front wiper switch Voltage
2
(Internal trouble)
Between (6) (1) ON 20 30 V
If voltage is normal but wiper does not operate, motor is defective.
Defective front wiper switch CN14 (male) Front wiper switch Resistance
3
OFF Min. 1 Mz
Between (2) (3)
ON Max. 1 z
Defective front wiper inter-
4 mittent selector relay (Inter- Replace front wiper intermittent selector
nal trouble) relay (Right No.) with another relay. If front
CN29
Possible causes wiper becomes normal at this time, intermit-
and standard tent selector relay is defective.
state and carry out troubleshooting.
5 mittent relay (Internal trou- Replace front wiper intermittent relay (Right
ble) No.) with another relay. If front wiper
CN28
becomes normal at this time, intermittent
relay is defective.
(female) (3), (5), CN28 (female) (3), or Max. 1 z
tance
CN23 (female) (3)
Wiring harness between CN14 (female) (2) Resis-
ness (Disconnection in wiring Max. 1 z
6 CN29 (female) (3) tance
or defective contact in con-
nector) Wiring harness between CN29 (female) (4) Resis-
Max. 1 z
CN28 (female) (4) tance
Max. 1 z
Max. 1 z
D155AX-6 57

Wiring harness between fuse (5) CN14
(female) (3), (5), CN28 (female) (3), CN23 Resis-
Possible causes Min. 1 Mz
(female) (3), or circuit branch end and chas- tance
and standard Ground fault in wiring har- sis ground
state cuit) Wiring harness between CN14 (female) (2) Resis-
Min. 1 Mz
CN29 (female) (3) and chassis ground tance
Min. 1 Mz
Min. 1 Mz
Trouble (3) Front windshield wiper does not operate intermittently.

Before carrying out troubleshooting, check that continuous operation is normal.
Related If fuse ( -4) is broken, intermittent operation of all windshield wipers becomes defective.
information Carry out troubleshooting with front wiper switch and intermittent switch ON.
During intermittent operation, wiper stops for 5 seconds after each cycle of operation.

Defective intermittent switch CN11 (male) Intermittent switch Resistance
1
OFF Min. 1 Mz
Between (5) (6)
ON Max. 1 z
2 mittent selector relay (Inter- Replace front wiper intermittent selector
nal trouble) relay (Right No.) with another relay. If front
CN29
wiper becomes normal at this time, intermit-
tent selector relay is defective.
Possible causes 3 mittent relay (Internal trou- Replace front wiper intermittent relay (Right
and standard ble) No.) with another relay. If front wiper
CN28
value in normal becomes normal at this time, intermittent
state relay is defective.
Disconnection in wiring har- Wiring harness between CN11 (female) (6) Resis-
Max. 1 z
ness (Disconnection in wiring CN29 (female) (1) tance
4
or defective contact in con- Wiring harness between CN29 (female) (5) Resis-
nector) Max. 1 z
Max. 1 z
Ground fault in wiring har- Wiring harness between CN11 (female) (6)
Resis-
5 ness (Contact with GND cir- CN29 (female) (1) or circuit branch end Min. 1 Mz
tance
Min. 1 Mz
58 D155AX-6
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.

Defective rear wiper motor CN37 Rear wiper switch Voltage
2
(Internal trouble)
Between (6) (1) ON 20 30 V
Defective rear wiper switch CN12 (male) Rear wiper switch Resistance
3
OFF Min. 1 Mz
Between (2) (3)
ON Max. 1 z
Defective rear wiper intermit-
4 tent selector relay (Internal Replace rear wiper intermittent selector
trouble) relay (Right No.) with another relay. If rear
CN33
Possible causes wiper becomes normal at this time, intermit-
and standard tent selector relay is defective.
state
Defective rear wiper intermit- Replace rear wiper intermittent relay (Right
5
tent relay (Internal trouble) No.) with another relay. If rear wiper
CN32
becomes normal at this time, intermittent
relay is defective.

(female) (3), (5), CN32 (female) (3), or Max. 1 z
tance
CN37 (female) (6)
ness (Disconnection in wiring Max. 1 z
6 CN33 (female) (3) tance
nector) Wiring harness between CN33 (female) (4) Resis-
Max. 1 z
Max. 1 z
Max. 1 z
D155AX-6 59

Wiring harness between fuse (5) CN12

(female) (3), (5), CN32 (female) (3), CN37 Resis-
Possible causes Min. 1 Mz
(female) (6), or circuit branch end and chas- tance
and standard Ground fault in wiring har- sis ground
state cuit) Wiring harness between CN12 (female) (2) Resis-
Min. 1 Mz
Min. 1 Mz
- CN32 (female) (4) and chassis ground tance
Min. 1 Mz
Trouble (5) Rear windshield wiper does not operate intermittently.

information Carry out troubleshooting with rear wiper switch and intermittent switch ON.

1
OFF Min. 1 Mz
Between (5) (6)
ON Max. 1 z
Defective rear wiper intermit-
2 tent selector relay (Internal Replace rear wiper intermittent selector
trouble) relay (Right No.) with another relay. If rear
CN33
tent selector relay is defective.
Defective rear wiper intermit- Replace rear wiper intermittent relay (Right
Possible causes 3
tent relay (Internal trouble) No.) with another relay. If rear wiper
and standard CN32
value in normal becomes normal at this time, intermittent
state relay is defective.
Max. 1 z
4
nector) Max. 1 z
Max. 1 z
Resis-
tance
Min. 1 Mz
60 D155AX-6
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
Carry out troubleshooting with right door wiper switch ON and intermittent switch OFF.

Defective right door wiper Right door wiper
2 CN17 Voltage
motor (Internal trouble) switch
Between (3) (1) ON 20 30 V
3 switch (Internal disconnec- CN13 (male) Resistance
switch
tion)
OFF Min. 1 Mz
Between (2) (3)
ON Max. 1 z
Defective right door wiper
4 intermittent selector relay Replace right door wiper intermittent selec-
(Internal trouble) tor relay (Right No.) with another relay. If
CN31
right door wiper becomes normal at this
Possible causes time, intermittent selector relay is defective.
state Defective right door wiper
5 intermittent relay (Internal Replace right door wiper intermittent relay
trouble) (Right No.) with another relay. If right door
CN30
tent relay is defective.

Max. 1 z
(female) (3), (5) or CN17 (female) (4) tance

Max. 1 z
(female) (3) tance
ness (Disconnection in wiring CN31 (female) (3) Max. 1 z
6 tance
nector) Max. 1 z
Max. 1 z
Max. 1 z
Max. 1 z
D155AX-6 61


(female) (3), (5), CN17 (female) (4), or cir- Min. 1 Mz
tance
cuit branch end and chassis ground
Possible causes
and standard Wiring harness between fuse (6) CN30 Resis-
value in normal (female) (3) or circuit branch end and chas- Min. 1 Mz
state cuit) sis ground
Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
62 D155AX-6
Trouble (7) Right door wiper does not operate intermittently.

information Carry out troubleshooting with right door wiper switch and intermittent switch ON.

1
OFF Min. 1 Mz
Between (5) (6)
ON Max. 1 z
2 intermittent selector relay Replace right door wiper intermittent selec-
(Internal trouble) tor relay (Right No.) with another relay. If
CN31
right door wiper becomes normal at this
time, intermittent selector relay is defective.
Possible causes 3 intermittent relay (Internal Replace right door wiper intermittent relay
and standard trouble) (Right No.) with another relay. If right door
CN30
value in normal wiper becomes normal at this time, intermit-
state tent relay is defective.
Max. 1 z
4
nector) Max. 1 z
Max. 1 z
Resis-
tance
Min. 1 Mz
D155AX-6 63
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
Carry out troubleshooting with left door wiper switch ON and intermittent switch OFF.

Defective left door wiper Left door wiper
2 CN24 Voltage
motor (Internal trouble) switch
Between (3) (1) ON 20 30 V
3 switch (Internal disconnec- CN15 (male) Resistance
switch
tion)
OFF Min. 1 Mz
Between (2) (3)
ON Max. 1 z
Defective left door wiper
4 intermittent selector relay Replace left door wiper intermittent selector
(Internal trouble) relay (Right No.) with another relay. If left
CN27
door wiper becomes normal at this time,
Possible causes intermittent selector relay is defective.
state Defective left door wiper
5 intermittent relay (Internal Replace left door wiper intermittent relay
trouble) (Right No.) with another relay. If left door
CN26
tent relay is defective.
Max. 1 z
(female) (3), (5) tance

Max. 1 z
(female) (3) or CN24 (female) (4) tance
ness (Disconnection in wiring CN27 (female) (3) Max. 1 z
6 tance
nector) Max. 1 z
Max. 1 z
Max. 1 z
Max. 1 z
64 D155AX-6


(female) (3), (5) or circuit branch end and Min. 1 Mz
tance
chassis ground
Possible causes
and standard Ground fault in wiring har- Wiring harness between fuse (6) CN26 Resis-
value in normal (female) (3), CN24 (female) (4) or circuit Min. 1 Mz
state branch end and chassis ground
cuit)
Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
D155AX-6 65
Trouble (9) Left door wiper does not operate intermittently.

information Carry out troubleshooting with left door wiper switch and intermittent switch ON.

1
OFF Min. 1 Mz
Between (5) (6)
ON Max. 1 z
2 intermittent selector relay Replace left door wiper intermittent selector
(Internal trouble) relay (Right No.) with another relay. If left
CN27
door wiper becomes normal at this time,
intermittent selector relay is defective.
Possible causes 3 intermittent relay (Internal Replace left door wiper intermittent relay
and standard trouble) (Right No.) with another relay. If left door
CN26
value in normal wiper becomes normal at this time, intermit-
state tent relay is defective.
Max. 1 z
4
nector) Max. 1 z
Max. 1 z
Resis-
tance
Min. 1 Mz
66 D155AX-6
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.

Defective front window WSH1 Front wiper switch Voltage
2 washer motor (Internal trou- ON
ble) Between (3) (4) 20 30 V
(Wash position)
If voltage is normal but washer does not operate, motor is defec-
tive.
Defective front wiper switch CN14 (male) Front wiper switch Resistance
3
(Internal disconnection) OFF Min. 1 Mz
Possible causes Between (5) (6) ON
(Wash position)
value in normal
state
Disconnection in wiring har- Wiring harness between fuse (5) CN14 Resis-
Max. 1 z
ness (Disconnection in wiring (female) (3), (5) tance
4
nector) Max. 1 z
WSH1 (female) (3) tance
Wiring harness between WSH1 (female) (4) Resis-
Max. 1 z
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
Min. 1 Mz
WSH1 (female) (3) and chassis ground tance
D155AX-6 67
Trouble (11) Water does not come out from rear window washer.
Related
information If fuse ( -5) is broken, operations of both front window washer and rear window washer become
defective.

Defective rear window WSH2 Rear wiper switch Voltage
2 washer motor (Internal trou- ON
ble) Between (3) (4) 20 30 V
(Wash position)
tive.
Defective rear wiper switch CN12 (male) Rear wiper switch Resistance
3
(Internal disconnection) OFF Min. 1 Mz
Possible causes Between (5) (6) ON
(Wash position)
value in normal
Max. 1 z
4
nector) Max. 1 z
Max. 1 z
tance
Min. 1 Mz
68 D155AX-6
Trouble (12) Water does not come out from right door washer.
Related
information If fuse ( -6) is broken, operations of both right door washer and left door washer become defec-
tive.

and carry out troubleshooting
Right door wiper
WSH2 Voltage
Defective right door washer switch
2
motor (Internal trouble) ON
Between (1) (2) 20 30 V
(Wash position)
tive.
CN13 (male) Resistance
3 switch (Internal disconnec- switch
Possible causes tion) OFF Min. 1 Mz
and standard Between (5) (6) ON
(Wash position)
state
Max. 1 z
4
nector) Max. 1 z
Max. 1 z
Ground fault in wiring har- Wiring harness between fuse (6) CN13
Resis-
tance
Min. 1 Mz
D155AX-6 69
Trouble (13) Water does not come out from left door washer.
Related
If fuse ( -6) is broken, operations of both right door washer and left door washer become defec-
information
tive.

Left door wiper
WSH1 Voltage
Defective left door washer switch
2
motor (Internal trouble) ON
Between (1) (2) 20 30 V
(Wash position)
tive.
CN15 (male) Resistance
3 switch (Internal disconnec- switch
Possible causes tion) OFF Min. 1 Mz
and standard Between (5) (6) ON
(Wash position)
state
Max. 1 z
4
nector) Max. 1 z
Max. 1 z
tance
Min. 1 Mz
70 D155AX-6
Circuit diagram related to windshield wiper and window washer
D155AX-6 71
E-27 KOMTRAX system does not operate normally 1

Trouble KOMTRAX system does not operate normally.
If KOMTRAX system administrator makes request for checking system on machine side for trouble,
Related carry out following troubleshooting.
information Even if KOMTRAX system has trouble, it does not particularly appear on machine.
Carry out all troubleshooting on service menu screen of machine monitor.

a Turn starting switch ON and check "Setting condition of termi-
nal" screen.
1 Defective transmission 1
Check item Normal display
Communication start check Completion
a Turn starting switch ON and check "Condition of positioning
and communication" screen.
N ###,##,##(Latitude)
2 Defective GPS
Positioning E ###,##,##(Longitude)
Possible causes
In positioning
and standard
value in normal If latitude and longitude are not displayed in 5 minutes on open
state ground, notify KOMTRAX service hot line.
Defective communication Check item Normal display
3
environment Communication Zone level 1 Zone level 3
If zone level 1 3 is not displayed within communication zone of
ORBCOMM, notify KOMTRAX service hot line.
4 Defective transmission 2
Number of items not transmitted 0 9 (Normally 0)
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
D155AX-6 Bulldozer
2006 KOMATSU
All Rights Reserved
74 D155AX-6
SEN00808-00
D155AX-6

D155AX-6 80001 and up
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
H-13 Blade lift speed or power is low ................................................................................................ 15

H-14 Blade tilt speed or power is low ................................................................................................ 16
H-15 Ripper lift speed or power is low............................................................................................... 17
H-16 Ripper tilt speed or power is low............................................................................................... 18
H-17 Hydraulic drift of blade lift is large............................................................................................. 18
H-18 Hydraulic drift of blade tilt is large............................................................................................. 19
H-19 Hydraulic drift of ripper lift is large ............................................................................................ 19
H-20 Ripper pin puller cylinder does not operate .............................................................................. 20
H-21 Blade does not pitch ................................................................................................................ 20
H-22 Abnormal sound comes out from around work equipment pump ............................................. 21
2 D155AX-6
Troubleshooting of hydraulic and mechanical system (H-mode)1

a The following information is summarized in the troubleshooting table. Before carrying out troubleshoot-
ing, understand that information fully.
Trouble Trouble which occurred in the machine

Related
information
Possible causes 2
and standard Possible causes of trouble
value in normal (Given numbers are refer-
state ence numbers, which do
Remarks on judgment
not indicate priority)
3
D155AX-6 3
H-1 Power is low (Drawbar pull is low) 1

Trouble Power is low (Drawbar pull is low).
Related
Before carrying out troubleshooting, check that power train oil level is normal.
information

a Prepare with engine stopped, then run engine at high idle and
carry out troubleshooting.
1 Defective engine
PCCS lever Engine speed
F3 stall 1,450 rpm
2 Defective power train pump Power train pump may be defective. Check it directly.
Prepare with starting switch ON, then run engine at high idle and
Torque converter Torque converter
3 Trouble in torque converter PCCS lever
inlet pressure outlet pressure
Max. 1.0 MPa 0.29 0.69 MPa
Neutral
{Max. 10.0 kg/cm2} {3.0 7.0 kg/cm2}
PCCS lever Transmission main relief pressure
Min. 2.84 MPa
Neutral TM
{Min. 29.0 kg/cm2}
Improper set pressure or
4 internal trouble of transmis- a Prepare with engine stopped, then keep engine stopped and
sion main relief valve carry out troubleshooting.
Check directly that free length of spring and number of shims are
normal and spool moves smoothly.
Possible causes Free length of spring (large): 122 mm
and standard Free length of spring (small): 108 mm
value in normal Number of shims: 6
state a Prepare with engine stopped, then run engine at low idle and
PCCS lever Transmission clutch Clutch pressure
Min. 2.26 MPa
F3 stall F
{Min. 23.0 kg/cm2}
Min. 2.45 MPa
Malfunction of transmission R3 stall R
5 {Min. 25.0 kg/cm2}
clutch valve (ECMV)
Min. 2.62 MPa
F1 stall 1ST
{Min. 26.7 kg/cm2}
Min. 2.40 MPa
F2 stall 2ND
{Min. 24.5 kg/cm2}
Min. 2.62 MPa
F3 stall 3RD
{Min. 26.7 kg/cm2}
Prepare with engine stopped, then run engine at high idle and
6 Defective brake valve Parking brake lever Steering brake Brake oil pressure
RB 2.16 MPa
Free
LB {22.0 kg/cm2}
Defective adjustment of
If check result of cause 6 is abnormal, parking brake lever or brake
7 parking brake lever or brake
pedal linkage is adjusted defectively. Check them directly.
pedal linkage
8 Trouble in transmission Transmission may have trouble in it. Check it directly.
4 D155AX-6
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).

a Prepare with starting switch ON, then run engine at high idle
Max. 1.0 MPa 0.29 0.69 MPa
Neutral
{Max. 10.0 kg/cm2} {3.0 7.0 kg/cm2}
a Prepare with engine stopped, then run engine at low idle and
Possible causes Malfunction of transmission
2 Min. 2.40 MPa
and standard clutch valve (ECMV) F2 stall 2ND
{Min. 24.5 kg/cm2}
value in normal
state Min. 2.62 MPa
F3 stall 3RD
{Min. 26.7 kg/cm2}
Trouble in transmission Transmission clutch (2nd or 3rd gear speed) may have trouble in it.
3
clutch Check it directly.
Malfunction of parking brake Parking brake may be malfunctioning (Dragging). Check linkage
4
(Dragging) and valves.
a Move to level place, start engine, and check.
Malfunction of brake (Drag- Run engine at low idle and set transmission in F2. If machine does
5
ging) not move at this time, brake is dragging. Carry out troubleshooting
for "H-8 Brake does not work".
6 Trouble in transmission Transmission may have trouble in it. Check it directly.
D155AX-6 5
H-3 Machine does not start at any gear speed 1

Trouble Machine does not start at any gear speed.
Related
information

Min. 2.84 MPa
Neutral TM
{Min. 29.0 kg/cm2}
Free length of spring (large): 122 mm
Free length of spring (small): 108 mm
Number of shims: 6
carry out troubleshooting (after checking transmission main
relief pressure is normal).
Possible causes Min. 2.26 MPa
F3 stall F
and standard {Min. 23.0 kg/cm2}
value in normal Malfunction of transmission Min. 2.45 MPa
state 3 R3 stall R
clutch valve (ECMV) {Min. 25.0 kg/cm2}
Min. 2.62 MPa
F1 stall 1ST
{Min. 26.7 kg/cm2}
Min. 2.40 MPa
F2 stall 2ND
{Min. 24.5 kg/cm2}
Min. 2.62 MPa
F3 stall 3RD
{Min. 26.7 kg/cm2}
Trouble in transmission Transmission clutch (F or R) may have trouble in it. Check it
4
clutch directly.
Brake pedal Steering brake Brake pressure
2.16 MPa
5 Malfunction of brake Released
RB {22.0 kg/cm2}
LB 0 MPa
Pressed
{0 kg/cm2}
If brake pressure is abnormal, carry out troubleshooting for "H-8
Brake does not work".
6 D155AX-6
H-4 Machine can travel only forward or in reverse 1

Trouble Machine can travel only forward or in reverse.
Related
information

Min. 2.84 MPa
Neutral TM
{Min. 29.0 kg/cm2}
Possible causes Free length of spring (large): 122 mm
and standard Free length of spring (small): 108 mm
value in normal Number of shims: 6
state a Prepare with engine stopped, then run engine at low idle and
Malfunction of transmission PCCS lever Transmission clutch Clutch pressure
3
clutch valve (ECMV) Min. 2.26 MPa
F3 stall F
{Min. 23.0 kg/cm2}
Min. 2.45 MPa
R3 stall R
{Min. 25.0 kg/cm2}
Defective transmission clutch If check result of cause 3 is abnormal, seal of transmission clutch
4
seal (F or R) may be defective. Check it directly.
Trouble in transmission Transmission clutch (F or R) may have trouble in it. Check it
5
clutch directly.
D155AX-6 7
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
information

Min. 2.84 MPa
Neutral TM
{Min. 29.0 kg/cm2}
Free length of spring (large): 122 mm
Free length of spring (small): 108 mm
Number of shims: 6
Possible causes
and standard PCCS lever Transmission clutch Clutch pressure
value in normal Min. 2.26 MPa
state F3 stall F
{Min. 23.0 kg/cm2}
Malfunction of transmission Min. 2.45 MPa
3 R3 stall R
clutch valve (ECMV) {Min. 25.0 kg/cm2}
Min. 2.62 MPa
F1 stall 1ST
{Min. 26.7 kg/cm2}
Min. 2.40 MPa
F2 stall 2ND
{Min. 24.5 kg/cm2}
Min. 2.62 MPa
F3 stall 3RD
{Min. 26.7 kg/cm2}
Defective transmission clutch If check result of cause 3 is abnormal, seal of transmission clutch
4
seal (F or R) may be defective. Check it directly.
Trouble in transmission
5 Transmission clutch may have trouble in it. Check it directly.
clutch
a Move to level place, start engine, and check.
Malfunction of brake (Drag- Run engine at low idle and set transmission in F2. If machine does
6
ging) not move at this time, brake is dragging. Carry out troubleshooting
for "H-8 Brake does not work".
8 D155AX-6
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

Improper set pressure or PCCS lever
Possible causes
1 malfunction of self-acting Blade control lever Control circuit basic pressure
and standard
pressure reducing valve Ripper control lever
value in normal
state 3.78 4.46 MPa
Neutral
{38.5 45.5 kg/cm2}
If abnormal sound comes out from peripheral devices of HSS,
Abnormal sound from periph-
2 carry out troubleshooting for "H-10 Abnormal sound comes out
eral devices of HSS
from around HSS pump or HSS motor".
H-7 Steering speed or steering force is low 1

Trouble Steering speed or steering force is low.
Related
information

Improper set pressure or carry out troubleshooting.
1 malfunction of HSS main PCCS lever HSS relief pressure
relief valve Left steering relief 38.2 41.7 MPa
Right steering relief {390 425 kg/cm2}
Possible causes a Prepare with engine stopped, then run engine at high idle and
and standard carry out troubleshooting.
value in normal
state
3.78 4.46 MPa
Neutral
{38.5 45.5 kg/cm2}
If abnormal sound comes out from peripheral devices of HSS,
Abnormal sound from periph-
3 carry out troubleshooting for "H-10 Abnormal sound comes out
eral devices of HSS
from around HSS pump or HSS motor".
D155AX-6 9
H-8 Brake does not work 1

Trouble Brake does not work.
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).

Brake pedal Steering brake Brake pressure
1 Malfunction of brake valve
2.16 MPa
Possible causes Released
RB {22.0 kg/cm2}
and standard
LB 0 MPa
value in normal Pressed
state {0 kg/cm2}
Defective adjustment of If check result of cause 1 is abnormal, brake pedal limit switch may
2
brake pedal limit switch be adjusted defectively. Check it directly.
If check result of cause 1 is abnormal, brake seal may be defec-
3 Defective brake seal
tive. Check it directly.
Slip or wear of brake disc or
4 Brake disc or plate may be slipping or worn. Check them directly.
plate
10 D155AX-6
H-9 Power train oil is overheated 1

Trouble Power train oil is overheated.
Before carrying out troubleshooting, check that power train oil temperature gauge indicates actual
Related
oil temperature (If it does not, carry out troubleshooting for "E-9 Power train oil temperature gauge
information
(Multi-gauge) does not indicate normally".
Before carrying out troubleshooting, check that transmission main relief pressure is normal (See H-1).

Engine cooling system may be defective or engine output may be
1 Defective engine
increased. Carry out troubleshooting for engine unit (S mode).
Defective power train pump Power train pump may be defective or air is in suction circuit.
2
or air in suction circuit Check them directly.
Possible causes
Max. 1.0 MPa 0.29 0.69 MPa
and standard Neutral
{Max. 10.0 kg/cm2} {3.0 7.0 kg/cm2}
value in normal
state Malfunction of transmission Transmission clutch may be malfunctioning (slipping). Check it
4
clutch (Slip) directly.
a Start engine and check.
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
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.

1 Use of improper oil Oil used may be improper. Check it directly.
Clogged hydraulic tank
Possible causes 2 Hydraulic tank strainer may be clogged. Check it directly.
strainer
and standard
value in normal Suction circuit of work equipment and HSS pump may have
3 Air in suction circuit
state sucked in air. Check it directly.
Trouble in work equipment or
4 Work equipment or HSS pump may have trouble in it.
HSS pump
5 Trouble in HSS motor HSS motor may have trouble in it. Check it directly.
12 D155AX-6
H-11 Speed of all work equipment is low 1

Trouble Speed of all work equipment is low.
Related
information

Defective PTO (work equip-
Work equipment and HSS pump drive section of PTO may be
1 ment and HSS pump drive
defective. Check them directly.
section)
Defective work equipment or Work equipment or HSS pump may be defective. Check them
2
HSS pump directly.
PCCS lever
3 Malfunction of unload valve Blade control lever Unload pressure
2.45 (+1.37/0) MPa
Possible causes Neutral {25 (+14/0) kg/cm2}
and standard a Prepare with starting switch ON, then run engine at high idle
state Improper set pressure or
4 malfunction of main relief Blade control lever Main relief pressure
valve 27.5 1.5 MPa
Raise relief
{280 15 kg/cm2}
3.78 4.46 MPa
Neutral
{38.5 45.5 kg/cm2}
If check result of cause 5 is abnormal, fan pump may have trouble
6 Trouble in fan pump
in it. Check it directly.
D155AX-6 13
H-12 No work equipment moves 1

Trouble No work equipment moves.
Related
information

Defective PTO (work equip-
Work equipment and HSS pump drive section of PTO may be
1 ment and HSS pump drive
defective. Check them directly.
section)
Defective work equipment or Work equipment or HSS pump may be defective. Check them
2
HSS pump directly.
PCCS lever
3 Malfunction of unload valve Blade control lever Unload pressure
2.45 (+1.37/0) MPa
Neutral {25 (+14/0) kg/cm2}
Improper set pressure or and carry out troubleshooting.
Possible causes
and standard 4 malfunction of main relief Blade control lever Main relief pressure
value in normal valve 27.5 1.5 MPa
Raise relief
state {280 15 kg/cm2}
3.78 4.46 MPa
Neutral
{38.5 45.5 kg/cm2}
Work equipment lock lever Solenoid valve output pressure
Malfunction of work equip-
6 0 MPa
ment lock solenoid valve Lock
{0 kg/cm2}
3.78 4.46 MPa
Free
{38.5 45.5 kg/cm2}
14 D155AX-6
H-13 Blade lift speed or power is low 1

Trouble Blade lift speed or power is low.
Related Check that blade has not been modified.
information If hydraulic drift of blade lift is large, carry out troubleshooting for "H-17 Hydraulic drift of blade lift is
large" first.

valve 27.5 1.5 MPa
Raise relief {280 15 kg/cm2}
Possible causes 2 malfunction of self-acting Blade control lever Control circuit basic pressure
and standard pressure reducing valve Ripper control lever
value in normal 3.78 4.46 MPa
state Neutral
{38.5 45.5 kg/cm2}
Malfunction of blade lift con- Spool of blade lift control valve may be malfunctioning. Check it
3
trol valve (spool) directly.
Suction valve of blade lift control valve may be malfunctioning.
Check it directly.
Malfunction of blade lift con-
4
trol valve (suction valve)
* This suction valve can be checked by replacing it with suction
valve of ripper lift or ripper tilt control valve and observing
change of phenomenon.
Air may be in blade lift cylinder. Bleed air and then judge from
5 Air in blade lift cylinder
D155AX-6 15
H-14 Blade tilt speed or power is low 1

Trouble Blade tilt speed or power is low.
information If hydraulic drift of blade tilt is large, carry out troubleshooting for "H-18 Hydraulic drift of blade tilt is
large" first.

valve 27.5 1.5 MPa
Left tilt relief {280 15 kg/cm2}
Possible causes carry out troubleshooting.
and standard
value in normal Improper set pressure or PCCS lever
state 2 malfunction of self-acting Blade control lever Control circuit basic pressure
3.78 4.46 MPa
Neutral
{38.5 45.5 kg/cm2}
Malfunction of blade tilt con- Spool of blade tilt control valve may be malfunctioning. Check it
3
Air may be in blade tilt cylinder. Bleed air and then judge from
4 Air in blade tilt cylinder
16 D155AX-6
H-15 Ripper lift speed or power is low 1

Trouble Ripper lift speed or power is low.
Related Check that ripper has not been modified.
information If hydraulic drift of ripper lift is large, carry out troubleshooting for "H-19 Hydraulic drift of ripper lift is
large" first.

1 malfunction of main relief Ripper control lever Main relief pressure
valve 27.5 1.5 MPa
Raise relief {280 15 kg/cm2}
state Neutral
{38.5 45.5 kg/cm2}
Malfunction of ripper lift con- Spool of ripper lift control valve may be malfunctioning. Check it
3
Suction valve of ripper lift control valve may be malfunctioning.
Check it directly.
Malfunction of ripper lift con-
4
* This suction valve can be checked by replacing suction valves
on head side and bottom side with each other and observing
Air may be in ripper lift cylinder. Bleed air and then judge from
5 Air in ripper lift cylinder
D155AX-6 17
H-16 Ripper tilt speed or power is low 1

Trouble Ripper tilt speed or power is low.
information Check that ripper has not been modified.

1 malfunction of main relief Ripper control lever Main relief pressure
valve 27.5 1.5 MPa
Tilt-in relief {280 15 kg/cm2}
state Neutral
{38.5 45.5 kg/cm2}
Malfunction of ripper tilt con- Spool of ripper tilt control valve may be malfunctioning. Check it
3
Suction valve of ripper tilt control valve may be malfunctioning.
Check it directly.
Malfunction of ripper tilt con-
4
* This suction valve can be checked by replacing suction valves
on head side and bottom side with each other and observing
Air may be in ripper tilt cylinder. Bleed air and then judge from
5 Air in ripper tilt cylinder
H-17 Hydraulic drift of blade lift is large 1

Trouble Hydraulic drift of blade lift is large.
information Before carrying out troubleshooting, check that oil is not leaking from work equipment circuit.

a Start engine and prepare, then stop engine and carry out trou-
bleshooting.
Perform following procedure. If hydraulic drift is increased at this
Possible causes time, seal of blade lift control valve spool is defective.
Defective seal of blade lift
and standard 1 1. Brace blade against ground by lifting operation to push up front
control valve (spool)
value in normal part of machine.
state 2. Stop engine and then turn starting switch ON.
3. Set blade control lever in "Lower" position and check phenom-
enon.
Defective seal of blade lift
2 Seal of blade lift cylinder may be defective. Check it directly.
cylinder
18 D155AX-6
H-18 Hydraulic drift of blade tilt is large 1

Trouble Hydraulic drift of blade tilt is large.

bleshooting.
Defective seal of blade tilt time, seal of blade tilt control valve spool is defective.
Possible causes 1 1. Brace blade against ground by tilting operation to push up front
and standard part of machine.
value in normal 2. Stop engine and then turn starting switch ON.
state 3. Set blade control lever in "Tilt left" position and check phenom-
enon.
Defective seal of blade tilt carry out troubleshooting.
2
cylinder Blade tilt cylinder Leakage from cylinder
Left tilt relief 12 cc/min
H-19 Hydraulic drift of ripper lift is large 1

Trouble Hydraulic drift of ripper lift is large.
Related Check that ripper has not been modified.

bleshooting.
Defective seal of ripper lift time, seal of ripper lift control valve spool is defective.
Possible causes 1 1. Brace ripper against ground by lifting operation to push up rear
and standard part of machine.
value in normal 2. Stop engine and then turn starting switch ON.
state 3. Set ripper control lever in "Lower" position and check phenom-
enon.
Defective seal of ripper lift carry out troubleshooting.
2
cylinder Ripper lift cylinder Leakage from cylinder
Lower relief 11 cc/min
D155AX-6 19
H-20 Ripper pin puller cylinder does not operate 1

Giant ripper specification
Trouble Ripper pin puller cylinder does not operate.
Related
Before carrying out troubleshooting, check that transmission main relief pressure is normal (See H-1).
information

Possible causes
and standard Malfunction of pin puller sole- Solenoid output
1 Pin puller switch Check point
value in normal noid pressure
state Pushed in Cylinder bottom side Min. 2.84 MPa
Pulled out Cylinder head side {Min. 29.0 kg/cm2}
2 Trouble in pin puller cylinder Pin puller cylinder has trouble in it. Check it directly.
H-21 Blade does not pitch 1

Dual tilt specification
Trouble Blade does not pitch.
Related
information

Possible causes
Malfunction of blade pitch Spool of blade pitch control valve may be malfunctioning. Check it
and standard 1
control valve (spool) directly.
value in normal
state Malfunction of blade pitch
2 Blade pitch cylinder may be malfunctioning. Check it directly.
cylinder
20 D155AX-6
H-22 Abnormal sound comes out from around work equipment pump 1
Trouble Abnormal sound comes out from around work equipment pump.
information Work equipment pump is used for HSS, too.

1 Use of improper oil Oil used may be improper. Check it directly.
Possible causes Clogged hydraulic tank
2 Hydraulic tank strainer may be clogged. Check it directly.
and standard strainer
value in normal Suction circuit of work equipment and HSS pump may have
state 3 Air in suction circuit
sucked in air. Check it directly.
Trouble in work equipment or
4 Work equipment or HSS pump may have trouble in it.
HSS pump
D155AX-6 21
D155AX-6 Bulldozer
2006 KOMATSU
All Rights Reserved
22 D155AX-6
SEN00852-01
D155AX-6

D155AX-6 80001 and up
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
S-15 Abnormal noise is made ............................................................................................................ 27

S-16 Vibration is excessive ................................................................................................................ 28
2 D155AX-6
Troubleshooting of engine (S-mode) 1

Method of using troubleshooting chart 1
The troubleshooting chart consists of the "ques-
Causes
tions", "check items", "causes", and "troubleshoot-
ing" blocks.
The questions and check items are used to pinpoint
high probability causes by simple inspection or
from phenomena without using troubleshooting
1 2 3 4
tools.
Next, troubleshooting tools or direct inspection are
applied to check the narrowed causes in order from
the most probable one to make final confirmation
according to the troubleshooting procedure.
[Questions] 1
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
<Example of troubleshooting> Exhaust gas is black(Incomplete combustion)

Let us assume that a trouble of "Exhaust gas is black" occurred and we checked the [Questions] and
[Check items] and found the following 3 items to be the causal symptoms; "Exhaust gas slowly became
black", "Power slowly became weaker", and "Dust indicator is lighting red".
S-7 Exhaust gas is black

(Incomplete combustion) Cause
Leakage of air between turbocharger and cylinder head
Defective coolant temperature sensor or wiring harness

General causes why exhaust gas is black
Seized turbocharger or interference of turbocharger

Insufficient intake of air
Clogged fuel spill piping (on cylinder head side)

Excessive injection of fuel
Defective condition of fuel injection
Defective contact of valve and valve seat

Improper selection of fuel
Stuck or seized supply pump plunger

Overheating
Clogged EGR gas pressure piping
Worn piston ring or cylinder liner

See "S-14 Coolant temperature becomes too high
Improper fuel injection pressure

Improper fuel injection timing
Clogged air cleaner element
(Overheating)"
Crushed or clogged muffler
Clogged or seized injector

Improper valve clearance
Abnormally worn injector

Control by controller in derate mode (limiting injection
rate (output) because of an error in electrical system)
Stuck EGR valve
EGR valve stuck open (There is much EGR gas and
intake of air is insufficient)
Clogged EGR gas pressure piping (Exhaust gas is
mixed in intake air during acceleration and deceleration)
Confirm recent repair history

Degree of use of machine Operated for long period
Suddenly became black
Exhaust gas color Gradually became blackB
Questions
Blue under light load

Non-specified fuel is used
Oil must be added more frequently
Suddenly
Power was lost
Gradually
Dust indicator is red (if it is installed)
Muffler is crushed
Air leaks between turbocharger and cylinder head or clamp is loosened
Engine is operated in low-temperature mode at normal temperature
Immediately after engine is started, temperature of exhaust manifold
of a cylinder is low
When engine is rotated, interference sound comes out from around
turbocharger
Check items
When engine is rotated, abnormal sound comes out from around

cylinder head
Torque converter stall speed or pump relief speed is high
(Fuel is injected excessively)
Exhaust noise is abnormal
Engine does not pick up smoothly and combustion is irregular
Blow-by gas is excessive
When spill hose from injector is disconnected, abnormally much fuel spills
Inspect air cleaner directly

Turbocharger is heavy to rotate with hand
Carry out troubleshooting according to "EGR Valve Servo Error 1 (*1)"
in E mode
Troubleshooting
Check EGR gas pressure piping directly (*2)

Compression pressure is low
Inspect valve clearance directly
When muffler is removed, exhaust gas color improves
Carry out troubleshooting according to "Rail Press Low Error (*3)" in E mode
When a cylinder is cut out for reduced cylinder mode operation, engine
speed does not change
Inspect fuel spill piping (on cylinder head side) directly
Carry out troubleshooting according to "Coolant Temp Sens
(High/Low) Error (*4) in E mode
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Adjust
Clean
Remedy
4 D155AX-6
There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 6 items in
the [Causes] section.
The method of pinpointing the [Causes] from the causal relationship and approaching the [troubleshooting]
is explained according to Step 1 - Step 3 shown below.
[Causes]: 6 items
Step 1
Clarify the relationship between the 3 items in the

[Questions] and [Check items] sections and the 6 items
in the [Causes] section.
[Questions] [Check items]: 3 items
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
S-1 Starting performance of engine is poor 1

General causes why starting performance is poor Causes
q Defective electrical system
Cracked EGR cooler (Coolant in exhaust pipe)
Leaking or clogged fuel piping or entry of air

q Insufficient supply of fuel
Clogged air breather hole of fuel tank cap

Defective contact of valve and vale seat

q
Defective alternator (generator section)

Defective alternator (regulator section)
q Improper selection of fuel
Defective intake air heater system

Coolant in exhaust pipe
Defective or deteriorated battery

q
Clogged feed pump gauze filter

a The common rail fuel injection system (CRI) recog-
Clogged fuel filter element

nizes the fuel injection timing electrically. Accord-
Worn piston ring, cylinder

ingly, even if the starting operation is carried out, the
engine may not start until the crankshaft revolves 2
Defective injector
turns at maximum. This phenomenon does not indi-
cate a trouble, however

Degree of use of
machine
Operated for long period E E E E E
Became worse gradually Q Q w w Q Q

Starting performance
Engine starts easily when warm w w
Questions
Non-specified fuel is used Q Q Q Q

Filters have not been replaced according to Operation and Maintenance Manual w w w Q Q
Engine oil must be added more frequently w
When engine is preheated or when temperature is low, preheating monitor does not
indicate normally (if monitor is installed) w
During operation, charge level monitor indicates abnormal charge
(if monitor is installed) w w
Dust indicator is red (if it is installed) w

Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w Q
Priming pump is too light or too heavy to operate w Q Q
Starting motor cranks engine slowly Q w
While engine is When air bleeding plug of fuel filter is removed, fuel does not
flow out w w
rotated with starting
motor When spill hose from injector is disconnected, little fuel spills w
Check items
Immediately after engine is started, temperature of exhaust manifold of a cylinder is

low w
Engine does not pick up smoothly and combustion is irregular Q Q w

Engine hunts (rotation is irregular) Q w Q Q
Blow-by gas is excessive w
Inspect air cleaner directly q

When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows
out (*1) q
Compression pressure is low q q

When air is bled from fuel system, air comes out q
Inspect fuel filter and strainer directly q
Troubleshooting
Inspect feed pump gauze filter directly q

Carry out troubleshooting according to "Rail Press (Very) Low Error (*2)" indicated by
code q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
not change q
When starting switch is turned to HEAT, intake air heater mount does not become
warm q
Is voltage of 20 30 V generated between alternator terminals B and E Yes q

while engine is running at low idle? No q
Specific gravity of electrolyte and battery voltage are low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
6 D155AX-6
*1: EGR cooler outlet gas piping

Loosen 4 mounting bolts (1) of the EGR cooler outlet gas piping and see if the coolant flows out.
A little condensate produced from cooled exhaust gas may flow out. If it is colorless and transparent,
however, it is not a problem.
*2: Displayed failure codes: [CA559] and [CA2249]
D155AX-6 7
S-2 Engine does not start 1

a) Engine does not rotate Causes
General causes why engine does not rotate
Cracked EGR cooler (Coolant in exhaust pipe)
Defective starting motor (safety relay section)

q Seized internal parts of engine
o See "S-4 Engine stops during operation"
Defective connection of battery terminal
Defective starting motor (motor section)

q Water hammer caused by coolant which entered cylinder
q Defective electrical system
Defective starting circuit wiring

q Trouble in drive devices on applicable machine side
o Carry out troubleshooting for devices on applicable machine
Broken flywheel ring gear

Defective battery relay
Questions
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
Speed of rotation is low Q w

When starting switch is
turned to START, start- Makes grating noise w w
ing pinion moves out, Soon disengages again w
but
Makes rattling noise and does not turn w Q Q w
When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows out (*1). q
Carry out troubleshooting on

Inspect flywheel ring gear directly q
applicable machine side

Troubleshooting
There is not voltage (20 30 V) between battery relay terminals B

and E q
Turn starting switch When terminals B and C of starting switch are connected, engine
OFF, connect cables, q
starts
turn starting switch ON,
and carry out trouble- When terminals B and C at safety relay outlet are connected, engine q
shooting starts
Even if terminals B and C at safety relay outlet are connected,
q
engine does not start
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy

8 D155AX-6

D155AX-6 9
b) Engine rotates but no exhaust gas comes out Causes

General causes why engine rotates but no exhaust gas
Malfunction of overflow valve (Does not close)

comes out

Fuel is not supplied
Wrong connection of supply pump PCV

q
Seized or abnormally worn feed pump

q Supply of fuel is extremely small
Broken supply pump shaft or key

q Improper selection of fuel (particularly in winter)
Defective supply pump PCV

Clogged fuel filter element
Malfunction flow damper

Insufficient fuel in tank
Defective fuel injector

Use of improper fuel
Questions
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

When air bleeding plug of fuel filter is removed, fuel does Q Q w Q
While engine is not flow out
rotated with starting
motor When spill hose from injector is disconnected, little fuel
spills Q w w w w Q

Inspect fuel filter directly q
Troubleshooting
Inspect feed pump directly q

Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indi- q q q q
cated by code
Carry out troubleshooting according to "PCV1 Short/Open Error (*2) or PCV2
q
Short/Open Error (*3)" indicated by code
Inspect overflow valve directly q
Engine can be started in reduced cylinder mode q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Remedy
Add
*1: Displayed failure codes [CA559] and [CA2249]

10 D155AX-6
c) Exhaust gas comes but engine does not start Causes

(fuel is injected)
Worn dynamic valve system (Valve, rocker lever, etc.)

General causes why exhaust smoke comes out but engine
does not start
Leaking or clogged fuel system or entry of air

q Lack of rotating force due to defective electrical system


q Insufficient intake of air
Clogged injector or defective spray
Defective intake air heater system


Clogged fuel filter or strainer
Use of improper fuel

Degree of use of machine Operated for long period E E E E
Suddenly failed to start w w Q
Questions
Non-specified fuel is used Q Q

Filters have not been replaced according to Operation and Maintenance Manual w w w
Engine oil must be added more frequently w
When engine is preheated or when temperature is low, preheating monitor does not indi-
cate normally (if monitor is installed) w
Dust indicator is red (if it is installed) w

Air breather hole of fuel tank cap is clogged Q
There are rust and water in fuel drained from fuel tank w w
There is not fuel in removed fuel filter w
Starting motor rotates engine slowly w
When engine is rotated, abnormal sound comes out from around cylinder head w
Check items
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

Inspect dynamic valve system directly q
Compression pressure is low q
Troubleshooting

code q
When injector unit is tested, spray condition is bad q

Coolant temperature gauge does not indicate normally (if it is installed) q
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
D155AX-6 11
S-3 Engine does not pick up smoothly 1

General causes why engine does not pick up smoothly Causes
Malfunction of flow damper (Large leakage from injector)

q

q Defective condition of fuel spray

q Control by controller in derate mode

(limiting injection rate (output) because of an error in

electrical system)
Clogged injector or defective spray

EGR valve stuck open

q

(There is much EGR gas and intake of air is insufficient)

Stuck EGR valve
Degree of use of E E E E E E
Operated for long period
machine
Questions
Engine pick-up suddenly became worse Q w Q Q Q

Non-specified fuel is used w w w w
Filters have not been replaced according to Operation and Maintenance Manual w w w
Oil must be added more frequently w
Dust indicator is red (if indicator is installed) w
Immediately after engine is started, temperature of exhaust manifold of a cylinder is low Q w
Blue under light load w
Exhaust gas color
Black w Q w w
Check items
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

Carry out troubleshooting according to "EGR Valve Servo Error (*1)" indicated by code q
Inspect valve clearance directly q
Troubleshooting
Turbocharger is heavy to rotate with hand q

code q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
change q q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy

12 D155AX-6
S-4 Engine stops during operation 1

General causes why engine stops during operation Causes
Seized parts inside engine
Broken dynamic valve system (valve, rocker arm, etc.)

q
Broken auxiliary equipment (pump, compressor, etc.)
Trouble in drive devices on applicable machine side

q Overheating
q Trouble in drive devices on applicable machine
Broken or seized piston or connecting rod

side
o Carry out troubleshooting for devices on appli-

Broken or seized crankshaft bearing
cable machine
Broken supply pump shaft or key

Leaking or clogged fuel piping
Broken or seized feed pump

Broken or seized gear train
Degree of use of
machine Operated for long period E E
Made abnormal noise stopped suddenly w w w w Q w Q w w

w Q Q
Questions
Overheated and stopped

Engine
Stopped slowly w Q Q
Hunted and stopped w Q Q Q Q
Non-specified fuel is used Q Q Q Q
Filters have not been replaced according to Operation and Maintenance
Manual w w
Fuel level monitor indicates low level (if monitor is installed) w

There are metal particles in oil drained from oil pan w w Q Q
Check items
Engine does not rotate at all w w

When engine is Engine rotates in opposite direction w
rotated with hand Engine moves by gear backlash w w
Supply pump shaft does not turn w
Engine rotates, but stops when load is applied to machine w

Carry out troubleshooting
Inspect piston and connecting rod directly q

on applicable machine
Inspect crankshaft bearing directly q

Troubleshooting
Inspect gear train directly q

Inspect feed pump directly q
Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)"
q q
indicated by code
Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is
q
removed
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy

Add
D155AX-6 13
S-5 Engine does not rotate smoothly 1

General causes why engine does not rotate smoothly Causes
Air in fuel system
Malfunction of flow damper (Large leakage from injector)

q
q Defective speed sensor
Clogged injector or defective spray (dirt in injector)

(Error at degree that it is not indicated)
Defective Bkup speed sensor or wiring harness

q Defective EGR valve
Defective Ne speed sensor or wiring harness

q Defective bypass valve

Low setting of low idle speed

Malfunction of bypass valve
Malfunction of EGR valve

Q Q Q Q Q
Questions
At a certain speed range

At low idle w Q Q Q Q Q Q Q
Engine hunts
Even when speed is raised Q Q Q Q Q
On slopes w Q Q
Filters have not been replaced according to Operation and Maintenance Manual w w
Check items
There are rust and water in fuel drained from fuel tank 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
Troubleshooting

When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
q q
change
Carry out troubleshooting according to "Eng Ne Speed Sensor Error (*3)" indicated by
q
code
Carry out troubleshooting according to "Eng Bkup Speed Sensor Error (*4)" indicated q
by code
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
Add

*2: Displayed failure code [CA1628] and [CA1629]
*3: Displayed failure code [CA689]
*4: Displayed failure code [CA778]
14 D155AX-6
S-6 Engine lack output (or lacks power) 1

General causes why engine lacks output Causes
Defective installation of charge pressure sensor (air leakage)

q
q Defective spray condition of fuel
Defective fuel temperature sensor or wiring harness

Defective charge pressure sensor or wiring harness
Clogged injector or defective spray (dirt in injector)

q Overheating
Defective drive of injector (signal or solenoid)

o See "S-14 Coolant temperature becomes too

high (Overheating)"

q Control by controller in derate mode
Air leakage from air intake piping

(limiting injection rate (output) because of an
Leaking or clogged fuel piping


error in electrical system)

Degree of use of machine Operated for long period E E E E E
Suddenly Q Q Q Q
Questions
Power was lost

Gradually Q Q Q Q Q Q Q
Filters have not been replaced according to Operation and Maintenance
Manual w
Engine oil must be added more frequently Q Q Q
Output becomes insufficient after short stop of operation w
Black w w
Exhaust gas is
Immediately after engine is started, temperature of exhaust manifold of a
cylinder is low w
w
Check items
turbocharger
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

Inspect air intake piping directly q
Boost pressure is low q q q
Troubleshooting

indicated by code q
When a cylinder is cut out for reduced cylinder mode operation, engine speed
does not change q q
Inspect boost pressure sensor mount directly q
Carry out troubleshooting according to "Chg Air Press Sensor High (Low)
Error (*2)" indicated by code q
Carry out troubleshooting according to "Fuel Temp Sensor High (Low) Error
(*3)" indicated by code q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Clean
*1: Displayed failure code [CA559] and [CA2249] Remedy

D155AX-6 15
S-7 Exhaust gas is black (incomplete combustion) 1

General causes why exhaust gas is black Causes
q Insufficient intake of air

q Excessive injection of fuel

q Defective condition of fuel injection
Clogged fuel spill piping (on cylinder head side)

q Overheating

o See "S-14 Coolant temperature becomes too

high (Overheating)"
Clogged EGR gas pressure piping

Control by controller in derate mode

q
Improper fuel injection pressure

(limiting injection rate (output) because of an
Crushed or clogged muffler

error in electrical system)
Abnormally worn injector

q EGR valve stuck open
(There is much EGR gas and intake of air is
Stuck EGR valve

insufficient)
q Clogged EGR gas pressure piping
(Exhaust gas is mixed in intake air during accel-
eration and deceleration)
Suddenly became black w Q Q Q Q
w w Q Q Q
Questions
Exhaust gas color Gradually became black

Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Air leaks between turbocharger and cylinder head or clamp is loosened w
Engine is operated in low-temperature mode at normal temperature Q Q Q
Immediately after engine is started, temperature of exhaust manifold of a
cylinder is low Q w
turbocharger w
Check items
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
When spill hose from injector is disconnected, abnormally much fuel spills w

Carry out troubleshooting according to "EGR Valve Servo Error (*1)" indicated
by code q
Inspect EGR gas pressure piping directly (*2) q
Troubleshooting

When muffler is removed, exhaust gas color improves q
indicated by code q q
does not change q
Inspect fuel spill piping (on cylinder head side) directly q
Carry out troubleshooting according to "Coolant Temp Sens High (Low) Error
(*4)" indicated by code q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Adjust
Clean
Remedy
16 D155AX-6

*2: EGR gas pressure piping
Remove 2 EGR gas pressure pipes (2) and check their inside for clogging.

D155AX-6 17
S-8 Oil consumption is excessive (or exhaust gas is blue) 1

General causes why oil consumption is excessive Causes
q Abnormal consumption of oil
Turbocharger
Worn or damaged valve (stem, guide, or seal)
Oil leakage from oil pan, cylinder head, etc.

q Long-time operation of engine at low idle or high
idle (Do not run engine at idle for more than 20
minutes continuously)
Clogged breather or breather hose

Dust sucked in from intake system
Oil leakage from EGR valve stem

q External leakage of oil

Worn seal at turbocharger end
Worn or damaged rear oil seal
Oil leakage from oil drain plug

q Wear of parts in lubrication system
Oil leakage from oil cooler
Oil leakage from oil piping

Worn seal at blower end
Oil leakage from oil filter

Broken piston ring
Broken oil cooler

E E E E E
Questions

Oil consumption suddenly increased w Q
Oil must be added more frequently Q w Q
Oil becomes dirty quickly Q Q w
Outside of engine is dirty with oil w w w w w
There are loose piping clamps in intake system w
Inside of turbocharger intake outlet pipe is dirty with oil w
Inside of turbocharger exhaust outlet pipe is dirty with oil Q w
Check items
There is oil in coolant w

Oil level in damper chamber is high w
Exhaust gas is blue under light load Q w w
Excessive Q Q w w
Amount of blow-by gas
None w
There is dust in intake manifold q

Inside of intake manifold is abnormally dirty q
Play of turbocharger shaft is excessive q q
Troubleshooting
Exhaust port of EGR valve is dirty with oil q

Check breather and breather hose directly q
Inspect rear oil seal directly q
Leakage from oil cooler is detected by pressure test q q
Oil leaks out of engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
18 D155AX-6
S-9 Oil becomes dirty quickly 1

General causes why oil becomes dirty quickly Causes
q Entry of exhaust gas into oil due to internal wear
Clogged turbocharger lubrication drain tube

Defective seal at turbocharger turbine end
q Clogging of lubrication passage
q Use of improper fuel
Clogged breather or breather hose

q Use of improper oil

q Overload operation
Defective oil filter safety valve

Worn valve or valve guide
Exhaust gas color is bad

Worn EGR valve guide
Clogged oil cooler

Clogged oil filter
Questions

Non-specified fuel is used Q
Engine oil must be added more frequently Q w
Even when engine oil temperature rises, oil filter clogging monitor indicates clogging w Q
(if monitor is installed)
There are metal particles in oil drained from oil pan Q Q w
Inside of exhaust pipe is dirty with oil w
Engine oil temperature rises quickly w
Check items
Exhaust gas is
Black w
Comes out excessively Q Q w Q
Blow-by gas
Does not come out at all w
Play of turbocharger shaft is excessive q

Exhaust port of EGR valve is dirty with oil q
Troubleshooting
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
S-10 Fuel consumption is excessive 1

General causes why fuel consumption is excessive Causes
Leakage of fuel

q
q Defective condition of fuel injection (fuel pressure or injection timing)
q Excessive injection of fuel
Fuel leakage from fuel filter, piping, etc.
Defective common rail pressure

Fuel leakage inside head cover
Defective supply pump plunger

Defective feed pump oil seal
Defective spray by injector

Malfunction of injector
E E E
Questions

Is large compared to other machines of same model Q Q Q Q
Fuel consumption Gradually increased Q Q
Suddenly increased Q Q
There is external leakage of fuel from engine w
Combustion is irregular w
Engine oil level rises and oil smells of diesel fuel w w
Immediately after engine is started, temperature of exhaust manifold of a cylinder is low w
Check items
Low idle speed is high Q

Torque converter stall speed or pump relief speed is high Q
Black Q Q Q Q
Exhaust gas is
White Q
Remove head cover and inspect inside directly q

Inspect feed pump oil seal directly q
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
S-11 Oil is in coolant

(or coolant spurts back or coolant level goes down) 1
General causes why oil is in coolant Causes
q Leakage in lubrication system
Damaged cylinder liner O-ring or holes caused by pitting
Broken hydraulic oil cooler or power train oil cooler on

q Leakage in cooling system
Insufficient protrusion of cylinder liner

Broken cylinder head or head gasket
Broken oil cooler core or O-ring

Crack in cylinder block
E E
Questions

Suddenly increased Q Q Q
Oil level
Gradually increased Q Q
Hard water is used as coolant Q Q
Oil level has risen and oil is milky Q Q w
There are excessive air bubbles in radiator and coolant spurts back w w
Check items
Hydraulic oil or power train oil on applicable machine side is milky w
When hydraulic oil or power train oil is drained, water flows out w
Carry out troubleshooting on

Leakage from cylinder head is detected by pressure test q

Troubleshooting
Inspect cylinder block and liner directly q q
Inspect cylinder liner directly q
Leakage from oil cooler is detected by pressure test q

Replace
Replace
Replace
Replace
Replace
Remedy

D155AX-6 21
S-12 Oil pressure drops 1

General causes why oil pressure drops Causes
q Leakage from, clogging, or wear of lubrication system
Defective oil pressure sensor or wiring harness

Leaking, crushed, or clogged hydraulic piping
q Defective oil pressure control
q Improper selection of fuel (improper viscosity)
q Deterioration of oil due to overheating
Clogged or broken pipe in oil pan
Defective oil pump relief valve
Leaking EGR hydraulic piping

Clogged strainer in oil pan
Defective EGR oil pump

Worn journal of bearing
Coolant or fuel in oil

Lack of oil in oil pan
Defective oil pump
Clogged oil filter

E E E E
Questions

Oil pressure monitor indicates low oil pressure (if monitor is installed) Q w
Non-specified oil is used Q Q
Filters have not been replaced according to Operation and Maintenance Manual w
Indicates pressure drop at low idle w Q Q
Oil pressure monitor Indicates pressure drop at low, high idle Q w w w Q Q Q
(if installed) Indicates pressure drop on slopes w
Sometimes indicates pressure drop w Q
Oil level monitor indicates oil lever drop (if monitor is installed) w
Oil level in oil pan is low w
External hydraulic piping is leaking or crushed w w
Check items
Oil is milky or smells of diesel oil w

There are metal particles in oil drained from oil pan w
There are metal particles in oil drained from oil filter w Q Q
There are metal particles in oil filter q

Inspect oil pan strainer and pipe directly q q
q
Troubleshooting
Oil pump is heavy to rotate or it has play

See S-13
Valve spring of oil pump relief valve is fatigued or damaged q

Inspect oil filter directly q
Relief valve of EGR oil pump is damaged or oil leaks through it q
Inspect EGR hydraulic piping directly q
Carry out troubleshooting according to "Eng Oil Press Sensor High (Low) Error (*1)"
q
indicated by code
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Remedy

Add
*1: Displayed codes [CA135] and [CA141]
22 D155AX-6
S-13 Oil level rises (Entry of coolant or fuel) 1

General causes why oil level rises Causes
q Coolant in oil (milky)
Clogged water pump drain hole (breather hole) or defective seal
Defective seal of auxiliary equipment (pump and compressor)

q Fuel in oil (smells diluted diesel fuel)
a If oil is in coolant, carry out troubleshooting for "S-11 Oil is in

coolant"
Cracked EGR cooler (Entry of coolant)

Fuel leakage inside cylinder block
Broken oil cooler core or O-ring

Worn or damaged rear oil seal
Cracks inside cylinder block
Defective thermostat seat

Defects in supply pump
Questions

Fuel consumption has increased w w
Coolant must be added more frequently Q Q w
There is oil in coolant Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q Q w
When engine is started, water drops from muffler Q Q
When radiator cap is removed and engine is run at low idle, abnormally many bubbles w Q
Check items
come out or coolant spurts back

Exhaust gas is white Q Q
Water pump drain hole (breather hole) is clogged w
When water pump drain hole (breather hole) is cleaned, coolant flows out w
Oil level in damper chamber on applicable machine side is low w
Oil level in hydraulic tank on applicable machine is low w
When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows out
q
(*1).
Remove and inspect head cover directly q
Troubleshooting
Inspect cylinder block and liner directly q q

Inspect rear oil seal directly q
Leakage from oil cooler is detected by pressure test q
Remove and inspect water pump directly q
Remove and inspect thermostat cover directly q
Remove and inspect supply pump directly q
Inspect seal of auxiliary equipment directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
24 D155AX-6

D155AX-6 25
S-14 Coolant temperature becomes too high (Overheating) 1

General causes why coolant temperature becomes too Causes
high
Rise of power train oil temperature on applicable machine side

q Lack of cooling air (deformation or damage of fan)

q Drop in heat dissipation efficiency
q Trouble in coolant circulation system
q Rise of oil temperature in power train
o Carry out troubleshooting on applicable machine
External leakage of coolant from EGR cooler

side
Defective radiator cap (pressure valve)
Defective coolant temperature gauge

Clogged or crushed radiator fins

Clogged or broken oil cooler
Malfunction of thermostat
Clogged radiator core

Broken water pump
Malfunction of fan
Low coolant level
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)
Inspect EGR cooler for coolant leakage q

on applicable machine side
Carry out troubleshooting
Inspect cylinder liner directly q

Inspect oil cooler directly q
Troubleshooting
Temperature difference between upper and lower tanks of radiator is large q

Thermostat does not open at cracking temperature q
Temperature difference between upper and lower tanks of radiator is slight q
Inspect radiator core directly q
Cracking pressure of radiator cap is low q
Inspect fan directly q
Coolant temperature is normal q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy

Add
26 D155AX-6
S-15 Abnormal noise is made 1

General causes why abnormal noise is made Causes
Abnormality due to defective parts

q
Broken dynamic valve system (valve, rocker lever, etc.)

q Abnormal combustion
Interference of turbocharger or seized turbocharger
Defective inside of muffler (Removal of bulkhead)

q Air sucked in from intake system
a Judge if the noise is an internal noise or an external
Excessive wear of piston ring or cylinder liner

noise before starting troubleshooting.
a The engine is operated in the low-temperature mode
(Defective coolant temperature sensor)

Removed or seized gear train bushing
while it is not warmed up sufficiently. Accordingly, the
Cracked or leaking EGR gas piping

engine sound becomes a little larger. This does not

indicate abnormality, however
Improper gear train backlash

a When the engine is accelerated, it is operated in the

acceleration mode and its sound becomes a little
Deformed cooling fan
Dirt caught in injector

larger for up to about 5 seconds. This does not indi-
cate abnormality, however

Degree of use of machine Operated for long period E
Questions
Gradually increased Q Q
Abnormal noise
Suddenly increased Q Q Q Q
Non-specified fuel is used Q
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
Immediately after engine is started, temperature of exhaust manifold of a w Q

cylinder is low
Exhaust gas is
Black Q w Q
Engine does not pick up smoothly and combustion is irregular w
Abnormal noise is loud when engine is accelerated Q Q Q Q

Inspect EGR gas piping directly q
When muffler is removed, abnormal noise disappears q
Troubleshooting

Inspect gear train directly q q
Inspect fan directly q
q q
does not change
Abnormal noise comes out only at start of engine q
Confirm with monitoring function on applicable machine side q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Adjust
Remedy
D155AX-6 27
S-16 Vibration is excessive 1

General causes why vibration is excessive Causes
q Defective parts (abnormal wear, breakage, etc.)
Misalignment between engine and devices on applicable machine side

q Misalignment between engine and applicable machine
q Abnormal combustion
a If abnormal noise is made and vibration is excessive, carry out trou-
bleshooting for "S-15 Abnormal noise is made", too
Stuck dynamic valve system (valve, rocker lever, etc.)
Broken parts in damper on applicable machine side

Loose engine mounting bolts or broken cushions
Worn main bearing or connecting rod bearing
Worn front support spigot joint

Improper gear train backlash
Improper injection timing

Worn camshaft bushing
E E E E
Questions

Suddenly increased Q Q
Vibration
Gradually increased Q Q Q Q
There are metal particles in oil drained from oil filter w w
There are metal particles in oil drained from oil pan w w
Oil pressure is low at low idle Q Q
Check items
Vibration occurs at medium speed Q Q

Vibration follows engine speed Q Q Q Q Q
Exhaust gas is black w

Inspect main bearing and connecting rod bearing directly q
Inspect gear train directly q
Troubleshooting
Inspect camshaft bushing directly q

Confirm with monitoring function on applicable machine side q
Inspect engine mounting bolts and cushions directly q
Radial runout or facial runout is detected q
Inspect front support spigot joint directly q
Inspect inside of damper directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Remedy
28 D155AX-6
D155AX-6 Bulldozer
2006 KOMATSU
All Rights Reserved
30 D155AX-6
SEN01204-02
D155AX-6
Machine Model Serial Number

D155AX-6 80001 and up
50 Disassembly and assembly1

General information on disassembly and
assembly
How to read this manual ................................................................................................................................. 2
Coating materials list....................................................................................................................................... 4
Special tool list ................................................................................................................................................ 7
Sketches of special tools .............................................................................................................................. 14
D155AX-6 1
SEN01204-02 50 Disassembly and assembly
How to read this manual 1

1. Removal and installation of assemblies
Special tools Removal

q Special tools which are deemed neces- q The "Removal" section contains procedures
sary for removal or installation of parts are and precautions for implementing the work,
described as A1,X1 etc. and their part know how and the amount of oil or coolant to
names, part numbers and quantities are be drained.
described in the special tool list. q Various symbols used in the "Removal" section
q Also the following information is described are explained and listed below.
in the special tool list. k : Precautions related to safety in execution
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
2. Disassembly and assembly of assem-

blies
Special tools Disassembly

q Special tools which are deemed neces- q In "Disassembly" section, the work procedures,
sary for disassembly and assembly of precautions and know-how for carrying out
parts are described as A1,X1 etc. and those procedures, and quantity of the oil and
their part names, part numbers and quan- coolant drained are described.
tities are described in the special tool list. q The meanings of the symbols used in "Disas-
q Also the following information is described sembly" section are as follows.
in the special tool list. k : Precautions related to safety in execution
1) Necessity of work.
t : Special tools that cannot be substituted a: This mark gives guidance or precautions when
and should always be used (installed). doing the procedure.
q : Special tools that will be useful if avail- 6: Quantity of oil or coolant drained
able and are substitutable with com-
mercially available tools.
2) Distinction of new and existing special
tools Assembly
N : Tools newly developed for this q In "Assembly" section, the work procedures,
model. They respectively have a precautions and know-how for carrying out
new part number. those procedures, and quantity of the oil and
R : Tools with upgraded part numbers. coolant added are described.
They are remodeled from already q The meanings of the symbols used in "Assem-
available tools for other models. bly" section are as follows.
Blank : Tools already available for other k : Precautions related to safety in execution
models. They can be used without of work
any modification. a: This mark gives guidance or precautions when
3) Circle mark Q in sketch column: doing the procedure.
q The sketch of the special tool is pre- 2 : Type of coating material
sented in the section of "Sketches of 3 : Tightening torque
special tools". 5 : Quantity of oil or coolant to be added
q Part No. of special tools starting with
* *** ****
79 T- - :
means that they can not be supplied
Sketches of special tools
q Various special tools are illustrated for the con-
from Komatsu in Japan (i.e. locally venience of local manufacture.
made parts ).
a General tools that are necessary for dis-

assembly and assembly are described
as [1], [2]etc. and their part names,
part numbers and quantities are not
described.
D155AX-6 3
Coating materials list 1

(Rev. 2007.06)
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
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
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
LG-10 Used as lubricant/sealant when the radiator

ThreeBond 790-129-9320 200 g Tube hoses are inserted.
1206E Can be coated with paint.
LG-11 Feature: Can be used together with gaskets.
ThreeBond 790-129-9330 200 g Tube Used for covers of the transmission case and
1121 steering case etc.
ThreeBond
790-129-9090 100 g Tube Gasket sealant used to repair engine.
1211
Molybdenum
Used to prevent scuffing and seizure of press-fit-

lubricant
disulfide
ted portions, shrink-fitted portions, and threaded

LM-P 09940-00040 200 g Tube
portions.
Used to lubricate linkages, bearings, etc.
Feature: Seizure and scuffing prevention com-

prevention
compound
pound with metallic super-fine-grain, etc.

Seizure
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
400 g Bellows-type resistance higher than molybdenum disulfide

Grease G2-T, SYG2-16CNT
container grease.
G0-T (*) SYG0-400T-A (*)
16 kg Can Not conspicuous on machine since color is
*: For cold district SYG0-16CNT (*)
white.
Biogrease SYG2-400B
G2-B, G2-BT (*) SYGA-16CNB 400 g Bellows-type Since this grease is decomposed by natural bac-
*: For use at high SYG2-400BT (*) container teria in short period, it has less effects on micro-
temperature and SYGA-16CNBT 16 kg Can organisms, animals, and plants.
under high load (*)
Feature: Silicone grease with wide using tem-
G2-S perature range, high resistance to thermal-oxi-
ThreeBond 200 g Tube dative degradation and performance to prevent
1855 deterioration of rubber and plastic parts.
Used for oil seals of the transmission, etc.
Feature: Urea (organic system) grease with heat
G2-U-S resistance and long life. Enclosed type.
427-12-11871 2 kg Can
ENS grease Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
D155AX-6 5
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)
Adhesive for cab glass

SUPER
Used as primer for painted surface on cab
SUNSTAR
Glass side.
Primer
PAINT PRIMER 22M-54-27230 20 ml

container (Using limit: 4 months after date of manu-
435-95
facture)
Used as primer for black ceramic-coated
SUNSTAR
surface on glass side and for hard polycar-
GLASS
22M-54-27240 150 ml Can bonate-coated surface.
PRIMER
(Using limit: 4 months after date of manu-
435-41
facture)
SUNSTAR Used as primer for sash (Almite).
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months after date of manu-
container
GP-402 facture)
SUNSTAR S is used for high-temperature season
PENGUINE and W for low-temperature season as
Polyethylene
SEAL 580 417-926-3910 320 ml adhesive for glass.
container
SUPER S or (Using limit: 4 months after date of manu-
W facture)
Adhesive
Used as adhesive for glass.

Sika Japan, Polyethylene
20Y-54-39850 310 ml (Using limit: 6 months after date of manu-
Sikaflex 256HV container
Adhesive for cab glass
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
SEKISUI Used to seal front window.

Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months after date of manu-
container
SEALANT facture)
Used to seal joint of glasses.
GE TOSHIBA
Translucent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Using limit: 12 months after date of manu-
TOSSEAL 381
facture)
6 D155AX-6
Special tool list 1

a Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they must be locally manufactured).
a Necessity : t . . . . . . Cannot be substituted, should always be installed (used)
: q . . . . . . Extremely useful if available, can be substituted with commercially available part
a New/Remodel: N. . . . . . Tools newly developed for this model and given new part Nos.
: R. . . . . . Tools remodeled from tools already available for other models and given
upgraded part Nos.
: Blank . . Tools already available for other models, usable without any modification
a Tools marked with Q in the sketch column are tools introduced in the sketches of the special tools (See
Sketches of special tools).
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
A 795T-421-1210 Push tool t 1 Q

Press fitting of engine rear
6 01050-31645 Bolt t 4
seal (Standard type)
Removal and installation 01050-31625 Bolt t 4
of engine front seal, rear 795T-421-1220 Push tool t 1 Q
seal Press fitting of engine rear
7 01050-31625 Bolt t 4
seal (Standard type)
01050-31645 Bolt t 4
795-521-1110 Push tool t 1 Press fitting of engine front
8
01050-31640 Bolt t 3 seal
791-612-1100 Installer t 1
Disassembly and assem-
F 790-101-4200 Puller (294 kN {30 ton}) t 1 Press fitting of bearing
bly of damper assembly
790-101-1102 Hydraulic pump t 1
791T-615-1300 Puller assembly t 1
Disassembly and assem- 1 791T-615-1310 Plate 1 Q Operation check of clutch
bly of transmission G
01010-82040 Bolt 1 piston
assembly
2 799-301-1600 Oil leak tester kit (A) t 1
791-662-1110 Bracket t 1
Removal and installation of
1 01010-31685 Bolt t 1
brake and carrier assembly
01017-31620 Bolt t 1
H 790-302-1500 Spanner kit t 1 Removal and installation of
bly of HSS case assembly 2
09003-09200 Spanner 1 nut (bevel pinion side)
790-302-1500 Spanner kit t 1 Removal and installation of
3
09003-08290 Spanner 1 nut (bevel gear side)
790-337-1032 Lifting tool t 1
Removal and installation 791-627-1320 Shackle t 2 Removal and installation of
J
of final drive assembly 791T-627-1910 Plate t 1 Q final drive assembly
01010-82080 Bolt t 2
D155AX-6 7
New/Remodel
Sym-
Necessity
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
790-431-1031 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
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
790-101-5451 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
790-201-1680 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
Removal and installation 791T-130-1010 Bracket t 6 N Q

of track frame assembly KK 01010-63060 Bolt t 12
and track roller assembly 01643-33080 Washer t 12
8 D155AX-6
New/Remodel
Sym-
Necessity
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
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
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
Removal and installation 791-630-1360 Spacer t 1

of No. 2, No. 3 and No. 4 790-101-2310 Block t 1
boggy assemblies 790-101-2360 Plate t 2
15
790-445-4130 Screw t 2
791-112-1180 Nut t 2
790-101-4000 Puller (490 kN {50 ton}) t 1
D155AX-6 9
New/Remodel
Sym-
Necessity
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
Removal and installation 17 796-430-1110 Push tool t 1

of No. 2, No. 3 and No. 4 L 18 790-701-3000 Seal checker t 1 Fixing of boggy
boggy assemblies 19 791T-630-1390 Guide t 1 Q
790-101-2310 Block t 1
790-445-4130 Screw t 2
796T-470-1130 Plate t 1 Q
20 790-101-2360 Plate t 2
790-112-1180 Nut t 2
790-101-4000 Puller (490 kN {50 ton}) t 1
790-101-1102 Pump t 1
21 791-601-1000 Oil pump t 1
791-685-8006 Compressor t 1
Disassembly and assem- 791-635-3160 Extension t 1

Compression of recoil
bly of recoil spring assem- M 2 791T-630-2610 Spacer t 1 Q
spring
bly 790-101-1300 Cylinder t 1
Pulling out of shaft and pull-
1 791T-630-1290 Plate t 1 Q ing out and press fitting of
Disassembly and assem- seal guide
bly of track roller assem- N 2 791T-630-1330 Push tool t 1 Q Press fitting of bushing
bly
790-101-2310 Block t 1
790-445-4130 Screw t 2
796T-470-1130 Plate t 1 Q
Disassembly and assem- 20 790-101-2360 Plate t 2 Pulling out and press fitting
Q
bly of boggy assembly 791-112-1180 Nut t 2 of pin assembly and shaft
790-101-4000 Puller (490 kN {50 ton}) t 1
790-101-1102 Pump t 1
21 791-601-1000 Oil pump t 1
1 790-102-1891 Nut wrench t 1
nut
bly of carrier roller assem- R 2 791-651-1510 Installer t 1 Installation of floating seal
bly 3 791T-630-1350 Spacer t 1 Press fitting of ring
10 D155AX-6
New/Remodel
Sym-
Necessity
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
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
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
791-685-9550 Nut t 3
791-675-5520 Guide t 1
791-675-5530 Pusher t 1
01010-51030 Bolt t 1
791-685-9620 Extension t 1
790-101-1102 Pump t 1
790-101-4200 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
New/Remodel
Sym-
Necessity
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
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
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})
12 D155AX-6
New/Remodel
Sym-
Necessity
bol
Sketch
Q'ty
791T-650-2130 Sleeve t 1 Q
790-101-2420 Adapter t 1
791-502-4140 Screw t 1
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
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
Sketches of special tools 1

Note) We will not be liable for any result of use of special tools
manufactured according to the following drawings.
A6: Push tool
A7: Push tool
14 D155AX-6
G1: Plate
J: Plate
D155AX-6 15
K1: Plate
K2: Plate
16 D155AX-6
K2: Push tool
K5: Plate
D155AX-6 17
K5: Plate
KK, L14: Bracket
18 D155AX-6
L1: Plate
L19: Guide
D155AX-6 19
L20, Q20: Plate
M2: Spacer
20 D155AX-6
N1: Plate
N2: Push tool
D155AX-6 21
V: Sleeve
V: Plate
22 D155AX-6
W: Sleeve
D155AX-6 23
D155AX-6 Bulldozer
2007 KOMATSU
All Rights Reserved
24 D155AX-6
SEN01205-02
D155AX-6

D155AX-6 80001 and up

Removal and installation of fuel supply pump assembly ................................................................................ 2
Removal and installation of fuel injector assembly ......................................................................................... 6
Removal and installation of cylinder head assembly .....................................................................................11
Removal and installation of radiator assembly ............................................................................................. 22
Removal and installation of aftercooler assembly......................................................................................... 25
Removal and installation of engine assembly ............................................................................................... 27
Removal and installation of engine hood assembly ...................................................................................... 32
Removal and installation of engine front seal ............................................................................................... 34
Removal and installation of engine rear seal ................................................................................................ 36
Removal and installation of fuel tank assembly ............................................................................................ 41
Removal and installation of fan drive assembly ............................................................................................ 42
Removal and installation of fan motor assembly .......................................................................................... 43
D155AX-6 1
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]
6. Remove oil level gauge guide (9).
7. Disconnect fuel hose (10), connector PCV 1

(11), PCV2 (12) and G (13).
8. Remove tubes, (14) through (17). [*3]
9. Remove stay (18) and clamp (19).
2. Open undercover (4).

k Open carefully using floor jack, wire
rope, etc.
2 D155AX-6
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.
11. Rotate crank shaft forward so that the middle

position (a) of "2.5 TOP" stamp line of damper
(26) and "3.4 TOP" stamp line aligns to the
pointer (27).
a Crank the crankshaft at hexagonal part (b)
of water pump drive shaft tip.
12. Remove engine front cover (28).
D155AX-6 3
15. Remove bracket (30), and loosen four mount- Installation

ing bolts (31).
1. Set fuel supply pump assembly (33).
16. Set tools A1, A2 and A3 on drive gear (32), a Before setting, check that key (d) of shaft
and tighten the center bolt of tool A1 to remove aligns to the key slot (e) of drive gear.
drive gear (32) from the shaft.
2. Temporarily tighten four mounting bolts (31)
17. Remove mounting bolts (31) and remove fuel and bracket (30) with fingers.
2 Mounting bolt: Liquid adhesive (LT-2)
supply pump assembly (33).
a Keep tool A1, A2 and A3 set on drive gear
(32) until fuel supply pump assembly is
installed, for the drive gear falls off without
the tools.
4 D155AX-6
3. Temporarily tighten high pressure pipes (23) [*4]

and (24) with fingers and tighten permanently a Install covers (21) and (22) with the notch in
with the following torque. the following direction.
3 Common rail side sleeve nut: q Cover (21): Cylinder block side
39.2 58.8 Nm {4 6 kgm} q Cover (22): Underside
Supply pump side sleeve nut:
39.2 49 Nm {4 5 kgm} [*5]
3 Nut (29): 176 196 Nm {18 20 kgm}
4. Tighten permanently four mounting bolts (31).
5. Tighten bracket (30) permanently.

3 Mounting bolt:
19.6 29.4 Nm {2.0 3.0 kgm}
6. Temporarily tighten clamps (34), (19) and (35),

and stays (18), (36) and (20), with fingers.
7. Tighten clamps (34), (19) and (35) perma-

nently.
a Tighten clamps in the order of (34), (19)
and (35).
3 Clamping bolt:
9.8 1 Nm {1 0.1 kgm}
8. Tighten stays (18), (36) and (20) permanently.

a Tighten stays in the order of (18), (36) and
(20).
9. Carry out the subsequent procedure in the

reverse order of removal.
[*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
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.
1. Remove the engine hood referring to the sec-

tion "Removal and installation of engine hood
assembly".
2. Remove tube (1) filter head side mounting bolt,

and remove oil filter head assembly (2).
3. Remove two joint bolts (3), and remove fuel

main filter head assembly (3a). [*1] 6. Remove clamp (7) and stay (8), and remove
gate type frame (9). [*2]
4. Remove stay (4).

7. Remove clamp (10), and remove cover (11).
8. Loosen sleeve nut (12).
9. Remove stays (13) through (16).
6 D155AX-6
13. Loosen sleeve nut (26), and remove high pres-

sure pipe (27) from injector.
14. Remove wiring harness clamping bolt (28) and

clip (29). [*6]
15. Remove two wiring harness capture nuts (30)

from fuel injector assembly. [*7]
a Tighten capture nuts alternately.
16. Remove holder mounting bolt (31).
10. Remove cylinder head cover (17). [*3]
17. Set L type bar [1] under fuel injector assembly

inlet connector (a), and remove slowly fuel
injector assembly (32) with holder (33) using
leverage action.
a Do not pull out solenoid valve portion at
11. Remove cover (18). [*4] the top of injector by pinching with pliers,
etc.
12. Remove mounting bolts (19) through (21), and
remove rocker arm and rocker shaft assembly
(22). [*5]
a Loosen lock nut (24), and loosen adjust-
ment screw (25) two or three turns to pre-
vent excessive force applied to push rod
(23), when installing rocker arm and
rocker shaft assembly.
D155AX-6 7
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).
6) Tighten bolts (31) to the specified torque.

3 Bolt (31):
58.8 73.5 Nm {6 7.5 kgm}
7) Tighten sleeve nuts (26) and (12).
3 Sleeve nuts (26) and (12):
39.2 49 Nm {4 5 kgm}
3) Set fuel injector assembly (32) with holder

(33) to cylinder head.
4) Attach spherical washer (37) to bolt (31),
and tighten temporarily bolt (31).
2 Spherical washer: Engine oil
(For details, see "Table of fuel,
coolant and lubricants" )
5) Tighten temporarily high pressure pipe
sleeve nuts (26) and (12).
k Install high pressure pipe after
ch ecking the f ollo wings. If an
abnormality takes place, it may
cause fuel leakage, and replace
high pressure pipe.
q Check visually taper seal portion (a
portion: within 2 mm from the tip) at
the joint section for visible vertical slit
scar (b) or patchy dent (c).
q Check the difference at (d) portion (tip
of taper seal portion: within 2 mm
from the tip) for any catches on a fin-
ger nail (no fatigue).
8 D155AX-6
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
[*6] [*7]
a Install wiring harness according to the follow-
ing procedure.
1) Install clip (29).
2) Tighten two capture nuts (30).
3 Capture nut:
2 0.2 Nm {0.2 0.02 kgm}
3) Tighten wiring harness clamping bolt (28).
10 D155AX-6

cylinder head assembly 1
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
A 4 790-331-1110 Wrench q 1
Removal
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]
10. Remove fuel tube (12), and remove priming

3. Remove stay (1). pump bracket assembly (13). [*3]
11. Remove bracket (14).
4. Remove oil filter head side mounting bolt of oil

tube (2), and remove oil filter head assembly
(3). 12. Disconnect connecters, BP, SBP, EGR and
SEGR.
5. Disconnect fuel hose (4).
6. Remove fuel tube (5), and remove fuel pre fil-

ter head assembly (6).
7. Remove bracket (7).
D155AX-6 11
13. Disconnect connector PEVA (19). 19. Remove air intake housing.
1) Remove tube (25) and block (26).
14. Disconnect terminal RHT (20).

2) To secure the room for operation, loosen
15. Remove breather tube (21). the tension of belt and move air condi-
tioner compressor (27a) downward, refer-
16. Remove wiring harness bracket (22). ring the section of Testing and adjusting,
"Testing and adjusting air conditioner com-
17. Remove air intake connector (23). [*4] pressor belt tension". [*5]
3) Remove air intake housing (27).
18. Remove venturi connector (24).

20. Remove oil tube bracket (28) and oil filler tube
bracket (29).
21. Disconnect fuel hose (30).
12 D155AX-6
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).
27. Remove charge pressure sensor (39) with

24. Disconnect connectors, TFUEL (34), TIM (35) plate (40) and bracket (41).
and PIM (36). a This is to secure the room for operation to
loosen turbocharger lubrication tube
clamp.
25. Remove spill tube (37). [*6]
28. Remove five stays (42) for high pressure pipe

clamp. [*7]
D155AX-6 13
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
31. Remove intake manifold (47). [*9]

34. Remove tube (52). [*10]
4 Intake manifold: 50 kg
14 D155AX-6
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]
36. Remove EGR tube (57). [*11]
37. Remove water tube (58). 42. Remove oil tube (66) and water tube (67). [*13]
38. Remove turbocharger side mounting bolt for oil

tube (59).
39. Remove heat insulation cover (60) and bracket

(61).
43. Remove turbocharger and exhaust manifold

assembly (68). [*14]
4 Turbocharger and exhaust manifold
assembly: 80 kg
D155AX-6 15
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).
50. Rotate crankshaft forward, align damper

"1.6TOP" stamp line (c) to pointer (91), and
then set the No.1 cylinder to the compression
top dead center.
a Crank the crankshaft at hexagonal part (d)
of water pump drive shaft tip.
45. Remove gate type frame (77) and clamp (78).

[*15]
46. Remove spill tube (79). [*16]
47. Remove cover (80) and high pressure pipe

(81) depending on the cylinder head assembly
to be removed. [*17] [*18]
16 D155AX-6
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.
52. Remove fuel injector assembly.

1) Remove wiring harness clamping bolt (92) 53. Remove two push rods (102).
and clip (93). [*22]
2) Remove two wiring harness capture nuts
(94) from fuel injector assembly. [*23]
a Loosen capture nuts alternately.
3) Unscrew bolt (95) to remove holder (96).
4) Push connecter (97) into rocker housing,
and remove injector wiring harness (98).
[*24]
a O-ring is installed in connector (97).
D155AX-6 17
54. Remove crosshead (103). Installation

55. Remove 3 mounting bolts (104), 3 bolts (105) 1. Install cylinder head assembly.
and bolt (106), and remove cylinder head 1) Install cylinder head gasket (115).
assembly (107). a Check that the mounting surface of
cylinder head and the inside of cylin-
ders are free from foreign material.
a Check that the gasket is free from
peeling or coming off of grommet.
2) Check cylinder head mounting bolts for

the following items, and if out of standard,
replace mounting bolt without reusing it.
q Bolt tightening should be 5 times or
more.
(The number of punch mark at the
head of bolt should be 5.)
q Bolt under head length service limit
(a)
Short bolt:Less than 170.8 mm
Long bolt: Less than 205.8mm
3) Install cylinder head assembly.

4) Tighten 3 mounting bolts (104), 3 mounting
bolts (105) in order of 1 through 6 as shown
in the figure.
2 Mounting bolt:
Lubricant with molybdenum dis-
ulfide (LM-P)
18 D155AX-6
3 Mounting bolt 2. After installing cross head (103), make adjust-

1st time: ment as follows.
137 157 Nm {14 16 kgm} 1) Loosen lock nut (111), and loosen adjust-
2nd time: ment screw (112).
284 294 Nm {29.0 30.0 kgm} 2) Lightly push cross head (103) contact sur-
3rd time: Retighten 90 (+30/0) with face (h) with rocker arm, and hold cross
tool A4. head to contact with push rod (102) side
a When tool A4 is not available, put valve stem (113).
marks (a) and (b) to bolt and cylinder 3) Screw slowly adjustment screw (112), and
head, and retighten bolt 90 (+30/0). check the position where adjustment
5) Tighten mounting bolt (106) (tightening screw touches valve stem (114).
order: 7th) with the following torque. 4) From the above condition, screw adjust-
3 Mounting bolt: ment screw (112) 20.
66.6 7.4 Nm {6.8 0.8 kgm} 5) While holding adjustment screw (112) with
a flat-head screwdriver, tighten locknut
(111).
3 Locknut:
58.7 5.9 Nm {6.0 0.6 kgm}
3. Install push rod (102).

a Raise push rod slightly, and check that
push rod is securely inserted in cam fol-
lower.
D155AX-6 19
4. carry out the rest of installation in the reverse

order of removal.
[*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
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
[*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}
[*22] [*23] [*24]

a Install injector wiring harness according to the
1) Install O-ring to injector wiring harness (98).
2) Install injector wiring harness (98) in rocker
housing, install holder (96) and tighten bolt
[*16]
3
(95).
Spill tube joint bolt:
3) Install clip (93).
9.8 12.7 Nm {1.0 1.3 kgm}
4) Tighten two capture nuts (94).
3 Capture nut: 2 0.2 Nm {0.2 0.02 kgm}
[*17]
a Install cover with the notch downward.
5) Install wiring harness clamping bolt (92).
[*19]
3 Water tube joint bolt:
9.8 12.7 Nm {1.0 1.3 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

radiator assembly 1
Removal
battery.
1. Drain the coolant.

6 Coolant: 82 l
2. Remove cover at the top of radiator, and dis-

connect connector LHD (1).
6. Sling radiator assembly (12) and remove it.

[*3]
4 Radiator assembly: 25 kg

4 Cover: 50 kg
4. Disconnect hoses (3) through (7). [*1]

a Remove mounting bolts for hoses (5)
through (7), and disconnect hoses with
tubes.
5. Remove bracket (8) through (11). [*2]

a Remove bracket (8) when removing left
radiator assembly.
22 D155AX-6
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
[*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
[*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)
3) Open radiator grill, remove fan net and

install four cushions (15) to lower tank
(16).
4) Sling the radiator assembly and set it on

the lower tank slowly.
a Check visually the installation condi-
tion from the machine front.

5 Coolant: 82 l
and lubricants")
24 D155AX-6
Removal and installation of 3. Open undercover.

aftercooler assembly 1
4. Disconnect the tube (3) from the lower part of
the after cooler. [*1]
Removal
battery.
1. Remove cover at the top of radiator, and dis-

connect connector LHD (1).
5. Remove four mounting bolts for tube (4). [*2]
6. Remove brackets, (5), (6) and (7).

4 Cover: 50 kg
7. Sling aftercooler assembly (8) and remove it.

4 Aftercooler assembly: 35 kg
D155AX-6 25
Installation
removal.
[*1] [*2]
clamp with new one.
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}
26 D155AX-6
Removal and installation of 6. Remove stay (2).

engine assembly 1
Removal
k Disconnect the cable from the negative ()
terminal of the battery.
k In the case that you do not drain the cool-
ant, if you disconnect the heater hose when
the coolant temperature in the radiator is
high, you may be scalded. In this case, wait
until the coolant temperature lowers and
then disconnect the heater hose.
(R134a) from air conditioner circuit in
advance.
a Ask professional traders for collecting and fill-
ing operation of refrigerant (R134a). 7. Remove heat insulation cover (3) and drain
a Never release the refrigerant (R134a) to the tube (4).
atmosphere.
k If refrigerant gas (R134a) gets in your eyes,

you may lose your sight. Accordingly, put
on protective goggles while you are collect-
ing the refrigerant (R134a) or filling the air
conditioner circuit with the refrigerant
(R134a). Collecting and filling work must be
conducted by a qualified person.
1. Drain the coolant.

6 Coolant: 82 l

tion "Removal and installation of engine hood 8. Remove muffler (5).
assembly". 4 Muffler: 50 kg
3. Collect the air conditioner refrigerant (R134a)

from air conditioner circuit. [*1]
4. Open undercovers (front and center)

k Open carefully using floor jack, wire
rope, etc.
5. Disconnect hose from air intake connector (1).

[*2]
9. Remove radiator assembly referring to the sec-

tion, "Removal and installation of radiator
assembly".
10. Remove aftercooler assembly referring to the

section, "Removal and installation of after-
cooler assembly".
D155AX-6 27
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
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.
24. Disconnect connectors EG1 (24) and EG2 (25).
18. Disconnect two hoses each from air condi-

tioner condenser (15) and oil cooler (16), and
remove frame (17).
25. Disconnect hose (26) from radiator lower tank.
19. Remove flame (18). [*5]
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
27. Temporarily sling engine assembly. Installation

28. Remove mounting bolts (28) and (29), four q Carry out installation in the reverse order to
pcs.each. [*7] removal.
[*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}
q Filling air conditioner circuit with refriger-

ant (R134a)
Fill the air conditioner circuit with refrigerant
(R134a).
a Quantity of refrigerant: 1,200 50 g
[*2] [*3]
clamp with new one.
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
q When reusing the hose, install it to the

clamp mark on it.
3 Bolt (BC):
25 5 Nm {2.55 0.5 kgm}
[*4]
2 Engine side tube flange:
Gasket sealant (LG-1)
[*5]
[*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}

5 Coolant: Approx. 82 l
and lubricants")
D155AX-6 31

engine hood assembly 1
Removal
battery.
1. Remove pre cleaner duct (1) and exhaust tube

(2). [*1]
5. Remove hose (10). [*2]
3. Open cover (4), and remove covers (5) through

(7).
a Carry out the same operation to the oppo-
site side.
6. Disconnect connector AF1 (11).
4. Remove two mounting bolts (9) for tube (8).
32 D155AX-6
7. Sling engine hood (12) and remove it. Installation

4 Engine hood: 170 kg q Carry out installation in the reverse order to
removal
[*1]
3 Pre cleaner duct and exhaust pipe mounting
bolt: 98 123 Nm {10.0 12.5 kgm}
[*2]
D155AX-6 33
Removal and installation of Removal with tool A5

engine front seal 1 1) Drill several holes about 3 mm in diameter into
front seal (3).
Special tools 2) Set tool A5 to the drilled holes.
(Tip: Drill type)
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.
2. Remove damper (1) and flange (2).
3. Remove front seal (3).
34 D155AX-6
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.
4) Tighten the bolts of tool A8 evenly to press

fit seal (3) until the end of tool A8 reaches
the end of crankshaft (5).
a Seal driving distance (a) from crank-
shaft: 9.1 10.1 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.
1) Set large inside diameter side (b) of plas-

tic inside cylinder (4) to the end of crank-
shaft (5).
a Take care not to mistake the direction
of the plastic inside cylinder.
2. Install flange (2).

3 Flange mounting bolt:
245 309 Nm {25.0 31.5 kgm}
3. Install damper (1).
2) Hold the metal ring of seal (3) with both

hands and push it in evenly as if you are
passing over the large inside diameter
side of plastic inside cylinder (4).
3) After pushing in the seal, remove plastic
inside cylinder (4).
a When removing the inside cylinder,
take care not to damage the seal lip.
D155AX-6 35
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
2) If the seal is sleeved, cut and remove Installation

sleeve (6) with a chisel and a hammer.
a When cutting, take care extremely not a Check the wear of the shaft and select the
to damage crankshaft (7). "standard" or "sleeved" Teflon seal (Laydown
3) Hitch the end of tool A5 to the metal ring lip seal) to replace the used seal.
of rear seal (4) and pull out the seal with If the shaft is worn to the degree of luster (If the
impacts of slide hammer (SH). wear depth which you feel with your finger is
a Do not use a drill etc. since chips may less than 10 mm) and does not have any flaw,
enter the engine. install "standard seal (A)". In other cases,
a If chips were made, remove all of install "sleeved seal (B)".
them. a (8): Plastic inside cylinder which is also used
q Tool A5 as installation guide.
a (6): Sleeve.
a Do not remove installation guide (8) from rear
seal (4) before installing the rear seal.
a Handle rear seal (4) and sleeve (6) as an
assembly and never separate them from each
other.
Left side: Standard seal Right side: Sleeved seal
a Seal type: Single seal

(Inside of flywheel housing is dry)
Left side: Standard seal, Right side: Sleeved
seal
a Clean, degrease, and dry the contact surface

of the seal to the flywheel housing side.
a Clean, degrease, and dry the seal lip surface
(periphery of the crankshaft).
a Check that the end corners and lip sliding sur-
face of the crankshaft and the housing are free
from flaw, burr and rust.
D155AX-6 37
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.
2) Hold the metal ring of rear oil seal (4) with

both hands and push it in evenly.
3) After pushing in the seal (4), remove plas-
tic inside cylinder (8).
a When removing the inside cylinder,
take care not to damage the seal lip. 2. Procedure for installing sleeved seal
a When installing the rear seal, do not apply
oil or grease to the shaft and sleeve inside
cylinder surface (C).
1) Set sleeve and rear seal assembly (9) to
tool A7 (for press fitting the sleeved seal).
2 Sleeve inside cylinder surface (C):
38 D155AX-6
2) Set sleeve of the rear seal to the end of 3. Flywheel

crankshaft (7) and tighten the 3 bolts Using eyebolt [1] (12 mm, P = 1.75), sling fly-
evenly to press fit sleeve and rear seal wheel (1), install it to the crankshaft, and
assembly (9) until the end of tool A7 tighten the bolts.
reaches the end of crankshaft (7). a If there are 5 punch marks on a bolt, do
a Tighten tool A7 (for press fitting the not use that bolt but replace it.
sleeved seal) first until it reaches the 2 Threads and seat of bolt: Engine oil
bolt (stem length 45 mm) and then (For details, see "Table of fuel, coolant
tighten the bolt (stem length 25 mm). and lubricants" )
4 Flywheel: 65 kg
3) Remove tool A7 (for press fitting the

sleeved seal) and install tool A6 (for press
fitting the seal).
4) Tighten the 3 bolts evenly to press fit
sleeve and rear seal assembly (9) until the
end of tool A6 (for press fitting the seal)
reaches the end of crankshaft (7).
a Tighten tool A6 (for press fitting the
seal) first until it reaches the bolt
(stem length 45 mm) and then tighten
the bolt (stem length 25 mm).
a Rear seal driving depth: 13.2 0.2
mm from end of crankshaft
a When installing, set the dowel pin of

the crankshaft to the dowel hole of
the flywheel.
D155AX-6 39
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.
q Carry out the following installation in the

reverse order to removal.
40 D155AX-6
Removal and installation of fuel 6. Remove 6 fuel tank mounting bolts (6) on the
tank assembly 1 right and left sides.
Removal
1. Remove cover (1) from the fuel tank bottom.
7. Sling the fuel tank assembly, move it back

about 100 mm, and disconnect hoses (7) and
(8).
v
2. Close fuel valve lever (2).
3. Disconnect fuel return hose (3).
4. Disconnect fuel supply hose (4).
8. Remove fuel tank assembly (9).

4 Fuel tank assembly:
90 kg (When empty)
950 kg (When full)
5. Open the cover and disconnect wiring harness

connector FTK (5).
Installation
q Carry out installation in the reverse order to
removal.
D155AX-6 41
Removal and installation of fan 4. Disconnect wiring harness connector FAR (5)
drive assembly 1 and remove wiring harness clamp.
Removal 5. Disconnect fan motor hoses (6), (7) and (8).

a Plug the hoses so that foreign matter will
k Disconnect the cable from the negative () not enter them.
1. Drain the hydraulic oil.

6 Hydraulic tank: Approx. 85 l
2. Remove 4 mounting bolts (1) and open mask

(2).
6. Using eyebolts [1], sling fan drive assembly (9)

and remove mounting bolts (10).
7. Lift off fan drive assembly (9).

4 Fan drive assembly: 125 kg
3. Remove 4 mounting bolts (3) and remove

guard (4).
Installation
removal.
q Refilling with oil

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"):
Approx. 85 l
42 D155AX-6
Removal and installation of fan Installation

motor assembly 1 q Carry out installation in the reverse order to
removal.
Removal
1. Remove the fan motor assembly. For details, [*1]
see "Removal and installation of fan drive Be sure to align the hole of lock plate (1) by turning
assembly". nut (2) in the tightening direction.
2. Remove the mounting bolt and lock plate (1). [*2]

[*1] 3 Mounting nut (2):
441 539 Nm {45 55 kgm}
3. Remove nut (2). [*2]
[*3]
a Clean and degrease the fitting areas of the fan
motor and fan.
4. Using puller [1], remove fan (3).
5. Remove 4 mounting bolts (4) and fan motor

assembly (5). [*3]
4 Fan motor assembly: 40 kg
D155AX-6 43
D155AX-6 Bulldozer
2007 KOMATSU
All Rights Reserved
44 D155AX-6
SEN01206-01
D155AX-6

D155AX-6 80001 and up

Power train, Part 1
Removal and installation of damper assembly ............................................................................................... 2
Disassembly and assembly of damper assembly ........................................................................................... 5
Removal and installation of power train unit assembly ..................................................................................11
Disconnection and connection of power train unit assembly ........................................................................ 15
D155AX-6 1

damper assembly 1
Removal
1. Drain the oil in damper case.
6 Damper case: 1.5 l
2. Remove floor frame assembly referring to the

section, "Removal and installation of floor
frame assembly".
3. Remove work equipment and HSS pump

assembly referring to the section, "Removal
and installation of work equipment and HSS 9. Remove mounting bolts for damper cover
pump assembly". assembly (5), and install two guide bolts [1]
diagonally. [*2]
4. Remove the cooling fan pump assembly refer-
ring to the section, "Removal and installation of 10. Using forcing bolt [2], pull out damper cover
cooling fan pump assembly". assembly (5) so that the lifting tool can be
applied, and then remove it. [*3]
5. Disconnect breather hose (1).
4 Damper cover assembly: 60 kg
6. Remove oil level gauge (2).
7. Sling universal joint assembly (3) and remove

it. [*1]
4 Universal joint assembly: 20 kg
8. Pull out torque converter side coupling (4).
2 D155AX-6
11. Remove damper assembly. Installation

1) Remove two mounting bolts for damper
assembly (6), and set guide bolts [3]. [*4] q Carry out installation in the reverse order of
2) Remove the rest of mounting bolts, and removal.
pull out damper assembly using forcing
bolt [4]. [*5] [*1]
3) Use eyebolt [5] to remove damper assem-
bly (6). Liquid adhesive (LT-2)
4 Damper assembly: 60 kg 98 123 Nm {10.0 12.5 kgm}
[*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
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
3) Apply gasket sealant to the flange portion of

damper cover assembly.
a Apply it to the engine side also.
a Apply it with the thickness 0.1 to 0.2 mm.
2 Damper cover mounting face:
4) Install the damper cover assembly to the

engine.
[*4] [*5]
3 Damper mounting bolt:
98 123 Nm {10.0 12.5 kgm}

5 Damper case: 1.5 l
(For details, see "Table of fuel, coolant and
lubricants")
3 Drain plug: 58.5 78.5 Nm {6 8 kgm}
4 D155AX-6
Disassembly and assembly of damper assembly 1
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})
D155AX-6 5
Disassembly 2) Remove collar (7-2) and O-ring of bearing

(7) from shaft (6), and pull out inner race
Disassembly of damper cover assembly (1) (7-1).
1. Coupling
Remove bolt (3) from cover (2), then remove
holder (4) and coupling (5).
3. Bearing and oil seal

1) Remove oil seal (9) from cover (2), and
pull out inner race (7-3) of bearing (7).
2. Shaft
1) Set damper cover assembly (1) to block
[1], and remove shaft (6) by tapping it from
output side with plastic hammer, etc.
a Shaft (6) will be pulled out with inner
race (7-1) of bearing (7) and oil seal
(8).
2) Remove outer races (7-4) and (7-5) of

bearing (7) from cover (2).
6 D155AX-6
Disassembly of damper assembly (10)

1. Unscrew bolt (11) to remove flange (12).
2. Remove outer body (13), inner body (14) and

cushion (15).
3. Pull out plug (17) from flange (16).

a This procedure applies only when replac-
ing plug.
D155AX-6 7
Assembly
Assembly of damper assembly (10)
1. Set flange (16) and outer body (13) to cylinder

[1], matching their bolt holes, and install inner
body (14).
2 Mating surface of flange and outer
body: Gasket sealant (LG-6)
2 Outer body inner surface:
Grease (G2-LI)
2 Cushion contact surface of inner body:
Grease (G2-LI)
8 D155AX-6
2. Install cushion (15).

a Apply grease (GL-LI) to entire surface of
cushion.
a After installing the cushion, fill clearances
(a) (16 points) between inner body (14)
and outer body (13) with grease of 30%
amount of the space.
Assembly of damper cover assembly (1)

1. Press fit outer races (7-4) and (7-5) of bearing
(7) to cover (2) using push tool [2].
3. Install flange (12) and tighten bolts (11).

3 Mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
2. Press fit inner race (7-1) of bearing (7) to shaft

(6) with tool F.
4. Fill (b) portion of inner body (14) with about 80

g of the following grease.
2 : Grease
Grease Supplier part name

Kyodo yushi Molylex
No.2 or an equivalent
Showa Shell Sekiyu
Lithium base extreme
Retinax AM or an
pressure grease with
equivalent
molybdenum disulphide
Nippon Oil Corporation
Molytex or an equiva-
lent
D155AX-6 9
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}
4. Set cover (2) to shaft (6), and press fit bearing

inner race (7-3) using tool F.
5. Install oil seals (8) and (9) to cover (2).

2 Press fitting surface of oil seal:
2 Oil seal lip surface: Grease (G2-LI)
a Apply gasket sealant at oil seal surface
thinly, and wipe off extra sealant.
10 D155AX-6
Removal and installation of power 5. Disconnect hoses (4) through (7).

train unit assembly 1
6. Disconnect hoses (8) through (11), and
Removal remove hose clamps (12) and (13).
k Park the machine at the level place, lower

the work equipment fully to the ground.
1. Drain the oil from hydraulic tank and power

train case.
6 Hydraulic tank: 85 l
Power train case: 90 l
2. Remove floor frame assembly referring to the

section, "Removal and installation of floor
frame assembly".
7. Disconnect hoses (14) and (15) at the rear of
3. Disconnect connectors PUMP (1) and HSS (2) hydraulic tank.
at power train unit right side.
8. Remove oil level gauge (16) and oil filler tube
(17).
9. Remove clamps (18) through (20), and remove

hose.
4. Disconnect 13 hoses (3) of split flange from

control valve.
D155AX-6 11
10. Remove the clamps for wirings (21) through 15. Remove final drive shaft cover (29).
(23), and move wires.
11. Disconnect tube (24).
16. Pull out drive shaft (30) to the position where

the spline portion of steering case side comes
out, using bolt [1] (M10 x 1.5).
12. Remove covers (25) at both sides of steering a If the shaft is hard to be pulled out, set
case. [*1] jack at the shoe grouser and lift up to the
position where the shaft can easily be
pulled out.
13. Remove cap (26). [*1]
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
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
20. Separate universal joint (35) at torque con-

verter side. [*3]
a After separating, push in yoke toward
torque converter and separate completely.
D155AX-6 13
Installation
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]
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).

Fill the oil through oil filler port to the specified
level. Start the engine to circulate the oil
through the piping, and recheck the oil level.
lubricants")
5 Power train case: Approx. 90 l
lubricants")
14 D155AX-6
Disconnection and connection of 5. Remove tube (5).

power train unit assembly 1 6. Remove work equipment and HSS pump assem-
bly (6).
Disconnection
4 Work equipment and HSS pump assem-
1. Set power train unit assembly (1) on block [1].
bly: 110 kg
4 Power train unit assembly: 2,400 kg
7. Remove cooling fan pump assembly (7).
4 Cooling fan pump assembly: 25 kg
2. Disconnect all the connectors from power train

unit to remove wiring harness referring to Dia-
grams and drawings section, "Electrical circuit
diagram, Connector table and arrangement 8. Remove tubes (8) and (9), and remove
drawing". scavenging pump assembly (10).
4 Scavenging pump assembly: 20 kg
3. Remove cover (2), and remove pressure
pickup hose (3). [*1]
a Disconnect 10 pressure pickup hoses at
power train unit side.
4. Disconnect hose (4).
D155AX-6 15
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
10. Remove tube (14).

13. Set PTO, torque converter and transmission
assembly (16) to block [2] with its PTO side
upward.
11. Remove coupling (15).
14. Remove block (18) with inside strainer.
16 D155AX-6
15. Remove cover (19), and remove spring (20)

and magnet assembly (21).
16. Remove pressure sensor block (22) and

remove two sleeves (23).
D155AX-6 17
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
19. Remove 19 mounting bolts, and remove PTO

assembly (27) by slinging it. [*3]
4 PTOAss'y: 200 kg
18 D155AX-6
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
D155AX-6 Bulldozer
2007 KOMATSU
All Rights Reserved
20 D155AX-6
SEN01207-01
D155AX-6

D155AX-6 80001 and up

Power train, Part 2
Disassembly and assembly of PTO assembly ................................................................................................ 2
Disassembly and assembly of torque converter assembly ............................................................................. 9
Disassembly and assembly of transmission assembly ................................................................................. 19
Disassembly and assembly of HSS case assembly ..................................................................................... 36
Removal and installation of HSS motor assembly ........................................................................................ 53
D155AX-6 1
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).
4) Remove bearing (7) and inner race (8)

from gear (9).
a Tighten bolts (M16 x 2.0) into taps (b)
alternately to push out bearing (7).
2) Remove pump drive gear lubrication tube

(2).
5) Remove bearing (40) from case (17).
2. Work equipment and HST pump drive gear

and cover assembly
1) Remove 3 mounting bolts (3) and set the
guide bolt.
2) Tighten forcing screws into hole (a) to
remove gear and cover assembly (4).
2 D155AX-6
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).
6) Remove case (17) from bearing (16).
3) While supporting cover (12) with block [1],

push in gear (13) to separate it from the
cover.
4. Scavenging pump drive gear assembly

1) Remove snap ring (18).
2) Remove gear (19) by pushing it into the
case.
4) Remove inner race (41) from gear (13).
D155AX-6 3
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).
5. Idler gear assembly

1) Remove the mounting bolt and plate (22).
6. Input shaft outer race

Remove snap ring (29) and input shaft outer
race (30).
2) Remove the mounting bolts and set guide

bolt [2].
3) Using forcing screws [3], remove shaft
(23).
a Keep holding the gear in the case.
4 D155AX-6
Assembly 1) Install snap ring (28) to gear (24) and

press fit outer race (27).
a Clean all the parts thoroughly and check them
for dirt or damage before installing.
a After press fitting each bearing, drop 6 cc of
TO30 or TO10 onto it and rotate it about 10
turns.
a Check that each snap ring is fitted to the
groove.
1. Input shaft outer race

Press fit input shaft outer race (30) and install
snap ring (29).
2) Using 3 guide bolts [4], insert shaft (23) to

the position shown in the figure.
a If shaft (23) is inserted all the way,
gear (24) cannot be installed.
2 O-ring: Grease (G2-LI)
2. Idle gear assembly

a Match the serial Nos. and match marks of
the bearing, outer race and spacer at
places [A] [C] and use them as an
assembly.
3) Install bearing (25) to shaft (23).

4) Install spacer (26).
D155AX-6 5
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}
3) Install snap ring (18).
7) Fix shaft (23) with the mounting bolts.
4. Cooling fan pump drive gear and cover

assembly
1) Press fit bearing (16) to case (17).
3. Scavenging pump drive gear

1) Press fit bearing (21) to the case and
install snap ring (20).
6 D155AX-6
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 Mounting bolt; Adhesive (LT-2)
3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
3) Press fit inner race (41) to gear (13).
5. Work equipment and HST pump drive gear

and cover assembly
1) Press fit bearing (40) to case (17).
4) Using the push tool, press fit gear (13) to

cover (12).
2) Press fit bearing (7) and inner race (8) to

gear (9).
D155AX-6 7
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}
4) nstall gear and cover assembly (4) to the

case.
3 Mounting bolt:
98 123 Nm {10.0 12.5 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
Disassembly and assembly of 3. Disassembly of drive case and housing

torque converter assembly 1 assembly
1) Remove snap ring (4) and spacer (5).
Disassembly
1. Input shaft
1) Remove mounting bolts (18 pieces).
Using forcing screw [11], remove input
shaft (1).
2) Using 2 forcing screws [5] from the turbine

side, remove bearing (8).
2) Remove snap ring (2) and bearing (3).
3) Remove the 30 mounting bolts. Using

eyebolts [2], remove housing assembly
(6).
2. Drive case and housing assembly

1) Remove 30 mounting bolts (57) between
the drive case and pump. Using eyebolts
[3], remov e dr ive case and housing
assembly (56).
D155AX-6 9
4) Remove 2 seal rings (7) from housing (9). 6. Turbine gear

Remove turbine gear (15).
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).
5. Discs and plate

Remove 2 discs (12) and plate (13). 2) Remove 2 snap rings (18) and remove
race (19) from stator (20).
10 D155AX-6
3) Remove snap ring (21). 9. Stator clutch assembly

1) Loosen 3 mounting bolts (31) gradually to
disconnect housing and shaft assembly
(32).
8. Pump
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).
3) Remove 12 mounting bolts (26) and

remove pump (28) from retainer (27).
4) Remove snap ring (29) and remove bear-
ing (30) from retainer (27).
D155AX-6 11
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).
6] Remove snap ring (50) and remove

spacer (51) and bearing (52) from
3] Remove seal ring (42), bushing (43) shaft (53).
and sleeve (44) from shaft (45). 7] Remove seal ring (54) from shaft
(53).
4] Remove snap ring (46) and gear (47).

8] Remove seal ring (55) from housing
(49).
12 D155AX-6
Assembly 4) Using the push tool and press, press fit

shaft and bearing assembly (48) to hous-
a Clean all the parts and check them for dirt or ing (49).
damage. Coat their sliding surfaces with
engine oil before installing.
a After press fitting each bearing, drop 10 cc of
TO30 or TO10 onto it and rotate it about 10
turns.
a When installing a bearing by expansion fit,
drop 10 cc of TO30 or TO10 onto it and rotate
it about 10 turns before freezing it in dry ice
etc.
groove.
1. Stator clutch assembly

1) Using push tool [3] and the press, press fit
bearing (52) to shaft (53).
5) Install bushing (43) and sleeve (44) to
shaft (45).
a Install the bushing and sleeve by
expansion fit.
6) Install seal ring (42) to shaft (45).
a Fix the seal ring securely with grease.
2 Seal ring: Grease (G2-LI)
2) Install spacer (51) and snap ring (50) to

shaft (53).
3) Install seal ring (54) to shaft (53).
a Fix the seal ring securely with grease.
2 Seal ring: Grease (G2-LI)
7) Install shaft assembly (41) to housing (49)

with 6 bolts (40).
3 Mounting bolt:
58.8 73.6 Nm {6.0 7.5 kgm}
D155AX-6 13
8) Reverse the housing assembly and install

gear (47) and snap ring (46).
12) Install 5 pins (35).

13) Install 2 stator clutch discs (37) and stator
9) Install seal ring (55) to housing (49). clutch plate (38).
a The seal ring must be installed in the
direction shown in the figure.
2 Periphery of seal ring:
Grease (G2-LI)
10) Install seal ring (33) to stator clutch piston
(34).
a The seal ring must be installed in the
Grease (G2-LI)
11) Install stator clutch piston (34) to housing
(49).
2 Seal ring contacting surface:
Grease (G2-LI)
14) Install 10 springs (36).
14 D155AX-6
15) Place housing (39) and tighten 3 mounting 2. Pump

bolts (a) from under side. 1) Press fit bearing (30) to retainer (27) and
a Tighten 3 mounting bolts (a) gradually install snap ring (29).
and evenly. 2) Install retainer (27) to pump (28).
2 Mounting bolt: Adhesive (LT-2) 2 Mounting bolt (26): Adhesive (LT-2)
3 Mounting bolt: 3 Mounting bolt (26):
98 123 Nm {10.0 12.5 kgm} 58.8 73.6 Nm {6.0 7.5 kgm}
16) Before installing the pump, insert 10
mounting bolts (b) of the transmission
assembly and torque converter assembly.
3) Install pump assembly (25) to stator shaft

and clutch assembly (24).
4) Install spacer (23) and snap ring (22).
3. Snap ring
Install snap ring (21) to the shaft.
D155AX-6 15
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).
3) Install 2 discs (12) and plate (13).
2) Install stator and race assembly (17) and

snap ring (16).
4) Install 2 seal rings (11) to piston (10).

a The seal rings must be installed in the
5. Drive case and housing 2 Periphery of seal ring:
1) Set turbine gear (15) on block [4]. Grease (G2-LI)
16 D155AX-6
5) Install piston (10). 8) Using push tool [6], push the inner race of
bearing (8) to press fit.
6) Install 2 seal rings (7) to housing (9).

a The seal rings must be installed in the 9) Install spacer (5) and snap ring (4).
Grease (G2-LI)
10) Install drive case and housing assembly

(56).
a Align plug (57) of the pump with the
7) Sling housing assembly (6) and install it to oil groove of the drive case.
the drive case. 2 Mounting bolt: Adhesive (LT-2)
a While aligning the 3 holes on the pis- 3 Mounting bolt:
ton top with the pins on the inside of 49.0 58.8 Nm {5.0 6.0 kgm}
the housing, lower the housing gradu- 3 Plug:
ally. 14.7 19.6 Nm {1.5 2.0 kgm}
3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
D155AX-6 17
6. Input shaft
1) Install bearing (3) and snap ring (2).
2) Install input shaft (1).

3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
18 D155AX-6
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)
Disassembly 4) Remove control valve assembly (6).
a Keep the removed discs and plates on a flat

place so that they will not warp.
1. Relief valve assembly

Remove relief valve assembly (1).
3. Snap ring
Remove snap ring (123) from output shaft
(124).
a Remove the snap ring at this time.
2. Control valve assembly

1) Remove cover assembly (2).
2) Remove the nut of wiring harness connec-
tor (2A) and push in the connector.
D155AX-6 19
4. Transmission case 6. Input shaft-front cover-No. 1 carrier assem-

1) Set the block with the torque converter bly
side up. 1) Using sling bar [3], remove input shaft-
2) Remove sleeve (7). front cover-No. 1 carrier assembly (11).
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).
3] Remove snap rings (18) and (126).

4] Drive out input shaft toward the
torque converter and remove front
cover (19).
20 D155AX-6
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.
6] Remove collar (128).

7] Remove snap ring (22) and No. 1 ring
gear (23). 9. Guide pin
8] Pull out shaft (24) and remove thrust Remove guide pins (35).
washer (25), gear (26), bearing (27)
and ball (28). 10. No. 2 disc, plate and spring
a Take care not to lose the ball. 1) Remove spring (36).
2) Remove springs (37), discs (38) and
plates (39).
7. No. 1 disc, plate and spring

1) Remove spring (29).
2) Remove springs (30), discs (31) and 11. Remove through bolt guide (40), lubricating oil
plates (32). relief valve (41) and spring (130).
D155AX-6 21
12. Snap ring 2] Remove spacer (47) from No. 2 car-

Remove snap ring (125). rier assembly (49).
3] Pull out shaft (50) and remove thrust
and ball (54).
a Take care not to lose the ball.
13. No. 2 housing and No. 2 carrier assembly

1) Using eyebolts [5], remove No. 2 housing
and No. 2 carrier assembly (42).
2) Remove No. 2 piston (43).
4] Remove snap ring (55) and ring gear
(56).
a Push the snap ring inward with a
pin (Diameter: Max. 3 mm) from
outside to warp and remove it.
3) Disassemble No. 2 housing and No. 2 car-

rier assembly according to the following
procedure.
1] Remove snap ring [44] and pull out
No. 2 carrier assembly (45) from No.
2 housing (46). 5] Remove seal ring (57) and snap ring
(58) from No. 2 housing (46) and
remove bearing (59).
22 D155AX-6
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).
15. No. 3 carrier assembly

1) Remove No. 3 carrier assembly (64). 17. No. 4 carrier and No. 3 ring gear assembly
1) Remove No. 4 carrier and No. 3 ring gear
assembly (76).
2) Disassemble No. 3 carrier assembly

1] Remove seal ring (65).
2] Pull out shaft (66).
3] Remove thrust washer (67), planetary
gear (68), bearing (69) and ball (70).
4] Remove snap ring (71) and bearing
(72).
D155AX-6 23
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).
20. No. 5 carrier and No. 4 ring gear assembly

1) Remove mounting bolts (94).
2) Remove No. 5 carrier and No. 4 ring gear
assembly (95).
18. No. 3 housing

1) Remove No. 3 housing (87).
3) Disassemble No. 5 carrier and No. 4 ring

gear assembly according to the following
procedure.
1] Drive out shaft (96) to remove thrust
and ball (100).
24 D155AX-6
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).
21. No. 5 sun gear

Remove No. 5 sun gear (104). 24. No. 5 ring gear
Remove No. 5 ring gear (111).
25. No. 5 piston

Remove No. 5 piston (112).
22. No. 4 housing assembly

1) Remove No. 4 housing assembly (105).
26. Cover assembly

1) Remove snap ring (113) and remove
cover assembly (114) from output housing
assembly (115).
D155AX-6 25
2) Remove seal rings (116) and (117) from Assembly

cover (118).
3) Remove bearing (119) from cover (118). q Precautions for assembly
a Coat the sliding surfaces of each part with
engine oil (For details, see "Table of fuel, cool-
ant and lubricants") before installing.
a When installing piston seal ring (a), direct the
pressure receiving side (b) toward housing (c).
a When installing a metallic seal ring, apply
grease (G2-LI) to it and fit it evenly.
27. Output housing

1) Remove snap ring (120) and remove
bearing (121) and spacer (122) from out-
put housing (123).
2) Remove bearing (121) from spacer (122).
1. Output housing
1) Using the push tool, press fit bearing (121)
to spacer (122).
26 D155AX-6
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
3) Using the push tool, install cover assem-

bly (114) to output housing assembly
(115).
a Press fit the inner race side of the
bearing to install.
4) Install snap ring (113).
D155AX-6 27
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}

1) Assemble the No. 5 carrier and No. 4 ring 9. No. 5 sun gear
gear assembly according to the following Install No. 5 sun gear (104).
procedure.
1] Set No. 4 ring gear (102) to carrier
(103) and install snap ring (101).
10. No. 4 discs, plates and springs

1) Install No. 4 discs (91), plates (92) and
springs (90).
2] Install bearing (99) to gear (98). a Install the 4 discs and 3 plates.
While fitting thrust washers (97) to 2) Install springs (89).
both sides of them, set them to the a Free length of spring: 70 mm
carrier.
3] Fit ball (100) and install shaft (96).
28 D155AX-6
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.
2) Install No. 4 carrier and No. 3 ring gear

assembly (76).
1) Assemble No. 4 carrier and No. 3 ring
gear assembly according to the following
procedure.
1] Using the push tool, press fit bearing
(85) to spacer (86).
13. No. 4 sun gear

Install No. 4 sun gear (75).
14. Output shaft

1) Install snap ring (74) to the output shaft.
2) While setting output shaft (73) to the
2] Using the push tool, press fit spacer spline of the sun gear, push it in.
(86) and bearing assembly (85) to the
No. 4 carrier.
3] Install snap ring (84).
4] Install bearing (83) to planetary gear
(82). While fitting thrust washers (81)
to both sides of them, set them to the
carrier.
5] While setting the shaft pin hole to the
carrier pin hole, install shaft (80A).
6] Check that the pin holes are aligned
and drive roll pin (80).
7] Install seal rings (79) and (78).
D155AX-6 29
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.
4] Install seal ring (65).
17. No. 2 housing and No. 2 carrier assembly

1) Assemble the No. 2 housing and No. 2
carrier assembly according to the follow-
ing procedure.
1] Press fit bearing (59) to No. 2 housing
(46) and install snap ring (58).
2) Install No. 3 carrier assembly (64). 2] Install seal ring (57).
3] Set No. 1 ring gear (56) and No. 2

carrier (45) and install snap ring (55).
30 D155AX-6
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).
6] Install No. 2 ring gear (48).

7] Install spacer (47). 4) Install tool G1 to the inside groove of the
a Direct the side of the cut inside No. 3 carrier, pull it up, and install snap
toward the carrier. ring (125).
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.
D155AX-6 31
19. Guide pin 3] Set No. 1 ring gear (23) to No. 1 car-
Install guide pins (35). rier and install snap ring (22).

springs (37).
a Install the 7 discs and 6 plates.
2) Install springs (36).
a Free length of spring: 81.7 mm
4] Press fit bearing (117) to input shaft

(21).
5] Install No. 1 carrier assembly (118) to
input shaft (21) and install snap ring
(18).
21. No. 1 housing assembly

1) Fit the seal ring and install No. 1 piston
(34).
2) Using eyebolts [4], install No. 1 housing
assembly (33), while aligning it with the
No. 2 piston.
a Press the housing to push in the
dowel pins.
6] Install collar (17).

7] Install No. 1 sun gear (16) and snap
ring (15).
22. Input shaft and No. 1 carrier assembly

1) Assemble the input shaft and No. 1 carrier
assembly according to the following pro-
cedure.
1] Install bearing (27) to gear (26).
While fitting thrust washers (25) to
both sides of them, set them to the
carrier.
32 D155AX-6
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.

1) Install collar (128).
spring (30).
a Install 6 discs and 5 plates. 25. Tie bolts
3) Install springs (29). Install tie bolts (9) (4 pieces). (The 4 bolts
a Free length of spring: 81.7 mm marked with * in the attached drawing).
3 166.7 9.8 Nm {17 1 kgm}
D155AX-6 33
26. Operation check of piston 29. Snap ring

Using tool G2, check the operating condition Raise the case assembly and install snap ring
and stroke of each piston. (123) to output shaft (124).
Piston Standard stroke (mm)
No. 1 7.2
No. 2 7
No. 3 5
No. 4 5
No. 5 6
30. Control valve assembly

1) Install control valve assembly (6).
3 Mounting bolt:
49.1 4.9 Nm {5.0 0.5 kgm}
27. Transmission case

Fit the O-ring. Using eyebolts [2], install trans-
mission case (8) and remaining 13 tie bolts (9).
3 Tie bolt: 166.7 9.8 Nm {17 1 kgm}
2) Install flanges (4) and (5) and sleeve (3).
28. Sleeve
Install sleeve (7).
34 D155AX-6
3) Install cover assembly (2).

2 Threaded part of mounting bolt:
Gasket sealant (LG-1 or LG-5)
31. Main relief valve assembly

Install main relief valve assembly (1).
3 Mounting bolt:
49.1 4.9 Nm {5.0 0.5 kgm}
D155AX-6 35
Disassembly and assembly of q Disassembly of brake and carrier assembly

HSS case assembly 1 1) Remove flange (2) and plate (3).
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.
3) Remove spacer (6), brake springs (7), pis-

ton (8) and cylinder (9).
36 D155AX-6
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).
5) Remove plate (13), discs (15), springs

(16) and plates (14) from the brake drum.
10) Remove planetary gear (25), bearing (26),
thrust washer (27), shaft (24) and ball
(28).
6) Remove the mounting bolts and remove

carrier assembly (19) from hub (18).
7) Remove gear assembly (20) form hub
assembly (18). 11) Remove snap ring (31) and remove stop-
per (32) from hub (18).
D155AX-6 37
2. Bevel pinion assembly 6] Remove bearing (109) from bevel

1) Using guide bolt [3] and forcing screws, pinion (40).
remove bevel pinion assembly (33) and
shims (34).
a Check the quantity and thickness of
the shims and keep them.
2) Disassembly of bevel pinion assembly
1] Remove bolts (35), plate (36) and pin
(37).
3. Sun gear
Remove sun gear (45).
a Remove the sun gear on the opposite side
similarly.
4. Gear
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).
2) Using gear puller [6], remove gear (49).
4] Remove bearing (42).

5] Remove outer races (43) and (107)
from cage (41).
38 D155AX-6
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.
7. Motor output gear

5. Valve seat 1) Remove flange (61) from case (62).
1) Pull out and remove 2 brake circuit tubes 2) Remove flange and gear assembly (63).
(51) and 2 lubrication tubes (52).
2) Remove valve seat (53).
3) Remove gear assembly (65) from flange

(64).
6. Lubrication tubes, oil level gauge pipe and
suction tube
1) Remove lubrication tubes (52) and (56).
D155AX-6 39
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).
2) Drive out shaft (73) with a plastic hammer

etc.
40 D155AX-6
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.
3] Remove hexagon socket head bolts

(95), plate (93) and shim (94).
4) Disassembly of bevel gear shaft and bevel

gear assembly
1] Using puller [11], remove inner race
(91) on the right side of shaft (92).
a Remove inner race (91) on the
left side of shaft (92) similarly.
4] Using tool H3, remove nut (96).
D155AX-6 41
5] Using puller [12], pull out left-hand Assembly

retainer (97) from shaft (92).
6] Remove bearing (98) from retainer q Precautions for assembly
(97). a Clean all the parts thoroughly and check them
a Drop engine oil (For details, see "Table of fuel,
coolant and lubricants") onto the rotary parts of
each bearing and rotate the bearing several
turns.
a When installing the piston seal ring, apply
grease (G2-LI) to it, direct the pressure receiv-
ing side toward the housing, and fit it evenly.
a Fix the rotary seal ring with grease (G2-LI) and
install it carefully so that it will not be caught.
groove.
7] Remove nut (99) and remove bevel
gear (100) from shaft (92).
1. Bevel gear shaft and bevel gear assembly

1) Assembly of bevel gear shaft and bevel
8] Remove bearing (101) from right- gear assembly
hand retainer (89). 1] Using the push tool, press fit bearings
(101) and (74) to right-hand retainer
(89).
42 D155AX-6
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
8] Fix the shaft. Using tool H3, tighten

3] Set bevel gear (100) to shaft (92) and nut (96).
tighten nut (99). 2 Nut: Adhesive (LT-2)
3 Nut: 3 Nut:
215.8 274.6 Nm {22.0 28.0 kgm} 735.5 902.2 Nm {75.0 92.0 kgm}
4] Install the seal ring. a Remove the bolts which the tool
will interfere with.
5] Install outer race (103), bearing (104),

spacer (105), bearing (104) and outer
race (103) to left-hand retainer (97) in
order.
6] Install plate (93) and fix it with several
hexagon socket head bolts.
D155AX-6 43
9] Adjustment of shim 2) Install left-hand retainer (88) and guide

Tighten the 4 bolts lightly and mea- bolts [9].
sure dimensions [a] and [c] to obtain 3) Using eyebolts [10], sling the right-hand
dimension [b] and then select a shim retainer. While aligning the guide bolts to
of dimension [b]. the bolt holes, install bevel gear shaft and
Shim thickness [b] = bevel gear assembly (90) to the case.
([a] [c]) (0.1 0.2 mm)
10] Set selected shim (94) and tighten
bolts (95).
4) Install the shim to the left-hand retainer

and tighten right-hand and left-hand
retainer mounting bolts (85) and (86).
11] Install right-hand retainer (89) to shaft a Shims of 0.1, 0.2 and 0.5 mm thick-
(92). ness are prepared.
a The left-hand retainer mounting bolts
need to be loosened later to adjust
the backlas h and tooth contact.
Tighten them at this time, however, to
check the starting torque of the bevel
gear shaft.
12] Install inner race (91) to shaft (92) by

shrink fit.
a Shrink fit temperature: 100 C for
about 20 minutes
44 D155AX-6
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})
3. Right-hand carrier drive gear

2. Intermediate gear to the case.
1) Install snap ring (83) and spacer (84) to 2) Using the push tool, press fit inner race
gear (77). Using the push tool, press fit (75) to shaft (73).
outer race (82). a Press fit to about 27 mm from the
2) Install lower bearing (78), spacer (81) and shaft face.
upper bearing (78). a Install to only 1 side.
3) Install shaft (73), while setting it to the

bearing.
D155AX-6 45
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
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).)
6] Rotate the nut until the phase of the

pin holes (8 places) of the nut
becomes the same as the phase of
the pin holes (5 places) of the pivot
shaft at a place. (The returning angle
must be 0 9 )
7] Insert pins (37) in the above holes,
install plate (36) and tighten bolts
(35).
2 Bolt: Adhesive (LT-2)
3 Bolt:
11.8 14.7 Nm {1.2 1.5 kgm}
2) Using guide bolts [3], set shim (34) and
install bevel pinion assembly (33). q When backlash is too large
a Shims of 0.1, 0.2 and 0.5 mm thick- Decrease the thickness of the shim
ness are prepared. on the left side of the machine and
increase the thickness on the right
side by the same quantity. (Move the
bevel gear in direction (B).)
D155AX-6 47
2) Adjustment of tooth contact Adjustment

Testing If the tooth contact pattern is not proper,
1] Apply red lead thinly to the tooth sur- adjust the tooth contact according to the
faces of the bevel gear and turn the following procedure.
bevel gear in the forward and reverse 1) If the bevel pinion is too far from the
directions, and then check the tooth center line of the bevel gear, the con-
contact pattern on the bevel gear. tact is at the small end of the bevel
gear tooth faces curved outward and
at the large end of the bevel gear
tooth faces curved inward.
q In this case, adjust the tooth contact
Adjust the thickness of the shims on
the bevel pinion side to move the
bevel pinion in direction (A). Move
the bevel gear in direction (B) and
then check the tooth contact pattern
and backlash again.
2] The tooth contact must be as follows.

(The standard distance is measured
from the tooth tip of the bevel pinion.)
a) Center of tooth contact: 20
40% of face width (from small
end)
b) Width of tooth contact: 30 50%
of face width
c) Center of tooth contact: 35
65% of tooth depth
d) Width of tooth contact: 60 80%
of tooth depth 2) If the bevel pinion is too close to the
Check that there is not a strong center line of the bevel gear, the con-
contact at tips (A), roots (B), tact is at the large end of the bevel
small end (C) or large end (D). gear tooth faces curved outward and
a If the bevel gear and bevel pinion the small end of the bevel gear tooth
are adjusted in this way, their faces curved inward.
teeth come in contact with each q In this case, adjust the tooth contact
other correctly when they are according to the following procedure.
loaded. Adjust the thickness of the shims on
the bevel pinion side to move the
bevel pinion in direction (A). Move
the bevel gear in direction (B), then
check the tooth contact pattern and
backlash again.
a Do not change the total thickness of
the shims on the right and left sides.
48 D155AX-6
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).
7. Motor output gear

to flange (61).
2) Using the push tool, press fit inner race
(67) and bearing (68) to gear (66).
2) Install valve seat (53), while setting it to

lubrication tube (52) installed in 8-1).
3) Install brake circuit tube (51) and lubrica-
tion tube (52).
3) Install gear assembly (65) to flange (64).
D155AX-6 49
9. Gear 11. Brake and carrier assemblies

1) Install inside bearing (55), snap ring (54) a Assemble both assemblies according to
and outside bearing (55) to gear (49). the same procedure.
2) Install gear (49), while setting it to the q Assembly of brake and carrier assembly
bevel gear shaft bearing. 1) Install stopper (32) to hub (18) and install
snap ring (31).
2) Install bushing (38).
(37).

(50).
4) Fit spacer (48) and install snap ring (47).
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.
4] Install sleeve (36) to carrier (35).
10. Sun gear

1) Install thrust washer (46) to sun gear (45).
2) Install sun gear (45).
50 D155AX-6
5] Install bushings (29) and (30) to gear 7) Hub

(108). 1] Using the push tool, press fit bearing
6] Set gear (108) to ring gear (22), (17) to hub (9).
install ring (21), and install the ring
gear to the gear.
2] Fit the seal ring and install hub (9).

7] Install gear assembly (20) to hub (18). 9) Install piston (8) and spring (7).
8] Install carrier assembly (19) to hub a Install the spring so that its outside
(18). will open.
3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
10) Brake cover assembly

1] Using the push tool, press fit bearing
5) Set brake drum (12) to hub assembly (18). (11) to brake cover (10).
6) Install discs (15), plates (14) and (13) and 2] Install guide bolt [2] to hub (9).
springs (16).
a Install the 5 discs, 4 plates (14) and 1
plate (13).
D155AX-6 51
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):
4] Using the push tool, press fit inner

race (4).
5] Install plate (3) and flange (2).
3 Flange:
58.8 73.6 Nm {6.0 7.5 kgm}
6] Periodically tighten the bolts tight-
ened temporarily in 3].
3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
52 D155AX-6
Removal and installation of HSS Installation

motor assembly 1 q Carry out installation in the reverse order to
removal.
Removal
k Disconnect the cable from the negative () q Refilling with oil (Hydraulic tank)
terminal of the battery. Add oil through the oil filler to the specified
1. Drain the oil. through the system. Then, check the oil level
again.
2. Remove the fuel tank assembly. For details, Approx. 85 l
see "Removal and installation of fuel tank
assembly".
3. Disconnect main hoses (1) and (2).
4. Disconnect drain hose (3).
5. Sling motor assembly (4), remove the 2 mount-

ing bolts, and lift off the motor assembly.
4 Motor assembly: 75 kg
D155AX-6 53
D155AX-6 Bulldozer
2007 KOMATSU
All Rights Reserved
54 D155AX-6
SEN02707-01
D155AX-6

D155AX-6 80001 and up

Power train, Part 3
Removal and installation of final drive assembly ............................................................................................ 2
Disassembly and assembly of final drive assembly........................................................................................ 4
D155AX-6 1
Removal and installation of final 3. Raising of machine

k 1) Using a jack (686 kN {70 ton}) and
drive assembly 1
the ripper of the work equipment,
Special tools raise the machine and set right and
left support stands [1] under the
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
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. Remove 8 mounting bolts (2) on the inside of

final drive assembly (1). [*1]
4. Remove guards (3) and (4).
2 D155AX-6
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.
9. Lift off final drive assembly (1).

4 Final drive assembly: 1,400 kg
6. Pull out drive shaft (6).

a Using forcing screws, pull out the drive
shaft until the spline can be pulled out.
a If the shaft cannot be pulled out, move the
sprocket forward or backward to a position
where the shaft can be pulled out.
Installation
removal.
[*1], [*2]
3 Final drive mounting bolt:
1,150 1,440 Nm {118 147 kgm}
7. Remove the upper mounting bolts of the final

drive assembly and install tool J. [*2]
D155AX-6 3
Disassembly and assembly of Disassembly

final drive assembly 1 1. Draining oil
Remove the drain plug to drain the oil in the
Special tools final drive case.
6 Final drive case: Approx. 31 l
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
790-431-1031 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
3 791-627-1280 Installer t 1
790-101-5441 Plate 1
4
K 790-101-5421 Grip 1
01010-51240 Bolt 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
790-201-1680 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
4 D155AX-6
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.
4. Sprocket hub assembly

1) Remove mounting bolts (4) and plate (5).
5) Reverse the sprocket hub assembly and

remove 9 sprockets (11).
2) Using tool K1, pull out sprocket hub

assembly (6).
a Bearing (7) comes off, too.
3) Using eyebolts [2], remove sprocket hub
assembly (6). 5. Wear guard
Remove wear guard (12).
D155AX-6 5
6. Cover assembly 6) Reverse the cover assembly and remove

1) Remove spacer (13). 6 lock plates (19).
2) Remove floating seal (14). 7) Remove ring gear (20).
a Keep the floating seal in a safe place
so that it will not be damaged.
3) Remove mounting bolts (15).
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.
2) Disassemble the carrier assembly accord-

ing to the following procedure.
1] Remove bolts (22) and holders (23).
5) Remove bearing (17) and spacer (18). 2] Pull out planetary gear shaft (24).
6 D155AX-6
3] Remove planetary gear (25), bear- 9. Holder

ings (26) and (27) and spacer (28) Remove mounting bolt (33) and holder (34).
from the carrier.
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).
3] Remove mounting bolts (38).

4] Using eyebolts [6], sling gear (39),
and slant the hub to remove the gear.
D155AX-6 7
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).
5) Remove sump plate (45) from case (36).

2) Using eyebolts [7], remove hub assembly
(40).
12. Cage assembly

1) Remove the mounting bolts of cage
3) Remove 2 bearing outer races (42) from assembly (46). Using forcing screws [8],
hub (41). remove the cage assembly from case
(36).
8 D155AX-6
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).
3) Remove shims (50).
13. Gear assembly

1) Remove gear assembly (51).
2) Using puller [9], remove bearings (52) and
(53) from gear (54).
D155AX-6 9
Assembly 2. Gear assembly

1) Using the push tool [11], press fit bearings
(52) and (53) to gear (54).
q Bearing press fitting force:
6 17 kN {0.6 1.7 ton}
2) Install the drive shaft cover.
3) Install gear assembly (51).
1. Oil seal and outer race
1) Using tool K4, press fit oil seal (56) to
case (36).
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:
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:
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
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}
3) Fit the O-ring to cage assembly (46),

install them, and adjust shim (50).
a When installing the cage assembly,
lower it gradually not to damage the
oil seal lip.
4) Adjustment of shim
q Adjust the pinion bearing clearance
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
Table 1 4. Hub and case assembly

Total 1) Install oil sump plate (45) to case (36).
Number of shims
a + b (mm)
to be used shim a When installing the plate, press its
thick- surface against case faces (a) and
Above Below t = 0.15 t = 0.5 t = 1.0 ness (b).
(mm) 2 Mounting bolt: Adhesive (LT-2)
3.05 3.15 5 1 1.75
3.15 3.25 2 1 1 1.80
3.25 3.35 9 1 1.85
3.35 3.45 6 1 1.90
3.45 3.55 3 1 1 1.95
3.55 3.65 2 2.00
3.65 3.75 7 1 2.05
3.75 3.85 4 1 1 2.10
3.85 3.95 1 2 2.15
3.95 4.05 8 1 2.20
4.05 4.15 5 1 1 2.25
4.15 4.25 2 2 2.30
4.25 4.35 9 1 2.35
4.35 4.45 6 1 1 2.40
4.45 4.55 3 2 2.45
4.55 4.65 1 2 2.50
4.65 4.75 7 1 1 2.55
4.75 4.85 4 2 2.60
4.85 4.95 1 1 2 2.65
4.95 5.05 8 1 1 2.70
5.05 5.15 5 2 2.75
5.15 5.25 2 1 2 2.80
5.25 5.35 9 1 1 2.85
5.35 5.45 6 2 2.90
2) Using tool K5, press fit bearing (44) to
5.45 5.55 3 1 2 2.95
case (36).
5.55 5.65 3 3.00 q Bearing press fitting force:
5.65 5.75 7 2 3.05 21 54 kN {2.1 5.5 ton}
5.75 5.85 4 1 2 3.10 3) Install collar (43).
5.85 5.95 1 3 3.15
5.95 6.05 8 2 3.20
6.05 6.15 5 1 2 3.25
6.15 6.25 2 3 3.30
6.25 6.35 9 2 3.35
6.35 6.45 6 1 2 3.40
6.45 6.55 3 3 3.45
6.55 6.65 1 3 3.50
6.65 6.75 7 1 2 3.55
6.75 6.85 4 3 3.60
6.85 6.95 1 1 3 3.65
6.95 7.05 8 1 2 3.70
7.05 7.15 5 3 3.75
7.15 7.25 2 1 3 3.80
7.25 7.35 9 1 2 3.85
12 D155AX-6
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).
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).
3 Mounting bolt:
230 289 Nm {23.5 29.5 kgm}
D155AX-6 13
7. Sun gear 3) Set the planetary gear assembly to the

Install sun gear (32) and thrust washer (31). carrier and press fit shaft (24).
a While aligning the holes of the bear-
ing spacer, press fit the shaft gradu-
ally.
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}
10 35 kN {1.0 3.6 ton}
5) Using 3 eyebolts [4], install carrier assem-

bly (21).
2) Install bearings (26) and (27) and spacer
(28) to planetary gear (25).
14 D155AX-6
9. Cover assembly 5) Using eyebolts [3], fit the O-ring to cover

1) Install ring gear (20) and 6 lock plates (19) assembly (16) and install them to the case
and tighten the mounting bolts. assembly.
2 Mounting bolt: Adhesive (LT-2) a The mating faces of the case and
cover must be free from a dent, rust,
oil, dirt and water.
a Apply the gasket sealant all around
the mating face (1 side) of the case
without breakage.
2 Mating face of case:
a Tighten the bolts within 20 minutes
after applying the gasket sealant.

3) Using tool K3, press fit bearing (17).
15 43 kN {1.5 4.4 ton}
6) Tighten mounting bolts (15).

3 Mounting bolt:
455 565 Nm {46.5 58 kgm}
4) Using tool K4, press fit floating seal (14).

a Degrease and dry the O-ring and O-
ring contact surface before installing
the floating seal.
a After installing the floating seal, check
that its tilt is 1 mm or less.
D155AX-6 15
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.
11. Sprocket hub assembly

1) Using tool K5, press fit bearing outer
races (9) and (10). 4) Using eyebolts [2], install sprocket hub
q Bearing press fitting force: assembly (6) to the cover assembly.
14 59 kN {1.5 4.4 ton} a Check that the sliding surface of the
floating seal is free from dirt and
apply engine oil (For details, see
"Table of fuel, coolant and lubricants")
thinly.
2) Install 9 sprockets (11) to the sprocket

hub.
3 Mounting bolt:
1,176 98 Nm {120 10 kgm}
16 D155AX-6
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}
15 43 kN {1.5 4.4 ton}
13. Drive shaft

Install drive shaft (1).
6) Install plate (5) and tighten mounting bolts
(4).
3 Mounting bolt: 2
230 289 Nm {23.5 29.5 kgm}

Tighten the drain plug and add oil through the
oil filler.
a After installing the final drive assembly to the
machine, check the oil level again.
5
12. Shaft
Final drive case: Approx. 31 l (TO30)
1) Fit the O-ring to the sprocket hub assem-
bly. Using eyebolts [1], install shaft (3). 3 Oil filler/Drain plug:
127 176 Nm {13 18 kgm}
3 Oil level gauge plug:
58.8 76.4 Nm {6 8 kgm}
D155AX-6 17
D155AX-6 Bulldozer
2007 KOMATSU
All Rights Reserved
18 D155AX-6
SEN01208-01
D155AX-6

D155AX-6 80001 and up

Undercarriage and frame
Removal and installation of track frame assembly.......................................................................................... 3
Removal and installation of idler assembly ..................................................................................................... 6
Disassembly and assembly of idler assembly ................................................................................................ 7
Removal and installation of recoil spring assembly .......................................................................................11
Disassembly and assembly of recoil spring assembly .................................................................................. 12
Removal and installation of track roller ......................................................................................................... 17
Disassembly and assembly of track roller assembly .................................................................................... 19
Removal and installation of No. 1 bogie assembly ....................................................................................... 22
Removal and installation of No. 2, No, 3 and No. 4 bogie assemblies ......................................................... 28
Disassembly and assembly of bogie assembly ............................................................................................ 34
Removal and installation of carrier roller assembly ...................................................................................... 37
Disassembly and assembly of carrier roller assembly .................................................................................. 38
Removal and installation of pivot shaft assembly ......................................................................................... 42
Spreading and installation of track shoe assembly ....................................................................................... 44
General disassembly and assembly of track shoe........................................................................................ 47
Disassembly and assembly of 1 link in field.................................................................................................. 61
D155AX-6 1
Disassembly and assembly of master link .................................................................................................... 65

Removal and installation of equalizer bar assembly ..................................................................................... 68
Disassembly and assembly of equalizer bar assembly................................................................................. 70
Removal and installation of segment teeth ................................................................................................... 72
2 D155AX-6
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".

3. Using tool KK, fix the bogie assembly.
5. Sling the track frame assembly to be removed.
6. Remove mounting bolts (1) and cover (2). [*1]
7. Remove the 2 mounting bolts and lock plate

(3).
8. Pull out pin (4).

a If the holes of the equalizer bar and track
frame are not aligned, the pin cannot be
pulled out easily. Accordingly, remove the
pin while adjusting the height of the track
4. Raise the machine according to the following frame.
procedure. k If the track frame on the opposite side
1) Raise the machine with a jack or the ripper is floated before the pin is removed,
and set right and left support stands [1] support it with blocks etc.
under the frame to float the rear part of the
machine.
D155AX-6 3
9. Remove guards (5) and (6).

4 Guard (6): 25 kg
10. Remove the mounting bolts and pull out cover

(7).
a Hoses are connected in the cover. Take
care.
16. Lift off track frame assembly (16). [*3]

4 Track frame assembly: 3,825 kg
11. Disconnect hoses (8), (9), (10) and (11) con-

nected in cover (7) pulled out and then remove
cover (7).
17. Remove seal (17) from pivot shaft (18). [*4]
12. Remove washer (12).
13. Remove seal (13). [*2]
14. Remove the 6 mounting bolts and washer (14).
15. Remove spacer (15) from the washer.
4 D155AX-6
Installation [*4]
a Install seal (17) according to the following pro-
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]
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.
q Refilling with oil (Pivot chamber)

5 Engine oil: Approx 9 l
lubricants")
[*3]
a When inserting the track frame assembly, take
care extremely not to damage the seal surface.
D155AX-6 5
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.

k Never stand in front of the idler assem-
bly to avoid danger.
2. Remove side covers (1).

a Remove the 1 inside cover and 1 outside
cover.
3. Loosen the support mounting bolts to remove

the shims and then remove support (2). [*1]
a Check the quantity and thickness of the
shims and keep them.
a Remove the 1 inside support and 1 out-
side support. Installation
removal.
[*1]
a Set the idler assembly to the center of the track
frame and adjust clearance (a) between the
track frame and guide plate with the shims.
q Standard clearance (a): 0.5 1.0 mm
q Standard shim thickness: 6 mm
4. Loosen guide tension bolts (3).

a Loosen the 2 inside bolts and 2 outside
bolts.
5. Remove idler guide mounting bolts (4).
6. Sling idler assembly (5) and pull it out forward

to remove.
4 Idler assembly: 350 kg
6 D155AX-6
Disassembly and assembly of 6. Remove the mounting bolts. Using forcing

idler assembly 1 screws [2], remove retainer (6).
Special tools 7. Remove plate (7).
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.
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
2. Set idler assembly (1) to blocks [1].
3. Remove nut (1) and pull out bolt (3).
4. Remove support (4).
5. Remove ring (5).
11. Using forcing screws [2], remove retainer (12).
12. Remove plate (13).
13. Lift off shaft (14).
D155AX-6 7
14. Remove floating seal (15) from rings (5) and Assembly
(11).
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}
16. Remove bushing (17) from idler (1).
2. Using tool L2, install floating seal (12) to retain-

ers (5) and (9).
a Dimension (b) of projection of the seal
shown in the figure (A) must be 7 11
mm.
a After inserting the seal, check that its tilt is
1 mm or less.
a Before inserting the seal, thoroughly
clean, degrease and dry the parts indi-
cated with the thick lines in figure (B) (the
O-ring and the O-ring contact surface).
3. Using tool L2, install floating seal (11) to rings

(8) and (4).
a Dimension (b) of projection of the seal
shown in the figure (A) must be 7 11
mm.
a After inserting the seal, check that its tilt is
1 mm or less.
a Before inserting the seal, thoroughly
clean, degrease and dry the parts indi-
cated with the thick lines in figure (B) (the
O-ring and the O-ring contact surface).
8 D155AX-6
6. Sling and reverse idler (1) and set it to blocks

[1].
7. Sling shaft (14) and set it to the idler.

a When installing the shaft, take care not to
damage the retainer fitting floating seal
installed below.
8. Install plate (7) and retainer (6).
9. Using the push tool, press fit ring (12) to the

shaft to dimension (c).
a Before installing the ring, apply engine oil
and lubricants") thinly to the mating face of
the floating seal.
a Ring press fitting dimension (c):
80 0.2 mm
4. Set idler (1) to blocks [1].
5. Install plate (13) and retainer (12).
10. Reverse idler (1) and set it to block [1].
D155AX-6 9
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
and lubricants") thinly to the mating face of
the floating seal.
12. Install supports (4) and (10) to shaft (14).

Insert bolts (3) and (9) and tighten nuts (2) and
(8).
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
Removal and installation of recoil Installation

spring assembly 1 q Carry out installation in the reverse order to
removal.
Removal
1. Remove the idler assembly. For details, see a While checking the recoil spring assembly
"Removal and installation of idler assembly". through the lubricator adjustment window,
install in the track frame.
2. Pull out the recoil spring assembly (1) forward
to remove.
4 Recoil spring assembly: 510 kg
D155AX-6 11
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
q If cylinder (10) has not been broken

Disassembly and shaft end nut (11) has not come
1. Remove yoke and piston assembly (2) from off, disassemble according to the fol-
recoil spring assembly (1). lowing procedure.
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
4. Disassembly of holder 7. Apply hydraulic pressure gradually to tool M2

1) Remove cover (15) from holder (14). to compress the spring and tighten nut (11)
2) Remove seal (16) and bushing (17) from until spacer (19) comes off and then remove
holder (14). the spacer.
8. Remove nut (11) and release the hydraulic oil

gradually to release the spring tension.
5. Remove the lock plate from cylinder (10) and

remove lubricator (18).
9. Remove recoil spring (20) and cylinder (10)

from recoil spring case (12).
10. Remove bushing (21) from cylinder (10).
11. Remove seal (22) and bushing (23) from recoil

spring case (12).
6. Set recoil spring assembly (1) to tool M2.

k Set the spring securely since its installed
load is heavy and dangerous.
a Installed load of spring:
314 kN {32,000 kg}
D155AX-6 13
q If cylinder (10) has been broken or shaft Assembly

end nut (11) has come off and the mount-
1. Using the push tool, press fit bushing (23) to
ing bolt of holder (13) is removed, recoil
recoil spring case (12) and install seal (22).
2 Bushing: Grease (G2-LI)
spring (20) will jump out forward. In this
case, disassemble according to the follow-
ing procedure.
k
2. Using the push tool, press fit bushing (21) to
Never stand in front of or at the rear of
cylinder (10).
2 Bushing: Grease (G2-LI)
the recoil spring assembly to avoid
danger until holder (13) and recoil
spring case (12) are separated and the
recoil spring is taken out and safety is
confirmed.
3. Temporarily install recoil spring (20) and cylin-

der (10) to recoil spring case (12) and set them
to tool M2.
2 Inside of case and parts in case:
1) Set recoil spring assembly (1) to tool M2.
k Set the spring securely since its
Grease (Apply G2-LI to minimum
thickness of 3 mm)
k Set the spring securely since its installed
installed load is heavy and danger-
ous.
load is heavy and dangerous.
314 kN {32,000 kg}
314 kN {32,000 kg}
2) Apply hydraulic oil gradually and fix recoil
a When compressing the spring, align it by
spring assembly (1).
using lever block [2] etc. so that the
threaded part will not be damaged.
a Installed length of spring: 656 mm
3) Remove the mounting bolts of holder (13).

4) Release the hydraulic oil gradually to
release the spring tension.
14 D155AX-6
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.
8. Install holder (13) to recoil spring case (12).

2 Mating faces of holder and case:
Grease (G2-LI)
D155AX-6 15
9. Assembly of yoke and piston assembly

1) Using the push tool and press, press fit
piston (9) to yoke (8).
q Yoke press fitting force:
392 kN {40 ton}
2) Install plate (7) and tighten bolt (6).

a Check that the plate is not on the
yoke.
3) Install ring (5), packing (4) and snap ring
(3).
2 Packing and ring: Grease (G2-LI)
10. Install yoke and piston assembly (2) to recoil

spring assembly (1).
16 D155AX-6
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.
4. Loosen the mounting bolts of roller cap. [*1]

a Loosen both inside and outside bolts.
a Do not remove the mounting bolts.
a When removing track roller assembly (2),

fix the related bogie assembly with the tool
according to the following table.
Bogie assembly to be fixed
Track roller with tool
assembly to be Bogie of track 5. Operate the blade and ripper to lower the
removed roller to be Related bogie machine.
removed a Operate the blade and ripper slowly while
No. 1 roller Note 1 No. 2 bogie running the engine at low idle.
No. 2 roller No. 2 bogie No. 1 bogie
6. Remove the mounting bolts and roller cap (3).
No. 3 roller No. 2 bogie No. 3 bogie [*2]
No. 4 roller No. 3 bogie No. 2 bogie a Take care not to damage the dowel pin
No. 5 roller No. 3 bogie No. 4 bogie installed.
No. 6 roller No. 4 bogie No. 3 bogie
No. 7 roller No. 4 bogie
D155AX-6 17
7. Operate the blade and ripper to raise the Installation

machine until track roller assembly (2) floats
above the bogie. [*3]
removal.
[*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.
2. Lower the machine until the roller cap bolts can

be installed and then install roller cap (3) tem-
porarily.
3. Align dowel pin (4) with the dowel pin hole of

the track roller and tighten the roller cap bolts.
8. Pull track roller assembly (2) out of the machine. a Take care not to break the dowel pin.
4 Track roller assembly (single flange): 2 Roller cap mounting bolt:
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
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.
5. Remove the mounting bolts. Using eyebolts

[3], remove shaft (5) and retainer together.
10. Remove 2 bushings (11) from roller (12).
D155AX-6 19
Assembly
for dirt or damage.
1. Set roller (12) to the press. Using tool N1,

press fit bushing (11).
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 roller end and bushing top
will be as follows.
q Press fitting dimension (a):
18 1 mm
q Bushing press fitting force: 5. Using tool N3, install floating seal (9) to seal
19 120 kN {2 12 ton} guides (2) and (6).
a Before installing the floating seal, thor-
2. Set shaft (5) to the roller. oughly clean, degrease and dry 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 projection (a) of
the seal is 7 11 mm.
3. Using tool N3, install floating seal (10) to

retainers (3) and (7).
oughly clean, degrease and dry the O-ring
and floating seal contact surface (hatched
areas). Take care that dirt will not stick to
the floating seal contact surface. 6. Using tool N2, press fit ring (2) to the shaft.
a After inserting the floating seal, check that q Ring press fitting force:
its tilt is 1 mm or less and projection (a) of 39 69 kN {4 7 ton}
4. Fit the O-ring and install retainers (3) and (7)

and plates (4) and (8) to the roller.
a Check that you can rotate the plates lightly
by the hand.
20 D155AX-6
a Press fit the ring so that press fitting

dimension (c) from the shaft end to the
ring top will be as follows.
Press fitting dimension (c): 48.5 0.2 mm
a Reverse the track roller assembly and
press fit ring (6) on the opposite side simi-
larly.
7. Using tool N4, apply the standard pressure to

the roller oil filler to check the seal for air leak-
age.
a Standard pressure: 0.1 MPa {1 kg/cm2}
a Check method: Keep the standard pres-
sure for 10 seconds and confirm that the
gauge pointer does not lower.
8. Using tool N4, add oil to the track roller assem-

bly.
5 Track roller oil: 820 880 cc (GO140)
9. After adding oil, check the oil level and tighten

the plug.
a Check of oil level: Slant the track roller
about 10 and check that the oil level is at
the bottom of the oil filler.
3 Plug: 160 250 Nm {16 25 kgm}
D155AX-6 21
Removal and installation of No. 1

bogie assembly 1
Special tools
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
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.
2. Spread the track shoe assembly. For details,

see "Spreading and installation of track shoe
assembly".
3. Install tool L14 to the No. 2 bogie assembly.

Operate the blade and ripper to raise the
machine until the track roller of No. 2 bogie
assembly (1) floats above the track link.
k Set the support stands and blocks
under the front and rear parts of the
frame to prevent the machine from low-
ering.
22 D155AX-6
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}
8. Using tool L22, remove track roller assembly

(5).
a While balancing the track roller assembly,
remove it.
4 Track roller assembly: 95 kg
3) Remove floating seals (9) from the ends of

rings (8) and (10).
a Keep the floating seals so that they
will not be damaged.
D155AX-6 23
4) Set pulling tool L16 to pull out rings (10) Installation

and (11).
1. Assembly of cartridge pin assembly
q Pulling force (Reference):
1) Press fit shaft (7) to ring (8).
216 402 kN {22 41 ton}
q Press fitting force of shaft (7):
1.96 15.68 kN {0.2 1.6 ton}
2 Between shaft (7) and ring (8):
Molybdenum disulfide grease
(LM-P)
5) Remove spacer (12).

6) Remove spacer (13) and floating seal (14)
between rings (10) and (11).
a Keep the floating seal so that it will
not be damaged.
2) Using tool L17, install floating seal (9) to
rings (8) and (10) and install floating seal
(12) to the opposite side of ring (10) and
ring (11).
7) Pull out the shaft and ring of the bogie on

the opposite side according to steps 1)
6).
11. Sling and pull out No. 1 bogie (13).

4 Bogie assembly: 60 kg
24 D155AX-6
a Before installing the floating seal,

thoroughly clean, degrease and dry
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.
6) Using tool L21, add oil to the cartridge pin

assembly to the specified level.
a Oil charge pressure:
0.49 MPa {5 kg/cm2}
5 Cartridge pin assembly (81 95%
of full level): 50 60 CC (GO140)
3) Install spacer (12) and ring (10) to shaft

(7) and ring (8).
4) Install spacer (13) to ring (10) and press fit
ring (11) with tool [1].
q Press fitting force of ring (11):
3.9 48 kN {0.4 4.9 ton}
2 Area between shaft (7) and ring:
(LM-P)
2. Sling and install No. 1 bogie (13).

a Sling No. 1 bogie (13) and put it in from
the front and set it to the mounting posi-
tion.
3. While aligning the pin holes of the track frame

and bogie, insert guide tool L19.
k When aligning the pin holes, never
insert your fingers in them.
5) Using tool L18, check the airtightness of

the floating seal.
D155AX-6 25
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}
8. Using tool L22, sling and set track roller

assembly (5).
a Set the oil filler plug out.
a While balancing the track roller assembly,
set it.
4 Track roller assembly: 95 kg
26 D155AX-6
9. Install roller cap (3) and tighten the bolts tem-

porarily.
a Take care not to damage the installed
dowel pin.
10. Align the dowel pin hole and tighten bolts (16).
Adhesive (LT-2)
662 829 Nm {67.5 84.5 kgm}
11. Install the track shoe assembly. For details,

assembly".
12. Adjust the track tension. For details, see Test-

ing and adjusting, "Testing and adjusting track
tension".
D155AX-6 27
Removal and installation of No. 2, 2. Remove the undercovers.

No, 3 and No. 4 bogie assemblies1 a Remove the undercovers which will be
obstacles to removal of the bogie assem-
Special tools bly.
4 Engine undercover: 220 kg
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,
assembly".
28 D155AX-6
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}
5) Remove spacer (8).

6) Remove spacer (9) and floating seal (10)
between rings (6) and (7).
a Keep the floating seal so that it will
not be damaged.
3) Remove floating seals (5) from the ends of

rings (4) and (6).
a Keep the floating seals so that they
will not be damaged.
7) Pull out the shaft and ring of the bogie on
the opposite side according to steps 1)
6).
9. Operate the blade and ripper to raise the

machine until the bogie assembly can be
pulled out.
k Set a block between the track roller and
track link of the bogie which is not
being removed so that the machine will
not lower.
D155AX-6 29
10. Sling bogie assembly (1) and slide it out on Installation

steel plate [2] to remove.
4 Bogie assembly: 525 kg 1) Press fit shaft (3) to ring (4).
q Press fitting force of shaft (6):
1.96 15.68 kN {0.2 1.6 ton}
2 Area between shaft (7) and ring (8):
(LM-P)
2) Using tool L17, install floating seal (9) to

rings (6) and (4) and install floating seal
(10) to the opposite side of ring (6) and
ring (7).
30 D155AX-6
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.
2. Sling and lower bogie assembly (1) onto block

[1] and steel plate [2].
3. Apply lever block [4] between the guard of

bogie assembly (1) and the guard of the bogie
assembly on the opposite side.
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:
(LM-P)
D155AX-6 31
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.
2) Set support stands [7] and hydraulic jacks

[8].
7. Insert cartridge pin assembly (11) in the pin

hole.
a Set arrow (b) at the end face of the car-
tridge pin assembly up (in the installed
state on the machine).
8. Using tool L20, press fit cartridge pin assembly

(11).
a Push in the cartridge pin assembly with
cover (2).
3) Lower the machine with front and rear a Push in the cartridge pin assembly to
jacks [6] and [7] and install fixing tool L14 machined surface (c) of the track frame.
to bogie assembly (1). 2 Outside of pin:
a Press fitting force of cartridge pin assem-
bly: 216 402 kN {22 41 ton}
32 D155AX-6
12. Install the track shoe assembly. For details,

assembly".
13. Adjust the track tension. For details, see Test-

ing and adjusting, "Testing and adjusting track
tension".
9. Using tool L21, add oil to the cartridge pin

a Oil charge pressure: 0.49 MPa {5 kg/cm2}
5 Cartridge pin assembly (81 95% of full
level): 50 60 cc (GO140)
10. Press fit the cartridge pin assembly on the

opposite side according to steps 6-5) 9.
11. Install covers (2).

a Install the covers to 2 places of inside and
outside.
D155AX-6 33
Disassembly and assembly of 2. Cover

bogie assembly 1 Remove cover (3).
Special tools 3. Cartridge pin assembly

Remove cartridge pin assembly (4) according
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).
dowel pin.
4 Track roller assembly
(single flange): 95 kg
(double flange): 105 kg
34 D155AX-6
Assembly 4. Refilling with oil

Using tool Q21, add oil to the cartridge pin
Assemble cartridge pin assembly (4) according
a Oil charge pressure: 0.49 MPa {5 kg/cm2}
to the procedure in "Removal and installation
of bogie assembly". 5 Cartridge pin assembly (81 95% of full
level): 50 60 cc (GO140)
2. Bogies
Set outer bogie (6) and inner bogie (5).
3. Cartridge pin assembly

1) Set tool Q20.
5. Cartridge pin assembly (Opposite side)

Press fit the cartridge pin assembly on the
opposite side according to steps 3 4.
a After press fitting the cartridge pin assem-
bly, adjust the inner bogie so that it will
2) Press fit cartridge pin assembly (4). slide lightly.
a Push in the cartridge pin assembly
with cover (3). 6. Cover
a Set arrow (a) at the end face of the Install covers (3).
cartridge pin assembly up (in the a Install the covers to 2 places of inside and
installed state on the machine). outside.
a Push in the cartridge pin assembly to
machined surface of the bogie.
2 Outside of pin:
(LM-P)
a Press fitting force of cartridge pin
assembly:
215.8 402.1 kN {22 41 ton}
D155AX-6 35
7. Track roller assembly

1) Sling 2 track roller assemblies (2) and set
them to the bogie.
a Set the track roller assemblies so that
their oil fillers will be directed out of
the machine when the bogie assem-
bly is installed.
(single flange): 95 kg
(double flange): 105 kg
2) Install the roller cap to each track roller
assembly and tighten the mounting bolts.
dowel pin.
Adhesive (LT-2)
662 829 Nm {67.5 84.5 kgm}
36 D155AX-6
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
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
Disassembly and assembly of 5. Using tool R1, remove nut (4).

carrier roller assembly 1
6. Using puller [2], remove the ring press fitting
Special tools part. Using eyebolts, remove bearing (5) and
roller (6) together.
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.
8. Using puller [3], remove ring (8) and the inner

2. Set carrier roller assembly (1) to block [1]. race of bearing (9) together.
3. Remove the mounting bolts and cover (2).
4. Remove ring (3).
9. Remove floating seal (10) from ring (8).
38 D155AX-6
10. Using push tool [4], remove ring (11). Assembly

11. Remove floating seal (12) from ring (11).
for dirt or damage.
1. Using push tool [5], press fit the inner race of

bearing (9) to the shaft.
2. Using push tool [6], press fit outer race (7) of

the bearing to the roller.
3. Set the inner races of roller (6) and bearing (5)

to the shaft.
4. Using push tool [7], press fit the inner race of

bearing (5) to the shaft.
a While rotating the roller, press fit the bear-
ing until the roller becomes a little heavy to
rotate.
D155AX-6 39
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.
6. Install ring (3).
11. Using tool R2, install floating seal (12) to ring

(11).
7. Fit the O-ring and install cover (2) and then
tighten the mounting bolts.
a Tighten the oil filler plug temporarily.

oughly clean, degrease and dry the O-ring
and O-ring contact surface (hatched
8. Reverse roller (6) and add oil between the areas).
shaft and roller. a After inserting the floating seal, check that
5
its tilt is 1 mm or less and projection (a) of
Refill capacity: 570 680 cc (GO140)
a Coat the sliding surfaces of the floating
seal and take care that dirt will not stick to
them.
40 D155AX-6
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.
15. Tighten the oil filler plug

3 Plug: 157 255 Nm {16 26 kgm}
13. Using tool R4, apply the standard pressure to

the roller oil filler to check the seal for air leak-
age.
a Standard pressure: 0.1 MPa {1 kg/cm2}
a Check method
Keep the standard pressure for 10 sec-
onds and confirm that the gauge pointer
does not lower.
D155AX-6 41
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})
Removal
1. Remove the track frame assembly. For details,
see "Removal and installation of track frame
assembly".
2. Remove seal (1) and ring (2). [*1]
42 D155AX-6
Installation
removal.
[*1]
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).
a Using tool V, press fit ring (2).

q Press fitting force:
8.8 22.5 kN {0.9 2.3 ton}
q Ring press fitting dimension:
475.5 1 mm
[*2]
2 Pivot shaft mounting bolt: Adhesive (LT-2)
3 Pivot shaft mounting bolt:
784 981 Nm {80 100 kgm}
D155AX-6 43
Spreading and installation of Spreading of track shoe assembly

track shoe assembly 1 (Ordinary)
a If no abnormality is detected by "Check before
Check before spreading track shoe
spreading track shoe assembly", perform the
assembly following procedure.
k Since it may be very dangerous to spread
the track shoe assembly, check the follow- 1. Set the master link in position.
ing items in advance. a Set master link (3) above the idler (a little
k Do not loosen the lubricator more than 1 after the center of the idler).
turn. If the grease does not come out suffi- a Set blocks [1] and [2] at the front of the
ciently, move the machine forward and in idler and between the carrier rollers so
reverse. that the mating part of the master link will
not open until the master bolt is pulled out.
1. Remove cover (1) and loosen lubricator (2) of
the adjustment cylinder to discharge the
grease.
k Do not loosen the lubricator more than
1 turn.
2. Lower the track shoe tension. [*1]

k Do not loosen lubricator (2) more than
1 turn.
a If the track shoe tension is not lowered
after the lubricator is loosened, move the
2. After the shoe is loosened, perform "Spreading machine forward and in reverse.
of track shoe assembly (Ordinary)".
3. If the track shoe is not loosened by the above

work, perform "Spreading of track shoe assem-
bly (When track frame has internal trouble)".
a The track frame may have an internal
trouble (damage of the recoil spring or
recoil spring set bolt, fall of the shaft end
nut, etc.)
44 D155AX-6
3. Remove track shoe (4). [*2] Spreading of track shoe assembly

a Loosen the 4 bolts by 1 2 turns each and (When track frame has internal trouble)
check that they rotate lightly, and then pull
them out. Do not pull them out one by one a If any abnormality is detected by "Check
without checking their looseness. before spreading track shoe assembly", per-
a If the bolts are loosened forcibly while they form the following procedure.
k If the track shoe is removed while the track
are still tight, their threads and master link
(3) may be damaged. frame has an internal trouble, it may spring
back. Even if the track shoe is removed,
the idler may jump out, and that can cause
a serious accident. Accordingly, spread
the track shoe according to the following
procedure.
1. Remove the work equipment. For details, see

"Removal and installation of blade assembly".
2. Lower the track shoe tension. [*1]

k Do not loosen lubricator (2) more than
1 turn.
a If the track shoe tension is not lowered
after the lubricator is loosened, move the
machine forward and in reverse to dis-
4. Sling the front end of the master link and move charge the grease.
the machine slowly in reverse to spread track a Check that all the grease has been dis-
shoe assembly (5). charged.
a Length of track shoe: Approx. 10.5 m
k Never stand in front of the idler to
3. Move the machine slowly forward against large
avoid danger. block [3] or a wall (or the blade of another
machine of the similar size of the machine to
be repaired, if available) to press the track
shoe on the idler side. When the recoil spring
and track shoe are distorted, stop and apply
the brake.
At this time, set the master link (3) between the
idler and front carrier roller.
a For safe work, apply lever block [4]
between the carrier roller support and link.
4. Remove track shoe (4) and disconnect master

link (3). [*2]
5. Move the machine slowly in reverse to spread

the track shoe.
D155AX-6 45
Installation
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:
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
General disassembly and a If it is obliged to cut a shoe nut with gas,

assembly of track shoe 1 keep the seal temperature below 80 C to
prevent thermal deterioration of the seal
Special tools and take measures to prevent the spatters
from entering through the clearances
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})
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
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.
2) Operate the left cylinder to pull out the pin

and bushing from the left link simulta-
neously.
a Check the pulling out force of the pin 3. Inspection
and bushing to see if press fitting Check the parts for the following items to see if
force for them necessary for reversed they can be used for an oil lubricated track or a
reassembly is obtained. grease lubricated track, then examine them
generally and determine to use them for an oil
lubricated track or a grease lubricated track.
a For judgment of reuse of the parts, see
"Parts judgment guide, Undercarriage, Oil
lubricated track".
1) Check the parts visually for damage. If a
part seems to be damaged, check it by
dye penetrant test or magnaflux inspec-
tion. If it has any crack, it cannot be used
again. Discard it.
3) Return the left cylinder and operate the

right cylinder to pull out the pin and bush-
ing from the right link simultaneously.
48 D155AX-6
2) Measure the outside diameters of the General assembly

press fitting parts of the pin and bushing
a For the whole assembly of the track shoe, see
and the inside diameters of the pin and
"Parts judgment guide, Undercarriage, Revers-
bushing fitting parts of the link with a
ing procedure for oil lubricated track".
micrometer and a cylinder gauge to see if
the interference is larger than the limit.
When recycling for oil lubricated track
When using the pin, bushing, and link for
an oil lubricated track, however, secure 1. Preparation work
the standard interference between the pin 1) Cleaning of seal assembly
and link. Remove the seal assembly from the link
a If the interference is less than the and divide it into the seal ring (1) and load
limit, replace the parts with new ones. ring (2), and then clean them.
a For the dimensional criteria, see a Since the seal ring (1) and load ring
"Maintenance Standard". (2) are deteriorated easily by the
cleaning liquid (trichloroethylene etc),
clean them quickly. After cleaning
them, wipe off the cleaning liquid from
them.
a Precautions for storage

1) Store the seal without removing it from the
link so that the counterbore portion will not
be rusted and take care not to damage the
seal lip. 2) When reusing the pin, chamfer its end cor-
2) Apply rust-preventive oil to the pin and ners smoothly with a grinder. Remove the
bushing fitting parts, shoe mating surface nodules sticking to the press fitting parts
and master link mating surface of the link. with the grinder, too.
3) When storing, apply rust-preventive oil to a If the ends are worn and sharpened,
all the surfaces of the pin, bushing and they may scuff the press fitting parts
spacer. Take care not to damage the ends and cause oil leakage.
of the bushing in particular.
D155AX-6 49
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.
6) Adjust the dimensions of the press fitting

1] Insert plug (3) through the plug inser- jig of the link press to keep the projection
tion window into the guide hole. of the pin and bushing constant and keep
2] Push the bar with the hand and insert the installed dimensions of the seal within
the plug until it stops. the standard range.
3] Push the plug with the bar to press a For the standard dimensions, see
the guide against pin (4). "Dimensions table of press fitting jig
a Driving distance (a) from pin end: of link press".
10 1 mm a If the pin end (part P) or the sides of
a If the chamfered part of the pin the link (parts Q and R) are worn, add
hole has been worn, chamfer it the dimensions of the worn parts
with a small-sized grinder (grind- when adjusting the standard dimen-
stone tip angle: 45 60) so that sions so that the projections of the
the plug will not be damaged. pins and bushings on the right and
a Coat the plug with oil (GO90) and left sides will be even.
drive it with the small diameter
end ahead.
50 D155AX-6
7) Adjust the relief pressure of the link press

so that the pressing force of the press will
not exceed the standard value.
a If the pressing force is too strong, the
spacer will be pressed forcibly against
the bushing. As a result, the spacer
may be broken and it and bushing
may be worn abnormally.
a Final pressing force for pin and bush-
ing: 862 kN {88 tons}
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.)
3) Using the shoe bolt hole pitch gauge,
2. Assembly of link press fit the master links until the distance
1) Apply oil (GO90) to the mating surfaces of between the shoe bolt holes of both links
the pin and bushing with a clean brush is the standard value.
and assemble them, and then set them a Blow off all the steel chips caused by
before the jaw of the link press. press fitting of the bushing with com-
a When reusing (reversing) the bush- pressed air.
ing, set the worn outside surface of 4) Reverse the master links and check that
the bushing on the shoe fitting side of they are press fitted in parallel.
the link (set the bushing with the worn
outside surface up on the link press).
5) Measure the projections of the bushing on

the right and left sides with a depth gauge.
2) Set shoe mounting faces of the right and a Adjust the press fitting jig of the link
left master links on bushing side up and press so that the projections on the
press fit the bushing. right and left sides will be even.
a At this time, use the master links on
the pin side as supports.
a Bushing press fitting force:
88 304 kN {9 31 ton}
D155AX-6 51
6) Send the master links and set the next pin

and bushing.
a When reusing a pin, install it so that
its side hole will be on the link tread
side similarly to a new one. If it is not
installed so, its strength may be low-
ered. Accordingly, indicate the direc-
tion of side hole (e) on the end face to
prevent a mistake.
9) Using spacer [4] for fine adjustment, press

fit the pin and bushing until the pin end is
fitted to the bottom of the receiving jig.
a Adjust the depth of the receiving jig
hole so that the projections of the pin
on the right and left sides will be
even.
7) Set the right link and install the spacer to

the pin.
a Check that the seal surface and bush-
ing end are free from dirt and apply oil
(GO90) to them with a clean cloth or
brush.
a When installing the spacer, wipe it
with a clean cloth.
10) Set the left link and install the spacer to

the pin.
a Apply oil similarly to the right link.
8) Set the right jig on the receiving side and

the left one on the pushing side and press
fit the pin and bushing simultaneously.
a If the pin and bushing have play when
they are press fitted, the seal may
come off the link. To prevent this,
press fit smoothly. If the seal comes
off the link, stop press fitting and set
the seal to the link correctly, and then
start press fitting again.
a Press fitting force for pin and bushing:
343 490 kN {35 50 ton}
52 D155AX-6
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.
12) Press fit until the link, spacer and bushing

are fitted together.
a Actually, you cannot see from outside
if the above parts are fitted. Accord-
ingly, control the hydraulic pressure of
the link press. Set the relief pressure
to a proper level and heighten the
hydraulic pressure to that level.
For setting of the relief pressure, see 14) After each link is assembled, bleed air
Preparation work. from the pin by using tool S6 and check
a Check that adjacent 2 links can turn the sealing performance.
around each other. a Keep the degree of vacuum inside the
pin at 91 95 kPa {680 710 mmHg}
for 5 seconds and check that the
pressure does not change.
If the pressure changes, disassem-
ble and check the seal. If the seal is
free from abnormality, assemble
again.
D155AX-6 53
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.
17) Assemble the master link on the pin side

at last.
a Check that the master links on the
right and left sides are press fitted in
parallel.
a Determine oil level (a) as follows;
supply oil (d) so that depth (L) of the 3. Installation of shoe
hollow of pin hole (c) will be in the fol- 1) Set the link assembly on the bed and
lowing range when the link is left with install the shoe with a shoe bolt impact
small plug side (b) up (with the link wrench and a torque wrench.
assembly on its side) for 30 minutes. a When reusing (reversing) the bush-
Dimension (L): 35 65 mm ing, set the worn outside face of the
bushing to the shoe mounting side of
the link (set the bushing with the worn
2 Shoe bolt:
(LM-P)
3 Shoe bolt (Regular link)
Initial torque:
590 60 Nm {60 6 kgm}
Retightening angle: 120 10
54 D155AX-6
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:
(LM-P)
3 Master bolt (Master link)
Initial torque:
590 60 Nm {60 6 kgm}
2) When reusing the pin, chamfer its end cor-

ners carefully with a grinder so that it will
be press fitted smoothly.
a Tighten the bolts in the following

order.
D155AX-6 55
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.
7) Adjust the dimensions of the press fitting

jig of the link press to keep the projection
of the pin and bushing constant and keep
the installed dimensions of the seal within
the standard range.
a For the standard dimensions, see
"Dimensions table of press fitting jig
of link press".
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 dimen-
sions so that the projections of the
pins and bushings on the right and
left sides will be even.
4) If the outside of the pin, surfaces of the

spacer, and ends and inside of the bush-
ing are dirty, clean them.
5) Apply grease to the outside of the pin and
surfaces of the spacer.
56 D155AX-6
2. Assembly of link 3) Using the shoe bolt hole pitch gauge,

1) Apply lithium grease (G2-LI) to the mating press fit the master links until the distance
surfaces of the pin and bushing and between the shoe bolt holes of both links
assemble them, then set them before the is the standard value.
jaw of the link press. a Blow off all the steel chips caused by
a When reusing (reversing) the bush- press fitting of the bushing with com-
ing, set the worn outside surface of pressed air.
the bushing on the shoe fitting side of 4) Reverse the master links and check that
the link (set the bushing with the worn they are press fitted in parallel.
5) Measure the projections of the bushing on

2) Press fit the master links on both bushing the right and left sides with a depth gauge.
sides to the bushing with the shoe fitting a Adjust the press fitting jig of the link
faces up. press so that the projections on the
a At this time, use the master links on right and left sides will be even.
the pin side as supports.
a Press fitting force for bushing:
88 304 kN {9 31 ton}
D155AX-6 57
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.
9) Assemble the master link on the pin side

at last.
a Check that the master links on the
right and left sides are press fitted in
parallel.
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
2) When installing the assembled 2-piece

track shoes, place them on a level place in
1 line with the shoe side up.
3) Pull pin-side master link (1) and bushing-
side master link (2) together and set them
to each other by the mating faces.
4) Place shoe (3) and fit the mating surfaces
of the links.
5) Check that master bolts (4) can be tight-
ened easily with the fingers, then connect
the links with the master bolts.
2 Master bolt:
(LM-P)
3 Master bolt (Master link)
Initial torque:
590 60 Nm {60 6 kgm}
a Tighten the bolts in the following

order.
D155AX-6 59
Dimensions table of fitting jig of link press
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
Disassembly and assembly of 1

link in field 1
Special tools
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
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".
1. Using 2 bolts (2), install tool T1 (adapter, guide

and bolt) to link (1).
a The track bolts may be used as 2 bolts (2).
4. Set tool T5 (adapter, guide and pusher) and

apply pressure to pull out pin (3).
When the cylinder reaches the stroke end,
insert tool T5 (extension) between the adapter
and guide and repeat the work.
2. Assemble tool T2 (pump and cylinder of 1,470
kN {150 ton}) and tool T3 (frame, rod, adapter,
1 bolt and eyebolt) and sling them together and
set them on the shoe.
5. Set tool T6 (294 kN {30 ton}) puller) and spacer

[1] to the center of the roller tread of the link to
be disassembled and apply hydraulic pressure
to the puller to open and disconnect the link by
5 6 mm.
62 D155AX-6
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}
4. Set tools T9 and T10 as in the procedure for

pulling out the pin. Using tool T9 (adapter,
extension, guide, adapter and bolt) for (d) on
the bushing side and tool T10 (extension,
2) Set tool T7 to the end face of the link (on guide, adapter and bolt) for (c) on the pin side,
the pin side) and press fit pin (2). press fit (d) and (c) alternately.
a Set the pin with its side hole (a) a Pin press fitting force:
directed toward link tread (b). 284 686 kN {29 70 ton}
a Pin pressing force: a Bushing press fitting force:
284 686 kN {29 70 ton} 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
6. Set pin-side link (6) to bushing-side link (5) and

connect them by tool T12 (guide), and then
remove tool T11 (puller).
7. Set tool T5 to pin (7). Using tool T13 (adapter,

bolt and guide), press fit pin (7).
2 Pin press fitting hole of link:
Gasket sealant (198-32-19890)
Cylinder: (b), Frame side: (e)
a Set the pin with its side hole directed
toward the link tread.
a Pin press fitting force:
284 686 kN {29 70 ton}
64 D155AX-6
Disassembly and assembly of 2. Removal of master link

master link 1 1) Cutting and removal of master link on
bushing side with gas
Special tools Cut at (a) with gas and remove the
hatched part. Pull out master links (5) and
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
Disassembly 2) Removal of master link on pin side

Cut at (b) with gas and remove the
a For the using method of tool U2, see "Disas- hatched parts. Remove pin (10) from link
sembly in field". (11) by pressing it down with the press,
1. Removal of track shoe assembly and then remove pin (10) and link (12)
Remove the track shoe assembly from the from bushing (13) simultaneously.
track frame. For details, see "Spreading and Special tool : 1. Gas cutting machine
installation of track shoe assembly". : 2. Tool U2
D155AX-6 65
Assembly 2) Set spacer (3) and seal assembly (4) to

the counterbore of the link at the connect-
a For the using method of U2, see "Assembly of
ing section.
1 link in field".
1. Assembly of link on bushing side
1) Press fit master link (1) on the bushing
side to bushing (2) with the press.
a When press fitting the right and left
master links, take care extremely that
they will be in parallel.
a Do not damage the mating faces of
the master links and end of the bush-
ing.
Unit: mm
L1 169 0.7
L2 219.8 0.7
D1 27 drill hole
D2 24 x 2.0 3) Align the holes of the pin and bushing and
connect by guide pin [2].
4) Press fit pin (5) with tool U2 and install

2. Installation of link on bushing side
master link (1) on the bushing side.
2 Apply gasket sealant (198-32-19890)
1) Push open the central part of the link tread
with tool U1 as shown in the figure (Open
to the pin hole of the link.
the link tip by 10 mm).
a Direct the side hole of the pin toward
Dimension (a): 5 mm
the link tread.
66 D155AX-6
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.
4. Connection of master link

1) Place the assembled 2-piece track shoes
on a level place in 1 line with the shoe side
up.
2) Pull pin-side master link (13) and bushing-
side master link (14) together and set
them to each other by the mating faces.
3) Place the shoe and fit the mating surfaces
of the links.
3. Assembly of link on pin side 4) Check that the master bolts can be tight-
1) Set spacer (3) and seal assembly (4) to ened easily with the fingers, and then con-
the counterbore of the master link. nect the links with the master bolts.
2 Shoe bolt:
(LM-P)
3 Shoe bolt (Master link)
Initial torque:
590 60 Nm {60 6 kgm}
D155AX-6 67
Removal and installation of a Repeat steps 3 and 4 to remove the pin on

equalizer bar assembly 1 the opposite side.
k If the track frame assembly on the
Special tools opposite side is floated before the pin
is pulled out, support it on a block, etc.
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
2. Set a hydraulic jack under the center of the

equalizer bar to raise the machine and set sup-
port stands [1] and hydraulic jacks [2] under
the radiator guard.
7. Remove lock plate (6).
3. Remove 2 bolts (1) and cover (2). [*1]
4. Remove lock plate (3) and side pin (4). [*2]

a If the equalizer bar hole and track frame
hole are not aligned, the pin cannot be
removed easily. Accordingly, adjust the
hanging height of the track frame properly.
68 D155AX-6
8. Sling equalizer bar assembly (7) with a crane Installation

and a chain block.
removal.
[*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.
10. While operating the chain block and crane,

remove equalizer bar assembly (7). [*4]
4 Equalizer bar assembly: 240 kg
k Do not lower the machine after remov-
ing the equalizer bar assembly.
D155AX-6 69
Disassembly and assembly of Assembly

equalizer bar assembly 1 1. Center bushing
Using the press, press fit center bushing (5) to
Disassembly equalizer bar (4).
1. Remove the equalizer bar. For details, see a Press fitting force for center bushing:
"Removal and installation of equalizer bar 47.1 131.4 kN {4.8 13.4 ton}
assembly". 2 Periphery of spherical bushing:
2. Side bushing
1) Remove seal (1).
2) Remove ring (2).
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:
(LM-P)
3. Center bushing
Remove center bushing (5) from equalizer bar
(4).
70 D155AX-6
3) Install ring (2) on the opposite side.

4) Using the press, press fit seal (1).
a Press fitting force for seal:
6.9 18.6 kN {0.7 1.9 ton}
a The metallic part of the seal must not
project from the equalizer bar end.
D155AX-6 71
Removal and installation of Installation

segment teeth 1 q Carry out installation in the reverse order to
removal.
Removal
1. Stop the machine in a position where the seg- [*1]
ment teeth can be removed easily (between a When installing, press segment teeth (1)
the shoe and track frame). toward the center of sprocket hub (2) and
tighten the nuts in the order of [1] o [2] o [3].
2. Remove the mounting bolts and segment teeth 2 Threaded part of segment teeth mounting
(1). [*1] nut: Adhesive (LT-2)
3 Segment teeth mounting nut:
1,176 98 Nm {120 10 kgm}
72 D155AX-6
D155AX-6 73
D155AX-6 Bulldozer
2007 KOMATSU
All Rights Reserved
74 D155AX-6
SEN01209-01
D155AX-6

D155AX-6 80001 and up

Hydraulic system
Removal and installation of hydraulic tank assembly...................................................................................... 2
Removal and installation of hydraulic pump assembly ................................................................................... 4
Disassembly and assembly of hydraulic cylinder assembly ........................................................................... 7
D155AX-6 1
Removal and installation of 5. Disconnect return hose (3).

hydraulic tank assembly 1
6. Disconnect hoses (4) and (5).
Removal
7. Disconnect suction tube (6).
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.
1. Drain the oil from the hydraulic tank.

2. Remove the fuel tank assembly. For details,

assembly".
8. Disconnect hoses (7) and (8).
3. Remove control valve cover (1).
9. Remove the 4 mounting bolts at the hydraulic

tank bottom and lift off hydraulic tank assembly
4. Disconnect hose (2) between the control
(9).
valves from the hydraulic tank.
4 Hydraulic tank assembly: 100 kg
2 D155AX-6
Installation
removal.
q Refilling with oil (Hydraulic tank)

again.
5 Hydraulic oil (For details of specifica-
tion, see "Table of fuel, coolant and
lubricants"): Approx. 85 l
q Bleeding air
Bleed air from each part. For details, see Test-
ing and adjusting, "Bleeding air from each
part".
D155AX-6 3
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.
1. Drain the oil from the hydraulic tank and power

train case.
6 Hydraulic tank: Approx. 85 l 5) Disconnect hoses (8), (9) and (10).
6) Remove block (11).
6 Power train case: Approx. 90 l
2. Remove the floor frame assembly. For details,

see "Removal and installation of floor frame
assembly".
a Remove the floor frame assembly only
when removing the work equipment and
HSS pump assembly and power train and
lubricating oil pump assembly.
q Removal of work equipment and HSS pump

assembly
1) Disconnect the centralized pressure
pickup ports and block (1) together.
2) Remove floor frame mount (2). 7) Disconnect wiring harness connectors
TVC (12), FAC (13) and HDT (14).
8) Remove wiring harness bracket (15).
4 D155AX-6
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
10) Sling work equipment pump assembly

(17), remove 2 mounting bolts (18), and lift
off work equipment pump assembly (17).
4 Work equipment pump assembly:
110 kg
q Removal of cooling fan pump assembly

1) Remove the floor mat and cover.
2) Disconnect wiring harness connector FAC
(1).
D155AX-6 5
3) Disconnect hoses (2), (3) and (4). Installation

4) Disconnect suction tube (5).
5) Sling cooling fan pump assembly (6), q Carry out installation in the reverse order to
remove 4 mounting bolts (7), and lift off removal.
cooling fan pump assembly (6).
q Refilling with oil (Hydraulic tank and power
4 Cooling fan pump assembly: 25 kg train case)
again.
Approx. 85 l
5 Power train oil (For details, see "Table
of fuel, coolant and lubricants"):
Approx. 90 l
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
Disassembly and assembly of Disassembly

hydraulic cylinder assembly 1 1. Remove the tubes.
a Blade lift cylinder and ripper cylinder
Special tools
2. Piston rod assembly
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.
790-201-1721 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
790-201-1630 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
3. Piston assembly q Ripper tilt cylinders

q Blade lift cylinder 1) Remove the mounting bolts and
1) Remove the mounting bolts and spacer (16).
spacer (6) and pull out valve (7). 2) Pull out piston assembly (17).
2) Pull out piston assembly (8). 3) Remove backup rings (18) and O-ring
3) Remove backup rings (9) and O-ring (19).
(10).
4) Remove retainer (11).
4) Disassembly of piston assembly

1] Remove wear rings (20).
5) Disassembly of piston assembly 2] Remove piston ring (21).
1] Remove wear rings (12).
2] Remove piston ring (13).
a Do not remove seat (14) and
valve (15) from the piston.
q Ripper lift cylinder and ripper tilt cylinder

1) Set piston rod assembly (5) to tool
Y1.
8 D155AX-6
2) Remove lock screw (22) of piston

assembly (17).
q Screw size: M12 x Pitch 1.75
4. Head assembly
1) Remove head assembly (2) or (4).
a If screw (22) is crushed so much

that it cannot be removed,
tighten it and cut threads of the
screw hole, and then remove it.
2) Disassembly of head assembly

1] Remove O-ring (27). (Blade lift cylin-
der only)
2] Remove O-ring (28) and backup ring
(29).
3) Using tool Y6, remove piston assem- 3] Remove packing (30).
bly (17) from piston rod (23). 4] Remove ring (31).
5] Remove snap ring (32) and dust seal
(33).
6] Remove snap ring (34) and bushing
(35).
4) Disassembly of piston assembly

1] Remove backup ring and O-ring
(24).
2] Remove wear ring (25).
3] Remove piston ring (26).
D155AX-6 9
Assembly 3] Using tool Y4, install dust seal (33).
a Apply engine oil (For details, see "Table of fuel,

coolant and lubricants") to the sliding surface
of each part. When assembling, take care not
to damage the rod packing, dust seal and O-
ring.
1. Head assembly
1) Assembly of head assembly
1] Using tool Y3, press fit bushing (35).
5] Install ring (31).

6] Install packing (30).
7] Install O-ring (28) and backup ring
(29).
8] Install O-ring (27). (Blade lift cylinder
only)
2] Install snap ring (34)
10 D155AX-6
2) Install head assembly (2) or (4) to the pis-

ton rod.
2) Install piston assembly (17) to piston

rod (23) and set piston rod assembly
2. Piston assembly (5) to tool Y1.
q Ripper lift cylinder and ripper tilt cylinder
1) Assembly of piston assembly
1] Using tool Y5, expand piston ring
(26).
a Set the piston ring to tool Y5
and turn the handle of the
tool by 8 10 turns to
expand the piston ring.
2] Remove piston ring (26) from
tool Y5 and install it to the piston.
3] Using tool Y5, compress piston
ring (26).
3) When reusing piston rod (23) and pis-

t on a s s e mb l y ( 1 7 ) , i n s ta l l th e m
a Remove burrs and fins from the
threaded part with a file.
a Clean the parts thoroughly and
remove metal chips and dirt.
1] Using tool Y6, tighten piston
assembly (17) into piston rod
(23) until the screw holes are
aligned.
4] Install wear ring (25).

5] Install backup ring and O-ring
(24).
a Before installing the backup
ring, warm it in water at 50
60 C.
a Apply grease to the O-ring
and backup ring so that the
backup ring will not open.
D155AX-6 11
2] Install screw (22).

a Before installing the screw,
degrease and dry its
threaded part thoroughly.
a After installing the screw,
bend 4 places around it.
2 Threaded part of screw:
Adhesive (LOCTITE No. 262)
3 Screw:
58.9 73.6 Nm {6.0 7.5 kgm}
4] Install screw (22).

a Before installing the screw,
degrease and dry it thor-
oughly.
2 Threaded part:
Adhesive (LOCTITE No. 262)
3 Screw:
58.9 73.6 Nm {6.0 7.5 kgm}
4) When either or both of piston rod (23)

and piston assembly (17) are new,
install them according to the following
procedure.
1] Using tool Y6, tighten piston
assembly (17).
3 Piston assembly:
294 29.4 Nm {30 3.0 kgm}
2] Make 1 screw hole to install the
screw.
a Apply the drill to the groove
in the threads between the
piston and piston rod and q Blade tilt cylinder
cut threads horizontally. 1) Using tool Y5, install piston ring (21)
q Thread cutting dimensions and wear ring (20), similarly to steps
(mm): 2-1)-1] 4] above.
Tap drill diameter: 10.3
Tap drill depth: 27
Tap size: 12 x 1.75
Tapping depth: 20
3] After making the screw hole,
remove chips and dirt and clean
thoroughly.
12 D155AX-6
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}
3. Piston rod assembly

q Blade lift cylinder
1) Set cylinder (1) to tool Y1.
2) Install piston rod assembly (3) to the
cylinder.
2 Sealing part: Grease (G2-LI)
a Push in the piston rod to the
stroke end.
q Blade lift cylinder 3) Using tool Y2, tighten head assembly
1) Using tool Y5, install piston ring (13) (2).
and wear ring (12), similarly to steps 3 Head assembly:
2-1)-1] 4] above. 932 93.0 Nm {95 9.5 kgm}
2) Install retainer (11).

3) Fit O-ring (10) and install backup ring
(9).
a Before installing the backup ring,
warm it in water at 50 60 C.
a Apply grease to the O-ring and
backup ring so that the backup
ring will not open.
4) Install piston assembly (8).
D155AX-6 13
q Blade tilt cylinder, ripper lift cylinder and

ripper tilt cylinder
1) Install piston rod assembly (5) to the
cylinder.
2 Sealing part: Grease (G2-LI)
a Push in the piston rod to the
stroke end.
2) Tighten head assembly (4) with the
mounting bolts.
3 Mounting bolt:
q Blade tilt
(343 34.3 Nm {35 3.5 kgm})
q Ripper lift
(343 34.3 Nm {35 3.5 kgm})
q Ripper tilt
(490 49 Nm {50 5.5 kgm})
14 D155AX-6
D155AX-6 15
D155AX-6 Bulldozer
2007 KOMATSU
All Rights Reserved
16 D155AX-6
SEN01210-01
D155AX-6

D155AX-6 80001 and up

Work equipment
Removal and installation of blade assembly ................................................................................................... 2
Disassembly and assembly of multi-shank ripper ........................................................................................... 4
D155AX-6 1
Removal and installation of blade

assembly 1
Removal
k Lower the work equipment to a level place
and set blocks [1] under the right and left
straight frames securely.
3. Remove right and left covers (3).
4. Disconnect hose (4).

a Plug the hoses so that dirt will not enter
the piping.
5. Remove right and left trunnion caps (5).
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. Sling lift cylinder assembly (2). Run the engine

and retract the piston fully. Install the cylinder
fixing device and fix the lift cylinder assembly
to the radiator guard.
a Bind the piston rod with wires etc. so that
it will not come out.
q Similarly, disconnect the cylinder on the
opposite side from the blade.
k Release the residual pressure in the
piping, referring to Testing and adjust-
ing, "Releasing residual pressure in
hydraulic circuit". Then, loosen the
hydraulic tank cap gradually to release
the internal pressure of the hydraulic
tank.
2 D155AX-6
Installation
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".
again.
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
Disassembly and assembly of

multi-shank ripper 1
Disassembly
a Plug the disconnected pipings and hoses so
that dirt will not enter them.
1. Run the engine and set the ripper in the maxi-

mum raising and maximum tilt-in position.
2. Sling shank (1), remove the lock pin to remove

mounting pin (2), and lower shank (1) slowly to
remove.
4 Shank: 270 kg 5. Sling tilt cylinder assembly (5), remove the lock
plate, and pull out pin (6) on the rod side.
a Run the engine, retract the piston rod fully,
and lower it to the arm.
a Install the pin to the beam temporarily
since it is used when the beam is
removed.
k Release the residual pressure in the
piping, referring to Testing and adjust-
ing, "Releasing residual pressure in
hydraulic circuit". Then, loosen the
hydraulic tank cap gradually to release
the internal pressure of the hydraulic
tank.
3. Set support stands [1] under the beam, set

block [2] under the arm, and lower the ripper
assembly.
6. Disconnect lift cylinder hose (7) and tilt cylinder

hose (8) and move them toward the fuel tank.
4. Sling lift cylinder assembly (3), remove the lock

plate, and pull out pin (4) on the rod side.
a Run the engine, retract the piston rod fully,
and lower it to the arm.
4 D155AX-6
7. Sling lift cylinder assembly (3), remove the lock Assembly

plate, pull out pin (9), and lift off lift cylinder
assembly (3). 1. Sling arm (12), install right and left pins (13),
and fix them with the lock plates.
4 Lift cylinder assembly: 190 kg
4 Arm: 650 kg
8. Sling tilt cylinder assembly (5), pull out pin (9), a Set block [2] under the arm.
and lift off tilt cylinder assembly (5).
4 Tilt cylinder assembly: 260 kg
2. Sling beam (10), install right and left pins (11),

and fix them with the lock plates.
4 Beam: 1,250 kg
9. Sling beam (10), remove the lock plates, pull
out right and left pins (11), and lift off beam a Set support stands [1] under the beam.
(10).
4 Beam: 1,250 kg
10. Sling arm (12), remove the lock plates, pull out
right and left pins (13), and lift off arm (12).
4 Arm: 650 kg
D155AX-6 5
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.
4. Sling lift cylinder assembly (3), push in pin (9),

and fix it with the lock plate.
4 Lift cylinder assembly: 190 kg
a After installing, lower the rod side to the
arm.
8. Run the engine and set the ripper in the maxi-

mum raising and maximum tilt-in position.
9. Pass a wire through the shank mounting hole

of the beam and sling shank (1). Install pin (2)
and fix it with the lock pin.
4 Shank: 270 kg
5. Connect tilt cylinder hose (8) and lift cylinder

hose (7).
6. Sling tilt cylinder assembly (5), run the engine,

extend the piston rod, align the pin holes,
install pin (6), and fix it with the lock plate.
6 D155AX-6
10. Greasing
After assembling, supply sufficient amount of
grease to each pin.
2 Pin: Grease (G2-LI)

again.
Only necessary quantity
D155AX-6 7
D155AX-6 Bulldozer
2007 KOMATSU
All Rights Reserved
8 D155AX-6
SEN01211-01
D155AX-6

D155AX-6 80001 and up

Cab and its attachments
Removal and installation of operator's cab assembly ..................................................................................... 2
Removal and installation of operator's cab glass (Stuck glass) ...................................................................... 4
Removal and installation of floor frame assembly ........................................................................................ 13
Removal and installation of air conditioner unit assembly ............................................................................ 16
D155AX-6 1
Removal and installation of 6. Disconnect wiring harness connector DSH (9).

operator's cab assembly 1 [*2]
Removal
1. Remove cigarette lighter cover (1) and discon-

nect wiring harness connector ACC.
2. Remove garnishes (2) and (3).
7. Remove mounting bolts (10) at the bottom of

the operator's cab.
a Remove the bolts on the right and left
side. [*3]
3. Disconnect 4 window washer hoses (5). [*1]
4. Disconnect wiring harness connectors CBPW

(6) and WST (7).
8. Remove mounting bolts (11) in the operator's

cab.
a Remove the bolts on the right, left and
rear side. [*4]
2 D155AX-6
9. Lift off operator's cab assembly (12). Installation

4 Operator's cab assembly: 410 kg q Carry out installation in the reverse order to
removal.
[*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.
a 3 Part marked with A (M16):

279 27.9 Nm {28.5 2.8 kgm}
Part marked with (M20):
294 29.4 Nm {30.0 3.0 kgm}
Part marked with a (M24):
294 29.4 Nm {30.0 3.0 kgm}
2) Retighten bolts (1) (21) (M20, M24) by 60

10 .
D155AX-6 3
Removal and installation of operator's cab glass (Stuck glass) 1
* 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
Special tools (The following figure shows the operator's cab of a

wheel loader.)
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
1. Using seal cutter [1], cut the adhesive between

broken window glass (6) and operator's cab
(metal sheet) (7). a If the window glass is broken finely, it may
be removed with knife [4] and a screw-
driver.
a Widening the cut with a screwdriver, cut
the adhesive and both-sided adhesive
tape with knife [4].
(The following figure shows the operator's cab of a

wheel loader.)
a If a seal cutter is not available, make holes

on the adhesive and both-sided adhesive
tape with a drill and pass a fine wire (piano
wire, etc.) [2] through the holes. Grip the
both ends of the wire with priors [3], etc.
(or hold them by winding them onto some-
thing) and move the wire to the right and
left to cut the adhesive and both-sided
adhesive tape. Since the wire may be 2. Remove the window glass.
broken by the frictional heat, apply lubri-
cant to it.
D155AX-6 5
Installation 3. Stick both-sided adhesive tape (3) along the

inside edges of the front window glass sticking
1. Using a knife and scraper [5], remove the section and both door window glass sticking
remaining adhesive and both-sided adhesive sections.
tape from the metal sheets (glass sticking sur- a Do not remove the release tape of the
faces) of the operator's cab. both-sided adhesive tape on the glass
a Remove the adhesive and both-sided sticking side before sticking the glass.
adhesive tape to a degree that they will a When sticking the both-sided adhesive
not affect adhesion of the new adhesive. tape, do not touch the cleaned surface as
Take care not to scratch the painted sur- long as possible.
faces. a Take care that the both-sided adhesive
(If the painted surfaces are scratched, tape will not float at each corner of the
adhesion will be lowered.) window frame.
a Do not lap the finishing end of both-sided
(The following figure shows the operator's cab of a adhesive tape (3) over the starting end but
wheel loader.) make clearance (a) of about 5 mm
between them.
2. Remove oil, dust, dirt, etc. from the sticking

surfaces of cab (7) and window glass (8) with
white gasoline.
a If the sticking surfaces are not cleaned
well, the glass may not be stuck perfectly.
a Clean the all black part on the back side of
the window glass.
a After cleaning the sticking surfaces, leave
them for at least 5 minutes to dry.
6 D155AX-6
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.
2) After positioning the glasses, stick tapes

[6] between front window glass (1) and
operator's cab (7) and the right, left, and
lower parts of each door window glass (2)
and each door (9), and then draw position-
ing line (e).
3) Cut the tapes between window glasses (1)

and (2) and operator's cab (7) with a knife,
and then remove the window glasses.
a Do not remove the tapes left on the
window glasses and operator's cab
before installing the window glasses.
D155AX-6 7
1) Break aluminum seal (11) of the outlet of

adhesive cartridge (10) and install the
nozzle.
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.
3) Set adhesive cartridge (10) to caulking

gun [7].
a An electric caulking gun is more effi-
cient.
8 D155AX-6
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.
5) Apply adhesive (13) to the outside of both-

sided adhesive tape (3) of the operator's
cab.
7. Stick the front window glass.

1) Using tool X1, match front window glass
(1) to line (e) on positioning tapes [6]
drawn in step 5 and stick it to operator's
cab (7).
a Since the window glass cannot be
removed and stuck again, stick it very
carefully.
a Stick the glass within 5 minutes after
applying the adhesive.
2) After sticking the window glass, press all
around it until it is stuck to the both-sided
adhesive tape.
a Press the corners of the window glass
firmly.
D155AX-6 9
3) Mask front window glass (1) and opera-

tor's cab (7) with masking tapes [8].
4) Fill the clearance between front window
glass (1) and operator's cab (7) with caulk-
ing material (14) all around the window.
2 Caulking material:
SEKISUI SILICONE SEALANT
a The usable period of the following
caulking material is 6 months after the
date of manufacture. Do not use the
caulking material after its usable
period.
8. Stick both door window glasses.

1) Using tool X1, match both door window
glasses (2) to lines (e) on positioning
tapes [6] drawn in step 5 and stick them to
both doors (9).
a Since the window glass cannot be
removed and stuck again, stick it very
carefully.
a Stick the glass within 5 minutes after
applying the adhesive.
2) After sticking each window glass, press all
around it until it is stuck to the both-sided
5) After applying caulking material (14) to adhesive tape.
front window glass (1), form it with the fin- a Press the corners of each window
gers as shown in the following figure. glass firmly.
a Use rubber spatula [9] to form the
caulking material around the handrail,
etc. where it is difficult to form with the
fingers.
10 D155AX-6
a If adhesive (13) is projected from the

trim seals (4) of stuck door window
glasses on both sides, remove it with
rubber spatula [9].
9. Fix the window glasses.

1) Using styrene foam blocks [10] and rubber
bands [11], fix the front window glass to fit
3) Fill the clearance between each door win-
it completely.
dow glass and trim in the range of dimen-
a You may use sealing tapes to fix the
sion (k).
front window glass.
i) Mask the range of dimension (k) of
each door window glass.
(The figure shows the operator's cab of a
ii) Fill clearance (m) between each door
hydraulic excavator.)
window glass (2) and trim seal (4)
with caulking material.
a The usable period of the following
caulking material is 6 months after the
date of manufacture. Do not use the
caulking material after its usable
period.
a Apply the caulking material to joint (c)
of the trim seal, too.
2 Caulking material:
SEKISUI SILICONE SEALANT
D155AX-6 11
2) Immediately after sticking both door win-

dow glasses, install door handles (5), and
lock the doors to fix the glasses.
10. After installing the window glasses, remove the

primer and adhesive from them and the opera-
tor's cab.
a Using white gasoline, wipe off the adhe-
sive before it is dried up.
a When cleaning the glasses, do not give an
impact to them.
11. Protect the stuck window glasses.

1) Keep the stopper rubbers, styrene foam
blocks, and rubber bands installed for 10
hours (at temperature of 20C and humid-
ity of 60%).
2) After applying the adhesive, wait for at
least 24 hours, before operating the
machine actually.
12 D155AX-6
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]

advance.
ing operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the
7. Remove duct flange mounting bolts (6).
atmosphere.

2. Remove the fuel tank assembly. For details,

assembly".
8. Lift off battery top cover (7).
3. Remove control valve cover. 4 Cover: 75 kg
4. Disconnect wiring harness connector WESL

(1). [*2]
D155AX-6 13
9. Disconnect and remove hose and flange (8) 14. Remove mounting bolts (17) in front of the floor
from flange (9). frame. [*5]
10. Disconnect ground wire (10).
15. Remove mounting bolts (18) at the rear right

and left of the floor frame. [*6]
11. Disconnect 4 window washer hoses (11).
12. Disconnect wiring harness clamp (12).
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
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
not enter them.
12 15 Nm {1.2 1.5 kgm}
20 25 Nm {2.0 2.5 kgm}
30 35 Nm {3.0 3.5 kgm}
q Filling air conditioner circuit with refriger-

ant (R134a)
(R134a).
[*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
Removal and installation of air 5. Remove cover (2).

conditioner unit assembly 1
Removal
advance.
6. Disconnect air conditioner hoses (3) and (4).
[*2]
ing operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the
7. Disconnect heater hoses (5) and (6).
atmosphere.

2. Remove the operator's cab assembly. For

details, see "Removal and installation of opera-
tor's cab".
8. Remove the 4 mounting bolts of work equip-
3. Remove the cover at the right lower part of the ment controller assembly (7) and disconnect
operator's seat. the assembly.
4. Lift off operator's seat assembly (1).

4 Operator's seat assembly: 55 kg
16 D155AX-6
9. Remove filter (8).
Installation
removal.
[*1], [*2]
a When installing the hoses of the air conditioner
not enter them.
11. Disconnect wiring harness connectors AC01
(10) and AC02 (11).
12 15 Nm {1.2 1.5 kgm}
12. Disconnect wiring harness clamp (12) and
move wiring harness (13) aside.
20 25 Nm {2.0 2.5 kgm}
30 35 Nm {3.0 3.5 kgm}
13. Disconnect 2 duct hoses (14).
14. Remove the 7 mounting bolts and air condi-

tioner unit assembly (15). q Filling air conditioner circuit with refriger-
ant (R134a)
(R134a).
D155AX-6 17
D155AX-6 Bulldozer
2007 KOMATSU
All Rights Reserved
18 D155AX-6
SEN02708-01
D155AX-6

D155AX-6 80001 and up

Electrical system
Removal and installation of engine controller assembly ................................................................................. 2
Removal and installation of power train controller assembly .......................................................................... 3
Removal and installation of work equipment controller assembly .................................................................. 3
D155AX-6 1
Removal and installation of Installation

engine controller assembly 1 q Carry out installation in the reverse order to
removal.
Removal a Before installing, remove foreign materials
k Disconnect the cable from the negative () (dirt, water, etc.) from the wiring harness
terminal of the battery. connector of the engine controller assem-
bly.
1. Open the left engine side cover and lift off side
cover assembly (1). [*1]
3 Connector mounting screw:
4 Side cover assembly: 40 kg 2.82 Nm {0.288 kgm}
2. Remove 2 oil filters (2).
3. Disconnect wiring harness connectors EGC1

(3), EGC2 (4) and EGC3 (5). [*1]
4. Remove the engine controller assembly (6).
2 D155AX-6
Removal and installation of power Removal and installation of work

train controller assembly 1 equipment controller assembly 1
Removal Removal
k Disconnect the cable from the negative () k Disconnect the cable from the negative ()
terminal of the battery. terminal of the battery.
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
removal.
a Before installing, remove foreign materials
(dirt, water, etc.) from the wiring harness
connector of the work equipment control-
ler assembly.
[*1]
2.82 Nm {0.288 kgm}
Installation
removal.
a Before installing, remove foreign materials
(dirt, water, etc.) from the wiring harness
connector of the power train controller
assembly.
[*1]
2.82 Nm {0.288 kgm}
D155AX-6 3
D155AX-6 Bulldozer
2007 KOMATSU
All Rights Reserved
4 D155AX-6
SEN00616-02
D155AX-6

D155AX-6 80001 and up
90 Diagrams and drawings 1

Hydraulic diagrams and drawings
Power train hydraulic circuit diagram .............................................................................................................. 3
Hydraulic circuit diagram (1/2) ........................................................................................................................ 5
Hydraulic circuit diagram (2/2) ........................................................................................................................ 7
D155AX-6 1
SEN00616-02 90 Diagrams and drawings
2 D155AX-6
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
D155AX-6 9
D155AX-6 Bulldozer
2007 KOMATSU
All Rights Reserved
10 D155AX-6
SEN00617-03
D155AX-6

D155AX-6 80001 and up
90 Diagrams and drawings 1

Electrical diagrams and drawings
Electrical circuit diagram ................................................................................................................................. 3
Electrical circuit diagram for inside cab........................................................................................................... 5
Connectors table and arrangement drawing................................................................................................... 7
D155AX-6 1
2 D155AX-6
Electrical circuit diagram
Electrical circuit diagram D155AX-6
SEN00617-03
D155AX-6 3
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
D155AX-6 9
D155AX-6 Bulldozer
2007 KOMATSU
All Rights Reserved
10 D155AX-6

Sen00596-05 D155ax-6

Transféré par

Informations du document

Titre original

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

Sen00596-05 D155ax-6

Transféré par

Droits d'auteur :

Formats disponibles

SEN00596-05

BULLDOZER 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

Composition of shop manual 1

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN00596-05

00 Index and foreword SEN00597-05

10 Structure, function and maintenance standard SEN00602-01

20 Standard value table SEN00611-01

30 Testing and adjusting SEN00612-01

Troubleshooting by failure and error codes, Part 7 SEN00722-01

50 Disassembly and assembly SEN00614-02

90 Diagrams and drawings SEN00615-03

Foreword and general information SEN00599-01

10 Structure, function and maintenance standard

Parking brake solenoid valve ...................................................................................................... 69

20 Standard value table

Measuring exhaust temperature .............................................................................................. 8

T-boxes and T-adapters table.................................................................................................. 31

Failure code [CA322] Inj #1 (L#1) Open/Short Error ............................................................... 44

Troubleshooting by failure and error codes, Part 4 SEN00719-01

Failure code [DFAFKB] RL lever 2: Short circuit...................................................................... 42

Failure code [DXH5KB] 2nd clutch ECMV: Short circuit.......................................................... 6

Troubleshooting of electrical system (E-mode) SEN00807-01

Troubleshooting of engine (S-mode) SEN00852-01

50 Disassembly and assembly

Disassembly and assembly of idler assembly............................................................................. 7

90 Diagrams and drawings

BULLDOZER 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

Safety notice 1 (Rev. 2007/02)

1. General precautions 7) If welding repairs are needed, always

4. Precautions for sling work and making

8. Precautions for disconnecting and con-

a Example of O-ring (Fitted to every joint of

a For tightening torque, see the precautions for

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

2 Coat Places to be coated with adhesives, etc. during assembly.

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

q Usually, the size of a hole and the size of

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value

Handling electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector

5) Oil or dirt stuck to connector