D155ax 61

SEN00596-14
BULLDOZER
D155AX -6
SERIAL NUMBERS
80001
and up
SEN00598-14
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
00 Index and foreword
Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 4
D155AX-6
SEN00598-14
Composition of shop manual
The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
File overview and other materials in sections in the order shown below and utilize them accordingly.
Section Title
Form Number
Shop Manual, contents binder, binder label and tabs
SEN00596-14

Index
Foreword and general information
SEN00597-14
SEN00598-14 q
SEN00599-04
01 Specification
Specification and technical data
SEN00600-05
SEN00601-04 q
10 Structure, function and maintenance standard

Engine and cooling system
Power train, Part 1
Power train, Part 2
Undercarriage and frame
Hydraulic system
Work equipment
Cab and its attachments
Electrical system
SEN00602-05
SEN00603-00
SEN00604-01
SEN00605-02
SEN00606-01
SEN00607-03 q
SEN00608-01
SEN00609-01
SEN00610-03
20 Standard value table

Standard service value table
SEN00611-03
SEN00678-03
30 Testing and adjusting

Testing and adjusting, Part 1
SEN00612-05
SEN00679-05
SEN00680-02
SEN00681-04
SEN00682-02
40 Troubleshooting
Failure code table and fuse locations
General information on troubleshooting
Troubleshooting by failure and error codes, Part 1
SEN00613-06
SEN04628-02
SEN00851-02
SEN00716-02
SEN00717-03
SEN00718-04
SEN00719-01
SEN00720-02
D155AX-6

Troubleshooting of electrical system (E-mode)
Troubleshooting of hydraulic and mechanical system (H-mode)
Troubleshooting of engine (S-mode)
SEN00598-14
SEN00721-03
SEN00722-01
SEN00723-01
SEN00807-02
SEN00808-02
SEN00852-02
50 Disassembly and assembly

General information on disassembly and assembly
Power train, Part 1
Power train, Part 2
Power train, Part 3
Hydraulic system
Work equipment
Electrical system
SEN00614-05
SEN01204-04
SEN01205-05
SEN01206-03
SEN01207-03
SEN02707-01
SEN01208-02
SEN01209-02
SEN01210-01
SEN01211-02
SEN02708-01
80 Air conditioner
Structure, function, testing, adjusting, and troubleshooting
SEN04682-01
SEN04683-01
90 Diagrams and drawings

Hydraulic diagrams and drawings
Electrical diagrams and drawings
SEN00615-06
SEN00616-04
SEN00617-05
D155AX-6
q
q
q
SEN00598-14
Table of contents

Index
SEN00598-14
Composition of shop manual.......................................................................................................
2
Table of contents .........................................................................................................................
4
SEN00599-04
Safety notice................................................................................................................................
2
How to read the shop manual .....................................................................................................
7
Explanation of terms for maintenance standard..........................................................................
9
Handling of electric equipment and hydraulic component........................................................... 11
Handling of connectors newly used for engines.......................................................................... 20
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
SEN00601-04
Specification dimension drawings ...............................................................................................
2
Specifications ..............................................................................................................................
3
Weight table ................................................................................................................................
9
Table of fuel, coolant and lubricants ............................................................................................ 12
SEN00603-00
Engine and cooling system .........................................................................................................
2
Radiator, oil cooler ...................................................................................................................
2
Engine mount...........................................................................................................................
5
Cooling fan pump.....................................................................................................................
6
Cooling fan motor .................................................................................................................... 14
Power train, Part 1
SEN00604-01
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
Power train, Part 2
SEN00605-02
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
D155AX-6
SEN00598-14
Brake ECMV ............................................................................................................................... 64

Parking brake solenoid valve ...................................................................................................... 68
Sudden stop prevention valve..................................................................................................... 70
Final drive.................................................................................................................................... 72
Sprocket ...................................................................................................................................... 78
SEN00606-01
Track frame .................................................................................................................................
2
Recoil spring ...............................................................................................................................
4
Idler .............................................................................................................................................
6
Track roller ..................................................................................................................................
8
Carrier roller ................................................................................................................................ 10
Track shoe................................................................................................................................... 12
Main frame .................................................................................................................................. 18
Suspension ................................................................................................................................. 20
Hydraulic system
SEN00607-03
Work equipment hydraulic piping diagram ..................................................................................
2
Work equipment control piping diagram......................................................................................
5
Work equipment control ..............................................................................................................
8
Hydraulic tank and filter............................................................................................................... 10
Accumulator ................................................................................................................................ 14
PCCS lever ................................................................................................................................. 15
Work equipment lock valve ......................................................................................................... 19
Control valve ............................................................................................................................... 20
Work equipment cylinder............................................................................................................. 56
Piston valve................................................................................................................................. 58
Quick drop valve ......................................................................................................................... 60
Self pressure reducing valve....................................................................................................... 65
Work equipment
SEN00608-01
Cylinder stay ...............................................................................................................................
2
Blade ...........................................................................................................................................
4
Cutting edge, end bit ...................................................................................................................
6
Ripper..........................................................................................................................................
8
SEN00609-01
Cab mount + ROPS pin...............................................................................................................
2
ROPS cab ...................................................................................................................................
3
Air conditioner .............................................................................................................................
4
Electrical system
SEN00610-03
Engine control .............................................................................................................................
2
Engine control system.................................................................................................................
3
Deceleration potentiometer .........................................................................................................
4
Monitor system............................................................................................................................
6
Sensors ....................................................................................................................................... 25
Palm command control system ................................................................................................... 28
KOMTRAX system ...................................................................................................................... 31
SEN00678-03
Standard value table for engine ..................................................................................................
2
Standard value table for machine................................................................................................
3
SEN00679-05
Tools for testing, adjusting, and troubleshooting .........................................................................
3
Measuring engine speed.............................................................................................................
7
Measuring intake air pressure (boost pressure)..........................................................................
9
Measuring exhaust temperature ................................................................................................. 10
D155AX-6
SEN00598-14
Measuring exhaust gas color ...................................................................................................... 12

Adjusting valve clearance............................................................................................................ 13
Measuring compression pressure ............................................................................................... 14
Measuring blow-by pressure ....................................................................................................... 16
Measuring engine oil pressure .................................................................................................... 17
Testing EGR valve and bypass valve drive oil pressure.............................................................. 18
Handling fuel system parts .......................................................................................................... 19
Releasing residual pressure from fuel system ............................................................................ 19
Measuring fuel pressure.............................................................................................................. 20
Measuring fuel return rate and fuel leakage................................................................................ 21
Bleeding air from fuel circuit ........................................................................................................ 25
Measuring fuel circuit for leakage................................................................................................ 27
Testing and adjusting alternator belt tension ............................................................................... 28
Testing and adjusting air conditioner compressor belt tension.................................................... 29
Measuring fan speed................................................................................................................... 30
Measuring fan circuit oil pressure................................................................................................ 31
Bleeding air from fan pump ......................................................................................................... 32
Adjusting fuel control dial and decelerator pedal......................................................................... 33
SEN00680-02
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
SEN00681-04
Special functions of machine monitor (EMMS)............................................................................
2
SEN00682-02
Testing and adjusting, Part 4 .......................................................................................................
2
Handling of power supply circuit of engine controller ..............................................................
2
Preparation work for troubleshooting of electrical system .......................................................
3
Pm Clinic..................................................................................................................................
5
40 Troubleshooting
SEN04628-02
Failure codes table ......................................................................................................................
2
Fuse locations .............................................................................................................................
9
Information in troubleshooting table ............................................................................................ 13
SEN00851-02
Points to remember when troubleshooting ..................................................................................
2
Sequence of events in troubleshooting .......................................................................................
3
D155AX-6
SEN00598-14
Check before troubleshooting .....................................................................................................

4
Classification and procedures for troubleshooting ......................................................................
5
Connection table for connector pin numbers ..............................................................................
8
T-branch box and T-branch adapter table ................................................................................... 44
SEN00716-02
Failure code [1500L0] Transmission clutch: Abnormal ...............................................................
3
Failure code [15SAL1] Forward clutch: Fill high..........................................................................
4
Failure code [15SALH] Forward clutch: Fill low ..........................................................................
5
Failure code [15SBL1] Reverse clutch: Fill high .........................................................................
6
Failure code [15SBLH] Reverse clutch: Fill low ..........................................................................
7
Failure code [15SEL1] Speed 1st clutch: Fill high.......................................................................
8
Failure code [15SELH] Speed 1st clutch: Fill low........................................................................
9
Failure code [15SFL1] Speed 2nd clutch: Fill high...................................................................... 10
Failure code [15SFLH] Speed 2nd clutch: Fill low....................................................................... 11
Failure code [15SGL1] Speed 3rd clutch: Fill high ...................................................................... 12
Failure code [15SGLH] Speed 3rd clutch: Fill low....................................................................... 13
Failure code [15SJL1] L/U: Fill high ............................................................................................ 14
Failure code [15SJLH] L/U: Fill low ............................................................................................. 16
Failure code [2301L1] Right brake: Fill high................................................................................ 18
Failure code [2301LH] Right brake: Fill low ................................................................................ 19
Failure code [2302L1] Left brake: Fill high .................................................................................. 20
Failure code [2302LH] Left brake: Fill low ................................................................................... 21
Failure code [7RFAKA] ECM HOLD RELAY: Disconnection....................................................... 22
Failure code [AA10NX] Air Cleaner Clogging ............................................................................. 24
Failure code [AB00MA] Battery Charge Abnormal...................................................................... 26
Failure code [B@BAZG] Eng Oil Press Low ............................................................................... 28
Failure code [B@BCNS] Eng Water Overheat............................................................................ 28
Failure code [B@BCZK] Eng Water Level Low........................................................................... 29
Failure code [B@CENS] T/C Oil Overheat ................................................................................. 29
Failure code [B@HANS] Hyd Oil Overheat................................................................................. 30
SEN00717-03
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.................................................................... 40
Failure code [CA271] PCV1 Short Error ..................................................................................... 41
Failure code [CA272] PCV1 Open Error ..................................................................................... 42
Failure code [CA273] PCV2 Short Error ..................................................................................... 43
Failure code [CA274] PCV2 Open Error ..................................................................................... 44
Failure code [CA322] Inj #1 (L#1) Open/Short Error................................................................... 46
Failure code [CA323] Inj #5 (L#5) Open/Short Error................................................................... 48
D155AX-6
SEN00598-14
Failure code [CA324] Inj #3 (L#3) Open/Short Error ................................................................... 50

Failure code [CA342] Calibration Code Incompatibility ............................................................... 58
Failure code [CA351] Injectors Drive Circuit Error ...................................................................... 60
Failure code [CA352] Sens Supply 1 Volt Low Error................................................................... 62
Failure code [CA386] Sens Supply 1 Volt High Error .................................................................. 64
Failure code [CA441] Battery Voltage Low Error......................................................................... 66
Failure code [CA442] Battery Voltage High Error ........................................................................ 66
Failure code [CA449] Rail Press Very High Error........................................................................ 67
Failure code [CA451] Rail Press Sensor High Error ................................................................... 68
Failure code [CA452] Rail Press Sensor Low Error .................................................................... 70
Failure code [CA553] Rail Press High Error................................................................................ 70
Failure code [CA554] Rail Press Sensor In Range Error ............................................................ 71
Failure code [CA559] Rail Press Low Error................................................................................. 72
Failure code [CA689] Eng Ne Speed Sensor Error ..................................................................... 76
SEN00718-04
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
SEN00719-01
Troubleshooting by failure and error codes, Part 4 .....................................................................
3
Failure code [DB90KT] WE controller: Abnormality in controller .............................................
3
D155AX-6
SEN00598-14
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
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
SEN00720-02
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
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
D155AX-6
SEN00598-14
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
SEN00721-03
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
SEN00722-01
Troubleshooting by failure and error codes, Part 7 .....................................................................
3
Failure code [DXH4KB] 1st clutch ECMV: Short circuit ...........................................................
3
Failure code [DXH4KY] 1st clutch ECMV: Short circuit ...........................................................
4
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection ......................................................
5
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit ..........................................................
6
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit ..........................................................
7
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection .......................................................
8
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit...........................................................
9
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit........................................................... 10
10
D155AX-6
SEN00598-14
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
SEN00723-01
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
Troubleshooting of electrical system (E-mode)
SEN00807-02
3
Information in troubleshooting table ............................................................................................
E-1 When starting switch turned ON, machine monitor displays nothing ...................................
4
E-2 When starting switch turned ON (before starting engine), basic check item lights up..........
6
E-3 Engine does not start (Engine does not turn) .......................................................................
8
E-4 Preheater does not operate.................................................................................................. 10
D155AX-6
11
SEN00598-14
E-5 Precaution item lights up while engine is running ................................................................. 14

E-6 Emergency stop item lights up while engine is running ........................................................ 16
E-7 Engine coolant temperature gauge does not indicate normally............................................ 18
E-8 Fuel level gauge does not indicate normally......................................................................... 19
E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally....................... 21
E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally ............................ 22
E-11 Contents of display by machine monitor are different from applicable machine ................. 25
E-12 Machine monitor does not display some items................................................................... 25
E-13 Function switch does not work............................................................................................ 25
E-14 Operation mode does not change ...................................................................................... 26
E-15 Gearshift mode does not change........................................................................................ 26
E-16 Customize function does not operate normally................................................................... 27
E-17 Customize memory function does not normally.................................................................. 27
E-18 Float mode does not change .............................................................................................. 28
E-19 Alarm buzzer cannot be stopped ........................................................................................ 28
E-20 Air conditioner does not operate normally (including air conditioner fault history).............. 29
E-21 When starting switch is turned OFF, service meter is not displayed................................... 42
E-22 Machine monitor cannot be set in service mode ................................................................ 42
E-23 Ripper pin puller cylinder does not operate ........................................................................ 44
E-24 Backup alarm does not sound or does not stop ................................................................. 46
E-25 Headlamp, rear lamp, and ripper point lamp do not light up............................................... 48
E-26 Windshield wiper and window washer do not operate........................................................ 52
E-27 KOMTRAX system does not operate normally ................................................................... 68
Troubleshooting of hydraulic and mechanical system (H-mode)
SEN00808-02
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
H-23 Fan speed abnormal (Abnormally large sound or vibration of fan) ................................ 21
SEN00852-02
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
12
D155AX-6
SEN00598-14
S-7 Exhaust gas is black (incomplete combustion).....................................................................

S-8 Oil consumption is excessive (or exhaust gas is blue) .........................................................
S-9 Oil becomes dirty quickly......................................................................................................
S-10 Fuel consumption is excessive...........................................................................................
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) .................................
S-12 Oil pressure drops ..............................................................................................................
S-13 Oil level rises (Entry of coolant or fuel) ...............................................................................
S-14 Coolant temperature becomes too high (Overheating) ......................................................
S-15 Abnormal noise is made .....................................................................................................
S-16 Vibration is excessive .........................................................................................................
16
18
19
20
21
22
24
26
27
28

General information on disassembly and assembly
SEN01204-04
How to read this manual .............................................................................................................
2
Coating materials list...................................................................................................................
4
Special tool list ............................................................................................................................
7
Sketches of special tools............................................................................................................. 15
SEN01205-05
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 ............................................................................. 28
Removal and installation of engine hood assembly .................................................................... 33
Removal and installation of engine front seal ............................................................................. 35
Removal and installation of engine rear seal .............................................................................. 39
Removal and installation of fuel tank assembly .......................................................................... 44
Removal and installation of fan drive assembly .......................................................................... 45
Removal and installation of fan motor assembly......................................................................... 46
Power train, Part 1
SEN01206-03
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
Power train, Part 2
SEN01207-03
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
Power train, Part 3
SEN02707-01
Removal and installation of final drive assembly ........................................................................
2
Disassembly and assembly of final drive assembly ....................................................................
4
SEN01208-02
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
D155AX-6
13
SEN00598-14
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
Hydraulic system
SEN01209-02
Removal and installation of hydraulic tank assembly ..................................................................
2
Removal and installation of hydraulic pump assembly................................................................
4
Disassembly and assembly of hydraulic cylinder assembly........................................................
7
Work equipment
SEN01210-01
Removal and installation of blade assembly ...............................................................................
2
Disassembly and assembly of multi-shank ripper .......................................................................
4
SEN01211-02
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
Electrical system
SEN02708-01
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
80 Air conditioner
Structure, function, testing, adjusting, and troubleshooting
SEN04683-01
Structure and function .................................................................................................................
3
Air conditioner component .......................................................................................................
3
Configuration and function of refrigerating cycle .....................................................................
4
Outline of refrigerating cycle ....................................................................................................
5
Air conditioner unit ...................................................................................................................
7
Functions of major components in the air conditioner unit ......................................................
9
Control plate ............................................................................................................................ 11
Compressor ............................................................................................................................. 13
Condenser ............................................................................................................................... 14
Receiver drier .......................................................................................................................... 15
Testing, adjusting and troubleshooting ........................................................................................ 17
Caution about refrigerant ......................................................................................................... 17
Troubleshooting procedure ...................................................................................................... 18
Block diagram .......................................................................................................................... 19
Circuit diagram and arrangement of connector pins................................................................ 20
Detail of air conditioner unit ..................................................................................................... 22
Part and connector locations ................................................................................................... 24
Testing air leakage (duct)......................................................................................................... 31
Testing with self-diagnosis function ......................................................................................... 33
Testing temperature control ..................................................................................................... 36
Testing vent (mode) changeover ............................................................................................. 39
Testing Recirc/Fresh changeover ............................................................................................ 42
Testing inner sensor................................................................................................................. 44
Testing evaporator temperature sensor ................................................................................... 45
Testing sunlight sensor ............................................................................................................ 48
Testing (dual) pressure switch for refrigerant........................................................................... 49
Testing relays and diodes ........................................................................................................ 51
Troubleshooting chart 1 ........................................................................................................... 53
14
D155AX-6
SEN00598-14
Troubleshooting chart 2 ...........................................................................................................

Troubleshooting for electrical system (E mode) ......................................................................
E-1 Power supply system (Air conditioner does not operate) ..............................................
E-2 Compressor system (Air is not cooled) .........................................................................
E-3 Blower motor system (No air comes out or air flow is abnormal) ..................................
E-4 Temperature cannot be controlled.................................................................................
E-5 Vent (mode) cannot be changed over ...........................................................................
E-6 Recirc/Fresh air cannot be changed over .....................................................................
Troubleshooting with gauge pressure......................................................................................
Connection of service tool .......................................................................................................
Precautions for connecting air conditioner piping....................................................................
Handling of compressor oil ......................................................................................................
1. Control of compressor oil ..............................................................................................
2. Adding of compressor oil...............................................................................................
3. Compressor replacement ..............................................................................................
4. Applying compressor oil for O-ring ................................................................................
54
57
58
62
65
70
72
74
76
78
79
80
80
80
81
81

SEN00616-04
Power train hydraulic circuit diagram ..........................................................................................
3
Hydraulic circuit diagram (1/2) Serial No.: 80001 80806..........................................................
5
Hydraulic circuit diagram (2/2) Serial No.: 80001 80806..........................................................
7
Hydraulic circuit diagram (1/2) Serial No.: 80807 and up............................................................
9
Hydraulic circuit diagram (2/2) Serial No.: 80807 and up............................................................ 11
SEN00617-05
Electrical circuit diagram (1/12)...................................................................................................
3
5
7
9
Electrical circuit diagram (5/12)................................................................................................... 11
Electrical circuit diagram (10/12)................................................................................................. 21
Electrical circuit diagram (11/12) ................................................................................................. 23
Electrical circuit diagram (12/12)................................................................................................. 25
Electrical circuit diagram for inside cab ....................................................................................... 27
Connectors table and arrangement drawing ............................................................................... 29
D155AX-6
15
SEN00598-14
D155AX-6 Bulldozer
Form No. SEN00598-14
2012 KOMATSU
All Rights Reserved
Printed in Japan 02-12
16
D155AX-6
SEN00599-04
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up

Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling of electric equipment and hydraulic component .............................................................................11
Handling of connectors newly used for engines ........................................................................................... 20
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
SEN00599-04
Safety notice
(Rev. 2008/08)
1
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 situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1.
General precautions
k Mistakes in operation are extremely
dangerous. Read the Operation and
Maintenance Manual carefully before
operating the machine. In addition,
read this manual and understand its
contents before starting the work.
1) Before carrying out any greasing or
repairs, read all the safety labels stuck to
the machine. For the locations of the
safety labels and detailed explanation of
precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always
keep the tools and parts in their correct
places. Always keep the work area clean
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while
working.
3) When carrying out any operation, always
wear safety shoes and helmet. Do not
wear loose work clothes, or clothes with
buttons missing.
q
Always wear safety glasses when hitting parts with a hammer.
q
Always wear safety glasses when
grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or
more workers, always agree on the operating procedure before starting. Always
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, forklift, service car, etc.
7)
8)
9)
If welding repairs are needed, always

have a trained and experienced welder
carry out the work. When carrying out
w elding work, alw ays wear welding
gloves, apron, shielding goggles, cap and
other clothes suited for welding work.
Before starting work, warm up your body
thoroughly to start work under good condition.
Avoid continuing work for long hours and
take rests at proper intervals to keep your
body in good condition. Take rests in
specified safe places.
Safety points
1 Good arrangement
2 Correct work clothes
3 Following work standard
4 Making and checking signs
5
Prohibition of operation and handling by

unlicensed workers
6 Safety check before starting work

7
Wearing protective goggles

(for cleaning or grinding work)
Wearing shielding goggles and protectors

(for welding work)
9 Good physical condition and preparation

10
Precautions against work which you are

not used to or you are used to too much
D155AX-6
2.
3.
SEN00599-04
Preparations for work

1) Before adding oil or making any repairs,
park the machine on a hard and level
ground, and apply the parking brake and
block the wheels or tracks to prevent the
machine from moving.
2) Before starting work, lower the work
equipment (blade, ripper, bucket, etc.) to
the ground. If this is not possible, insert
the lock pin or use blocks to prevent the
work equipment from falling. In addition,
be sure to lock all the control levers and
hang warning signs on them.
3) When disassembling or assembling, support the machine with blocks, jacks, or
stands before starting work.
4) Remove all mud and oil from the steps or
other places used to get on and off the
machine. Always use the handrails, ladders or steps when getting on or off the
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
machine. If it is impossible to use the
handrails, ladders or steps, use a stand to
provide safe footing.
6)
Precautions during work

1) Before disconnecting or removing components of the oil, water, or air circuits, first
release the pressure completely from the
circuit. When removing the oil filler cap, a
drain plug, or an oil pressure pickup plug,
loosen it slowly to prevent the oil from
spurting out.
2) The coolant and oil in the circuits are hot
when the engine is stopped, so be careful
not to get scalded. Wait for the oil and
coolant to cool before carrying out any
work on the oil or water circuits.
3) Before starting work, stop the engine.
When working on or around a rotating
part, in particular, stop the engine. When
checking the machine without stopping
the engine (measuring oil pressure,
revolving speed, temperature, etc.), take
extreme care not to get rolled or caught in
rotating parts or moving parts.
4) Before starting work, remove the leads
from the battery. Always remove the lead
from the negative () terminal first.
5) When raising a heavy component (heavier
than 25 kg), use a hoist or crane. Before
starting work, check that the slings (wire
ropes, chains, and hooks) are free from
damage. Always use slings which have
ample capacity and install them to proper
places. Operate the hoist or crane slowly
to prevent the component from hitting any
other part. Do not work with any part still
raised by the hoist or crane.
11)
D155AX-6
7)
8)
9)
10)
12)
13)
14)
15)
16)
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.
When removing components, be careful
not to break or damage the electrical wiring. Damaged wiring may cause electrical
fires.
When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips
onto the floor, wipe it up immediately. Fuel
or oil on the floor can cause you to slip
and can even start fires.
As a general rule, do not use gasoline to
wash parts. Do not use it to clean electrical parts, in particular.
Be sure to assemble all parts again in their
original places. Replace any damaged
parts and parts which must not be reused
with new parts. When installing hoses and
wires, be sure that they will not be damaged by contact with other parts when the
machine is operated.
When installing high pressure hoses,
make sure that they are not twisted. Damaged tubes are dangerous, so be
extremely careful when installing tubes for
high pressure circuits. In addition, check
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
installed.
When assembling or installing parts,
always tighten them to the specified
torques. When installing protective parts
such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are
installed correctly.
When aligning 2 holes, never insert your
fingers or hand. Be careful not to get your
fingers caught in a hole.
When measuring hydraulic pressure,
check that the measuring tools are correctly assembled.
Take care when removing or installing the
tracks of track-type machines. When
removing the track, the track separates
suddenly, so never let anyone stand at
either end of the track.
If the engine is operated for a long time in
a place which is not ventilated well, you
may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.
SEN00599-04
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 well seen
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.
3) Keep putting on gloves during sling work.
(Put on leather gloves, if available.)
4) Measure the weight of the load by the eye
and check its center of gravity.
5) Use proper sling according to the weight
of the load and method of slinging. If too
thick wire ropes are used to sling a light
load, the load may slip and fall.
6) Do not sling a load with 1 wire rope alone.
If it is slung so, it may rotate and may slip
out of the rope. Install 2 or more wire
ropes symmetrically.
k Slinging with 1 rope may cause
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original winding 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 forming 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 allowable 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
sling a load vertically, up to 19.6 kN {2,000
kg} of total weight can be suspended.
This weight is reduced to 9.8 kN {1,000
kg} when the 2 ropes make a hanging
angle of 120. If the 2 ropes sling a 19.6
kN {2,000 kg} load at a lifting angle of
150, each of them is subjected to a force
as large as 39.2 kN {4,000 kg}.
8)
When installing wire ropes to an angular

load, apply pads to protect the wire ropes.
If the load is slippery, apply proper material to prevent the wire rope from slipping.
9) Use the specified eyebolts and fix wire
ropes, chains, etc. to them with shackles,
etc.
10) Apply wire ropes to the middle portion of
the hook.
q
Slinging near the tip of the hook may
cause the rope to slip off the hook
during hoisting. The hook has the
maximum strength at the middle portion.
11) Do not use twisted or kinked wire ropes.

12) When lifting up a load, observe the following.
q
Wind in the crane slowly until wire
ropes are stretched. When settling
the wire ropes with the hand, do not
grasp them but press them from
above. If you grasp them, your fingers
may be caught.
q
After the wire ropes are stretched,
stop the crane and check the condition of the slung load, wire ropes, and
pads.
D155AX-6
If the load is unstable or the wire rope

or chains are twisted, lower the load
and lift it up again.
q
Do not lift up the load slantingly.
13) When lifting down a load, observe the following.
q
When lifting down a load, stop it temporarily at 30 cm above the floor, and
then lower it slowly.
q
Check that the load is stable, and
then remove the sling.
q
Remove kinks and dirt from the wire
ropes and chains used for the sling
work, and put them in the specified
place.
SEN00599-04
13) If the hoist stops because of a power failure, turn the power switch OFF. When
turning on a switch which was turned OFF
by the electric shock prevention earth
leakage breaker, check that the devices
related to that switch are not in operation
state.
14) If you find an obstacle around the hoist,
stop the operation.
15) After finishing the work, stop the hoist at
the specified position and raise the hook
to at least 2 m above the floor. Do not
leave the sling installed to the hook.
5.
6.
Precautions for using mobile crane

a Read the Operation and Maintenance
Manual of the crane carefully in advance
and operate the crane safely.
Precautions for using overhead hoist crane
k When raising a heavy part (heavier
than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a
part heavier than 25 kg is indicated
after the mark of 4.
1) Before starting work, inspect the wire
ropes, brake, clutch, controller, rails, over
wind stop device, electric shock prevention earth leakage breaker, crane collision
prevention device, and power application
warning lamp, and check safety.
2) Observe the signs for sling work.
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east,
west, south, and north) and the directions
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move
the crane while the slung load is swinging.
6) Do not raise or lower a load while the
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 immediately in an emergency.
D155AX-6
7.
Selecting wire ropes

1) Select adequate ropes depending on the
weight of parts to be hoisted, referring to
the table below.
Wire ropes
(Standard Z twist ropes without galvanizing)
(JIS G3525, No. 6, Type 6X37-A)
Nominal
Allowable load
diameter of rope
mm
kN
ton
10
8.8
0.9
12
12.7
1.3
14
17.3
1.7
16
22.6
2.3
18
28.6
2.9
20
35.3
3.6
25
55.3
5.6
30
79.6
8.1
40
141.6
14.4
50
221.6
22.6
60
318.3
32.4
The allowable load is one-sixth of the

breaking strength of the rope used
(Safety coefficient: 6).
SEN00599-04
8.
Precautions for disconnecting and connecting hoses and tubes in air conditioner
circuit
1) Disconnection
k For the environment, the air conditioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when disconnecting the refrigerant gas circuit and then reuse it.
a Ask professional traders for collecting
and filling operation of refrigerant
(R134a).
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recovering or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2)

a
Example of O-ring (Fitted to every joint of

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

installation in each section of "Disassembly
and assembly".
Connection
1] When installing the air conditioner circuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not damaged or deteriorated.
4] When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.
D155AX-6
How to read the shop manual

q
q
q
1.
SEN00599-04
Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
Materials and specifications are subject to change without notice.
Shop manuals are divided into the Chassis volume and Engine volume. For the engine unit, see the
engine volume of the engine model mounted on the machine.
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 disassembly 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.
80. Appendix
The section explains the equipment which can not be included in the other sections. This section
explains the structure, function, testing, adjusting, and troubleshooting of the equipment.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q
Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q
Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
D155AX-6
SEN00599-04
2.
3.
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.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 )
Revisions
Revised brochures are shown in the shop manual composition table.
Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol
Item
Safety
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing work.
Weight
Weight of parts of component or parts. Caution necessary when

selecting hoisting wire, or when working posture is important, etc.
Tightening
torque
Coat
Oil, coolant
Drain
Remarks
Special safety precautions are necessary when performing work.
Places that require special attention for tightening torque during

assembly.
Places to be coated with adhesives, etc. during assembly.
Places where oil, etc. must be added, and capacity.
Places where oil, etc. must be drained, and quantity to be drained.
4.
Units
In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
D155AX-6
SEN00599-04
Explanation of terms for maintenance standard
The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the
machine maintenance work. The following terms are used to explain the criteria.
1.
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 temporary standard size is set and an allowable difference from that size is indicated.
q
The above size set temporarily is called
the standard size and the range of difference 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
120
Tolerance
0.022
0.126
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)
Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft.
The tightness of fit is decided by the tolerance.
Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Standard size
60
D155AX-6
Tolerance
Shaft
Hole
0.030
+0.046
0.076
+0
SEN00599-04
2.
Standard clearance and standard value

q
The clearance made when new parts are
assembled is called the standard clearance, which is indicated by the range
from the minimum clearance to the maximum clearance.
q
When some parts are repaired, the clearance is generally adjusted to the standard
clearance.
q
A value of performance and function of
new products or equivalent is called the
standard value, which is indicated by a
range or a target value.
q
When some parts are repaired, the value
of performance/function is set to the standard value.
3.
Standard interference
q
When the diameter of a hole of a part
shown in the given standard size and tolerance table is smaller than that of the
mating shaft, the difference between those
diameters is called the interference.
q
The range (A B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the standard interference.
q
After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4.
Repair limit and allowable value or allowable dimension

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, it must
be replaced or repaired.
q
The performance and function of a product lowers while it is used. A value which
the product can be used without causing a
problem is called the allowable value or
allowable dimension.
q
If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from various tests or experiences in most cases,
however, it must be judged after considering the operating condition and customer's
requirement.
10
5.
Clearance limit
Parts can be used until the clearance
between them is increased to a certain
limit. The limit at which those parts cannot
be used is called the clearance limit.
q
If the clearance between the parts
exceeds the clearance limit, they must be
replaced or repaired.
q
6.
Interference limit
The allowable maximum interference
between the hole of a part and the shaft of
another part to be assembled is called the
interference limit.
q
The interference limit shows the repair
limit of the part of smaller tolerance.
q
If the interference between the parts
exceeds the interference limit, they must
be replaced or repaired.
q
D155AX-6
Handling of electric equipment and hydraulic component
SEN00599-04
To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on Handling electric equipment and
Handling hydraulic equipment (particularly gear oil and hydraulic oil).
Points to remember when handling electric

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, connectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fitted 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 (defective contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not
correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connecting and disconnecting the connector about
10 times.
2)
Defective crimping or soldering of connectors

The pins of the male and female connectors are in contact at the crimped terminal
or soldered portion, but if there is excessive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
D155AX-6
11
SEN00599-04
12
3)
Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the soldering may be damaged, or the wiring
may be broken.
4)
High-pressure water entering connector

The connector is designed to make it difficult for water to enter (drip-proof structure), 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 shortcircuited 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 surface 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 compressed 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 compressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air completely before cleaning with compressed air.
D155AX-6
3.
SEN00599-04
Removing, installing, and drying connectors and wiring harnesses

1) Disconnecting connectors
1] Hold the connectors when disconnecting.
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 connectors apart.
a Never pull with one hand.
2]
q
When removing from clips

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

clip, pull the connector in a parallel
direction to the clip for removing stoppers.
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 connectors

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 disassembled for a long time, it is particularly easy for improper contact to
occur, so always cover the connector.
D155AX-6
13
SEN00599-04
2)
14
Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or damage to the connector pins.
Check that there is no damage or
breakage to the outside of the connector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or breakage, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stopper clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring harness.
For connectors fitted with boots, correct any protrusion of the boot. In
addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position.
a If the connector cannot be corrected easily, remove the clamp
and adjust the position.
q
If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
D155AX-6
3)
Heavy duty wire connector (DT 8-pole, 12pole)

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) horizontally 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
SEN00599-04
Disconnection
Connection (Example of
incomplete setting of (a))
15
SEN00599-04
4)
16
Drying wiring harness

If there is any oil or dirt on the wiring harness, 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 follows.
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
oil and water from the compressed 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 connector.
After drying, leave the wiring harness
disconnected and carry out a continuity test to check for any short circuits
between pins caused by water.
a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
D155AX-6
4.
Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These control all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the controller.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness connectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5.
Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before disconnecting 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 connectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnecessary abnormality displays will be
generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the reading of the tester.
a If there is any change, there is probably defective contact in that circuit.
D155AX-6
SEN00599-04
17
SEN00599-04
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 performance 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 cleaning 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 equipment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7.
Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment cannot remove, so it is an extremely effective
device.
D155AX-6
SEN00599-04
19
SEN00599-04
Handling of connectors newly used for engines

a
1.
Mainly, following engines are object for following connectors.

q
95E-5
q
107E-1
q
114E-3
q
125E-5
q
140E-5
q
170E-5
q
12V140E-3
Slide lock type
(FRAMATOME-3, FRAMATOME-2)
q
95 170, 12V140 engines
q
Various pressure sensors and NE
speed sensor
Examples)
Intake air pressure sensor in intake
manifold: PIM
(125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(95, 107, 114 engines)
Ne speed sensor of flywheel housing:
NE
(95 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
2.
Pull lock type (PACKARD-2)

95 170, 12V140 engines
q
Various temperature sensors
Example)
Intake air temperature sensor in
intake manifold: TIM
Fuel temperature sensor: TFUEL
Oil temperature sensor: TOIL
Coolant temperature sensor: TWTR,
etc.
Disconnect the connector by pulling lock
(B) (on the wiring harness side) of connector (2) outward.
Disconnect connector (1) according to the following procedure.

1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connector (1) toward you.
a Even if lock (L2) is pressed, connector (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screwdriver while press lock (L2), and then
pull out connector (1) toward you.
20
D155AX-6
3.
SEN00599-04
Push lock type

q
95, 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the following procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q
114 engine
107, 114 engines

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.
107 engine
2)
If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
D155AX-6
21
SEN00599-04
4)
95, 125 170, 12V140 engines

While pressing lock (E) of the connector,
pull out connector (5) in the direction of
the arrow.
Example)
Fuel pressure sensor in common rail:
PFUEL etc. (AMP-3)
4.
Turn-housing type (Round green connector)

140 engine
Example)
Intake air pressure sensor in intake manifold (CANNON-04): PIM etc.
1)
Disconnect connector (6) according to the

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 harness side.
2)
Connect the connector according to the

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)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22
D155AX-6
SEN00599-04
How to read electric wire code

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 symbols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX
0.85
L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.
Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.
Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indicated.)
1.
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)
Type
Low-voltage
wire for
automobile
Thin-cover
low-voltage
wire for
automobile
Symbol
AV
AVS
Heat-resistant low-voltAEX
age wire for
automobile
D155AX-6
Material
Conductor
Insulator
Conductor
Annealed copper for electric appliance

Soft polyvinyl chloride
Insulator
Soft polyvinyl chloride
Conductor

Heat-resistant crosslinked
polyethylene
Insulator
Using
temperature
range (C)
Example of use
General wiring
(Nominal No. 5 and above)
30 to +60
General wiring
(Nominal No. 3 and below)
General wiring in extremely
50 to +110 cold district, wiring at high-temperature place
23
SEN00599-04
2.
Dimensions
(Table 2)
Nominal No.
0.5f
(0.5)
0.75f
(0.85)
1.25f
(1.25)
2f
2
3f
3
5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51
0.56
0.76
0.88
1.27
1.29
1.96
2.09
3.08
3.30
5.23
area (mm2)
d (approx.)
1.0
1.2
1.5
1.9
1.9
2.3
2.4
3.0
AVS
Standard
2.0
2.2
2.5
2.9
2.9
3.5
3.6
CovAV
Standard
4.6
er D
AEX
Standard
2.0
2.2
2.7
3.0
3.1
3.8
4.6
Nominal No.
Number of
strands/Diameter of strand
Conductor
Sectional
area (mm2)
d (approx.)
AVS
Standard
CovAV
Standard
er D
AEX
Standard
15
20
30
40
50
60
85
100
50/0.45
84/0.45
41/0.80
70/0.80
85/0.80
7.95
13.36
20.61
35.19
42.73
54.29
63.84
84.96
109.1
3.7
5.5
5.3
4.8
7.0
7.0
6.0
8.2
8.2
8.0
10.8
10.8
8.6
11.4
11.4
9.8
13.0
13.0
10.4
13.6
13.6
12.0
16.0
16.0
13.6
17.6
17.6
108/0.80 127/0.80 169/0.80 217/0.80
f of nominal No. denotes flexible.
24
D155AX-6
3.
SEN00599-04
Color codes table
(Table 3)
Color Code
B
Br
BrB
BrR
BrW
BrY
Ch
Dg
G
GB
GL
Gr
GR
GW
GY
L
LB
Lg
LgB
LgR
Color of wire
Color Code
LgW
LgY
LR
LW
LY
O
P
R
RB
RG
RL
RW
RY
Sb
Y
YB
YG
YL
YR
YW
Black
Brown
Brown & Black
Brown & Red
Brown & White
Brown & Yellow
Charcoal
Dark green
Green
Green & Black
Green & Blue
Gray
Green & Red
Green & White
Green & Yellow
Blue
Blue & Black
Light green
Light green & Black
Light green & Red
Color of wire
Light green & White
Light green & Yellow
Blue & Red
Blue & White
Blue & Yellow
Orange
Pink
Red
Red & Black
Red & Green
Red & Blue
Red & White
Red & Yellow
Sky Blue
Yellow
Yellow & Black
Yellow &Green
Yellow & Blue
Yellow & Red
Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: GW means that the background is Green and marking is White.
4.
Types of circuits and color codes
(Table 4)
Type of wire
Charge
Ground
Start
Light
Instrument
Signal
Type of
circuit
Others
D155AX-6
AVS or AV
R
B
R
RW
Y
G
L
Br
Lg
O
Gr
P
Sb
Dg
Ch
AEX
R
B
R
D
Y
G
L
WG
RB
YR
GW
LW
BrW
LgR
RY
YB
GR
LR
BrR
LgY
RG
YG
GY
LY
BrY
LgB
RL
YL
GB
LB
BrB
LgW
YW
GL
Gr
Br
25
SEN00599-04
Precautions when carrying out operation
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1.
q
q
q
q
q
q
q
q
q
q
Precautions when carrying out removal work

If the coolant contains antifreeze, dispose of it correctly.
After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
When draining oil, prepare a container of adequate size to catch the oil.
Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires.
Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
Check the number and thickness of the shims, and keep in a safe place.
When raising components, be sure to use lifting equipment of ample strength.
When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
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
number
02
03
04
05
06
10
12
2)
26
Sleeve nut (elbow end)
07376-70210
07376-70315
07376-70422
07376-70522
07376-70628
07376-71034
07376-71234
02789-20210
02789-20315
02789-20422
02789-20522
02789-20628
07221-21034
07221-21234
Split flange type hoses and tubes

Nominal
number
04
05
3)
Plug (nut end)
Flange (hose end)
Sleeve head (tube end)
Split flange
07379-00400
07379-00500
07378-10400
07378-10500
07371-30400
07371-30500
If the part is not under hydraulic pressure, the following corks can be used.
Nominal
number
Part Number
06
08
10
12
14
16
18
20
22
24
07049-00608
07049-00811
07049-01012
07049-01215
07049-01418
07049-01620
07049-01822
07049-02025
07049-02228
07049-02430
Dimensions
D
d
L
6
5
8
8
6.5
11
10
8.5
12
12
10
15
14
11.5
18
16
13.5
20
18
15
22
20
17
25
22
18.5
28
24
20
30
27
07049-02734
27
22.5
34
D155AX-6
2.
q
q
q
q
q
q
q
q
q
q
q
q
q
a
3.
SEN00599-04
Precautions when carrying out installation work

Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
Bend the cotter pins and lock plates securely.
When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 3 drops of adhesive.
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.
Clean all parts, and correct any damage, dents, burrs, or rust.
Coat rotating parts and sliding parts with engine oil.
When press fitting parts, coat the surface with anti-friction compound (LM-P).
After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
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.
When using the machine for the first time after repair or long storage, follow the same procedure.
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 specified 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
SEN00599-04
4)
5)
28
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.
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.
D155AX-6
SEN00599-04
Method of disassembling and connecting push-pull type coupler

k
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.
Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1.
Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2.
Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
D155AX-6
29
SEN00599-04
Type 2
1.
Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to disconnect it. (Fig. 8)
2.
Connection
q
Hold the tightening portion and push body
contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)
30
D155AX-6
SEN00599-04
Type 3
1.
Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10)
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal portion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to disconnect it. (Fig. 12)
2.
Connection
q
Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)
D155AX-6
31
SEN00599-04
Standard tightening torque table

1.
Table of tightening torques for bolts and nuts

a Unless there are special instructions, tighten metric nuts and bolts to the torque below.
a
The following table applies to the bolts in Fig. A.
Thread diameter of bolt

mm
6
8
10
12
14
16
18
20
22
24
27
30
33
36
39
a
Tightening torque
Nm
11.8 14.7
27 34
59 74
98 123
157 196
245 309
343 427
490 608
662 829
824 1,030
1,180 1,470
1,520 1,910
1,960 2,450
2,450 3,040
2,890 3,630
kgm
1.2 1.5
2.8 3.5
6.0 7.5
10.0 12.5
16 20
25 31.5
35 43.5
50 62
67.5 84.5
84 105
120 150
155 195
200 250
250 310
295 370
The following table applies to the bolts in Fig. B.

mm
6
8
10
12
a Fig. A
Width across flats

mm
10
13
17
19
22
24
27
30
32
36
41
46
50
55
60
Width across flats

mm
10
13
14
27
Tightening torque
Nm
kgm
5.9 9.8
0.6 1.0
13.7 23.5
1.4 2.4
34.3 46.1
3.5 4.7
74.5 90.2
7.6 9.2
a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
32
D155AX-6
2.
Table of tightening torques for split flange bolts

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

mm
10
12
16
3.
Width across flats

mm
14
17
22
Tightening torque
Nm
59 74
98 123
235 285
kgm
6.0 7.5
10.0 12.5
23.5 29.5
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.
Nominal No.
02
03,04
05,06
10,12
14
4.
SEN00599-04
Thread diameter
mm
14
20
24
33
42
Width across flats

mm
Tightening torque Nm {kgm}

Range
Target
35 63 { 3.5 6.5}
44 { 4.5}
84 132 { 8.5 13.5}
103 {10.5}
Varies depending
on type of connec- 128 186 {13.0 19.0}
157 {16.0}
tor.
363 480 {37.0 49.0}
422 {43.0}
746 1,010 {76.0 103}
883 {90.0}
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
No.
08
10
12
14
16
18
20
24
30
33
36
42
52
D155AX-6
Thread diameter
mm
8
10
12
14
16
18
20
24
30
33
36
42
52
Width across flats

mm
14
17
19
22
24
27
30
32
32
36

Range
Target
5.88 8.82 {0.6 0.9}
7.35 {0.75}
9.81 12.74 {1.0 1.3}
11.27 {1.15}
14.7 19.6 {1.5 2.0}
17.64 {1.8}
19.6 24.5 {2.0 2.5}
22.54 {2.3}
24.5 34.3 {2.5 3.5}
29.4 {3.0}
34.3 44.1 {3.5 4.5}
39.2 {4.0}
44.1 53.9 {4.5 5.5}
49.0 {5.0}
58.8 78.4 {6.0 8.0}
68.6 {7.0}
93.1 122.5 { 9.5 12.5}
107.8 {11.0}
107.8 147.0 {11.0 15.0}
127.4 {13.0}
127.4 176.4 {13.0 18.0}
151.9 {15.5}
181.3 240.1 {18.5 24.5}
210.7 {21.5}
274.4 367.5 {28.0 37.5}
323.4 {33.0}
33
SEN00599-04
5.
Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Nominal
No. of
hose
Width
across
flats
02
19
03
04
05
06
(10)
(12)
(14)
6.
22
24
27
32
36
41
46
55
Range
34 54 { 3.5 5.5}
34 63 { 3.5 6.5}
54 93 { 5.5 9.5}
59 98 { 6.0 10.0}
84 132 { 8.5 13.5}
128 186 {13.0 19.0}
177 245 {18.0 25.0}
177 245 {18.0 25.0}
197 294 {20.0 30.0}
246 343 {25.0 35.0}
Target
44 { 4.5}
74 { 7.5}
78 { 8.0}
103 {10.5}
157 {16.0}
216 {22.0}
216 {22.0}
245 {25.0}
294 {30.0}
Taper seal
Thread size
(mm)
14
18
22
24
30
33
36
42
Face seal
Nominal No.
Thread
Number of
diameter (mm)
threads, type of
(Reference)
thread
9/16-18UN
14.3
11/16-16UN
17.5
13/16-16UN
20.6
1-14UNS
25.4
1-3/16-12UN
30.2
Table of tightening torques for face seal joints

a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to
be used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).
Outer
diameter
of pipe
(mm)
Width
across
flats
(mm)
8
10
12
15 (16)
22 (20)
19
22
24 (27)
30 (32)
36

Range
Target
14 16 {1.4 1.6}
24 27 {2.4 2.7}
43 47 {4.4 4.8}
60 68 {6.1 6.8}
90 95 {9.2 9.7}
15 {1.5}
25.5 {2.6}
45 {4.6}
64 {6.5}
92.5 {9.4}
Face seal
Thread diameter
Nominal No.
(mm)
Number of threads,
(Reference)
type of thread
9/16-18UN
14.3
11/16-16UN
17.5
13/16-16UN
20.6
1-14UN
25.4
1-3/16-12UN
30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
7.
Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Bolts and nuts
Thread size
mm
6
8
10
12
14
34
Nm
10 2
24 4
43 6
77 12
kgm
1.02 0.20
2.45 0.41
4.38 0.61
7.85 1.22
D155AX-6
8.
Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size
mm
6
8
10
12
14
9.
SEN00599-04
Tightening torque
Nm
82
10 2
12 2
24 4
36 5
kgm
0.81 0.20
1.02 0.20
1.22 0.20
2.45 0.41
3.67 0.51
Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Material
Thread size (inch)
1/16
1/8
1/4
3/8
1/2
3/4
D155AX-6
Tightening torque
In cast iron or steel
In aluminum
Nm
kgm
Nm
kgm
15 2
1.53 0.20
51
0.51 0.10
20 2
2.04 0.20
15 2
1.53 0.20
25 3
2.55 0.31
20 2
2.04 0.20
35 4
3.57 0.41
25 3
2.55 0.31
55 6
5.61 0.61
35 4
3.57 0.41
75 8
7.65 0.82
45 5
4.59 0.51
35
SEN00599-04
Conversion table
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 horizontal 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
(A)
36
(B)
0
10
20
30
40
0
0
0.394
0.787
1.181
1.575
1
0.039
0.433
0.827
1.220
1.614
2
0.079
0.472
0.866
1.260
1.654
3
0.118
0.512
0.906
1.299
1.693
4
0.157
0.551
0.945
1.339
1.732
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.047
2.441
2.835
3.228
3.622
2.087
2.480
2.874
3.268
3.661
2.126
2.520
2.913
3.307
3.701
5
0.197
0.591
0.984
1.378
1.772
(C)
2.165
2.559
2.953
3.346
3.740
6
0.236
0.630
1.024
1.417
1.811
7
0.276
0.669
1.063
1.457
1.850
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
1 mm = 0.03937 in
8
9
0.315
0.354
0.709
0.748
1.102
1.142
1.496
1.536
1.890
1.929
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
D155AX-6
SEN00599-04
Millimeters to inches
0
10
20
30
40
0
0
0.394
0.787
1.181
1.575
1
0.039
0.433
0.827
1.220
1.614
2
0.079
0.472
0.866
1.260
1.654
3
0.118
0.512
0.906
1.299
1.693
4
0.157
0.551
0.945
1.339
1.732
5
0.197
0.591
0.984
1.378
1.772
6
0.236
0.630
1.024
1.417
1.811
1 mm = 0.03937 in
7
8
9
0.276
0.315
0.354
0.669
0.709
0.748
1.063
1.102
1.142
1.457
1.496
1.536
1.850
1.890
1.929
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.047
2.441
2.835
3.228
3.622
2.087
2.480
2.874
3.268
3.661
2.126
2.520
2.913
3.307
3.701
2.165
2.559
2.953
3.346
3.740
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
1 kg = 2.2046 lb
6
7
8
9
13.23
15.43 17.64
19.84
35.27
37.48 39.68
41.89
57.32
59.53 61.73
63.93
79.37
81.57 83.78
85.98
101.41 103.62 105.82 108.03
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
Kilogram to pound
0
10
20
30
40
0
0
22.05
44.09
66.14
88.18
1
2.20
24.25
46.30
68.34
90.39
2
4.41
26.46
48.50
70.55
92.59
3
6.61
28.66
50.71
72.75
94.80
4
8.82
30.86
51.91
74.96
97.00
5
11.02
33.07
55.12
77.16
99.21
50
60
70
80
90
110.23
132.28
154.32
176.37
198.42
112.44
134.48
156.53
178.57
200.62
114.64
136.69
158.73
180.78
202.83
116.85
138.89
160.94
182.98
205.03
119.05
141.10
163.14
185.19
207.24
121.25
143.30
165.35
187.39
209.44
123.46
145.51
167.55
189.60
211.64
125.66
147.71
169.76
191.80
213.85
127.87
149.91
171.96
194.01
216.05
130.07
152.12
174.17
196.21
218.26
Liters to U.S. Gallons
0
10
20
30
40
0
1
2
0
0.264 0.528
2.642
2.906 3.170
5.283
5.548 5.812
7.925
8.189 8.454
10.567 10.831 11.095
3
0.793
3.434
6.076
8.718
11.359
4
1.057
3.698
6.340
8.982
11.624
1 l = 0.2642 U.S.Gal
5
6
7
8
9
1.321
1.585
1.849
2.113
2.378
3.963
4.227
4.491 4.755
5.019
6.604
6.869
7.133 7.397
7.661
9.246
9.510
9.774 10.039 10.303
11.888 12.152 12.416 12.680 12.944
50
60
70
80
90
13.209
15.850
18.492
21.134
23.775
14.001
16.643
19.285
21.926
24.568
14.265
16.907
19.549
22.190
24.832
14.529
17.171
19.813
22.455
25.096
D155AX-6
13.473
16.115
18.756
21.398
24.040
13.737
16.379
19.020
21.662
24.304
14.795
17.435
20.077
22.719
25.361
15.058
17.700
20.341
22.983
25.625
15.322
17.964
20.605
23.247
25.889
15.586
18.228
20.870
23.511
26.153
37
SEN00599-04
Liters to U.K. Gallons
0
10
20
30
40
0
0
2.200
4.399
6.599
8.799
1
0.220
2.420
4.619
6.819
9.019
2
0.440
2.640
4.839
7.039
9.239
3
0.660
2.860
5.059
7.259
9.459
4
0.880
3.080
5.279
7.479
9.679
5
1.100
3.300
5.499
7.699
9.899
50
60
70
80
90
10.998
13.198
15.398
17.598
19.797
11.281
13.418
15.618
17.818
20.017
11.438
13.638
15.838
18.037
20.237
11.658
13.858
16.058
18.257
20.457
11.878
14.078
16.278
18.477
20.677
12.098
14.298
16.498
18.697
20.897
1 l = 0.21997 U.K.Gal
6
7
8
9
1.320
1.540 1.760
1.980
3.520
3.740 3.950
4.179
5.719
5.939 6.159
6.379
7.919
8.139 8.359
8.579
10.119 10.339 10.559 10.778
12.318
14.518
16.718
18.917
21.117
12.528
14.738
16.938
19.137
21.337
12.758
14.958
17.158
19.357
21.557
12.978
15.178
17.378
19.577
21.777
kgm to ft.lb
0
10
20
30
40
0
0
72.3
144.7
217.0
289.3
1
7.2
79.6
151.9
224.2
296.6
2
14.5
86.8
159.1
231.5
303.8
3
21.7
94.0
166.4
238.7
311.0
4
28.9
101.3
173.6
245.9
318.3
5
36.2
108.5
180.8
253.2
325.5
6
43.4
115.7
188.1
260.4
332.7
1 kgm = 7.233 ft.lb

7
8
9
50.6
57.9
65.1
123.0 130.2
137.4
195.3 202.5
209.8
267.6 274.9
282.1
340.0 347.2
354.4
50
60
70
80
90
361.7
434.0
506.3
578.6
651.0
368.9
441.2
513.5
585.9
658.2
376.1
448.5
520.8
593.1
665.4
383.4
455.7
528.0
600.3
672.7
390.6
462.9
535.2
607.6
679.9
397.8
470.2
542.5
614.8
687.1
405.1
477.4
549.7
622.0
694.4
412.3
484.6
556.9
629.3
701.6
419.5
491.8
564.2
636.5
708.8
426.8
499.1
571.4
643.7
716.1
100
110
120
130
140
723.3
730.5 737.8
745.0
752.2 759.5
766.7
773.9 781.2
788.4
795.6
802.9 810.1
817.3
824.6 831.8
839.0
846.3 853.5
860.7
868.0
875.2 882.4
889.7
896.9 904.1
911.4
918.6 925.8
933.1
940.3
947.5 954.8
962.0
969.2 976.5
983.7
990.9 998.2 1005.4
1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150
160
170
180
190
1084.9
1157.3
1129.6
1301.9
1374.3
38
1092.2
1164.5
1236.8
1309.2
1381.5
1099.4
1171.7
1244.1
1316.4
1388.7
1106.6
1179.0
1251.3
1323.6
1396.0
1113.9
1186.2
1258.5
1330.9
1403.2
1121.1
1193.4
1265.8
1338.1
1410.4
1128.3
1200.7
1273.0
1345.3
1417.7
1135.6
1207.9
1280.1
1352.6
1424.9
1142.8
1215.1
1287.5
1359.8
1432.1
1150.0
1222.4
1294.7
1367.0
1439.4
D155AX-6
SEN00599-04
kg/cm2 to lb/in2
0
10
20
30
40
0
0
142.2
284.5
426.7
568.9
1
14.2
156.5
298.7
440.9
583.2
2
28.4
170.7
312.9
455.1
597.4
3
42.7
184.9
327.1
469.4
611.6
4
56.9
199.1
341.4
483.6
625.8
5
71.1
213.4
355.6
497.8
640.1
6
85.3
227.6
369.8
512.0
654.3
1 kg/cm2 = 14.2233 lb/in2

7
8
9
99.6
113.8
128.0
241.8
256.0
270.2
384.0
398.3
412.5
526.3
540.5
554.7
668.5
682.7
696.9
50
60
70
80
90
711.2
853.4
995.6
1,138
1,280
725.4
867.6
1,010
1,152
1,294
739.6
881.8
1,024
1,166
1,309
753.8
896.1
1,038
1,181
1,323
768.1
910.3
1,053
1,195
1,337
782.3
924.5
1,067
1,209
1,351
796.5
938.7
1,081
1,223
1,365
810.7
953.0
1,095
1,237
1,380
825.0
967.2
1,109
1,252
1,394
839.2
981.4
1,124
1,266
1,408
100
110
120
130
140
1,422
1,565
1,707
1,849
1,991
1,437
1,579
1,721
1,863
2,005
1,451
1,593
1,735
1,877
2,020
1,465
1,607
1,749
1,892
2,034
1,479
1,621
1,764
1,906
2,048
1,493
1,636
1,778
1,920
2,062
1,508
1,650
1,792
1,934
2,077
1,522
1,664
1,806
1,949
2,091
1,536
1,678
1,821
1,963
2,105
1,550
1,693
1,835
1,977
2,119
150
160
170
180
190
2,134
2,276
2,418
2,560
2,702
2,148
2,290
2,432
2,574
2,717
2,162
2,304
2,446
2,589
2,731
2,176
2,318
2,460
2,603
2,745
2,190
2,333
2,475
2,617
2,759
2,205
2,347
2,489
2,631
2,773
2,219
2,361
2,503
2,646
2,788
2,233
2,375
2,518
2,660
2,802
2,247
2,389
2,532
2,674
2,816
2,262
2,404
2,546
2,688
2,830
200
210
220
230
240
2,845
2,987
3,129
3,271
3,414
2,859
3,001
3,143
3,286
3,428
2,873
3,015
3,158
3,300
3,442
2,887
3,030
3,172
3,314
3,456
2,901
3,044
3,186
3,328
3,470
2,916
3,058
3,200
3,343
3,485
2,930
3,072
3,214
3,357
3,499
2,944
3,086
3,229
3,371
3,513
2,958
3,101
3,243
3,385
3,527
2,973
3,115
3,257
3,399
3,542
D155AX-6
39
SEN00599-04
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1C = 33.8F
F
40.4
37.2
34.4
31.7
28.9
40
35
30
25
20
40.0
31.0
22.0
13.0
4.0
11.7
11.1
10.6
10.0
9.4
11
12
13
14
15
51.8
53.6
55.4
57.2
59.0
7.8
8.3
8.9
9.4
10.0
46
47
48
49
50
114.8
116.6
118.4
120.2
122.0
27.2
27.8
28.3
28.9
29.4
81
82
83
84
85
177.8
179.6
181.4
183.2
185.0
28.3
27.8
27.2
26.7
26.1
19
18
17
16
15
2.2
0.4
1.4
3.2
5.0
8.9
8.3
7.8
7.2
6.7
16
17
18
19
20
60.8
62.6
64.4
66.2
68.0
10.6
11.1
11.7
12.2
12.8
51
52
53
54
55
123.8
125.6
127.4
129.2
131.0
30.0
30.6
31.1
31.7
32.2
86
87
88
89
90
186.8
188.6
190.4
192.2
194.0
25.6
25.0
24.4
23.9
23.3
14
13
12
11
10
6.8
8.6
10.4
12.2
14.0
6.1
5.6
5.0
4.4
3.9
21
22
23
24
25
69.8
71.6
73.4
75.2
77.0
13.3
13.9
14.4
15.0
15.6
56
57
58
59
60
132.8
134.6
136.4
138.2
140.0
32.8
33.3
33.9
34.4
35.0
91
92
93
94
95
195.8
197.6
199.4
201.2
203.0
22.8
22.2
21.7
21.1
20.6
9
8
7
6
5
15.8
17.6
19.4
21.2
23.0
3.3
2.8
2.2
1.7
1.1
26
27
28
29
30
78.8
80.6
82.4
84.2
86.0
16.1
16.7
17.2
17.8
18.3
61
62
63
64
65
141.8
143.6
145.4
147.2
149.0
35.6
36.1
36.7
37.2
37.8
96
97
98
99
100
204.8
206.6
208.4
210.2
212.0
20.0
19.4
18.9
18.3
17.8
4
3
2
1
0
24.8
26.6
28.4
30.2
32.0
0.6
0
0.6
1.1
1.7
31
32
33
34
35
87.8
89.6
91.4
93.2
95.0
18.9
19.4
20.0
20.6
21.1
66
67
68
69
70
150.8
152.6
154.4
156.2
158.0
40.6
43.3
46.1
48.9
51.7
105
110
115
120
125
221.0
230.0
239.0
248.0
257.0
17.2
16.7
16.1
15.6
15.0
1
2
3
4
5
33.8
35.6
37.4
39.2
41.0
2.2
2.8
3.3
3.9
4.4
36
37
38
39
40
96.8
98.6
100.4
102.2
104.0
21.7
22.2
22.8
23.3
23.9
71
72
73
74
75
159.8
161.6
163.4
165.2
167.0
54.4
57.2
60.0
62.7
65.6
130
135
140
145
150
266.0
275.0
284.0
293.0
302.0
14.4
13.9
13.3
12.8
12.2
6
7
8
9
10
42.8
44.6
46.4
48.2
50.0
5.0
5.6
6.1
6.7
7.2
41
42
43
44
45
105.8
107.6
109.4
111.2
113.0
24.4
25.0
25.6
26.1
26.7
76
77
78
79
80
168.8
170.6
172.4
174.2
176.0
68.3
71.1
73.9
76.7
79.4
155
160
165
170
175
311.0
320.0
329.0
338.0
347.0
40
D155AX-6
D155AX-6
SEN00599-04
41
SEN00599-04
D155AX-6 Bulldozer
2008 KOMATSU
All Rights Reserved
42
D155AX-6
SEN00601-04
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
01 Specification

Specification dimension drawings ................................................................................................................... 2
Specifications .................................................................................................................................................. 3
Weight table .................................................................................................................................................... 9
Table of fuel, coolant and lubricants.............................................................................................................. 12
D155AX-6
SEN00601-04
01 Specification
Specification dimension drawings
Item
Unit
Sigma-tilt dozer + Variable

multiple shank ripper
Semi U-tilt dozer + Variable

multiple shank ripper
Overall length
mm
8,225
8,275
Overall height (with ROPS)
mm
3,395
3,395
Overall width
mm
4,060
4,130
Item
Unit
Sigma-tilt dozer + Variable

giant ripper
Semi U-tilt dozer + Variable

giant ripper
Overall length
mm
8,225
8,275
Overall height (with ROPS)
mm
3,395
3,395
Overall width
mm
4,060
4,130
D155AX-6
01 Specification
SEN00601-04
Specifications
Machine model
D155AX-6
Serial number
80001 and up
Weight
Bare tractor
With HD Sigma-tilt dozer + variable multishank ripper + ROPS cab + air conditioner +
560mm HD shoe + side cover
32,100
41,200
kg
With semi U-tilt dozer + variable multi-shank

ripper + ROPS cab + air conditioner + 560mm
HD shoe + side cover
40,800
Minimum turning radius (F1, center of machine)
mm
2.1
Gradeability
deg.
30
Stability (front, rear, left, right)
deg.
35
Forward
Reverse
Transmission speed ranges

Overall height Overall width Overall length
Dimensions
Ground pressure
Performance
1st
3.8
2nd
5.6
km/h
3rd (low speed)
7.5
3rd
11.6
1st
4.6
2nd
6.8
km/h
3rd (low speed)
9.2
3rd
14.0
Bare tractor
79.85 {0.81}
With Sigma-tilt dozer + variable multi-shank

ripper + ROPS cab + air conditioner + side
cover
kPa
{kg/cm2}
With semi U-dozer + variable multi-shank

ripper + ROPS + cab + air conditioner +
560mm HD shoe + side cover
105.84 {1.08}
Bare tractor
With semi U-tilt dozer + tractor
105.84 {1.08}
4,875
mm
6,180

ripper
8,225
Bare tractor
2,765
With semi U-dozer + tractor
mm
4,130

ripper
4,060
To top of exhaust pipe
3,385
To top of cab
(to top of control lever)
With ROPS cab installed
D155AX-6
mm
2,210
3,395
SEN00601-04
01 Specification
Machine model
D155AX-6
Serial number
80001 and up
Dimensions
Track gauge
2,000
Length of track on ground

Track shoe width (Standard)
3,050
mm
Minimum ground clearance

(To bottom surface of undercover)
450
Name
SAA6D140E-5
4-cycle, water-cooled, in-line, vertical type,
direct injection, with turbocharger, aftercooler
and (EGR) cooler
Type of engine
No. of cylinders - Bore x Stroke
mm
6 140 x 165
l {cc}
15.24 {15,240}
kW {HP}/rpm
239 {320}/1,900
Nm {kgm}/rpm
1,715 {175}/1,300
Max. speed at no load
rpm
2,050
Min. speed at no load
rpm
740
g/kWh {g/HPh}
212 {158}
Piston displacement
Performance
Engine
Flywheel horsepower
Max. torque
Min. fuel consumption ratio

Starting motor
24V, 11kW
Alternator
24V, 75A
Battery
12V, 170Ah x 2
Radiator core type
Rectangle wave fin
Torque converter
3-element, 1-stage, 1-phase

Planetary gear, multiple disc clutch,
hydraulically actuated, (electrically type)
force-feed lubrication gear pump,
forward 3-speed, reverse 3-speed,
electrically actuated type
Hydraulic, HSS pump
HSS motor
Bevel gear shaft
HSS
Power train system
Transmission
MPa
{kg/cm2}
l/min@rpm
MPa
{kg/cm2}
Variable swash plate type (HPV190)

Max. delivery pressure: 39.6 {404}
Theoretical delivery: 427@2,249
Fixed swash plate type (KMF140)
Max. pressure: 41.2 {420}
Spiral bevel gear, force-feed lubrication
gear pump
HSS steering system
Differential planetary gear, hydraulic motor

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

hydraulically actuated, pedal operated
Final drive
560
Spur gear 1-stage, planetary gear 1-stage,

splash type lubrication
D155AX-6
Undercarriage
01 Specification
SEN00601-04
Machine model
D155AX-6
Serial number
80001 and up
Suspension
Rigid, balancing beam type
Carrier roller
2 each side
Track roller
7 each side
Track shoe (shoe width: 560 mm)
Assembly type, single grouser,

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+1+3 tandem spool type, hydraulically
assisted type, electrical control
Control valve
Variable multi-shark ripper type

For ripper tilt
+ Ripper tilt
For ripper lift
+ Ripper lift
For blade lift

For blade tilt
+ (Blade lift + blade tilt + steering)
For steering
Dimensions of blade tilt Dimensions of blade tilt

Dimensions of blade lift
(For semi U-dozer)
(For sigma-tilt dozer)
Hydraulic cylinder
Work equipment hydraulic system
Type
D155AX-6
Reciprocal, piston type
Cylinder bore
mm
110
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
Cylinder bore
mm
160
mm
90
Max. piston stroke
mm
205
mm
1,395
mm
1,190
Cylinder bore
mm
160
mm
90
Max. piston stroke
mm
210
mm
1,475
mm
1,265
Dimensions of blade
Dimensions of ripper tilt Dimensions of ripper lift (For sigma-tilt dozer tilt and pitch)
Hydraulic cylinder
Work equipment hydraulic system
SEN00601-04
01 Specification
Machine model
D155AX-6
Serial number
80001 and up
Cylinder bore
mm
160
mm
90
Max. piston stroke
mm
165
mm
1,430
mm
1,265
Cylinder bore
mm
180
mm
100
Max. piston stroke
mm
565
mm
1,730
mm
1,165
Cylinder bore
mm
200
mm
110
Max. piston stroke
mm
605
mm
1,815
mm
1,210
Fan drive system
Hydraulic tank
Box type (control valve externally installed)
Cooling fan pump
MPa
{kg/cm2}
l/min@rpm
Variable swash plate (LPV45)

Theoretical delivery pressure: 103@2,296
Cooling fan motor
MPa
{kg/cm2}
Fixed swash plate (LMF65)

D155AX-6
01 Specification
SEN00601-04
Machine model
D155AX-6
Serial number
80001 and up
Hydraulic sigma-tilt dozer
Hydraulic semi U-tilt dozer
Hydraulic U-tilt dozer
Type
Performance
Dimensions
Performance
Dimensions
Performance
Dimensions
Semi U-tilt dozer

Full U-dozer
Work equipment
Sigma tilt dozer
Blade support method
D155AX-6
Brace type (right tilt cylinder)
Blade lifting height (from ground level)
mm
1,311
Blade lowering depth (from ground level)
mm
627
Max. blade tilt
mm
1,000
Blade cutting angle variation
deg.
Blade capacity (SAE)
m3
9.4
Blade width
mm
4,060
Blade height
mm
1,790
Blade cutting angle
deg.
46
mm
1,250
mm
590
Max. blade tilt
mm
1,000
deg.
m3
9.4
Blade width
mm
4,130
Blade height
mm
1,790
Blade cutting angle
deg.
52
mm
1,250
mm
590
Max. blade tilt
mm
1,080
deg.
m3
11.9
Blade width
mm
4,225
Blade height
mm
1,790
Blade cutting angle
deg.
52
Performance
Performance
Performance
Dimensions Performance Dimensions Performance
Variable multi-shank ripper Full U-dozer + pitch Semi U-tilt dozer + pitch Sigma-tiltd ozer + pitch
Variable giant ripper
Work equipment
SEN00601-04
01 Specification
Machine model
D155AX-6
Serial number
80001 and up
Max. tilt
mm
1,000
Max. pitch angle
deg.
Max. pitch-back angle
deg.
Max. tilt
mm
1.000
Max. pitch angle
deg.
deg.
Max. tilt
mm
1,080
Max. pitch angle
deg.
deg.
Max. digging depth
mm
903
Max. lifting height
mm
950
Ripping angle of point

Max. beam width
30 70
mm
Shank positions
2,320
2
Max. digging depth
mm
1,255
Max. lifting height
mm
950
Ripping angle of point
30 70
Max. beam width
mm
1,401
Shank positions
No. of holes
D155AX-6
01 Specification
SEN00601-04
Weight table
k This weight table is for reference in handling or transporting components.

Unit: kg
Machine model
D155AX-6
Serial number
80001 and up
Engine, damper assembly
1,900
Engine assembly
1,759
Damper assembly
120
Universal joint
18
Engine mount parts (wiring)
Radiator assembly
(including built-in oil cooler hydraulic cooler and codenser)
333
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

(2-ECMV assembly, secondary brake valve)
Power train filter assembly
6
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)

(double flange x1)
93 x 4
105 x 3
Carrier roller assembly
D155AX-6
45 x 2
SEN00601-04
01 Specification
Unit: kg
Machine model
D155AX-6
Serial number
80001 and up
Track shoe assembly (560 mm, wet type)
2,260 x 2
Pivot shaft assembly (Left)

(When dual tilt spcification, Left and right)
119
Pivot shaft assembly (Right)
136
Equalizer bar
231
Hydraulic tank assembly (including hydraulic filter)
99
Control valve
(Blade lift + blade tilt + ripper lift + ripper tilt + steering)
123
Engine underguard
220
Transmission underguard
285
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)
Blade
3,200 (Standard 2,929)
Straight frame
1,690 (Standard 1,534)
Center brace
250 x 1
Pitch cylinder assembly
130 x 2
Semi U-tilt dozer assembly
5,623 (Standard 4,962)
Blade
3,459 (Standard 2,954)
Straight frame
1,687 (Standard 1,531)
Tilt brace
97 x 1
Center brace
250 x 1
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
252 x 1
10
D155AX-6
01 Specification
SEN00601-04
Unit: kg
Machine model
D155AX-6
Serial number
80001 and up
Giant ripper assembly
3,090
Bracket, beam, arm
1,850
Shank
333 x 1
Lift cylinder assembly
184 x 1
252 x 1
Pin puller cylinder assembly
Cab assembly
410
Dashboard
54
Floor frame (including air conditioner unit)
611
Side cover
20
Air conditioner unit assembly
10
D155AX-6
11
SEN00601-04
01 Specification
Table of fuel, coolant and lubricants

a
12
For details of the notes (Note 1, Note 2 - - -) in the table, see Operation and Maintenance Manual.
D155AX-6
01 Specification
SEN00601-04
Unit: l
Refilling points
D155AX-6
Specified capacity
Refill capacity
Engine oil pan
45
37
Damper case
1.5
1.5
Power train case
130
90
Fainal drive case (each)
31
31
Hydraulic system
(with blade, without ripper)
240
91.5
Cooling system
(including reservoir tank)
82
Fuel tank
625
D155AX-6
13
SEN00601-04
01 Specification
D155AX-6 Bulldozer
2012 KOMATSU
All Rights Reserved
14
D155AX-6
SEN00603-00
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
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
D155AX-6
SEN00603-00

Radiator, oil cooler
Radiator
D155AX-6
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Overflow hose
Air bleed hose
Inlet hose
Coolant filler cap
Radiator core assembly
Reservoir tank
Inlet hose (for circulating at low coolant
temperature)
Outlet hose
Lower tank (power train oil cooler built-in)
Fan
Drain plug
Cushion
Breather cap
Pressure valve
a:
b:
c:
Aftercooler
Aftercooler outlet hose
Aftercooler inlet hose
SEN00603-00
Outline
q
The reservoir tank is provided for radiator.
q
The power train oil cooler is built in the lower
tank of the radiator.
Radiator
Rectangle
wave fin
Core type
Fin pitch
4.0
(m )
41.99 x 2
Relief
pressure
(MPa {kg/cm2})
0.09 {0.9}
Vacuum
pressure
(MPa {kg/cm2})
0.005 {0.05}
Heat dissipation area

Pressure
valve
(mm)
2
Specification
Aftercooler: Rectangle wave fin 8.0/2P
D155AX-6
SEN00603-00
Oil cooler
1.
2.
Hydraulic cooler
Power train oil cooler
A:
B:
Power train oil cooler outlet port

Power train oil cooler inlet port
Outline
q
The power train oil cooler is built in the lower
tank of the radiator.
Core type
Inner fin type
Cooling method
Heat dissipation area (m2)
Power train
oil cooler
Hydraulic
cooler
PTO-OL
Rectangle
wave (4.0P)
TF8-C
TF6-P
Built in lower
tank
Air cooled
2.47
4.51
D155AX-6
SEN00603-00
Engine mount
Unit: mm
No.
Check item
Clearance between bracket
and cushion
Criteria
Standard
size
60
Free height of mount rubber
D155AX-6
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
0.1
0.3
+0.046
+0.046
0.1
0.346
Standard clearance
Clearance limit
86
84
Replace
SEN00603-00
Cooling fan pump
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.
2.
Servo valve
Air bleeder
D155AX-6
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
SEN00603-00
Shaft
Oil seal
Case
Rocker cam
Shoe
Piston
Cylinder block
Valve plate
Spring
Servo piston
D155AX-6
SEN00603-00
Function
q
The pump converts the engine rotation transmitted to its shaft to oil pressure and delivers
pressurized oil corresponding to the load.
q
It is possible to change the delivery by changing the swash plate angle.
q
q
q
Cylinder block (7) seals the pressurized oil to

valve plate (8) and carries out relative rotation.
This surface is designed so that the oil pressure balance is maintained at a suitable level.
The oil inside each cylinder chamber of cylinder block (7) is suctioned and discharged
through valve plate (8).
Structure
Cylinder block (7) is supported to shaft by
spline (11).
q
Shaft (1) is supported with front and rear bearings (12).
q
The end of piston (6) has a spherical hollow
and is combined with shoe (5).
q
Piston (6) and shoe (5) form a spherical bearing.
q
Shoe (5) is kept pressed against plane (A) of
rocker cam (4) and slid circularly.
q
Rocker cam (4) slides around ball (13).
q
Piston (6) carries out relative movement in the
axial direction inside each cylinder chamber of
cylinder block (7).
q
D155AX-6
Operation of pump
q
Cylinder block (7) rotates together with shaft
(1), and shoe (5) slides on flat surface (A).
q
At this time, rocker cam (4) slants around ball
(13). As a result, angle (a) between center line
(X) of rocker cam (4) and the axis of cylinder
block (7) changes.
q
Angle (a) is called the swash plate angle.
SEN00603-00
q
q
D155AX-6
With the condition of center line (X) of rocker

cam (4) has swash plate angle (a) to axial
direction of cylinder block (7), flat surface (A)
functions as cam against shoe (5).
In this way, piston (6) slides on the inside of
cylinder block (7), so a difference between volumes (E) and (F) is created inside cylinder
block (7).
A single piston (6) sucks and discharges the oil
by the amount (F) - (E).
As cylinder block (7) rotates and the volume of
chamber (E) becomes smaller, the pressurized
oil is discharged.
On the other hand, the volume of chamber (F)
grows larger and, in this process, the oil is suctioned.
SEN00603-00
10
As center line (X) of rocker cam (4) matches

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

pump delivery.
D155AX-6
SEN00603-00
Servo valve
P:
PE:
PH:
T:
EPC valve basic pressure

Control piston pressure
Pump discharge pressure
Drain port
D155AX-6
1.
2.
3.
4.
5.
6.
7.
8.
Plug
Lever
Retainer
Seat
Spool
Piston
Sleeve
Spring
11
SEN00603-00
Function
q
The servo valve controls the current input to
the EPC valve and the pump delivery (Q) so
that they will be related as shown in the diagram.
q
q
12
The output pressure of the EPC valve flows in

the piston chamber to push piston (6).
Piston (6) pushes spool (5) until it is balanced
with the spring.
Then, the land of the servo piston pressure

passage is connected to the pump discharge
passage by the notch of spool (5) and the discharge pressure is led to the servo piston.
When the rocker cam is pushed up by the
servo piston, a position feedback is applied
and lever (2) moves to compress spring (8).
When spool (5) is pushed back, the pump discharge circuit and the servo piston circuit are
cut off.
Pressure in the servo piston chamber drops
and the rocker cam returns in the direction of a
maximum swash plate angle.
These processes are repeated until the swash
plate is fixed to a position where the EPC output pressure is balanced with spring (8) force.
The greater the EPC output pressure, the
smaller the swash plate angle. Conversely, the
smaller the EPC output pressure, the greater
the swash plate angle.
D155AX-6
SEN00603-00
Cooling fan motor
Type: LMF110(65)
P: From fan pump

T: From cooler to tank
TC: To tank
14
Specifications
Type: LMF110(65)
Capacity: 65.1 cc/rev
Rated speed: 1,250 rpm
Rated flow: 81.4 l/mm
Check valve crack pressure: 78.5 kPa {0.8 kg/cm2}
D155AX-6
1.
2.
3.
4.
5.
6.
Output shaft
Case
Thrust plate
Piston assembly
Cylinder block
Valve plate
SEN00603-00
7.
8.
9.
10.
11.
12.
End cover
Center spring
Check valve
Pilot valve
Spool for reversible valve
Safety valve
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
13 Spool return spring
14 Check valve spring
D155AX-6
Free length x Installation

outer diameter
length
Repair limit
Installation
load
Free
length
62.66 x 19.8
53.5
146 N
{14.9 kg}
16.4 x 8.9
11.5
13.7 N
{1.4 kg}
Installation
load
Replace spring
if damaged or
117 N
{11.9 kg} deformed.
11.0 N
{1.12 kg}
15
SEN00603-00
1. Hydraulic motor
Function
q
This hydraulic motor is called a swash platetype axial piston motor. It converts the energy
of the pressurized oil sent from the hydraulic
pump into rotary motion.
Principle of operation
q
The oil sent from the hydraulic pump flows
through valve plate (7) into cylinder block (5).
This oil can flow on only one side of the (Y-Y)
line connecting the top dead center and bottom
dead center of the stroke of piston (4).
q
The oil sent to one side of cylinder block (5)
presses piston (4) [4 or 5 pieces], and generates force (F1)[F1 = P x xD2/4].
q
This force is applied to thrust plate (2). Since
thrust plate (2) is fixed to the angle of (a)
degrees to the output shaft(1), the force is
divided into components (F2) and (F3).
q
The radial component (F3) generates torque [T
= F3 x ri] against the (Y-Y) line connecting the
top dead center and bottom dead center.
q
The result of this torque [T = (F3 x ri)] rotates
cylinder block (5) through the piston.
q
Since this cylinder block (5) is splined to the
output shaft, the output shaft revolves to transmit the torque.
16
D155AX-6
SEN00603-00
2. Suction valve
Function
q
If the fan pump stops, the pressurized oil does
not flow into the motor. Since the motor continues revolution because of the force of inertia,
however, the pressure on the outlet side of the
motor rises.
q
When the oil stops flowing in from inlet port (P),
suction valve (1) sucks in the oil on the outlet
side and supplies it to port (MA) where there is
not sufficient oil to prevent cavitation.
Operation
1)
q
2)
q
When the pump is stopped

If the engine is stopped and the input revolution of the fan pump lowers to 0 rpm, the pressurized oil from the pump is not supplied to
port (P) any more. As the pressurized oil is not
supplied to the (MA) side of the motor, the
motor speed lowers gradually to stop.
If the motor shaft is revolved by the force of
inertia while the oil flow in the port (P) is reducing, the oil in port (T) on the outlet side is sent
by the suction valve (1) to the (MA) side to prevent cavitation.
When pump is started

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
SEN00603-00
3. Operation of reversible valve

1)
q
q
q
18
When the ON-OFF solenoid is de-energized.

If ON-OFF solenoid (1) is de-energized, the
pressurized oil from the pump is blocked by
ON-OFF selector valve (2), and port (C) opens
for the tank circuit.
Spool (3) is pushed to the right by spring (4).
Motor port (MA) opens and pressurized oil
flows in to revolve the motor in forward (clockwise).
2)
q
q
q
When the ON-OFF solenoid is energized.

If ON-OFF solenoid (1) is energized, ONOFF selector valve (2) changes to let the pressurized oil from the pump flow through port (C)
into spool chamber (D).
The pressurized oil in chamber (D) pushes
valve spool (3) to the left against spring (4).
Motor port (MB) opens and pressurized oil
flows in to revolve the motor in reverse (counterclockwise).
D155AX-6
SEN00603-00
4. Safety valve
Function
q
When the engine is started, the pressure in
port (P) of the fan motor is heightened in some
cases.
q
Safety valve (1) is installed to protect the fan
system circuit.
Operation
q
If the pressure in port (P) rises above the
cracking pressure of safety valve (1), valve (2)
of safety valve (1) opens to release the pressurized oil into port (T).
q
By this operation, generation of abnormal pressure in port (P) is prevented.
D155AX-6
19
SEN00603-00
D155AX-6 Bulldozer
2005 KOMATSU
All Rights Reserved
Printed in Japan 12-05 (02)
20
D155AX-6
SEN00604-01
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up

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
SEN00604-01
Power train skeleton
Outline
q
The power generated by engine (1) has its torsional vibration dampened by damper (2), and
then passes through universal joint (3), and is
transmitted to torque converter (8).
q
The power from the engine is transmitted
through the oil by torque converter (8) to the
transmission input shaft (turbine shaft) in
accordance with the change in load. (with L/U)
q
Transmission (9) uses a combination of a planetary gear system and hydraulic clutches to
reduce the speed and shift the gears (3 forward gears and 3 reverse gears). It connects
2 sets of clutches selected according to the
change in load, and transmits the power to
bevel gear (10) from the bevel pinion at the
rear end of the transmission.
The power transmitted to the bevel gear shaft

is transmitted to HSS (Hydrostatic Steering
System) (11). Hydraulic, HSS pump (5) is
driven by PTO (6), and output oil of the
Hydraulic, HSS pump drives HSS motor (12).
The rotation of the pair of the HSS gears on
the right and left is controlled by HSS motor
(12). The steering is carried out by generating
a difference in speed on the right and left. It is
also possible to use the HSS mechanism to
rotate the right and left sides in opposite directions to carry out pivot turns.
Brake (13) of the HSS is used for braking the
machine. Brake (13) is a wet, multiple disc
clutch, spring boosted type. The power sent
from brake (13) is transmitted to final drive
(14).
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).
D155AX-6
1.
2.
3.
4.
5.
6.
7.
8.
9.
Engine (SAA6D140E-5)
Damper
Universal joint
Scavenging pump (SAR(4)140)
Hydraulic, HSS pump (HPV190)
PTO
Power train lubricating pump
(SAR(3)100+(3)40)
Torque converter
Transmission
D155AX-6
SEN00604-01
10.
11.
12.
13.
14.
15.
16.
17.
18.
Bevel gear
HSS unit
HSS motor (KMF140)
Brake
Final drive
Sprocket
Track shoe
Cooling fan pump (LPV45)
Cooling fan motor (LMF65)
SEN00604-01
Overall drawing of power train unit
D155AX-6
1.
2.
3.
HSS unit
Transmission
Power train, lubricating pump
(SAR(3)100+(3)40)
4. Power train oil strainer
5. HSS motor (KMF140)
6. Main relief, torque converter relief valve
7. Torque converter, PTO
8. Scavenging pump (SAR(4)140)
9. Cooling fan pump (LPV45)
10. Hydraulic, HSS pump (HPV190)
11. Brake control valve
D155AX-6
SEN00604-01
Outline
q
The power train unit can be broadly divided
into torque converter, PTO (7), transmission
(2), and HSS unit (1).
So, a fter the power train unit h as be en
removed, it can be disassembled into the
torque converter, PTO (7), transmission (2),
and HSS unit (1).
q
HSS unit consists of the bevel pinion unit,
bevel gear shaft, HSS motor, planetary gear
and brake.
SEN00604-01
Power train hydraulic piping drawing
D155AX-6
1.
2.
3.
4.
5.
6.
7.
8.
9.
SEN00604-01
Hydraulic, HSS pump (HPV190)

Centralized pressure detection port
Power train, lubrication pump
(SAR(3)100+(3)40)
Brake control valve
HSS motor (KMF140)
Main relief, torque converter relief valve
Power train oil filter
Scavenging pump (SAR(4)140)
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
SEN00604-01
Damper, universal joint
D155AX-6
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
SEN00604-01
Breather
Dipstick
Drain plug
Output shaft
Flywheel
Outer body
Coupling
Universal joint
Cover
Rubber coupling
Inner body
Unit: mm
No.
12
Check item
Clearance between flywheel
housing and cover
13
Clearance between flywheel

and damper
14
Outside diameter of coupling

oil seal contact surface
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
511.18
0.022
0.092
+0.070
+0.070
0.022
0.162
0.2
466.72
0.020
0.083
+0.063
+0.070
0.020
0.146
0.2
Standard size
Tolerance
Repair limit
90
0.087
0.087
89.8
Replace
Outline
q
The damper, dampens the torsional vibration
caused by the change in engine torque and
the impact torque generated when accelerating suddenly or when carrying out heavy-duty
digging. In this way, it acts to protect the torque
converter, transmission, and other parts of the
power train.
q
The damper has few component parts: it uses
a rubber coupling, so the vibration is absorbed
by the damping effect of the rubber material.
Operation
q
The motive force from the engine passes
through flywheel (5) and is transmitted to outer
body (6).
The torsional vibration of the engine is absorbed
by rubber coupling (10), and the power is transmitted to inner body (11). It passes through universal joint (8), and is then transmitted to the
torque converter and transmission.
D155AX-6
SEN00604-01
Torque converter, PTO

a
PTO: Abbreviation for Power Take Off
A:
B:
C:
From power train pump

To power train oil cooler
From main relief valve
10
D:
E:
F:
From transmission case

To transmission case
From power train oil cooler
D155AX-6
D155AX-6
SEN00604-01
11
SEN00604-01
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
12
Work equipment, HSS pump mounting port

Cooling fan pump mounting port
Scavenging pump mounting port
Power train and steering lubrication pump
Mounting port
Torque converter case
Coupling
Input shaft (number of teeth: 58)
PTO idler gear (number of teeth: 66)
PTO idler gear shaft
Lockup clutch housing
Turbine
Drive case
Race
Stator
Pump
Retainer
Stator clutch front housing
Pump shaft
Stator clutch rear housing
Stator shaft
Stator clutch hub
Stator clutch plate
Stator clutch disc
Stator clutch piston
Transmission input shaft
Lockup clutch plate
Lockup clutch disc
Lockup clutch piston
Turbine boss
PTO Gear A (number of teeth: 49)
PTO Gear B (number of teeth: 48)
Scavenging pump drive gear
(number of teeth: 56)
Torque converter control valve
Power train oil strainer
Sleeve
D155AX-6
Outline
q
The torque converter is a 3-element, 1-stage,
and 2-phase type, which is integral with the
transmission.
q
The torque converter is equipped with a wet
double disc clutch type torque converter lockup
device and a stator clutch in order to reduce
fuel consumption, to increase the operability,
and to reduce the horsepower consumption by
the engine.
q
For higher efficiency of continuous light dozing
and leveling operation, the torque converter is
locked up and the engine power is transferred
directly to the transmissions input shaft.
q
When the torque converter is locked up (the
pump and turbine is integrated into 1 unit), the
oil is still supplied to the torque converter.
Accordingly, the oil flowing from the pump
through the turbine to the stator is obstructed
by the stator blades and cannot flow in any
direction. As a result, this oil resists the rotation
of the pump and turbine (it is agitated).
q
To reduce the rotating resistance of the pump
and turbine, the stator clutch is disengaged
simultaneously with lockup of the torque converter so that the stator can rotate freely.
As the stator is dragged and turned by the
pump and turbine, the oil returns from the turbine to the pump smoothly against less resistance.
SEN00604-01
Structure
q
Pump (15) is integrated with coupling (6), input
shaft (7), lockup clutch housing (10), and drive
case (12), and rotated by the engine power.
q
Turbine (11) is integrated with turbine boss
(29) and transmission input shaft (25), and
rotated by the oil from pump (15).
q
Stator (14) is integrated with stator shaft (20)
and stator clutch hub (21), and fixed to torque
converter case (5) through the stator clutch
unit.
q
The lockup clutch unit consists of clutch plate
(26) meshed with drive case (12), clutch disc
(27) meshed with turbine boss (29), and clutch
piston (28) which slides inside clutch housing
(10) integrated with drive case (12).
q
The stator clutch unit consists of clutch hub
(21) attached to stator shaft (20) with spline,
clutch disc (23) meshed with clutch hub (21),
clutch plate (22) supported by the pins on
clutch front housing (17) and clutch rear housing (19), and clutch piston (24) which slides
inside clutch front housing (17).
Clutch front housing (17) is fixed to sleeve (35)
with torque converter case (5).
q
The PTO unit consists of input shaft (7), PTO
idler gear (8), PTO gear A(30), PTO gear B(31)
and scavenging pump drive gear (32).
Conditions for lockup range and torque converter range

Torque converter output shaft speed
Lockup range
Torque converter
range
Forward
1st
Min. 1,313 rpm
Max. 1,262 rpm
Forward
2nd
Min. 1,899 rpm
Max. 1,876 rpm
Forward
3rd
Min. 1,366 rpm
Max. 1,355rpm
Reverse
1st
Min. 1,244 rpm
Max. 1,216 rpm
Reverse
2nd
Min. 1,196 rpm
Max. 1,177 rpm
Reverse
3rd
Min. 1,622 rpm
Max. 1,613 rpm
D155AX-6
13
SEN00604-01
14
D155AX-6
SEN00604-01
Unit: mm
No.
Check item
Criteria
Outer diameter of oil seal

contact surface of the coupling
Remedy
Standard size
Tolerance
Repair limit
100
-0.054
-0.054
99.8
35
+0.025
+0.025
35.1
Width
2.56
-0.01
-0.03
2.3
Thickness
1.7
0.1
1.55
Inner diameter of the seal ring

contact surface of the stator
shaft
65
+0.030
+0.025
65.1
Width
-0.01
-0.03
2.7
Thickness
2.7
0.1
2.55

contact surface of the sleeve
90
+0.035
+0.025
90.1
Width
-0.01
-0.03
2.7
Thickness
3.7
0.12
3.55

contact surface of the retainer
150
+0.040
+0.025
150.5
Backlash between the input

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

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

idler gear and PTO gear B
0.198 0.484
Backlash between the input

shaft and the scavenging pump
drive gear
0.198 0.484
Inner diameter of the seal

ring contact surface of the input
shaft
2
Wear of the transmission input shaft

seal ring
Wear of the transmission input shaft

seal ring
4
Wear of the stator
shaft seal ring
Thickness of the
lockup clutch disc
Replace
Repair by hard
chrome plating
or replace
Replace
0.1
4.5
5.0
0.1
4.5
Overall thickness of
the lockup clutch assembly
15.0
0.17
13.9
Thickness of the stator clutch

disc
5.0
0.1
4.5
11 Thickness of the stator clutch

plate
5.0
0.1
4.5
Overall thickness of the stator

clutch assembly
15.0
0.17
13.9
D155AX-6
Repair by hard
chrome plating
or replace
Replace
5.0
10 Thickness of the
lockup clutch plate
Repair by hard
chrome plating
or replace
Repair by hard
chrome plating
or replace
Replace
15
SEN00604-01
Unit: mm
No.
Check item
Fitting tolerance
of the PTO idler
12 gear
and bearing
Criteria
Shaft
Hole
Standard
clearance
Clearance
limit
Outer
diameter
140
-0.025
-0.018
-0.008
-0.033
-0.033
0.010
Inner
diameter
80
0.025
-0.019
0
-0.015
-0.015
0.019
Outside
diameter
(cover side)
180
-0.025
-0.025
+0.026
-0.014
-0.014
0.051
120
-0.025
-0.015
+0.022
-0.013
-0.013
0.037
100
+0.035
+0.013
-0.025
-0.020
-0.055
-0.013
65
+0.030
+0.011
-0.025
-0.015
-0.045
-0.011
120
-0.025
-0.015
+0.022
-0.013
-0.013
0.037
120
-0.025
-0.015
+0.022
-0.013
-0.013
0.037
55
+0.030
+0.011
-0.025
-0.015
-0.045
-0.011
Inner
diameter
(case side)
65
+0.030
+0.011
-0.025
-0.015
-0.045
-0.011
Outer
diameter
85
-0.025
-0.015
+0.010
-0.025
-0.025
0.025
Inner
diameter
45
+0.018
+0.002
-0.025
-0.012
-0.030
-0.002
Outside
diameter
(cover side)
Outside
Fitting tolerance of diameter
(case side)
fan pump
drive gear
Inner
bearing
diameter
(cover side)
Fitting tolerance of
the scavenging
15 pump
drive gear
bearing
Standard size
16 Stator clutch
return spring
Replace
Repair limit
Installation Installation
Installation
Free length
Free length
length
load
load
35
16
Remedy
Standard
size
Fitting tolerance of
Outside
HSS, work equipdiameter
ment,
(case side)
power train,
13 steering
Inner
lubrication pump
diameter
drive gear
(cover side)
bearing
Inner
diameter
(case side)
14
Tolerance
27
85.3 N
{8.7 kg}
32.9
72.6 N
{7.4 kg}
D155AX-6
SEN00604-01
Power transmitting route

When lockup clutch isdisengagedand stator
clutch is engaged
When lockup clutch isengagedand stator

clutch is disengaged
Drive case (4) is disconnected from turbine boss (8)

and turbine (7) and lockup torque converter works
as an ordinary torque converter.
Drive case (4) is connected to boss (8) and turbine

(7) and lockup torque converter is locked up.
The power from engine

O
Damper
O
Universal joint
O
Coupling (1)
O
Input shaft (2)
O
Clutch housing (3), drive case (4) and pump (5)
rotate together
O
Oil is used as medium
O
Turbine (7) and turbine boss (8)
O
Transmission input shaft (9)
q
If stator clutch (10) is "engaged" at this time,

torque converter case (11) and stator shaft (12)
are connected to each other to fix stator (13).
D155AX-6
The power from engine

O
Damper
O
Universal joint
O
Coupling (1)
O
Input shaft (2)
O
Clutch housing (3), drive case (4) and pump (5)
rotate together
O
Lockup clutch (6)
O
Turbine boss (8)
O
Transmission input shaft (9)
q
If stator clutch (10) is disengaged at this time,

torque converter case (11) and stator shaft (12)
are disconnected from each other, and stator
(13) is dragged and turned by pump (5) and
turbine (7).
17
SEN00604-01
Oil flow
18
The oil flows through the main relief valve and

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

Stator clutch oil pressure pickup port (SC)
Lockup clutch oil pressure pickup port (LC)
1.
2.
3.
Torque converter oil filter

Stator clutch ECMV
Lockup clutch ECMV
D155AX-6
SEN00604-01
19
SEN00604-01
Lockup clutch ECMV, stator clutch ECMV

a
a
ECMV: Abbreviation for Electronic Control Modulation Valve

Don't try to disassemble it since adjustment for maintaining the performance will be needed.
A: To clutch
P: From pump
T: Drain
DR: Drain
P1: Clutch oil pressure pickup port
P2: Pilot oil pressure pickup port
1.
2.
3.
4.
5.
6.
7.
20
*1:
Operated clutches
Stamp of the nameplates
Lockup
E*******
Stator
A*******
Fill switch connector

Proportional solenoid connector
Pressure detection valve
Fill switch
Proportional solenoid
Pressure control valve
Nameplate (*1)
D155AX-6
ECMV for lockup clutch

Outline
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.
SEN00604-01
Operation
When traveling in torque converter range
When changing from torque converter travel to

direct travel
At gear shift (in direct travel)
D155AX-6
When traveling in torque converter range, current is not supplied to proportional solenoid (1).
Pressure control valve (3) drains the oil from
clutch port (A) through drain port (T), and
lockup clutch is released.
Also at this time, fill switch (5) is turned off
because oil pressure is not applied to pressure
detection valve (4).
21
SEN00604-01
When traveling in direct range

(Torque converter travel o direct travel)
During filling
22
When traveling in direct (lockup) range, current

is supplied to proportional solenoid (1), the oil
pressure force balanced with the solenoid
force is applied to chamber (B) and pushes
pressure control valve (3) to the left.As a
result, pump port (P) and clutch port (A) are
opened and oil starts filling the clutch. If the
clutch is filled with oil, fill switch (5) is turned
on.
Pressure adjustment
If current flows in proportional solenoid (1), the

solenoid generates thrust in proportion to the
current. This thrust of the solenoid is balanced
with the sum of the thrust generated by the oil
pressure in clutch port and the tension of pressure control valve spring (2), and then the
pressure is settled.
While shifting gears, the lockup clutch oil pressure 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.
D155AX-6
ECMV for stator clutch

Outline
q
This valve acts to set the lockup clutch oil pressure to the set pressure, and also to switch the
lockup clutch.
SEN00604-01
Operation
When traveling in direct range
It forms a modulation wave pattern, so the stator clutch is engaged smoothly to reduce the
shock when shifting gear. In addition, it prevents generation of peak torque in the power
train. As a result, it provides a comfortable ride
for the operator and greatly increases the
durability of the power train.
Direct travel o torque converter travel
D155AX-6
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 stator clutch is released.
23
SEN00604-01
When traveling in torque converter range

(Direct travel o torque converter travel)
During filling
24
When traveling in torque converter range current is supplied to proportional solenoid (1), the
oil pressure force balanced with the solenoid
force is applied to chamber (B) and pushes
pressure control valve (3) to the left.As a
result, pump port (P) and clutch port (A) are
opened and oil starts filling the clutch. If the
clutch is filled with oil, fill switch (5) is turned
on.
Pressure adjustment

D155AX-6
D155AX-6
SEN00604-01
25
SEN00604-01
Transmission control
a
a
1.
2.
3.
4.
5.
26
For steering operation of the Palm Command Steering Control lever (PCCS lever), see Steering, brake
control.
PCCS: Abbreviation for Palm Command Control System
Brake pedal
Lock lever
PCCS lever
(Forward-Reverse, Gear shift)
3A. UP switch
(Gear is shifted up each time this switch is
pressed.)
3B. DOWN switch
(Gear is shifted down each time this switch
is pressed.)
Transmission neutral lock
Transmission control valve
Lever positions
A: Neutral
B: Forward
C: Reverse
D: OFF
E: Shift UP
F: Shift DOWN
G: Free
H: Lock
D155AX-6
SEN00604-01
Outline
q
The transmission is controlled with PCCS lever
(3).
The PCCS lever is used to select the travel
direction and shift the gear.
q
Since the safety mechanism is employed,
transmission neutral safety switch (4) does not
work and the engine does not start unless lock
lever (2) is in the LOCK position.
D155AX-6
27
SEN00604-01
Transmission
28
D155AX-6
A:
B:
C:
D:
E:
F:
G:
H:
J:
1st clutch pressure pickup port (1ST)

3rd clutch pressure pickup port (3RD)
R clutch oil pressure pickup port (R)
2nd clutch pressure pickup port (2ND)
F clutch oil pressure pickup port (F)
To brake control valve
From steering case
From power train oil cooler
D155AX-6
SEN00604-01
K:
L:
M:
N:
P:
R:
S:
T:
U:
To torque converter
To scavenging pump
To torque converter case
From torque converter case
To R clutch
To 3rd clutch
To 1st clutch
To 2nd clutch
To F clutch
29
SEN00604-01
30
D155AX-6
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
Transmission ECMV
Main relief valve and torque converter relief
valve
Transmission case
Sleeve
Transmission input shaft
Tie bolt
R ring gear (hub)
R planetary pinion (number of teeth: 26)
R ring gear (number of internal teeth: 86)
F planetary pinion (number of teeth: 24)
F ring gear (number of internal teeth: 91)
3rd planetary pinion (number of teeth: 35)
3rd ring gear (number of internal teeth: 89)
2nd planetary pinion (number of teeth: 31)
2nd ring gear (number of internal teeth: 91)
1st ring gear (number of internal teeth: 91)
1st planetary pinion (number of teeth: 27)
Transmission output shaft
(3rd sun gear)(number of teeth: 19)
1st clutch housing
1st clutch piston
1st sun gear (number of teeth: 37)
1st carrier
2nd clutch housing
2nd clutch piston
2nd sun gear (number of teeth: 29)
2nd carrier
3rd clutch housing
3rd clutch piston
3rd carrier
F clutch housing
F clutch piston
F carrier
R clutch housing
F sun gear (number of teeth: 44)
R clutch piston
Washer spring
Clutch plate
Clutch disc
Piston return spring
R carrier
Front housing
R sun gear (number of teeth: 34)
D155AX-6
SEN00604-01
Outline
q
The transmission adopted is a forward 3-gear
speed and reverse 3-gear speed transmission
which consists of the planetary gear mechanisms and the disc clutches.
q
Out of the 5 sets of planetary gear mechanisms and disc clutches, 2 clutches are fixed
hydraulically by the operation of ECMV to
select 1 rotation direction and 1 gear speed.
q
The transmission transfers the power received
by the transmission input shaft to the output
shaft while changing the gear speed (forward
1st-3rd or reverse 1st-3rd) by any combination
of the F, R clutches and 3 speed clutches.
Number of plates and disk used
Clutch No.
Number of
plates
Number of discs
R clutch
F clutch
3rd clutch
2nd clutch
1st clutch
Combinations of clutches at respective gear

speeds and reduction ratio
Gear speed
Operated clutches
Reduction
ratio
Forward 1st
F x 1st
1.705
Forward 2nd
F x 2nd
1.151
Forward 3rd
F x 3rd
0.540
Neutral
Reverse 1st
R x 1st
1.406
Reverse 2nd
R x 2nd
0.949
Reverse 3rd
R x 3rd
0.445
*: The 1st, 2nd, or 3rd clutch is filled with low-pressure

oil.
31
SEN00604-01
32
D155AX-6
SEN00604-01
Unit: mm
No.
Check item
Criteria
Standard size
Free length
R clutch spring (12 pcs.)
Remedy
Repair limit
Installation
Free length
length
load
load
81.7
72.4
59.8 N
{6.1 kg}
76.8
51.0 N
{5.2 kg}
F clutch spring (12 pcs.)
81.7
76.4
34.3 N
{3.5 kg}
76.8
29.4 N
{3.0 kg}
3rd clutch spring (12 pcs.)
70.0
50.2
97.1 N
{9.9 kg}
65.8
82.4 N
{8.4 kg}
2nd clutch spring (12 pcs.)
70.0
51.6
90.2 N
{9.2 kg}
65.8
76.5 N
{7.8 kg}
1st clutch spring (12 pcs.)
66.0
51.8
66.7 N
{6.8 kg}
62.0
56.9 N
{5.8 kg}
Total thickness of R clutch

assembly consisting of 6 discs
and 6 plates
Standard size
Tolerance
Repair limit
51.6
0.35
48.4
Total thickness of F clutch

and 6 plates
57.0
0.36
53.3
Total thickness of the 3rd clutch

and 3 plates
31.2
0.26
29.1
Total thickness of the 2nd clutch

and 3 plates
31.2
0.26
29.1
Total thickness of 1st clutch

10 assembly consisting of 3 discs
and 2 plates
22.6
0.22
21.0
11 Thickness of the clutch disc
5.4
0.1
4.9
12 Thickness of the clutch plate
3.2
0.1
2.9
Width
2.56
-0.01
-0.03
2.30
Thickness
1.7
0.1
1.55
Width
3.0
-0.01
-0.03
2.70
Thickness
2.7
0.1
2.55
Wear of front housWidth

ing, F clutch housing,
15
and 3rd carrier
Thickness
seal ring
4.0
-0.01
-0.04
3.60
5.0
0.15
4.85
Width
4.0
-0.01
-0.04
3.60
Thickness
4.0
0.15
3.85
Width
4.0
-0.01
-0.04
3.60
Thickness
4.0
0.15
3.85
Wear of the input

13
shaft seal ring (small)
Wear of the input

14
shaft seal ring (large)
Wear of the 2nd car16

rier seal ring (large)
Wear of the 2nd car17

rier seal ring (small)
D155AX-6
Replace
33
SEN00604-01
Unit: mm
No.
18
Check item
Wear of the 1st carrier seal ring (large)
Wear of the 1st car19

rier seal ring (small)
Backlash between
20 sun gear and
planetary pinion
21
Backlash between
planetary pinion and
ring gear
Criteria
Remedy
Standard size
Tolerance
Repair limit
Width
4.0
-0.01
-0.04
3.60
Thickness
4.0
0.15
3.85
Width
4.0
-0.01
-0.04
3.60
Thickness
5.0
0.15
4.85
R, F,
3rd, 1st
0.14 - 0.35
2nd
0.13 - 0.32
0.15 - 0.39
F, 2nd,
1st
0.15 - 0.38
3rd
0.16 - 0.42
Replace
Disc clutch
Structure
q
q
34
The disc clutch consists of piston (2), plates

(3), discs (4), pin (5), return spring (6) etc. to fix
ring gear (1).
Inside teeth of disc (4) are engaged with outside teeth of ring gear (1).
Plate (3) is assembled to clutch housing (7)
with pin (5).
Operation
When clutch is engaged (fixed)
The oil from ECMV is sent with pressure to the

rear side of piston (2) through oil the passage
of housing (7) and pushes piston (2) leftward.
Piston (2) contacts plate (3) closely against
disc (4) to stop rotation of disc (4) by use of the
friction force generated between them.
Since inside teeth of disc (4) are engaged with
outside teeth of ring gear (1), move of ring gear
(1) is stopped.
D155AX-6
When clutch is disengaged (released)
q
q
As the oil from ECMV is stopped, piston (2) is

pushed back rightward by return spring (6).
The friction force between plates (3) and discs
(4) is released and ring gear (1) is released.
SEN00604-01
Oil passage in speed clutch

a The figure shows the case in which 1st gear
speed is selected.
D155AX-6
When the steering/directional/gear shift lever is

set in the neutral position, the 1st, 2nd, or 3rd
speed is selected.
The piston chamber of the clutch corresponding to the selected gear speed is filled with oil
by electronically controlling the hydraulic circuit
of each clutch.
When the steering/directional/gear shift lever is
shifted from the neutral position to theforward or reverse position, the pump is
required to supply oil of quantity to fill the piston chamber of the F clutch or R clutch.
When the gear speed is changed from forward 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.
The time lag in the gear shifting operation is
reduced by controlling the oil in the clutch circuit as explained above.
35
SEN00604-01
Power transmitting route

Forward 1st speed
36
D155AX-6
SEN00604-01
F ring gear (4) of F clutch and 1st ring gear (19) of 1st clutch are fixed hydraulically.
The power from torque converter
O
Input shaft (1)
O
F sun gear (2)
O
F planetary pinion (3)
O
F carrier (10)
O
3rd carrier (11)
O
3rd planetary pinion (12)
O
3rd ring gear (13)
O
2nd carrier (14)
O
2nd planetary pinion (15)
O
2nd ring gear (16)
O
1st carrier (17)
O
1st planetary pinion (18)
O
1st sun gear (20)
O
Output shaft (22)
D155AX-6
2nd sun gear (21)
37
SEN00604-01
Forward 2nd speed
38
D155AX-6
SEN00604-01
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
SEN00604-01
Forward 3rd speed
40
D155AX-6
SEN00604-01
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
SEN00604-01
Reverse 1st speed
42
D155AX-6
SEN00604-01
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
SEN00604-01
Transmission ECMV
a
a
44

D155AX-6
SEN00604-01
AF:
AR:
A1:
A2:
A3:
P:
T:
Dr:
PF:
PR:
P1:
P2:
P3:
To F clutch
To R clutch
To 1st clutch
To 2nd clutch
To 3rd clutch
Drain
Drain
F clutch oil pressure pickup port
R clutch oil pressure pickup port
1st clutch oil pressure pickup port
2nd clutch oil pressure pickup port
3rd clutch oil pressure pickup port
Operation table of ECMV
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
3rd clutch proportional solenoid

1st clutch proportional solenoid
R clutch proportional solenoid
F clutch proportional solenoid
2nd clutch proportional solenoid
3rd clutch fill switch
2nd clutch fill switch
1st clutch fill switch
R clutch fill switch
F clutch fill switch
Transmission oil filter
Connector for 1st clutch proportional solenoid
Connector for 3rd clutch fill switch
Connector for 3rd clutch proportional solenoid
Connector for R clutch proportional solenoid
Connector for 2nd clutch fill switch
Connector for 2nd clutch proportional solenoid
Connector for F clutch proportional solenoid
Connector for 1st clutch fill switch
Connector for R clutch fill switch
Connector for F clutch fill switch
D155AX-6
sgear
speed
ECMV
N
F1
F2
F3
1st
2nd
3rd
Q
Q
Q
R1
R2
R3
Q
Q
Q
When the directional lever is in (neutral) position, the speed clutch of the speed selected by
gear shift lever activates.
45
SEN00604-01
1.
2.
3.
4.
5.
6.
7.
8.
46
Fill switch
Body (upper)
Body (lower)
Filter
Sleeve
D155AX-6
Outline of ECMV
q
The ECMV consists of 1 pressure control valve
and 1 fill switch.
q
A proportional solenoid in this valve receives a
current sent from the controller and this valve
converts it to an oil pressure.
q
Fill switch
This switch detects that the clutch is filled with
oil and has the following functions.
1. Outputs a signal (a fill signal) to the controller
to notify that filling is completed when the
clutch is filled with oil.
2. Keeps outputting signals (fill signals) to the
controller to notify whether oil pressure is
applied or not while oil pressure is applied to
the clutch.
SEN00604-01
ECMV and proportional solenoid

q
For each ECMV, 1 proportional solenoid is
installed.
The proportional solenoid generates thrust
shown below according to the command current from the controller.
The thrust generated by the proportional solenoid is applied to the pressure control valve
spool to generate oil pressure as shown in the
figure below. Accordingly, the thrust is changed
by controlling the command current to operate
the pressure control valve to control the flow
and pressure of the oil.
Current - propulsion force characteristics of
proportional solenoid
Propulsion force - Hydraulic pressure characteristics of proportional solenoid
Range A: Before shifting gear (When draining)

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).
D155AX-6
ECMV and fill switch

For each ECMV, 1 fill switch is installed.
If the clutch is filled with oil, the fill switch is
turned ON by the pressure of the clutch. The
oil pressure is built up according to this signal.
47
SEN00604-01
Operation of ECMV
q
ECMV is controlled with the command current
sent from the controller to the proportional
solenoid and the fill switch output signal.
The relationship between the proportional
solenoid command current of ECMV, clutch
input pressure, and fill switch output signal is
shown below.
Before shifting gear (when draining) (Range A

in chart)
Range A: Before shifting gear (When draining)

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 pressure 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
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).
D155AX-6
During filling (Range B in chart)
If current is supplied to proportional solenoid

(1) with no oil in the clutch, the oil pressure
force balanced with the solenoid force is
applied to chamber (B) and pushes pressure
control valve (3) to the right. As a result, pump
port (P) and clutch port (A) are opened and oil
starts filling the clutch. If the clutch is filled with
oil, fill switch (5) is turned on.
D155AX-6
SEN00604-01
Pressure adjustment (Range C in chart)

49
SEN00604-01
Main relief valve and torque converter relief valve
Unit: mm
No.
Check item
Clearance between main relief
valve and body
Clearance between the torque converter relief valve and the body
Criteria
Standard
size
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
28
-0.035
-0.045
+0.013
+0.013
0.035
0.058
0.078
22
-0.035
-0.045
+0.013
+0.013
0.035
0.058
0.078
Standard size
3
Main relief valve spring

(outside)
Remedy
Repair limit
Installation
Free length
Free length
length
load
load
122
78.0
481 N
{49 kg}
118.3
457 N
{46.6 kg}
Main relief valve spring

(inside)
108
78.0
368 N
{37.5 kg}
104.8
349 N
{35.6 kg}
Torque converter relief valve

spring
50
40.5
182 N
{18.6 kg}
48.5
174 N
{17.7 kg}
6.
7.
8.
9.
10.
50
Body
Piston
Piston
Main relief valve
Replace
A: Drain (Torque converter relief)

B: Drain
C: From pump
D: Drain
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
D155AX-6
Outline
SEN00604-01
Operation of main 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 protect 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
brake at set pressure.
Set pressure:
3.18 0.1 MPa {32.4 1.0 kg/cm2}
(Engine at rated speed)
The oil from the hydraulic pump flows to chamber (F) through the filter, port (C) of the relief
valve and orifice (a) of main relief valve (1).
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)
to the torque converter.
Operation
Operation of torque converter relief valve
The oil from the main relief valve is conducted

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).
As the oil pressure to the torque converter
rises beyond the set pressure, the oil conducted to chamber (G) pushes piston (4) and
the resulting reaction force pushes torque converter 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
SEN00604-01
Lubrication relief valve
Unit: mm
No.
Check item
Criteria
Standard size
Lubrication relief valve spring
Free length
26
2.
3.
4.
F clutch housing
R clutch housing
Piston
A:
B:
C:
From oil cooler

Drain
Drain
Remedy
Repair limit
Installation
Free length
length
load
load
Replace
23.6
12.5 N
{1.27 kg}
25.2
11.9 N
{1.21 kg}
Outline
q
The oil leaving the torque converter passes
through the power train oil cooler built in the
radiator lower tank. It then goes through the
lubrication relief valve and lubricates the transmission and PTO.
q
The lubrication relief valve is installed to the
right side face of the F clutch housing. It keeps
the lubricating oil pressure below the set pressure.
Specified value
52
Normal pressure
(MPa{kg/cm2})
0.14 0.05
{1.4 0.5}
Cracking pressure
(MPa{kg/cm2})
0.30 0.03
{3.0 0.3}
D155AX-6
SEN00604-01
Scavenging pump
Type: SAR(4)140
Unit: mm
No.
Check item
Side clearance
Clearance between plain bearing inner diameter and gear

shaft outer diameter
Pin driving depth
Spline shaft rotating torque
Delivery amount
Oil: SAE10WCD
Oil temperature: 45 55C
Criteria
Remedy
Standard clearance
Clearance limit
0.11 0.16
0.19
0.06 0.14
0.20
Replace
Standard size
Tolerance
Repair limit
21
-0.5
-0.5
9.8 14.7 Nm {1.0 1.5 kgm}

Rotation speed
(rpm)
Delivery pressure
MPa{kg/cm2}
Standard
delivery
(l/min)
Delivery
limit
(l/min)
2,200
2.94{30}
300
266
Outline
q
The scavenging pump is installed to the torque
converter case and is driven with the power
from the engine. It returns the oil collected in
the bottom of the transmission case to the
steering case.
D155AX-6
53
SEN00604-01
Power train and steering lubrication pump
Type: SAR(3)100+(3)40
1.
2.
54
Power train pump

Steering lubrication pump
Outline
q
The power train pump and the steering lubrication pump are installed to the torque converter
case. They are driven by the power from the
engine to supply the oil pressure to the torque
converter, the transmission and the steering
unit.
D155AX-6
SEN00604-01
Unit: mm
No.
Check item
Criteria
Type
Side clearance
SAR(3)100
SAR(3)40
Clearance between plain bearing inner diameter

and gear shaft outer diameter
Pin driving depth
SAR(3)40
SAR(3)100
SAR(3)40
Rotating torque of spline shaft
Delivery amount
Oil: SAE10WCD
Oil temperature: 45 55C
D155AX-6
Clearance limit
0.10 - 0.15
0.19
0.06 - 0.15
0.20
SAR(3)100
Type
5
Remedy
Standard clearance
Replace
Standard size
Tolerance
Repair limit
14
-0.5
-0.5
13.7 - 23.5 Nm {1.4 - 2.4 kgm}

Type
Rotation
speed
(rpm)
Delivery
pressure
(MPa{kg/
cm2})
Standard
delivery
(l/min)
Delivery
limit
(l/min)
SAR(3)100
2,500
2.94{30}
241
96
SAR(3)40
2,500
2.94{30}
239
85
55
SEN00604-01
D155AX-6 Bulldozer
2007 KOMATSU
All Rights Reserved
56
D155AX-6
SEN00605-02
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
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 ........................................................................................................................ 68
Sudden stop prevention valve....................................................................................................................... 70
Final drive ..................................................................................................................................................... 72
Sprocket ........................................................................................................................................................ 78
D155AX-6
SEN00605-02
HSS system
D155AX-6
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
PCCS lever
Power train controller
Control valve
Hydraulic, HSS pump
Engine
EPC valve
Hydraulic tank
Sprocket
Final drive
HSS motor
HSS open circuit
Servo valve
Engine throttle controller
A:
B:
C:
D:
E:
FORWORD REVERSE signal

STEERING signal
Engine control information
Work equipment pressure signal
CAN communication network
D155AX-6
SEN00605-02
Outline
q
HSS system is an abbreviation for the Hydrostatic Steering System.
q
The HSS system consists of a set of control
valve, hydraulic, HSS pump, and HSS motor
as shown in the figure. It turns the machine
continuously without lowering the travel speed
by making a difference in speed between both
tracks.
q
The power train controller controls the EPC
valve of the control valve to control the revolving direction and revolving speed of the HSS
motor according to the tilting direction and
angle of the PCCS lever. The HSS motor acts
on the planetary gear mechanism of the bevel
gear shaft to make a difference in speed
between both sprockets. As a result, the
machine turns.
q
The power train controller senses the engine
speed and oil pressure at each part and controls the hydraulic, HSS pump and control
valve to drive the hydraulic, HSS pump so that
the engine will not stall.
q
The engine speed signal and other engine
control information items are sent and received
through the CAN communication network
which connects the engine throttle controller
and power train controller.
SEN00605-02
HSS motor
Type: KMF140
PA: From control valve

PB: From control valve
T: To tank
1.
2.
3.
4.
Outline
q
This motor is composed of the fixed capacity
bent axis type piston motor, the counterbalance valve, the check valve and relief valve.
Specifications
Type: KMF140
Theoretical delivery: 141.1 cm3/rev
Rated output pressure: 41.2 MPa {420 kg/cm2}
Rated rpm: 2,205 rpm
HSS motor
Check valve
Counterbalance valve
Relief valve
D155AX-6
D155AX-6
SEN00605-02
SEN00605-02
D155AX-6
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
SEN00605-02
Drive shaft
Motor case
Piston
Cylinder block
Valve plate
Housing
Cover
Counterbalance valve spool
Check valve
Spool
Safety valve
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
12 Check valve spring
Free length x Installation

outer diameter
length
Repair limit
Installation
load
Free
length
Installation
load
62.5 x 20
39
3.04 N
{0.31 kg}
1.96 N
{0.25 kg}
13
Spool return spring

(Large)
43.4 x 35
41
241 N
{24.6 kg}
155 N
{19.7 kg}
14
Spool return spring

(Small)
40.44 x 21.9
38
96.1 N
{9.8 kg}
76.9 N
{7.84 kg}
D155AX-6
Replace spring
if damaged or
deformed.
SEN00605-02
Operation of piston motor

Principle
q
Supposed that the axis of the disc is supported
and the disc can rotate freely.If force (F) is
applied to the disc diagonally, force (F) is
divided into vertical force to the disc (F1) and
circumferential force (F2). (F1) pushes the
disc to axis direction, and (F2) rotates the disc
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').
Operation
q
The pressurized oil sent from the main piston
pump enters from the piston motor inlet port,
and the oil pressure is applied to the back of
piston (3), and drive shaft (1) rotates by the
inclination (Q) of piston (3) and cylinder block
(4).
Structure
q
Seven pistons (3) are attached to the disc part
of drive shaft (1) with a manner just like a
spherical joint Pistons (3) forms an specific
agle with drive shaft (1), and stored in cylinder
block (4).
D155AX-6
SEN00605-02
Brake valve
q
1)
The brake valve consists of check valve (9),

counterbalance valve (8), and safety valve
(11).
Functions and operations of respective components shall conform to the following.
Counterbalance valve and check valve
Function
When the steering is operated on a downhill
slope, the gravity force tends to make the current driving speed faster than the speed by
motor (engine) rotation.
q
If the steering is operated while the engine is
running at low speed, the motor rotates under
no load and runs away. This may cause an
extremely dangerous condition.
q
These valves control the steering opration in
accordance with the engine speed (pump
delivery) in order to prevent such a dangerous
condition.
q
D155AX-6
Operation when pressurized oil is supplied

q
If steering lever is operated, the pressurized oil
from the control valve is supplied to port (PA).
q
It pushes open check valve (9A), and flows
from motor inlet port (MA) to motor outlet port
(MB).
q
The outlet port side of the motor is closed by
check valve (9B) and spool (8), so the pressure at the side where the oil is being supplied
rises.
SEN00605-02
10
The pressurized oil at the side where the oil is

being supplied flows from orifice (E1) of spool
(8) into chamber (S1).
When the pressure in chamber (S1) becomes
higher than the spool switching pressure, spool
(8) is pushed to the right.
Port (MB) and port (PB) are connected, opening the motor outlet port side and starting the
motor rotating.
Brake operation when traveling downhill

q
When steering is operated on a downhill slopes,
if the machine attempts to run away, the motor
will rotate under no load, and the oil pressure at
the inlet port of motor will drop.
q
Through orifice (E1), the pressure in chamber
(S1) drops.
q
If the pressure in chamber (S1) drops below
the spool switching pressure, spool (8) is
pushed to the left by spring (13), (14), and outlet port (MB) is throttled.
q
The pressure at the outlet port side rises, generating rotation resistance on the motor to prevents the machine from running away.
q
Spool (8) moves to a position where it balances 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.
D155AX-6
2)
SEN00605-02
Safety valve
(Both operated safety valve.)
Function
q
When the operation of the steering is finished,
counterbalance valve closes the circuit at the
inlet and outlet ports of the motor.
q
Since the motor is rotated by inertial force,
pressure in the motor outlet port side is abnormally increased, potentially resulting in damages on the motor and piping.
q
The safety valve releases this abnormal pressure to the inlet port side of the motor in order
to prevent damages to the equipment.
As the pressure goes above the set pressure,

[Difference in areas of circles (D1) and (D2) x
Pressure] compresses spring (2).
Poppet (1) is moved leftward and the pressurized oil flows into chamber (MA) of the opposite circuit.
Bidirectional action
(1) When pressure in chamber (MB) has become
high (when rotating clockwise)
q
the check valve of the counterbalance valve
closes the circuit at outlet ports (MB).
q
The motor tries to continue rotation resorting to
inertial force, thus pressure on the outlet port
(MB) is increased.
D155AX-6
11
SEN00605-02
(2) When pressure in chamber (MA) has become

high (when rotating counterclockwise)
q
the check valve of the counterbalance valve
closes the circuit at outlet ports (MA) of the
motor.
q
The motor tries to continue rotation resorting to
inertial force, thus pressure on the outlet port
(MA) is increased.
12
As the pressure goes above the set pressure,

[Difference in areas of circles (D1) and (D3) x
Pressure] compresses spring (2).
Poppet (1) is moved leftward and the pressurized oil flows into chamber (MB) of the opposite circuit.
D155AX-6
D155AX-6
SEN00605-02
13
SEN00605-02
Hydraulic, HSS pump
Type: HPV190
14
D155AX-6
SEN00605-02
Outline
q
This pump consists of a variable displacement
swash plate type piston pump, PC valve, and
EPC valve.
IM: PC mode selector current
PA: Pump discharge port
PB: Pump discharge pressure input port
PD1: Case drain port
PD2: Drain plug
PEN: Control pressure pickup port
PEPC: EPC basic pressure port
PEPCC: EPC basic pressure pickup port
PLS: Load pressure input port
PLSC: Load pressure pickup port
PM: PC mode selector pressure pickup port
PS: Pump suction port
1.
2.
3.
4.
Front pump
LS valve
PC valve
PC-EPC valve
D155AX-6
15
SEN00605-02
1.
2.
3.
4.
5.
6.
7
8.
9.
10.
11.
16
Shaft
Cradle
Case
Rocker cam
Shoe
Piston
Cylinder block
Valve plate
End cap
Servo piston
PC valve
D155AX-6
SEN00605-02
Function
q
The pump converts the engine rotation transmitted to its shaft to oil pressure and delivers
pressurized oil corresponding to the load.
q
It is possible to change the delivery by changing the swash plate angle.
Structure
q
Cylinder block (7) is supported to shaft (1) by
spline (12).
q
Shaft (1) is supported by each bearing (13).
q
The end of piston (6) has a spherical hollow
and is combined with shoe (5).
q
Piston (6) and shoe (5) form a spherical bearing.
q
Rocker cam (4) has flat surface (A), and shoe
(5) is always pressed against this surface while
sliding in a circular movement.
q
Rocker cam (4) conducts high pressure oil to
cylinder surface (B) with cradle (2), which is
secured to the case, and forms a static pressure bearing when it slides.
D155AX-6
q
q
Piston (6) carries out relative movement in the

axial direction inside each cylinder chamber of
cylinder block (7).
Cylinder block (7) seals the pressurized oil to
valve plate (8) and carries out relative rotation.
This surface is designed so that the oil pressure balance is maintained at a suitable level.
The oil inside each cylinder chamber of cylinder block (7) is suctioned and discharged
through valve plate (8).
17
SEN00605-02
Operation of pump
q
Cylinder block (7) rotates together with shaft
(1), and shoe (5) slides on flat surface (A).
q
When this happens, rocker cam (4) moves
along cylindrical surface (B), so angle (a)
between center line (X) of rocker cam (4) and
the ax ial di rec tio n of cy li nder b loc k (7)
changes.
q
Angle (a) is called the swash plate angle.
q
q
18
As center line (X) of rocker cam (4) matches

the axial direction of cylinder block (7) (swash
plate angle (a) = 0), the difference between
volumes (E) and (F) inside cylinder block (7)
becomes 0.
Suction and discharge of pressurized oil is not
carried out in this state. Namely pumping
action is not performed. (Actually, however, the
swash plate angle is not set to 0)
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).
In this way, piston (6) slides on the inside of
cylinder block (7), so a difference between volumes (E) and (F) is created inside cylinder
block (7).
A single piston (6) sucks and discharges the oil
by the amount (F) (E).
As cylinder block (7) rotates and the volume of
chamber (E) becomes smaller, the pressurized
oil is discharged.
On the other hand, the volume of chamber (F)
grows larger and, in this process, the oil is suctioned.
D155AX-6
SEN00605-02
Control of delivery
q
If the swash plate angle (a) becomes larger,
the difference between volumes (E) and (F)
b ec o me s l ar g er a nd pu m p d el i v e r y ( Q )
increases.
q
Swash plate angle (a) is changed with servo
piston (10).
q
Servo piston (10) reciprocates straight according to the signal pressure of the PC and the LS
valve.
q
This straight line movement is transmitted to
rocker cam (4) through slider (14).
q
Being supported by cradle (2) on the cylindrical
surface, rocker cam (4) slides on the surface
while continuing revolving movement.
q
The area receiving the pressure is different at
the left and right sides of servo piston (10), and
the receiving pressure at the small diameter
piston end is always connected with the main
pump discharge pressure (self pressure) (PP).
q
Output pressure (PEN) of the LS valve is
brought to the chamber receiving the pressure
at the large diameter piston end.
q
The movement of servo piston (10) is controlled by the relationship of the size of the
pressure (PP) at the small diameter piston end
and the pressure (PEN) at the large diameter
piston end , and the comparative size of the
ratio of the area receiving the pressure at the
small diameter piston end and large diameter
piston end.
D155AX-6
19
SEN00605-02
1. LS valve
PA: Pump port

PDP: Drain port
PLP: LS control pressure output port
PLS: LS pressure input port
PP: Pump port
PPL: Control pressure input port
PSIG: Drain port
1.
2.
3.
4.
5.
6.
7.
8.
Sleeve
Piston
Spool
Spring
Seat
Sleeve
Plug
Locknut
Function
q
The LS (load sensing) valve detects the load
and controls the delivery.
q
This valve controls pump delivery (Q) according to differential pressure ( PLS) [ = (PP
P L S ) ] ( c a l l e d L S d i ff e r e n ti a l p r e s s u r e )
between pump discharge pressure (PP) and
control valve outlet port pressure (PLS).
q
Pump discharge pressure (PP), pressure
(PLS) [called LS pressure] coming from the
control valve output enter this valve.
q
The relationship between the differential pressure ( PLS) [ = (PP) (PLS)], the difference
LS pressure (PLS), and delivery (Q) is as
shown in the diagram.
20
D155AX-6
SEN00605-02
Operation
1)
When the control valve is situated at neutral
The LS valve is a three-way selector valve,

with pressure (PLS) (LS pressure) from the
inlet port of the control valve brought to spring
chamber (B), and pump discharge pressure
(PP) brought to port (H) of sleeve (8).
Magnitude of the force resulting from this LS
pressure (PLS), force of spring (4) and the
pump delivery pressure (self pressure) (PP)
determine the position of spool (6).
Before the engine is started, servo piston (10)
is pushed to the right.(See right drawing)
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 interconnected to the drain circuit through the control
valve spool)
Spool (6) is pushed to the right, and port (C)
and port (D) will be connected.
Pump discharge pressure (PP) enters the
large diameter end of piston from port (K).
q
q
q
q
D155AX-6
The same pump discharge pressure (PP)

enters the small diameter end of piston port
(J).
Because of the difference in area of servo piston (10), it moves in the direction to make the
swash plate angle smaller.
21
SEN00605-02
2)
Action for the direction of maximizing the pump delivery
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).
When spool (6) moves, port (D) and port (E)
are interconnected and connected to the PC
valve.
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.)
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
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 pressure (PP) rises], pump discharge pressure
(PP) pushes spool (6) to the right.
When spool (6) moves, pump discharge pressure (PP) flows from port (C) to port (D), and
from port (K), it enters the large piston diameter end.
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
SEN00605-02
23
SEN00605-02
4)
When servo piston is balanced
Let us take the area receiving the pressure at

the large diameter end of the piston as (A1),
the area receiving the pressure at the small
diameter end as (A0), and the pressure flowing
into the large diameter end of the piston as
(PEN).
If pump discharge pressure (PP) of the LS
valve and the combined force of spring (4) and
LS pressure (PLS) are balanced, and the relationship becomes (A0) x (PP) = (A1) x (PEN),
servo piston (10) stops at that position.
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 distance from port (C) to port (D) is almost the
same.]
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
The position where spool (6) is balanced and

stopped is the standard center, and the force of
spring (4) is adjusted so that it is determined
when (PP) (PLS) = 1.96 MPa {20kg/cm2}.
D155AX-6
SEN00605-02
2. PC valve
PA: Pump port

PA2: Pump pressure pilot port
PDP: Drain port
PM: Mode selector pressure pilot port
PPL: Control pressure output port (to LS valve)
1.
2.
3.
4.
5.
6.
7.
8.
Wiring
Cover
Seat
Retainer
Spool
Pin
Servo piston assembly
Plug
Function
q
When the pump discharge pressure (PP) is
high, the PC valve controls the pump so that
no more oil than the constant flow (in accordance with the discharge pressure) flows even
if the stroke of the control valve becomes
larger. It carries out equal horsepower control
so that the horsepower absorbed by the pump
does not exceed the engine horsepower.
q
If the load during the operation becomes larger
and the pump discharge pressure (PP) rises, it
reduces the delivery from the pump.
q
If the pump discharge pressure drops, it
increases the delivery from the pump.
q
In this case the relationship between pump discharge pressure (PP) and pump delivery (Q)
with the electric current value (X) given to PCEPC valve solenoid as the parameter is shown
in the diagram.
D155AX-6
25
SEN00605-02
Operation
1)
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 combined 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
SEN00605-02
27
SEN00605-02
Action of spring
q
The load of spring (4) at the PC valve is determined by the position of the swash plate.
q
If servo piston (9) moves to the right, spring (4)
is compressed.
q
Spring load changes as servo piston (9) makes
spring (4) elongate or contract.
q
If the command current (X) to PC-EPC valve
solenoid (1) changes, so does the force pushing piston (2).
q
The load of spring (4) also changes according
to the PC-EPC valve solenoid command current (X).
28
D155AX-6
q
q
q
q
q
q
q
SEN00605-02
Port (C) of the PC valve is connected to port

(E) of the LS valve.
Pump discharge pressure (PP) is applied to
the small piston diameter end of servo piston
(9), port (A) and port (B).
When pump discharge pressure (PP) is small,
spool (3) is on the left.
Ports (C) and (D) are connected, and the pressure entering the LS valve becomes drain
pressure (PT).
If port (E) and port (G) of the LS valve are connected, the pressure entering the large diameter end of the piston from port (J) becomes
drain pressure (PT), and servo piston (9)
moves to the left side.
The pump delivery will be set to the increasing
trend.
Spring (4) extends as servo piston (9) moves
and weakens the spring force.
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 connected.
The pressure on port (C) rises and the pressure on the large diameter end of the piston
also rises. Thus, the leftward move of servo
piston (9) is stopped.
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 created by pressure (PP) acting on spool (3) are
in balance.
D155AX-6
29
SEN00605-02
(2) When the load on the actuator is large and pump discharge pressure (PP) is high
Outline
q
When the load is large and pump discharge
pressure (PP) is high, the force pushing spool
(3) to the right becomes larger and spool (3)
moves to the position shown in the diagram
above.
q
As shown in the diagram above, part of the
pressurized oil from port (B) flows out to port
(D) from port (C) through the LS valve, and the
pressure oil flowing from port (C) to the LS
valve becomes approximately half of pump discharge pressure (PP).
30
Operation
q
When port (E) and port (G) of the LS valve are
connected, this pressure from port (J) enters
the large diameter end of servo piston (9),
stopping servo piston (9).
q
If pump discharge pressure (PP) increases further and spool (3) moves further to the right,
pump discharge pressure (PP) flows to port
(C) and acts to make the delivery the minimum.
q
If servo piston (9) moves to the right, spring (4)
is compressed and push back spool (3).
q
When spool (3) moves to the left, the openings
of port (C) and port (D) become larger.
q
The pressure on port (C) (= J) is decreased
and the rightward move of servo piston (9) is
stopped.
q
The position in which servo piston (9) stops
when this happens is further to the right than
the position when pump discharge pressure
(PP) is low.
D155AX-6
The relationship between pump discharge

pressure (PP) and pump delivery (Q) is shown
in the diagram.
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.
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 pressure (PP), the relationship between pump discharge pressure (PP) and pump delivery (Q)
moves from (A) to (B) in accordance with the
increase of command current (X).
D155AX-6
SEN00605-02
31
SEN00605-02
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
q
32
If there is a failure in the pump controller, the

emergency pump drive switch is turned ON to
hand the control to the resistor side.
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 control the current flowing to PC-EPC valve solenoid (1).
The current becomes constant, so the force
pushing piston (2) is also constant.
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.
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.
Since the pressure on the small diameter end

of the piston large, servo piston (9) moves in
the direction to make the delivery larger.
D155AX-6
SEN00605-02
(2) When the main pump is under heavy load
q
q
If the emergency pump drive switch is turned

on In the same way as in above, the command
current (X) sent to PC-EPC valve solenoid (1)
becomes constant.
For this reason, the force of piston (2) pushing
spool (3) is constant.
If pump discharge pressure (PP) increases,
spool (3) moves to the right from the position
where the load of the pump is smaller, and balanced at the above diagram position.
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.
The curb of pump discharge pressure (PP) and
pump delivery (Q) is shown in the diagram. It
is determined corresponding to the electric current value sent from the PC-EPC valve solenoid through the resistor even when the
emergency pump driving switch turns ON.
D155AX-6
The curve resulting when the emergency pump

drive switch is ON is situated further to the left
(B) than when the pump controller is normal
(A).
33
SEN00605-02
3. PC-EPC valve
C:
P:
T:
To PC valve
From self pressure reducing valve
To tank
1.
2.
3.
4.
5.
6.
7.
Connector
Coil
Body
Spring
Spool
Rod
Plunger
34
D155AX-6
Function
q
The EPC valve consists of the proportional
solenoid portion and the hydraulic valve portion.
q
On receiving signal current (i) from the controller, the EPC valve generates EPC output pressure in proportion to the signal current and
outputs it to the PC valve.
SEN00605-02
Operation
1)
q
q
q
D155AX-6
When signal current is 0 (Coil is de-energized)

When there is no signal current flowing from
the controller to coil (2), coil (2) is de-energized.
Spool (5) is pushed to the left by spring (4).
Since port (P) is closed, the pressurized oil
from self pressure reducing valve does not
flow to the PC valve.
The oil from the PC valve is drained through
ports (C) and (T) to the tank.
35
SEN00605-02
2)
q
q
q
q
q
q
36
When signal current is very small (coil is

energized)
When a very small signal current flows to coil
(2), coil (2) is energized, and a propulsion force
is generated on the right side of plunger (7).
Rod (6) pushes spool (5) to the right, and pressurized oil flows from port (P) to port (C).
Pressures on port (C) increases and the force
to act on spool (5) surface and the spring load
on spring (4) become larger than the propulsion force of plunger (7).
Spool (5) is pushed to the left, and port (P) is
shut off from port (C).
Port (C) and port (T) are connected.
Spool (5) moves up and down so that the propulsion force of plunger (7) may be in balance
with pressure of port (C) + spring load of spring
(4).
Circuit pressure between the EPC valve and
PC valve is controlled in proportion to the size
of the signal current.
3)
q
q
q
q
When signal current is maximum (coil is

energized)
As the signal current flows to coil (2), coil (2) is
energized.
When this happens, the signal current is at its
maximum, so the propulsion force of plunger
(7) is also at its maximum.
Spool (5) is pushed toward the right side by rod
(6).
Hydraulic oil from port (P) flows to port (C) with
maximum flow rate. As the result, the circuit
pressure between the EPC and PC valves
becomes maximum.
Since port (T) is closed, pressurized oil does
not flow to the tank.
D155AX-6
SEN00605-02
Hydraulic oil cooler bypass valve
1.
2.
3.
Body
Valve
Spring
A:
B:
Hydraulic oil cooler inlet

To hydraulic tank
Outline
q
This valve is installed in the oil cooler inlet circuit. If any abnormal pressure is generated in
the oil flowing to the oil cooler, this valve acts
to return the oil directly to the hydraulic tank.
Set pressure
Cracking pressure ( MPa {kg/cm })
2
D155AX-6
0.5 {5.1}
37
SEN00605-02
Steering, brake control

a
a
38
Regarding the transmission-related description of the operation of the PCCS lever, see Transmission
control.
PCCS: Palm Command Control System
D155AX-6
1.
2.
3.
4.
5.
6.
7.
Potentiometer
Lock lever
PCCS lever (Steering)
Limit switch
Rod (From brake pedal)
Brake pedal
Positions of levers and pedals

A: Neutral
B: Forward straight
C: Reverse straight
D: Left turn
E: Right turn
F: Brake OFF
G: Brake ON
H: Free
J: Lock
D155AX-6
SEN00605-02
Outline
q
PCCS lever (3) sends electric signals to power
train controller (5). Upon receiving those signals, power train controller (5) sends signals to
the EPC valve of the control valve to change
the delivery of the pump and operate the steering motor.
q
Brake pedal (7) receives signals from potentiometer (1) through rod (6). Then, power train
controller (5) sends signals to the brake valve
to operate the brake.
q
Lock lever (2) is connected to limit switch (4)
and used as the parking brake lever, too.
When it is in lock position "J", power train controller (5) does not send turning signals to the
EPC valve of the control valve.
39
SEN00605-02
Steering unit
(Bevel gear shaft, HSS and brake)

a
40
HSS: Abbreviation for Hydrostatic Steering System
D155AX-6
A:
B:
C:
D:
E:
SEN00605-02
To transmission case
From scavenging pump, steering lubrication pump
R.H. brake oil pressure pickup port (RB)
L.H. brake oil pressure pickup port (LB)
From the pin puller solenoid valve (Drain)
D155AX-6
41
SEN00605-02
42
D155AX-6
D155AX-6
SEN00605-02
43
SEN00605-02
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
44
Bevel gear speed sensor

Drain plug
Drain valve
HSS motor mounting port
Brake control valve
Output shaft
Case
Cylinder
Brake spring
Brake piston
Brake plate
Brake disc
Brake drum
Brake hub
Tube
Bevel gear shaft
Bevel gear (number of teeth: 32)
Gear A (number of teeth: 45)
Sun gear (number of teeth: 34)
Pinion shaft
Planetary pinion (number of teeth: 35)
Ring gear (number of internal teeth: 104)
Hub
Carrier
Bevel gear shaft bearing B
Bevel gear shaft bearing A
Shim A (for bevel gear adjustment)
Retainer
Shim B (for bevel gear adjustment)
Nut (for bevel gear shaft)
Spacer
Nut (for bevel pinion)
Cage
Shim C (for bevel pinion adjustment)
Bevel pinion bearing
Bevel pinion (number of teeth: 17)
Gear B (number of teeth: 16)
Shaft
HSS motor
Drive gear (number of teeth: 19)
Gear D (number of teeth: 28)
Gear C (number of teeth: 16)
D155AX-6
SEN00605-02
Outline
Bevel gear shaft
q
The engine power is transmitted through the
torque converter to the transmission. Then, the
bevel gear shaft system engages bevel pinion
(36) with bevel gear (17) to turn the engine
power at a right angle into the lateral direction
and reduce the rotation speed.
q
The bevel gear shaft system adopts the spiral
bevel gear at bevel pinion (36) and bevel gear
(17), and it adopts the splash lubrication with
the oil from the steering lubrication pump and
the scavenging pump for lubrication.
q
The bevel gear shaft system consists of bevel
pinion (36), bearing (35) which supports bevel
pinion, cage (33), bevel gear (17) which
meshes with the bevel pinion, bevel gear shaft
(16), bearing (25) and (26) which support bevel
shaft gear, and retainer (28).
HSS
HSS is constructed from transfer area which
transmits rotation of HSS motor (39) to gear A
(18) by turning it in reverse direction, and the
planet area which adjusts inputs from ring gear
(22) and sun gear (19) and then outputs to carrier (24).It changes the turning of the machine
by turning off the rotation of HSS motor (39), or
by making it move in normal rotation or reverse
rotation.
q
The transfer unit employs a spur gear speed
reduction mechanism and is lubricated with oil
splashed by the steering lubrication pump and
scavenging pump.
q
Planet area adopts forced lubrication with oil
from steering lubrication pump and scavenging
pump for lubrication.
q
The transfer unit consists of drive gear (40)
connected to the HSS motor (39) by spline,
gear D (41) meshed with the drive gear, gear C
(42) meshed with gear D, gear B (37) connected to shaft (38), gear A (18) supported by
the bearing on the bevel gear shaft and the
steering case to support these parts.
q
The planet area consists of sun gear (19),
planetary pinion (21), pinion shaft (20), ring
gear (22), hub (23) meshed with bevel gear
shaft (16) and ring gear (22), and carrier (24)
attached to brake hub (14).
q
D155AX-6
Brake
q
The brake is connected to the L.H. and R.H.
HSS respectively. It controls the power transmitted from HSS to final drive to brake the
machine.
q
Brake adopts wet multiple disc clutch type and
spring-boosted type, and it is hydraulic actuated type which activates brake control valve
(5) by the operation of brake pedal.
q
It adopts forced lubrication which sends oil
from steering lubrication pump and scavenging
pump to case (7) and brake drum (13) through
passage inside steering case, and then to
brake disc (12) and brake plate (11).
q
When the engine is stopped, back pressure of
brake piston (10) descends even if the brake
pedal is not depressed, which initiates the
brake to operate. However, parking brake
lever must be in lock position, because the
brake is released as the oil pressure within
the circuit rises when the engine is restarted.
q
The brake consists of brake hub (14) attached
to carrier (24), brake disc (12) meshed with the
brake hub, brake drum (13), brake plate (11)
whose outside perimeter meshes with brake
drum (13), brake piston (10) and brake spring
(9) which bring brake disc and brake plate
together, and cylinder (8) which supports all of
them, case (7) and output shaft (6).
Brake drum (13) and case (7) are fixed to the
steering case.
Also, output shaft (6) meshes to brake hub (14)
by spline and is held by spacer (31) in the axial
direction.
45
SEN00605-02
46
D155AX-6
SEN00605-02
Unit: mm
No.
Check item
Criteria
Standard size
Tolerance
Repair limit
Thickness
4.5
0.1
4.0
Strain
0.05
0.14
Repair or
replace
Thickness
2.9
0.1
2.6
Replace
Strain
0.05
0.15
Repair or
replace
Total assembled thickness of 6

plates and 5 discs
41.5
0.33
38.3

contact surface of the retainer
100
+0.035
+0.035
100.5
Width
0.01
0.03
2.7
Thickness
0.12
3.85
280
+0.081
+0.081
280.1
220
+0.072
+0.081
220.1
Brake disc
Replace
Brake plate
Wear of the bevel

gear shaft seal ring
Large
Inner diameter of the diameter
parts
seal ring
contact surface
Small
of the brake piston
diameter
parts
Standard size
6
Remedy
Brake spring
(2 pieces for 1 set)
Clearance between bevel gear

and reamer bolt
Free length
Installation Replace
Free length
length
load
load
33
19.6
Standard
size
Shaft
+0.019
+0.001
16
Repair limit
32.0
33.9 kN
{3,460 kg}
Hole
Standard
clearance
Clearance
limit
+0.027
+0.027
-0.0190.026
0.026
35.7 kN
{3,640 kg}
Tolerance
Backlash between the brake

hub and the disc
0.23 0.42
Backlash between the brake

drum and the plate
0.23 0.42
10
Backlash between sun gear and

planetary pinion
0.17 0.52
11
Backlash between planetary

pinion and ring gear
0.17 0.54
12
Standard shim thickness of the

retainer
2.0
13
Standard shim thickness for

plate
0.7
14
Preload of bevel gear shaft

bearing A
Starting torque for no-loading: 2.94 Nm {0.3 kgm}
D155AX-6
Adjust the shim
Adjust
47
SEN00605-02
48
D155AX-6
SEN00605-02
Unit: mm
No.
Check item
Criteria
Backlash between bevel gear

and bevel pinion
0.25 0.33
Backlash between drive gear

and gear D
0.19 0.62
Backlash between gear D and

gear C
0.18 0.58
Backlash between gear B and

gear A
0.19 0.61
Backlash between gear D and

gear A
0.20 0.67

cage
D155AX-6
Remedy
Adjust or
replace
Replace
2.0
Adjust the shim
49
SEN00605-02
Operation of steering unit

When steering is at Neutral (straight travel)
Rotation direction of HSS motor

PCCS lever
Neusteering operation tral
Left turn
Right turn
PCCS lever forFree, NeuNeuward 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
side of machine
Stop
Left
Left Right Right Right Left
*: Counter-rotation
50
D155AX-6
SEN00605-02
When steering operation of PCCS lever is at "neutral", HSS motor (7) is stopped.
The power from transmission
O
Bevel pinion (1)
O
Bevel gear (2)
O
Bevel gear shaft (3)
O
Hub (4)
O
Ring gear (5)
O
Planetary pinion (6)
O
Carrier (15)
O
Brake hub (16)
O
Output shaft (17)
D155AX-6
51
SEN00605-02
When steering operation is at Left turn (forward travel)
*A: Transmission output

*B: HSS motor output
*C: Combined output
*1.
*2.
*3.
*4.
52
Transmission output speed

HSS motor output speed
Left bevel gear shaft output speed (*1-*2)
Right bevel gear shaft output speed (*1+*2)
D155AX-6
SEN00605-02
If PCCS lever shifts the steering operation into "left turn" when traveling forward, HSS motor (7) rotates
counterclockwise, viewing from the left side of the machine body.
(Forward)
Bevel pinion (1)
O
Bevel gear (2)
O
O
Hub (4)
O
Ring gear (5)
The power from HSS motor (7)

(Counterclockwise, viewing from
the left side of the machine body.)
O
Drive gear (8)
O
Gear D (9)
Gear C (10)
O
Shaft (11)
O
Gear B (12)
O
L.H. gear A (13)
R.H. gear A (13)
(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
SEN00605-02
When steering operation is at Left turn (reverse travel)

*C: Combined output
*1.
*2.
*3.
*4.
54

Left bevel gear shaft output speed (*1-*2)
Right bevel gear shaft output speed (*1+*2)
D155AX-6
SEN00605-02
If PCCS lever shifts the steering operation into "left turn" when traveling reverse, HSS motor (7) rotates
clockwise, viewing from the left side of the machine body.
(Reverse)
Bevel pinion (1)
O
Bevel gear (2)
O
O
Hub (4)
O
Ring gear (5)

side of the machine body.)
O
Drive gear (8)
O
Gear D (9)
L.H. gear A (13)

O
L.H. sun gear (14)
Gear C (10)
O
Shaft (11)
O
Gear B (12)
O
R.H. gear A (13)
(Counteclockwise, viewing from
O
R.H. sun gear (14)

O
Carrier (15)
O
Brake hub (16)
O
Output shaft (17)
D155AX-6
55
SEN00605-02
When steering operation is at Right turn (forward travel)

*C: Combined output
*1.
*2.
*3.
*4.
56

Left bevel gear shaft output speed (*1+*2)
Right bevel gear shaft output speed (*1-*2)
D155AX-6
SEN00605-02
If PCCS lever shifts the steering operation into "right turn" when traveling forward, HSS motor (7) rotates
clockwise, viewing from the left side of the machine body.
(Forward)
Bevel pinion (1)
O
Bevel gear (2)
O
O
Hub (4)
O
Ring gear (5)

O
Drive gear (8)
O
Gear D (9)
Gear C (10)
O
Shaft (11)
O
Gear B (12)
O
L.H. gear A (13)
R.H. gear A (13)
the left side of the machine body.) the left side of the machine body.)
O
O
L.H. sun gear (14)
R.H. sun gear (14)

O
Carrier (15)
O
Brake hub (16)
O
Output shaft (17)
D155AX-6
57
SEN00605-02
When steering operation is at Right turn (reverse travel)

*C: Combined output
*1.
*2.
*3.
*4.
58

Left bevel gear shaft output speed (*1+*2)
Right bevel gear shaft output speed (*1-*2)
D155AX-6
SEN00605-02
If PCCS lever shifts the steering operation into "right turn" when traveling reverse, HSS motor (7) rotates
counterclockwise, viewing from the left side of the machine body.
(Reverse)
Bevel pinion (1)
O
Bevel gear (2)
O
O
Hub (4)
O
Ring gear (5)

O
Drive gear (8)
O
Gear D (9)
Gear C (10)
O
Shaft (11)
O
Gear B (12)
O
L.H. gear A (13)
R.H. gear A (13)
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
59
SEN00605-02
Brake operation
When the brake is released
When the PCCS lever is in the neutral position and the brake pedal is released, the maximum brake pressure is applied to the back of
brake piston (1) by the brake control valve.
As the oil pressure rises, brake piston (1) compresses brake spring (2) and moves to the left
to eliminate the pressing force between discs
(3) and plates (4).
The power transmitted from bevel gear shaft
through HSS to brake hub (6) is transmitted to
output shaft (7), then to the final drive.
When the brake is applied
60
If the brake pedal is depressed, the brake

pressure applied to the back of brake piston (1)
starts to lower by the brake control valve.
At this time, brake piston (1) is pushed back to
the right by the tension of the brake spring (2)
to press discs (3) and plates (4) against brake
drum (5).Brake drum (5) is fixed to the steering
case.
Power towards brake hub (6) or output shaft
(7) is controlled by compressing disc (3) and
plate (4).
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.
D155AX-6
D155AX-6
SEN00605-02
61
SEN00605-02
Brake control valve
62
D155AX-6
P:
L:

From scavenging pump, steering lubrication
pump
PS: To the pin puller solenoid valve
LB: To left brake
LL: To left brake lubrication circuit
RB: To right brake
RL: To right brake lubrication circuit
BSL: To bevel gear shaft and planet area bearing
lubrication circuit
BPL: To the bevel pinion bearing lubrication circuit
TFL: To HSS transfer area lubrication circuit
DLB: Drain (L.H. brake)
DRB: Drain (R.H. brake)
DB: Drain (Sudden stop prevention valve)
DBP: Drain (Sudden stop prevention valve pilot)
DPB: Drain (Parking brake)
PLB: Left brake oil pressure pickup port
PRB: Right brake oil pressure pickup port
1.
2.
3.
4.
5.
6.
7.
L.H. brake ECMV

R.H. brake ECMV
Steering oil filter
Valve seat
Parking brake solenoid valve
Sudden stop prevention valve
Check valve
D155AX-6
SEN00605-02
Outline
q
The brake control valve consists of 2 ECMVs,
parking brake solenoid valve and the sudden
stop prevention valve installed on the valve
seat, to control the brake.
q
The brake control valve is located in the circuit
between the power train pump and the brake
piston, and consists of 2 sets of brake ECMV
(L.H. and R.H.).
q
The brake control valve sends the oil from the
power train pump to the brake to control leftand-right disc clutches.
q
The controller sends signals to each ECMV
according to the right or left stroke of the
PCCS lever and adjusts the gradual or sharp
turns.
q
If the brake pedal is depressed, the controller
sends commands to the brake ECMV according to the pedal stroke to apply the L.H. and
R.H. brake, thus stopping the machine.
q
The controller, connected electrically to the
PCCS lever and the brake pedal operates the
brake by controlling each ECMV and solenoid
valve.
q
The sudden stop prevention valve is installed
to prevent the machine from stopping suddenly, when an abnormality takes place in the
electric system.
q
When the parking brake lever is set in the
lock position, the controller sends signals to
the parking brake solenoid valve to drain the oil
between the L.H. and R.H. brake ECMV and
the brake pistons to operate the brake. Also
the parking brake solenoid valve is connected
electrically to the brake pedal.
63
SEN00605-02
Brake ECMV
a
a

A: To brake
P: From pump
S: To parking brake solenoid valve
T: Drain
DR: Drain
P1: Brake oil pressure pickup port
1.
2.
3.
4.
5.
6.
7.
64
Fill switch connector

Proportional solenoid connector
Fill switch
Nameplate (*1)
*1:
Operated clutches
Stamp of the nameplates
Brake
R*******
Outline
q
The brake ECMV keeps the brake oil pressure
to the set pressure and furthermore changes
the circuit to the piston chamber of brake.
D155AX-6
SEN00605-02
Outline of ECMV
q
The ECMV consists of 1 pressure control valve
and 1 fill switch.
q
A proportional solenoid in this valve receives a
current sent from the controller and this valve
converts it to an oil pressure.
q
Fill switch
This is a switch to detect that a clutch or brake
is filled with oil and has the following functions.
1. At the moment when the clutch or brake is
filled with oil, the fill switch outputs the signal
(fill signal) to the controller to notify the finishing of filling.
2. While the oil pressure is applied to the clutch
or brake, the fill switch outputs the signal (fill
signal) to the controller to notify the presence
of the oil pressure.
ECMV and proportional solenoid
q
One proportional solenoid is mounted for
each ECMV.
The propulsion force is generated according to the command current from the controller.
The propulsion force generated by the
proportional solenoid is actuated on the
spool of the pressure control valve and
generates the oil pressure. Accordingly, by
controlling the amount of the command
current, the propulsion force changes and
the pressure control valve is actuated,
then the oil flow and oil pressure is controlled.
ECMV and fill switch
For each ECMV, 1 fill switch is installed.
If the clutch is filled with oil, the fill switch
is turned ON by the pressure of the
clutch. The oil pressure is built up according to this signal.
Operation of ECMV
The ECMV is controlled by the command
current from the controller to the proportional solenoid and the fill switch output
signal.
D155AX-6
65
SEN00605-02
When the PCCS lever is in neutral position, brake pedal is released, and parking brake lever is in
free position: Straight travel
(L.H. and R.H. brake arereleased, parking brake isreleased)
66
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.
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 piston is pushed to the left to compress the brake
spring, then the brake is released.
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.
D155AX-6
SEN00605-02
When the PCCS lever is in neutral, brake pedal is depressed, and parking brake lever is in free
position: Stop
(L.H. and R.H. brake are operated, parking brake is released)
When the brake pedal is depressed, proportional solenoids (1) of L.H. and R.H. brake
ECMV are de-energized to open the sealing
part of ball (2).
The controller outputs the command current to
proportional solenoids (1) according to the
brake pedal stroke.
Proportional solenoid (1) generates the propulsion force in proportion to the command current. This propulsion force is balanced with the
sum of the propulsion force generated by the
oil pressure in the back pressure port of the
brake piston and the tension of spring (4), then
the brake pressure is set up to adjust the brake
force.
When the brake pedal is depressed fully, the
brake pedal switch is turned ON, and the
parking brake solenoid valve is energized to
drain the pilot pressure of the brake ECMV port
(S).This carries out the same function as when
the parking brake lever is set at the lock position.
D155AX-6
67
SEN00605-02
P: From brake ECMV

T: Drain
Dr: Drain
1.
2.
3.
4.
Parking brake lever solenoid valve

Brake pedal solenoid valve
Connector for parking brake lever solenoid valve
Connector for brake pedal solenoid valve
Solenoid valve
5. Coil (ON-OFF type)
6. Push pin
7. Spring
8. Spool
9. Body
68
D155AX-6
SEN00605-02
When PCCS lever is in neutral position, brake pedal is released, and parking brake lever is
inlock position : Parking
(L.H. and R.H. brake are operated, parking brake is operated)
When the parking brake lever is in the lock

position, the parking brake lever switch is
turned ON and coil (1) of the parking brake
solenoid valve is energized.
Spool (3) is pushed to the right direction by
push pin (2), then port (P) and (T) are opened
to drain the pilot pressure of the L.H. and R.H.
brake ECMV.
The oil which had flown into the brake piston
back pressure port is drained through the
brake ECMV.
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.
When the engine is started again, as port (P)
and (T) are still opened, the brake is continuously applied.
D155AX-6
When the parking brake lever is in the free

position, the parking brake lever switch is
OFF and coil (1) of the parking brake solenoid valve is de-energized.
Spool (3) is returned to the left, and close port
(P) and (T) to remain the pilot pressure of the
L.H. and R.H. brake ECMV.
The oil pressure from the brake ECMV is
applied to the back pressure port of the brake
piston, and brake is released.
69
SEN00605-02
A: From power train pump

B: From brake ECMV
dr1: Drain
dr2: Drain
1.
EPC valve
2. Coil (proportional type)
3. Push pin
4. Valve
5. Ball
6. Spool
7. Body
70
D155AX-6
SEN00605-02
Outline
q
The sudden stop prevention valve is installed
to prevent the machine from stopping suddenly
when an abnormality takes place in the electric
system.
q
Sudden stop prevention valve (1) is installed in
the drain circuit of the brake ECMV so that the
sudden oil pressure drop of port (DR) and consequently the sudden brake can be avoided
when coil (2) of brake ECMV is de-energized.
q
If an abnormality takes place in the electric
system, also coil (3) of the sudden stop prevention valve (1) is de-energized. Then, the oil
of port (DR) is drained through orifice (a) so
that the brake is applied gradually.
D155AX-6
71
SEN00605-02
Final drive
Outline
q
The final drive is a single stage spur gear, single stage planetary gear reduction type. The
lubrication is of splash type using the rotation
of the gears. The final drive can be removed
and installed as a single unit.
q
Floating seal (1) is installed to the rotating sliding portion of the sprocket to prevent the entry
of dirt or sand and to prevent leakage of lubricating oil.
72
D155AX-6
D155AX-6
SEN00605-02
73
SEN00605-02
74
D155AX-6
1.
2.
3.
4.
5.
6.
7.
8.
9.
SEN00605-02
Floating seal
Sun gear
Carrier
Sprocket boss
Sprocket teeth
Cover
Planetary gear
Ring gear
Cover
10.
11.
12.
13.
14.
15.
16.
17.
No.1 pinion
Final drive case
Bearing cage
No.1 gear
No.1 gear hub
Shaft
Wear guard
Pivot shaft
Unit: mm
No.
Check item
Criteria
Remedy
Standard clearance
Clearance limit
0.25 0.77
0.77
18
Backlash between No.1 pinion

and No.1 gear
19
Backlash between sun gear

and planetary gear
0.20 0.55
0.55
20
Backlash between planetary

gear and ring gear
0.22 0.71
0.71
21
Outside diameter of No.1 pinion oil seal contact surface
22
Thickness of thrust collar of

inner body roller bearing
23
Clearance between outer

diameter of planet gear shaft
and inner diameter of carrier
hole. (Small diameter)
24
Clearance between outer

diameter of planet gear shaft
and inner diameter of carrier
hole.(Large diameter)
25

No.1 pinion bearing cage
26
Wear of wear guard
D155AX-6
Replace
Standard size
Tolerance
Repair limit
95
0.087
0.087
94.913
23
Standard
size
Repair or
replace
22.95
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
68.262
0.015
0.034
0.009
0.039
- 0.024
+ 0.025
(Max.
Replace
clearance)
+ 0.025
90
0.036
0.058
0.066
0.101
- 0.065
- 0.008
0.008
Adjust
Standard size
Repair limit
67
21
Repair or
replace
75
SEN00605-02
Path of power transmission
76
The power from the bevel gear shaft and steering clutch is transmitted to 1st pinion (10) to
rotate 1st gear (13) meshed with the 1st pinion
and sun gear (2) meshed with the 1st gear.
The rotation of sun gear (2) is transmitted to
planetary gear (7). Since ring gear (8) meshed
with the planetary gear is fixed to cover (6), the
planetary gear (7) rotates along the ring gear
(8) and revolves around the sun gear (2).
Then, the rotating force of sun gear (2) forms

the rotating force of carrier (3), which supports
the planetary gear (7), via shaft (15), and is
transmitted to sprocket boss (4).
The rotating direction of carrier (3) is the same
with sun gear (2).
The rotational force transmitted to sprocket
boss (4) is further transmitted to sprocket teeth
(5).
D155AX-6
D155AX-6
SEN00605-02
77
SEN00605-02
Sprocket
Unit: mm
No.
Check item
Wear of sprocket tooth tip
Wear of sprocket tooth root
3
4
78
Criteria
Standard clearance
Remedy
Repair limit
351
339
23.7
17.5
Wear of width of sprocket

tooth tip
83
75
Wear of width of sprocket

tooth root
103
95
Rebuid or
replace
D155AX-6
SEN00605-02
Sprocket tooth shape of full scale
D155AX-6
79
SEN00605-02
D155AX-6 Bulldozer
2009 KOMATSU
All Rights Reserved
80
D155AX-6
SEN00606-01
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up


Track frame ..................................................................................................................................................... 2
Recoil spring ................................................................................................................................................... 4
Idler ................................................................................................................................................................. 6
Track roller ...................................................................................................................................................... 8
Carrier roller .................................................................................................................................................. 10
Track shoe .................................................................................................................................................... 12
Main frame .................................................................................................................................................... 18
Suspension ................................................................................................................................................... 20
D155AX-6
SEN00606-01
Track frame
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Equalizer bar
Pivot shaft
Idler
Track frame
Carrier roller
Sprocket
Sprocket cover guard
Track roller
Track roller support guard
Minor bogie
Major bogie
First bogie
Outline
q
The track rollers are mounted on an K-shaped
bogie. This increases the actual ground contact area between the track shoes and the
ground on rough surfaces, and helps increase
the drawbar pull.
q
The K-shaped bogies are equipped with rubber
pads to absorb the shock from the ground surface.
Track roller, bogie
Track roller flange type arrangement
1st
2nd
3rd
4th
5th
6th
7th
D: Double
S: Single
D155AX-6
SEN00606-01
Unit: mm
No.
Check item
Deformation of track frame
D155AX-6
Criteria
Remedy
Item
Repair limit
Curvature
7 (over length of 3,000)
Twisting
3 (over length of 300)
Dents (pipe portion)
12
Correct or
replace
SEN00606-01
Recoil spring
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Yoke
Dust seal
Rod
Recoil spring
Wear ring
Lubricator
Nut
Housing
Cylinder
Holder
Bushing
Outline
q
Recoil spring (4) is used to adjust the track tension by pumping in or releasing grease from
lubricator (6) to move rod (3) forward or backward. The recoil spring also acts to dampen
any sudden shock brought to bear on the idler.
D155AX-6
SEN00606-01
Unit: mm
No.
1
11
Check item
Criteria
Press-fitting force for

idler yoke
Clearance between rod
and bushing
392 kN {40 ton}

Standard
size
120
Tolerance
Recoil spring
D155AX-6
Adjust
Shaft
Hole
Standard
clearance
Clearance
limit
0.036
0.090
+0.277
+0.062
0.098
0.367
1.0
Standard size
4
Remedy
Repair limit
Free length
Installed
length
Installed
load
Free length
Installed
load
859
656
314 kN
{32,000 kg}
804
288 kN
{29,400 kg}
Replace
SEN00606-01
Idler
D155AX-6
SEN00606-01
Unit: mm
No.
Check item
Criteria
Standard size
Remedy
Repair limit
Outer diameter of protrusion
792
Outer diameter of tread
750
725
Depth of tread
21
33.5
Thickness of tread
24
11.5
Width of tread
58.5
Overall width
240
Clearance between shaft

and bushing
Interference between shaft

and ring
Standard
size
140
Standard
size
75
Play of shaft in axial direction
D155AX-6
Tolerance
Rebuild or
replace
Shaft
Hole
Standard
clearance
Clearance
limit
0.350
0.413
+0.265
+0.003
0.353
0.678
Tolerance
Shaft
Hole
+0.046
+0.046
+0.13
0.18
Standard size
Standard Interference
interference
limit
0.130
0.226
Repair limit
0.4 0.9
Replace
bushing
Rebuild or
replace
SEN00606-01
Track roller
D155AX-6
SEN00606-01
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
285
275
Outer diameter of flange

(outside flange)

(inside flange)
250
210
Thickness of tread
57.5
37.5
Overall width
295
Width of tread
(single flange)
61
Width of tread
(double flange)
61
Flange width
(outside of double flange)
25
Flange width
(inside of double flange)
22
10
Shaft flange width
246
11
Clearance between shaft

and bushing
12
13
Interference between shaft

and ring
End play
D155AX-6
Standard size
125
Standard size
65
Tolerance
Shaft
Hole
0.350
0.413
+0.260
+0.010
Standard
clearance
0.360 0.673
Replace
Tolerance
Shaft
Hole
+0.046
+0.000
0.15
0.20
Rebuild or
replace
Standard
interference
0.150 0.246
Standard size
Clearance limit
0.44 0.91
Adjust or
replace
SEN00606-01
Carrier roller
10
D155AX-6
SEN00606-01
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
220
190
167
Width of tread
63
Thickness of tread
37.5
26
Width of flange
Interference between
shaft and ring
Clearance between
shaft and support
21
Standard size
70
Standard size
68
Play of roller in axial direction
D155AX-6
Rebuild or
replace
Tolerance
Shaft
Hole
+0.166
+0.120
+0.030
+0.030
Tolerance
Shaft
Hole
0.2
0.2
+0.300
+0.030
Standard
interference
0.090 0.166
Standard
clearance
Replace
0 0.5
Standard clearance
0.010 0.230
11
SEN00606-01
Track shoe
Dry type
12
P portion shows the link of bushing press fitting end.

D155AX-6
SEN00606-01
Unit: mm
No.
1
Check item
Bushing outside diameter

Thickness of bushing metal
Link height
Thickness of link metal

(bushing press-fitting portion)
Shoe bolt
bushing and link
Remedy
Standard size
Repair limit
228.85
231.85 (Heavy-duty areas)

233.85 (Standard areas)
Link pitch
Criteria
When turned
Standard size
Normal load
Impact load
81
75.0
77.0
15.8
9.8
11.8
Standard size
Repair limit
144
128
45.5
29.5
Tightening torque
(Nm {kgm})
Additional tightening
angle (deg.)
588.4 58.8 {60 6}
120 10
Standard size
Tolerance
Reverse or
replace
Repair or
replace
Retighten
Standard
interference
Shaft
Hole
77.0
+0.404
+0.304
+0.074
+0.074
0.230 0.404
8a
regular pin and link
48.5
+0.484
+0.334
0.038
0.100
0.372 0.584
8b
master pin and link
48.5
+0.230
+0.200
0.038
0.100
0.238 0.330
Adjust or
replace
Standard clearance
9
Clearance between links
D155AX-6
One side
Both side
1.4
2.8
13
SEN00606-01
Sealed and lubricated track
14
P portion shows the link of bushing press fitting end.
D155AX-6
SEN00606-01
Unit: mm
No.
1
2
3
Check item
Thickness of bushing metal

Link height
Thickness of link metal

(bushing press-fitting portion)
a. Regular link
b. Master link
Repair limit
228.85
Bushing outside diameter
Shoe bolt
Remedy
Standard size
Link pitch
Criteria
bushing and link
regular pin and link
231.85
When turned
Standard size
Normal load
Impact load
81
72.5
75.0
15.8
7.3
9.8
Standard size
Repair limit
144
128
45.5
29.5
Tightening torque
(Nm {kgm})
Additional tightening
angle (deg.)
588.4 58.8 {60 6}
120 10
588.4 58.8 {60 6}
180 10
Tolerance
Standard
size
Reverse or
replace
Repair or
replace
Retighten
Standard
interference
Shaft
Hole
77.0
+0.404
+0.304
+0.074
+0.074
0.230 0.404
48.5
+0.484
+0.334
0.038
0.100
0.372 0.584
Adjust or
replace
Standard clearance
9
Clearance between links
D155AX-6
One side
Both side
1.4
2.8
15
SEN00606-01
Single shoe, heavy duty shoe
Unit: mm
No.
1
16
Check item
Criteria
Remedy
Standard size
Repair limit
single
80
30
heavy duty
80
30
Overall height single

of shoe
heavy duty
97
47
99
49
Height of
grouser
Repair or
replace
D155AX-6
D155AX-6
SEN00606-01
17
SEN00606-01
Main frame
18
D155AX-6
1.
2.
3.
4.
5.
6.
7.
8.
SEN00606-01
Main frame
Cage
Clamp
Cover
Seal
Coupling
Cap
Plate
Unit: mm
No.
10
Check item
Clearance between
equalizer bar shaft
and bushing
Press-fitting force for
equalizer bar shaft
mounting bushing
D155AX-6
Criteria
Standard
size
95
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
0.036
0.090
+0.213
+0.129
0.165
0.303
1.0
29.42 68.65 kN {3 7 ton}
Replace
Adjust
19
SEN00606-01
Suspension
20
D155AX-6
1.
2.
3.
4.
5.
SEN00606-01
Equalizer bar
Pivot shaft assembly
Cover
Thrust plate
Thrust plate
6.
7.
8.
10.
11.
Pivot shaft
Seal cage
Seal
Side pin
Center pin
Unit: mm
No.
Check item
Press-fitting force for side

pin bushing
12
Press-fitting force for center

pin bushing
13
Clearance between center

pin and bushing
14
Clearance between side pin

and bushing
15
side pin boss and bushing
16
17
18
Interference between pivot

shaft and seal stopper ring
Clearance between pivot
shaft and bushing (outer)
Clearance between pivot
shaft and bushing (inner)
Criteria
Remedy
27.46 64.7 kN {2.8 6.6 ton}
47.07 131.41 kN {4.8 13.4 ton}

Tolerance
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
95
0.036
0.090
+0.279
+0.213
0.249
0.369
1.0
70
0.030
0.060
+0.046
+0.046
0.030
0.106
1.0
Standard
size
Tolerance
Standard Interference
interference
limit
Shaft
Hole
130
+0.033
+0.015
0.028
0.068
0.043
0.101
179
+0.083
+0.043
0.053
0.093
0.096
0.176
Standard
size
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
148
0.145
0.208
+0.099
+0.035
0.180
0.307
1.0
175
0.145
0.208
+0.095
+0.025
0.170
0.303
1.0
Replace
bushing
Outline
q
The front of the track frame rocks up and down
using the rear pivot shafts (6) as a fulcrum.
Equalizer bar (1) rocks using center pin (11) as
a fulcrum. The left and right track frames are
connected by side pin (10).
D155AX-6
21
SEN00606-01
D155AX-6 Bulldozer
2007 KOMATSU
All Rights Reserved
22
D155AX-6
SEN00607-03
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up

Hydraulic system
Work equipment hydraulic piping diagram ...................................................................................................... 2
Work equipment control piping diagram ......................................................................................................... 5
Work equipment control .................................................................................................................................. 8
Hydraulic tank and filter ................................................................................................................................ 10
Accumulator .................................................................................................................................................. 14
PCCS lever ................................................................................................................................................... 15
Work equipment lock valve ........................................................................................................................... 19
Control valve ................................................................................................................................................. 20
Work equipment cylinder .............................................................................................................................. 56
Piston valve................................................................................................................................................... 58
Quick drop valve ........................................................................................................................................... 60
Self pressure reducing valve......................................................................................................................... 65
D155AX-6
SEN00607-03
Work equipment hydraulic piping diagram
Semi U-dozer
1.
2.
3.
4.
Blade tilt cylinder

R.H. blade lift cylinder
Accumulator
Control valve
5.
6.
7.
8.
Hydraulic tank
Hydraulic, HSS pump
L.H. blade lift cylinder
Oil cooler
D155AX-6
SEN00607-03
Multi-shank ripper
1.
2.
3.
4.
Control valve
Divider block
Ripper lift cylinder
Ripper tilt cylinder
D155AX-6
SEN00607-03
Giant ripper
1.
2.
3.
4.
5.
6.
Control valve
Divider block
Pin puller cylinder
Ripper tilt cylinder
Pin puller solenoid valve
D155AX-6
SEN00607-03
Work equipment control piping diagram
Blade, ripper control

Serial No.: 80001 80806
1.
2.
Accumulator
Control valve
D155AX-6
3.
4.
Work equipment lock valve

Self pressure reducing valve
SEN00607-03
Serial No.: 80807 and up
1.
2.
3.
Accumulator
Control valve
4.
5.

Filter
D155AX-6
D155AX-6
SEN00607-03
SEN00607-03
Work equipment control
D155AX-6
1.
2.
3.
4.
SEN00607-03
Work equipment lock lever

Blade control lever
Ripper control lever
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
SEN00607-03
Hydraulic tank and filter
Serial No.: 80001 80772
1.
2.
3.
4.
5.
6.
10
Pressure valve
Drain valve
Drain plug
Cover
Cover
Hydraulic tank
7.
8.
9.
10.
11.
12.
Strainer
Suction valve
Spring
Hydraulic filter element
Oil filler cap
Sight gauge
D155AX-6
SEN00607-03
Specified
value
Tank capacity
Hydraulic
tank
Breather
Level
inside
tank
(l)
125
Hi
(l)
95
Center
(l)
91.5
Low
(l)
75
Cracking pressure
16.76.9
(kPa {kg/cm2}) {0.170.07}
0 0.49
Vacuum valve actuating
pressure
(kPa {kg/cm2}) {0 0.005}
Cracking pressure
(kPa {kg/cm2})
Hydraulic
filter
Mesh size
( m)
20/10/3
Filtering area
(cm2)
13,600
Filtering oil flow

Strainer
D155AX-6
14729.4
{1.50.31}
(l/min)
550
Mesh size
( m)
105
Filtering area
(cm2)
1,850
11
SEN00607-03
1.
2.
3.
4.
5.
6.
12
Pressure valve
Drain valve
Drain plug
Cover
Cover
Hydraulic tank
7.
8.
9.
10.
11.
12.
Strainer
Suction valve
Spring
Hydraulic filter element
Oil filler cap
Sight gauge
D155AX-6
SEN00607-03
Specified
value
Tank capacity
Hydraulic
tank
Breather
Level
inside
tank
(l)
125
Hi
(l)
95
Center
(l)
91.5
Low
(l)
75
Cracking pressure
16.72.5
(kPa {kg/cm2}) {0.170.025}
2.0 0.3
Vacuum valve actuating
pressure
(kPa {kg/cm2}) {0.02 0.003}
Cracking pressure
(kPa {kg/cm2})
Hydraulic
filter
Mesh size
( m)
20/10/3
Filtering area
(cm2)
13,600
Filtering oil flow

Strainer
D155AX-6
14729.4
{1.50.31}
(l/min)
550
Mesh size
( m)
105
Filtering area
(cm2)
1,850
13
SEN00607-03
Accumulator
For EPC valve
Function
q
The accumulator is installed between the
redusing valve and the EPC valve. Even if the
engine is started with the work equipment still
raised, the pressure of the nitrogen gas compressed inside the accumulator sends the pilot
pressure to the control valve to actuate it and
enable the work equipment to move down
under its own weight.
Operation
After the engine is stopped, when the EPC
valve is at neutral, chamber (A) inside the bladder is compressed by the oil pressure in chamber (B).
q
When the EPC valve is operated, the oil pressure in chamber (B) goes below 2.9 MPa {30
kg/cm2}, and the pressure of the nitrogen gas
in chamber (A) expands the bladder, so the oil
in chamber (B) acts as the pilot pressure and
actuates the main control valve.
q
1.
2.
3.
4.
5.
6.
Gas plug
Shell
Poppet
Holder
Bladder
Oil port
Specifications
Type of gas: Nitrogen
Gas volume: 500 cc
Max. actuation pressure: 6.86 MPa {70 kg/cm2}
Min. actuation pressure: 0.69 MPa {7 kg/cm2}
14
D155AX-6
PCCS lever
SEN00607-03
(For blade, ripper)

a
Do not disassemble.
Otherwise, adjustments will be required for the characteristics of voltage output and operating efforts.
1.
2.
3.
Boot
Nut
Connector
D155AX-6
15
SEN00607-03
(For steering)
a
Do not disassemble.
Otherwise, adjustments will be required for the characteristics of voltage output and operating efforts.
1.
2.
3.
4.
Boot
Bracket
Plate
Bolt
16
5.
6.
7.
Screw
Lever
Connector
D155AX-6
SEN00607-03
Function
1. Operating effort characteristics
(For blade and ripper)
q
It has the following characteristic for both
longitudinal and lateral operations.
q
Free return (operation effort characteristic
diagram)
2)
q
Operation for left and right steering

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
17
SEN00607-03
2.
q
18
Output voltage characteristics

The control unit is installed to the left control
stand and the control lever is installed directly
onto it.
The operating angle (stroke) of the control
levers sensed with potentiometers and signal
voltages are output to the transmission,
steering controller.
A potentiometer is installed in each of longitudinal
d ir e c t i o n a n d l a t e r a l d ir e c t i o n . E a c h
potentiometer outputs 2 signal voltages which are
opposite to each other as shown in the figure at
right.
D155AX-6
1.
2.
3.
SEN00607-03
Solenoid
Body
Spool
Outline
q
The work equipment lock valve is installed
between the basic pressure valve and control
valve in the work equipment control circuit. If
the work equipment lock lever is set in the
FREE position, the work equipment lock switch
operates and the work equipment lock valve
opens the work equipment control circuit so
that the operator can operate the work equipment.
Operation
q
The solenoid is operated by the electric signal
to move the spool. As a result, the circuit
between port (A) connected to the basic pressure valve and port (B) connected to the control valve is opened.
D155AX-6
19
SEN00607-03
Control valve
Outline
q
This manual explains the 5-spool valve (single
tilt specification) and 6-spool valve (dual tilt
specification).
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.
20
EPC valve
D155AX-6
SEN00607-03
Outside view
5-spool valve (single tilt specification)
D155AX-6
21
SEN00607-03
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.
22
EPC valve
D155AX-6
SEN00607-03
6-spool valve (dual tilt specification)
D155AX-6
23
SEN00607-03
Sectional view
(1/8)
5-spool valve
24
D155AX-6
SEN00607-03
(2/8)
6-spool valve
D155AX-6
25
SEN00607-03
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Steering spool
Blade tilt spool
Blade lift spool
Blade tilt (pitch) spool (only for 6-spool valve)
Ripper lift spool
Ripper tilt spool
Valve block
Valve block
Valve block (only for 6-spool valve)
Valve body
Steering priority valve
Load check valve
Pressure compensation valve
Filter
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Free length
Installation
x outer
length
diameter
Repair limit
Installation
load
Free
length
Installation
load
51.7 x 31.3
50
140 N
{14.3 kg}
112 N
{11.4 kg}
76.3 x 30
68.5
224 N
{22.8 kg}
179 N
{18.2 kg}
54.7 x 36.5
33.5
217 N
{22.1 kg}
173 N
{17.7 kg}
18
Load check valve

spring
20.8 x 12.2
13.5
12.7 N
{1.3 kg}
10.2 N
{1.04 kg}
19
Pressure compensation
valve spring
67.04 x 26.5
62.5
468 N
{47.7 kg}
374 N
{38.2 kg}
20
valve spring
108.3 x 29.5
81
562 N
{57.3 kg}
450 N
{45.8 kg}
21
valve spring
97.7 x 29.5
81
453 N
{46.2 kg}
362 N
{37 kg}
22
valve spring
109.4 x 29.5
81
563 N
{57.4 kg}
450 N
{45.9 kg}
23
Unload valve spring
86.7 x 30
66
192 N
{19.6 kg}
154 N
{15.7 kg}
26
Replace spring
if damaged or
deformed.
D155AX-6
SEN00607-03
(3/8)
5-spool valve
1.
2.
3.
4.
LS relief valve (for work equipment valve)

LS check valve (for work equipment valve)
LS check valve (for steering valve)
Preset check valve
D155AX-6
27
SEN00607-03
(4/8)
6-spool valve
1.
2.
3.
4.
28
LS relief valve (for work equipment valve)

LS check valve (for work equipment valve)
LS check valve (for steering valve)
Preset check valve
D155AX-6
SEN00607-03
(5/8)
1.
2.
Main relief valve

LS relief valve (for steering valve)
No.
3.
4.
Check item
Unload valve
Suction valve
Unit: mm
Remedy
Criteria
Standard size
Suction valve spring
Free length
Installation
x outer
length
diameter
64.9 x 12.5
D155AX-6
56
Repair limit
Installation
load
Free
length
6.4 N
{0.65 kg}
Installation
Replace spring if
load
damaged or
deformed.
5.1 N
{0.52 kg}
29
SEN00607-03
(6/8)
Suction valve spring is the same as section E-E.
1.
2.
EPC valve
Suction valve
30
D155AX-6
SEN00607-03
(7/8)
Section H-H is only for 6-spool valve.
D155AX-6
31
SEN00607-03
1. EPC valve
2. Suction valve
3. LS bypass valve
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Suction valve spring
Free length
Installation
x outer
length
diameter
46.8 x 7.5
32
40.6
Repair limit
Installation
load
Free
length
5.49 N
{0.56 kg}
Installation
Replace spring if
load
damaged or
deformed.
4.41 N
{0.45 kg}
D155AX-6
SEN00607-03
(8/8)
Suction valve spring is the same as section HH-HH.
1.
2.
EPC valve
Suction valve
D155AX-6
33
SEN00607-03
Operation of control valve

At hold (operation of unload valve)
Function
q
When the main spool (1) is at the hold position, it drains the excess oil discharged by the
pump, and prevents the pressure from being
formed in the circuit from rising.
Operation
When the main spool (1) is at the hold position, the pump discharge pressure passes from
chamber A through throttle (4) to chamber
(D).Chambers (C') and (C) are connected to
the drain circuit.
34
q
q
When the pressurized oil is supplied from the

pump, the pressure in chamber (D) rises, and
main spool (1) is pushed to the right by pressure which is determined by the cross-sectional area of piston (3) receiving the pressure.
When the received pressure becomes larger
than set load of spring (2), the main spool (1)
moves to the right and connects the passage
between chamber (A) and chamber (B), so the
oil from the pump is drained.
Main spool (1) is balanced at a position that
matches the supply of oil from the pump.
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).
D155AX-6
SEN00607-03
Control of oil flow

1.
1)
Steering valve
At hold
Function
q
Use of the CLSS circuit (Closed Center Load
Sensing System) makes it possible to control
the oil flow by adjusting the area of opening of
the spool driven by the EPC valve regardless
of the load.
q
q
Operation
q
When the steering spool (1) is at the hold
position, the pump discharge pressure is sent
from chamber (A) through the notch in spool
(3) of the steering priority valve, and passes
through chamber (B) to chamber (C).
D155AX-6
Chamber (G) is drained through chamber (H)

to chamber (F).
Since the pump discharge pressure is acting
on the left end of spool (3) of the steering priority valve, it compresses spring (4) and moves
to the right to the maximum stroke position.
In this condition, the area of the opening to
steering spool (1) is at its minimum.
35
SEN00607-03
2)
When steering to the left
PLS = Differential pressure between ports (K)

and (J) = 2.0 MPa {20 kg/cm2}
PLS' = Differential pressure between ports I
and D
PLS C
PLS'
Operation
q
When the PCCS lever is operated to turn the
machine to the left, pilot pressure (PI) acts
on the right end of steering spool (1) through
the EPC valve.
q
When the pressure becomes greater than the
set load of spring (2), the steering spool (1)
moves to the left. It becomes balanced at a
position that matches pilot pressure (PI).
36
Chamber (C) and chamber (D) are connected,

and the oil from the pump flows through ports
(A), (B), (C) and (D) to HSS motor (6).
At the same time, the load pressure in chamber (D) passes through LS orifice (5) and
chamber (H), and is sent to chamber (G). It is
also sent from LS circuit (O) to pump LS valve.
The condition of the pressure of pressure compensation valve spool (3) is chamber (B) pressure C chamber (C) pressure, and chamber (G)
pressure C chamber (D) pressure, so pressure
compensation spool (3) is controlled by the differential pressure of steering spool (1) (chamber (C) pressure - chamber (D) pressure), and
balances with spring (4).
D155AX-6
SEN00607-03
If the oil flow is too large, the differential pressure of steering spool (1) becomes larger, so
pressure compensation valve spool (3) moves
in the direction to throttle the oil flow.
On the other hand, if the oil flow is too small,
pressure compensation valve spool (3) moves
in the direction to increase the oil flow.
LS valve of the pump is controlled so that the
differential pressure between pump discharged
pressure (P) and LS pressure (LS) (LS differential pressure: PLS) remains constant, so a
suitable amount of oil flows to ensure that the
loss of pressure at the control valve ( PLS') is
equal to PLS.
The loss of pressure in the control valve is
determined by the area of the opening of steering spool (1), so the oil flow matches the opening of steering spool (1).
The return oil flow from HSS motor (6) passes
through chamber (E) and chamber (F), and is
drained.
D155AX-6
37
SEN00607-03
2.
a
38
Work equipment valve

(Blade lift, blade tilt, ripper lift, ripper tilt)
The diagram shows the blade lift valve and steering valve.
D155AX-6
SEN00607-03
Operation
q
When blade lift spool (1) is at the hold position, the pump discharge pressure (unload
pressure) is sent to chambers (D) and (D').
q
The pressure is not formed in chambers (H)
and (H'), so pressure compensation valve
spool (3) and steering priority valve spool (4)
are pushed completely to the right.
q
The pump pressure passes through chambers
(A) and (B) of steering priority valve spool (4),
and is sent to chamber (C) of the blade lift
valve. From here it goes through chamber (D)
and chamber (E) to chamber (F).
q
In the same way as described in topic (1)
Steering valve, the position of pressure compensation valve spool (3) is determined to
match the opening of blade lift spool (1), and
the oil flow is determined so that the pressure
loss of the control valve becomes equal to the
control differential pressure ( LS) of pump LS
valve.
D155AX-6
39
SEN00607-03
3.
40
Meter-out control when blade moves down under its own weight
D155AX-6
SEN00607-03
Function
q
If the blade moves down under its own weight,
the oil flow of return oil from blade lift cylinder
is controlled by the area of the opening of
blade lift spool (1).
Operation
When the port of blade lift spool (1) is opened
by pilot pressure (PI), because of the weight of
the blade, the oil from the cylinder head side
passes through ports (A), (B), (C) and (D), and
is drained to the tank.
q
The flow of return oil from the blade lift cylinder
is throttled by the area of opening between
ports (A) and (B), so the downward speed is
controlled.
q
The pressurized oil flowing from the blade lift
cylinder head end passes from the drain circuit
through suction valve (2) and is supplied to the
bottom end of the blade lift cylinder.
q
The oil discharged from the pump passes
through ports (A'), (B'), (C'), (D') and (E'), and
is supplied to the blade lift cylinder bottom.
q
D155AX-6
41
SEN00607-03
4.
42
Meter-out control when blade moves down under its own weight
(work equipment lever at float)
D155AX-6
SEN00607-03
Function
q
When the blade lift valve is at float, the cylinder port and drain port are connected to put
the circuit in a no-load condition.
q
When the blade lift valve is in the float condition, the pump passage and cylinder ports (A3)
and (B3) are separated so that the other control valves can be operated.
Operation
When the work equipment control lever is at
the lower position and the float button is
pressed, output pressure (PA3) of the EPC
valve becomes 3.4 MPa {35 kg/cm2 or more
and blade lift spool (1) is moved to the maximum stroke position.
q
Ports (A3) and (B3) and LS passage (O) are all
connected to the drain circuit, so there is no
load on the blade lift cylinder.
q
If the blade lift cylinder is driven by the weight
of the blade, the oil entering from port (A3)
flows to ports (A), (B), (B') and (A'), while the
rest of the pressurized oil flows through ports
(C) and (D), and is drained.
q
The oil flow is throttled by the area of opening
between ports (A) and (B) of blade lift spool
(1), and the cylinder speed is controlled.
q
The pump circuit chamber (E) and ports (A3)
and (B3) are separated, and pump discharge
pressure (P) is formed at chamber (E), so it is
possible to carry out compound operations
with other control valves.
q
D155AX-6
43
SEN00607-03
At relief
1. Steering valve
a The diagram shows the condition at relief for steering LS relief valve (5).
44
D155AX-6
SEN00607-03
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
If steering spool (1) is moved and the pressure
of HSS motor (7) becomes higher, the poppet
of steering LS relief valve (5) will start to open
and oil will be drained from LS circuit (O).
(Ports (E), (F), (G), (J), (K) and (L))
q
As a result, there will be a drop in pressure in
LS passage (O) starting from LS sensing hole
(F), and P2 will become larger.
q
For the same reason, if the pressure in chambers (H) and (I) drops, steering priority valve
spool (2) will push against spring (3) and move
to the right, and will make the opening between
chambers (B) and (C) smaller, so the flow to
chambers (B) and (C) will be throttled and P4
will become larger.
q
Because of the pump swash plate control, the
system circuit is balanced at a circuit pressure
which makes the pressure loss generated by
the flow at steering LS relief valve (5), P1 +
P2, equal to LS differential pressure ( LS).
q
When this happens, the pump LS valve
detects the differential pressure generated by
steering LS relief valve (5), and moves the
pump swash plate from the maximum to the
minimum position. The pump swash plate is
balanced at a position where the LS differential
pressure is 2.0 MPa {20 kg/cm2}.
q
When the pump is at the minimum swash plate
angle (minimum oil flow), if the minimum oil
flow is greater than the LS relief oil flow + leakage at any part, the pressure is confined in the
pump circuit (between the pump and chambers
(A) and (B)), so the LS differential pressure
rises.
q
If this differential pressure goes above the set
pressure for unload valve (4), the unload valve
is actuated to relieve the excess oil flow and
balance the circuit.
q
D155AX-6
45
SEN00607-03
2.
a
46
Blade lift, blade tilt, ripper lift and ripper tilt

The diagram shows the relief condition of work equipment LS relief valve (5) with the blade tilt at the end
of its stroke.
D155AX-6
SEN00607-03
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 pressure of the blade tilt cylinder becomes higher,
the poppet of work equipment LS relief valve
(5) will start to open and oil will be drained from
LS circuit (O). (Ports (E), (F), (G), (J), (K) and
(L))
q
As a result, there will be a drop in pressure in
LS passage (O) starting from LS sensing hole
(F), and P2 will become larger.
q
For the same reason, if the pressure in chambers (H) and (I) drops, pressure compensation
valve spool (2) will push against spring (3) and
move to the right, and will make the opening
between chambers (B) and (C) smaller, so the
flow to chambers (B) and (C) will be throttled
and P4 will become larger.
q
Because of the pump swash plate control, the
system circuit is balanced at a circuit pressure
which makes the pressure loss generated by
the flow at work equipment LS relief valve (5),
P1 + P2, equal to LS differential pressure
( LS).
q
When this happens, the pump LS valve
detects the differential pressure generated by
work equipment LS relief valve (5), and moves
the pump swash plate from the maximum to
the minimum position. The pump swash plate
is balanced at a position where the LS differential pressure is 2.0 MPa {20 kg/cm2}.
q
When the pump is at the minimum swash plate
angle (minimum oil flow), if the minimum oil
flow is greater than the LS relief oil flow + leakage at any part, the pressure is confined in the
pump circuit (between the pump and chambers
(A) and (B)), so the LS differential pressure
rises.
q
If this differential pressure goes above the set
pressure for unload valve (4), the unload valve
is actuated to relieve the excess oil flow and
balance the circuit.
D155AX-6
47
SEN00607-03
3.
a
48
Compound operation of steering and blade tilt

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.
D155AX-6
SEN00607-03
= P - P2
PO = Differential pressure between ports (H) and (K)
ressure P2 = LSO + PO
Function
q
When steering spool (1) and blade tilt spool (2)
are relieved at the same time, the pump pressure is separated by pressure compensation
valve spool (3) in the blade tilt valve, and the
port pressure is maintained at a constant
value.
Operation
q
If HSS motor (6) reaches the stall condition,
the load pressure increases and LS relief valve
(4) for the steering valve is actuated, so the
system is cut off.
q
For details, see 1. Steering valve.
q
When this happens, the pump discharge pressure (P) is maintained at 38.2 MPa {390 kg/
cm 2 } and this is sent to chamber (G) of the
blade tilt valve.
q
When blade tilt spool (2) is operated and the
load on the blade tilt valve is greater, blade tilt
valve LS relief valve (5) is actuated, and drain
oil flow (Q1) flows to LS circuit (O).
q
As a result, a differential pressure is generated
on the left and right sides of pressure compensation valve spool (3) by LS throttle (M) of
blade tilt spool (2), and it moves the full stroke
to the right.
q
When this happens, the opening between
chambers (D) and (E) is throttled to the minimum size (pump pressure separated).
q
Oil flow (Q1) is determined by pump discharge
pressure (P) and the total pressure loss (P
LSO) of ports (C), (D), (E), (F), (G), (I), (J) and
(K).
q
Furthermore, pressure (P2) (the pressure in
chamber (H)) becomes the total (LSO + PO)
of the circuit pressure loss of ports (H), (I), (J)
and (K), and the set pressure of work equipment LS relief valve (5).
D155AX-6
49
SEN00607-03
Compound operations
1. Steering and work equipment valve
a The diagram shows the condition when the steering and blade lift valve are operated at the same time.
50
D155AX-6
Function
q
The steering valve is equipped with steering
priority valve spool (3), so if the steering valve
and the downstream work equipment valve are
operated at the same time, priority is given to
the flow of oil to the steering valve, and the rest
of the oil discharged from the pump goes to the
work equipment valve.
Operation
When steering spool (1) is operated by EPC
valve output pressure (PI) and the oil flows, a
differential pressure is created between chambers (C) and (D).
q
Steering priority valve spool (3) is controlled by
this differential pressure, and at the same time,
the pump swash plate angle is controlled at
PLS = 2.0 MPa {20 kg/cm2}, and the flow of
oil to the steering valve is fixed.
q
For details, see 1. Steering valve of Control
of oil flow.
q
In this condition, if downstream work equipment blade lift spool (2) is operated, the pump
discharge pressure momentarily drops.
q
At this point, the differential pressure between
chambers (C) and (D) becomes smaller, and
steering priority valve spool (3) is moved to the
left by the pressure in chamber (E) in the direction to throttle the opening to the work equipment valve.
q
At the same time, PLS becomes smaller, so
the pump swash plate angle moves in the maximum direction to supply an oil flow to make up
the amount that the pressures drops.
q
D155AX-6
SEN00607-03
When pump swash plate does not reach maximum angle

q
When the maximum oil flow from the pump is
greater than the sum of the flow demanded by
the steering valve and work equipment valve,
an amount of oil that matches the opening of
steering spool (1) flows to the steering valve.
q
An amount of oil decided by the pump discharge pressure, the load pressure and the
area of the spool opening, flows to the work
equipment valve.
When pump swash plate is at maximum angle
When the maximum flow of oil from the pump
is smaller than the sum of the oil flow
demanded by the steering valve and work
equipment valve.
1)
q
When steering valve load Z work equipment

valve load.
An amount of oil that matches the opening of
steering spool (1) flows to the steering valve,
and the remaining oil flows to work equipment
valve.
2)
When steering valve load > work equipment

valve load.
q
Pump discharge pressure (P) is determined by
the steering valve load, but in this condition, if
the downstream work equipment valve where
the load is smaller is operated, the difference
in pressure will cause the oil to try to flow to the
work equipment valve, so the pump discharge
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 proportion 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.
51
SEN00607-03
2.
a
52
Compound operation of blade lift and blade tilt

The diagram shows the condition when the blade lift and blade tilt are operated at the same time.
D155AX-6
SEN00607-03
Function
q
It consists of a parallel circuit, so when compound operations are carried out, the oil flow is
divided according to the size of each spool
opening.
Operation
When blade tilt spool (1) and blade lift spool (2)
are at the hold position or are operated,
steering priority valve (3) is pushed completely
to the right, and the size of the opening to the
downstream area is at its maximum.
q
Blade tilt spool (1) and blade lift spool (2) are
actuated by PPC valve output pressure (PA2)
and (PB3), and each is balanced at a position
that matches its own EPC valve output pressure.
q
When pressure (P2) Z (P3)

q
Blade lift valve load pressure (P3) is sent to the
pump LS valve through LS passage (O).
1)
q
2)
q
When pump swash plate does not reach maximum angle

i s g r e at e r t h 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.
When pump swash plate is at maximum angle
i s s m a l l e r t h 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, the flow of oil to the blade tilt valve and
blade lift valve is divided according to differential pressure (PO) (P2) and differential pressure (PO) (P3).
In other words, more oil flows to (P2) where
the load is small.
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
53
SEN00607-03
Unload valve preset system

a The diagram shows the condition with preset check valve (3) open immediately after blade lift valve is
operated.
54
D155AX-6
SEN00607-03
Function
q
This improves the response of the system
including the pump swash plate and pressure
compensation valve by sending the pilot pressure (basic pressure of EPC valve) to the LS
circuit, and compensating the rise of the LS circuit pressure.
Operation
When blade lift valve spool (1) is at the hold
position, pilot pressure (P1) (basic pressure of
EPC valve) is sent through preset check valve
(3) to chamber (F) of the pressure compensation valve. This pressure is called preset pressure (P2).
q
Unload pressure (P) is being sent to chamber
(B), but (P1) + (F0) > (P) (F0: load of spring
(4)), so pressure compensation spool (2)
moves to the left and the size of the opening
between chambers (A) and (B) becomes the
maximum.
q
When blade lift spool (1) is switched, unload
pressure (P) flows immediately through chambers (A), (B), (C), (D) and (E) to the blade lift
cylinder, so the pressure at the port starts to
rise and the time lag becomes smaller.
q
At the same time, preset pressure (P2) is supplied to LS circuit (O), and the pressure in the
LS circuit rises.
q
Unload valve (7) closes, and oil is sent further
to the pump LS valve to improve the response
of the pump swash plate angle. This makes it
possible to reduce the response time for giving
the necessary oil flow.
q
D155AX-6
55
SEN00607-03
Work equipment cylinder
Blade lift cylinder
Blade tilt cylinder
Ripper cylinder
56
The piping of the lift cylinder and tilt cylinder of the variable multi-shank ripper is different from the
above.
D155AX-6
SEN00607-03
Unit: mm
No.
Check item
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
75
-0.030
-0.076
+0.279
+0.065
0.095
0.355
0.666
90
-0.036
-0.090
+0.270
+0.061
0.097
0.330
0.695
100
-0.036
-0.090
+0.257
+0.047
0.105
0.375
0.675
Ripper
TILT
110
-0.036
-0.090
+0.261
+0.047
0.105
0.375
0.675
Clearance between
piston rod support
shaft and blade
ball portion
Blade
LIFT
85
+0.3
+0.3
1.0
Clearance between
cylinder support
shaft and bushing
Blade
LIFT
85
-0.100
-0.174
0.100
0.228
0.5
Clearance between
piston rod spherical
surface and cap
Blade
TILT
115
-0.200
-0.300
60
-0.030
-0.050
+0.174
+0.100
0.130
0.224
1.0
Blade
TILT
Clearance between
cylinder bottom sup- Ripper
port shaft and bush- LIFT
ing
Ripper
TILT
90
-0.036
-0.090
+0.207
+0.120
0.156
0.297
1.0
100
-0.036
-0.090
+0.201
+0.119
0.156
0.291
1.0
Ripper
LIFT
90
-0.036
-0.090
+0.207
+0.120
0.156
0.297
1.0
Ripper
TILT
100
-0.036
-0.090
+0.201
+0.119
0.156
0.291
1.0
Blade
LIFT
Clearance between
piston rod and bush- Blade
TILT
ing
Ripper
LIFT
Clearance between
cylinder rod support shaft and bushing
D155AX-6
Replace
57
SEN00607-03
Piston valve
For blade lift cylinder

Outline
q
The piston valve is installed on the piston in
the blade lift cylinder. When the piston reaches
its stroke end, the valve releases the oil from
the hydraulic pump to reduce the oil pressure
being exerted on the piston.
When the blade is tilted, the blade is subject to
a tortional force owing to the uneven position
of the pistons in the two cylinders; that is the
piston on one side is still moving while the piston 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 contact with the cylinder head or the bottom and
serves to reduce the subsequent surge pressure in the cylinder by letting the oil escape
from the cylinder before the piston reaches its
stroke end.
2.
Piston valve OPEN

Just before piston rod (1) reaches the end of
its stroke, the tip of valve (6) contacts the cylinder bottom, so valve (6) and piston valve (3)
stop at that position and do not move further.
Only piston (2) moves further.
When this happens, the oil at the cylinder
head, which was sealed by piston valve (3),
escapes from piston valve seats (4) and (5),
and the pressure inside the cylinder stops rising.
Operation
1. Piston valve CLOSED
Pressurized oil from the hydraulic pump acts
on piston (2) and piston valve (3).
The piston valve (3) is pushed in the direction
of the arrow until piston valve seat (4) comes
into snug contact with the tapered section,
thereby, this causing the pressure in the cylinder to rise and moving piston (2) in the direction of the arrow.
58
D155AX-6
D155AX-6
SEN00607-03
59
SEN00607-03
Quick drop valve
(For blade lift cylinder)
60
D155AX-6
SEN00607-03
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.
2.
3.
4.
5.
6.
Body
Main spool
Plate
Body
Selector valve spool
EPC valve
Unit: mm
No.
Check item
Clearance between main
spool and valve body
Clearance between selector valve spool and valve
body
Criteria
Tolerance
Remedy
Shaft
Hole
Standard
clearance
36
-0.002
-0.007
+0.010
+0.010
0.008
0.010
0.015
-0.010
-0.022
+0.018
+0.010
0.010
0.015
0.02
Standard
size
Clearance
limit
Replace
Unit: mm
No.
Check item
Criteria
Standard size
10
Main spool return

spring
Selector valve spool return

spring
D155AX-6
Free length
Installation
x outer
length
diameter
Remedy
Repair limit
Installation
load
Free length
76.4 x 27
69.5
449 N
{45.8 kg}
20.9 x 13.8
12.5
97 N
{9.89 kg}
Installation
load
Replace
spring if dam359 N
aged or
{36.6 kg} deformed.
77.6 N
{7.91 kg}
61
SEN00607-03
1.
q
q
No circulating condition
Fine control of lowering blade (Stroke of lever is less than 70%.)
QDV mode: OFF
Outline
QDV: Abbreviation of Quick Drop Valve
q
The quick drop valve is installed between the
control valve and the blade lift cylinder.
q
When the blade control lever is set in lower
position, the quick drop valve prevents a vacuum on the cylinder bottom side and shortens
time lag in starting digging.
q
The blade lowering speed is mostly decided by
the pump delivery. However, it can be heightened by installing the quick drop valve.
62
Since the quick drop valve electronically controls the operation of the PCCS lever, the controller and EPC valve (QDV is built-in), it is
possible to select ON-OFF.
Operation
Because command current (X) from the controller to the EPC valve is 0A, main spool (2) is
not switched.
q
The circuits between port (VH) and port (PH) /
port (VB) and port (PB), are shut off.
q
The pressure oil of the lift cylinder head flows
from port (VH) to tank (T) through the control
valve.
q
D155AX-6
2.
q
q
SEN00607-03
Circulating condition
Lowering blade (Stroke of lever is more than 70%.)
QDV mode: ON
Operation
q
1,000 mA of command current (X) flows from
controller to EPC valve and the pilot pressure
from the EPC valve is taken to chamber (a) at
the main spool.
q
Main spool (1) moves to the right and the circuits between port (VH) and port (PH)/port
(VB) and port (PB), get into circulating condition.
q
Most of the pressurized oil which has been
flowing from port (PH) to port (VH), circulates
and flows to port (PB).
D155AX-6
The pressurized oil which has been flowing to

port (PB) merges with the pressure oil from
port (VB) and flows into the lift cylinder bottom.
The blade lowering speed is increased by the
quantity of oil flowing into the lift cylinder bottom.
Vacuum on the lift cylinder bottom is prevented.
63
SEN00607-03
3.
q
q
From the circulating condition of lowering blade to the blade tensed condition
Lowering blade (Stroke of lever is more than 70%.)
QDV mode: ON
Operation
q
Under the circulating condition of blade lowering, if the blade gets tensed, the lift cylinder
bottom pressure rises.
q
If the lift cylinder bottom pressure becomes
3.43 MPa {35kg/cm2} or more, selector valve
spool (2) moves to the left.
q
The pilot pressure from the EPC valve is
blocked and pressure chamber (a) of main
spool (1) is connected to drain circuit (TS).
q
Main spool (1) moves to the right by the force
of spring (3).
64
The lift cylinder bottom is connected to the circuit between port (PB) and port (VB), this
enables the blade to be tensed under no circulating condition.
D155AX-6
T:
P1:
P2:
PR:
SEN00607-03
To tank
From pump
To fan motor
Supply to PPC valve and EPC valve
D155AX-6
65
SEN00607-03
1.
2.
3.
4.
5.
66
Valve (sequence valve)

Spring
Screw
Poppet
Spring (pressure reducing valve pilot)
6.
7.
8.
9.
10.
Spring (pressure reducing valve main)

Valve (pressure reducing valve)
Spring (safety valve)
Ball
Filter
D155AX-6
SEN00607-03
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
11
Spring (pressure reducing

valve main)
Free length
Installation
x outer
length
diameter
Repair limit
Installation
load
Free
length
Installation
load
19.2 x 7.20
16.1
19.6 N
{2.0 kg}
17.7 N
{1.80 kg}
Spring
12 (pressure reduction valve
pilot)
17.8 x 7.20
12.7
28 N
{2.90 kg}
25.6 N
{2.60 kg}
13 Spring
71.0 x 18.0
59.0
200 N
{20.4 kg}
186 N
{19.0 kg}
14 Spring (safety valve)
16.1 x 7.80
13.4
61.7 N
{6.30 kg}
58.8 N
{6.0 kg}
Replace spring
if damaged or
deformed.
Function
q
The self pressure reducing valves reduce the
discharge pressure of the fan pump and supplies it to the PPC valve, the EPC valve, etc. as
the control pressure.
D155AX-6
67
SEN00607-03
Operation
At engine stop (total low pressure)
68
Spring (6) pushes the poppet (5) to the seat,

and the circuit between ports (PR) and (T) is
closed.
Spring (7) pushes valve (8) to the left side, and
the circuit between port (P1) and port (PR) is
open.
Spring (3) pushes the valve (2) to the upper
side, and the circuit between ports (P1) and
(P2) is closed.
D155AX-6
SEN00607-03
When load pressure (P2) is lower than output pressure (PR) of the self pressure reducing valve.
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).
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).
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
69
SEN00607-03
At raise of load pressure (P2)
70
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
(P2) increases and passage resistance
becomes smaller, reducing engine horsepower
loss.
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).
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
SEN00607-03
In the case of abnormal high pressure
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
71
SEN00607-03
D155AX-6 Bulldozer
2012 KOMATSU
All Rights Reserved
72
D155AX-6
SEN00608-01
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up

Work equipment
Cylinder stay ................................................................................................................................................... 2
Blade............................................................................................................................................................... 4
Cutting edge, end bit....................................................................................................................................... 6
Ripper ............................................................................................................................................................. 8
D155AX-6
SEN00608-01
Cylinder stay
1.
2.
3.
4.
5.
Yoke
Dust seal
Bushing
Bushing
Grease nipple
D155AX-6
SEN00608-01
Unit: mm
No.
Check item
Clearance between cylinder
yoke and bushing
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
125
0.172
0.235
+0.063
+0.046
0.172
0.298
Clearance between cylinder

yoke and bushing
100
0.170
0.224
+0.054
+0.046
0.170
0.278
Clearance between bushing

of cylinder support shaft and
yoke
110
0.172
0.035
+0.054
+0.046
0
0.089
0.5
D155AX-6
Replace
SEN00608-01
Blade
Sigma-tilt dozer
D155AX-6
SEN00608-01
Unit: mm
No.
Check item
Clearance between brace
and pin
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
60
0.3
0.5
+0.174
+0.100
0.4
0.674

pin and bracket
60
0.3
0.5
+0.5
+0.2
0.5 1.0

spherical surface and cap
115
0.2
0.3
+0.3
+0.6
0.2 0.6
Clearance between
brace pin and bracket
90
0.3
0.5
+0.3
+0.1
0.4 0.8

pin and brace
90
0.3
0.5
+0.5
+0.3
0.6 1.0
Clearance between joint

and blade bracket
140
0.2
0.7
+0.5
+0.3
0.5 1.2
Clearance between frame

pin and joint
70
0.5
0.6
+0.3
+0.6
0.5 0.9
Clearance between bracket

pin and blade bracket
70
0.5
0.6
+0.3
+0.6
0.5 0.9
Clearance between blade

bracket pin and joint
70
0.5
0.6
+0.3
+0.6
0.5 0.9
10
Clearance between center

brace spherical surface
and cap
165
0.2
0.3
+0.3
+0.6
0.2 0.6
11
Clearance between trunnion

160
0.5
1.0
+0.5
+0.0
0.5 1.5
12
Clearance between trunnion

195
0.5
1.0
+0.5
+0.0
0.5 1.5
D155AX-6
Replace
Adjust shims
or replace
Replace
Adjust shims
or replace
Replace
SEN00608-01
Cutting edge, end bit
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
330
260 (215 to turning)
Height of outside of end bit
300
235
Height of inside of end bit
330
260
Width of end bit
640
500
Height of cutting edge
Turn
or replace
Replace
D155AX-6
D155AX-6
SEN00608-01
SEN00608-01
Ripper
Variable multi-shank ripper
D155AX-6
SEN00608-01
Unit: mm
No.
Check item
Criteria
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
110
0.036
0.090
+0.207
+0.120
0.156
0.297
1.5
110
0.036
0.090
+0.459
+0.369
0.405
0.549
1.5
100
0.036
0.090
+0.207
+0.120
0.156
0.297
1.5
Clearance between tilt cylinder mounting pin and bushing
100
0.036
0.090
+0.457
+0.370
0.406
0.547
1.5
Clearance between lift cylinder

5,11 mounting pin and mounting
bracket or beam bracket
90
0.036
0.090
+0.207
+0.120
0.156
0.297
1.5

6,12 mounting pin and shank bushing
90
0.036
0.090
+0.207
+0.120
0.156
0.297
1.5
Clearance between arm

2,8

mounting pin and bushing
Clearance between tilt cylin3,9 der mounting pin and mounting bracket or beam bracket
4,10
Standard
size
Tolerance
13
Clearance between shank

mounting pin and shank
holder
Shaft 75
Hole 77
+0.300
0.300
+0.300
0.300
1.400
2.600
10.0
14

mounting pin and shank hole
Shaft 75
Hole 80
+0.300
0.300
+1.000
1.000
3.700
6.300
15.0
15
Wear of point
16
Wear of protector
D155AX-6
Standard size
Repair limit
335
225
115
90
Replace
SEN00608-01
Variable giant ripper
10
D155AX-6
SEN00608-01
Unit: mm
No.
Check item
Criteria
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
110
0.036
0.090
+0.207
+0.120
0.156
0.297
1.5
110
0.036
0.090
+0.459
+0.369
0.405
0.549
1.5
100
0.036
0.090
+0.207
+0.120
0.156
0.297
1.5
Clearance between tilt cylinder mounting pin and bushing
100
0.036
0.090
+0.457
+0.370
0.406
0.547
1.5

90
0.036
0.090
+0.207
+0.120
0.156
0.297
1.5

6,12 mounting pin and shank bushing
90
0.036
0.090
+0.207
+0.120
0.156
0.297
1.5

2,8

mounting pin and bushing
Clearance between tilt cylin3,9 der mounting pin and mounting bracket or beam bracket
4,10
Standard
size
Tolerance
13

mounting pin and shank
holder
Shaft 75
Hole 77
+0.300
0.300
+0.300
0.300
1.400
2.600
10.0
14

mounting pin and shank hole
Shaft 75
Hole 80
+0.300
0.300
+1.000
1.000
3.700
6.300
15.0
15
Wear of point
16
Wear of protector
D155AX-6
Standard size
Repair limit
335
225
115
90
Replace
11
SEN00608-01
D155AX-6 Bulldozer
2007 KOMATSU
All Rights Reserved
12
D155AX-6
SEN00609-01
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up


Cab mount + ROPS pin .................................................................................................................................. 2
ROPS cab ....................................................................................................................................................... 3
Air conditioner ................................................................................................................................................. 4
D155AX-6
SEN00609-01
Cab mount + ROPS pin
1.
2.
3.
4.
5.
Support
Damper mount (front)
Damper mount (rear)
ROPS pin (front)
ROPS pin (rear)
Outline
q
Viscous mounts are installed at two places at
the front and two places at the rear to secure
the floor frame and cab.
q
An oil-filled damper mount is used to absorb
the vibration.
q
The ROPS pins are installed to 2 places each
at the front and rear sections to fix the ROPS
(built in the cab) when the machine rolls over.
D155AX-6
ROPS cab
SEN00609-01
Cab assembly
1.
2.
3.
4.
5.
Front wiper
Front glass
Rear wiper
Door
ROPS sub (built in CAB)
D155AX-6
SEN00609-01
Air conditioner
Air conditioner piping
1.
2.
3.
4.
5.
6.
7.
8.
9.
Condenser
Hot water return piping
Hot water pick-up piping
Front window defroster
Side window defroster
Air outlet for face
Air outlet for center
Air outlet for rear
Air conditioner unit
10.
11.
12.
13.
14.
15.
Air outlet for foot

Receiver tank
Refrigerant piping
Valve (hot water outlet)
Air conditioner compressor
Valve (hot water inlet)
A:
B:
Fresh air
Recirculated air
D155AX-6
D155AX-6
SEN00609-01
SEN00609-01
D155AX-6 Bulldozer
2007 KOMATSU
All Rights Reserved
D155AX-6
SEN00610-03
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up

Electrical system
Engine control ................................................................................................................................................. 2
Engine control system..................................................................................................................................... 3
Deceleration potentiometer............................................................................................................................. 4
Monitor system................................................................................................................................................ 6
Sensors......................................................................................................................................................... 25
Palm command control system..................................................................................................................... 28
KOMTRAX system........................................................................................................................................ 31
D155AX-6
SEN00610-03
Engine control
1.
2.
3.
4.
5.
6.
7.
8.
9.
Decelerator pedal
Decelerator potentiometer
Starter switch
Fuel control dial
Battery relay
Battery
Starter
Fuel supply pump
Outline
q
The throttle signals of the fuel control dial are
sent to the power train controller and processed together with the 3rd throttle signal,
and then sent as the throttle commands
together with the throttle signals of the decelerator pedal to the engine throttle controller. The
engine throttle controller controls the engine
according to the commands.
D155AX-6
SEN00610-03
Engine control system
Outline
q
The engine throttle controller receives the fuel
control dial signal of the 1st throttle, decelerator pedal signal of the 2nd throttle, and 3rd
throttle signal which is the control signal from
the power train controller, and then controls the
fuel supply pump according to the command
signal having the lowest engine speed.
The control signals of the 3rd throttle are as
follows.
(1) Auto deceleration (F3, R3, F2, R2)
(2) Neutral deceleration
q
The power train controller calculates a proper
engine speed from information items (1), (2),
etc.
and sends it as the 3rd throttle signal to the
engine throttle controller.
D155AX-6
The information of the engine throttle controller

is possessed jointly by the other controllers
through the network and used for the optimum
control of the engine and machine body.
The auto deceleration is a function of setting
the engine speed low temporarily when the
travel direction is changed from F3, R3, F2,
and R2 (to protect the transmission clutch).
The neutral deceleration is a function of limiting the high idle speed when the transmission
is set in neutral.
SEN00610-03
Deceleration potentiometer
1.
2.
3.
4.
5.
6.
7.
Connector
Lever
Body
Potentiometer
Cuppling
Shaft
Stopper
Outline
q
The deceleration potentiometer is installed to
the inside of the dashboard and connected to
the decelerator pedal by linkage.
q
If the decelerator pedal is pressed, it rotates
the throttle potentiometer shaft through the
linkage and the potentiometer resistance
changes.
Constant voltage is applied between pins (A)
and (C) of the potentiometer and a voltage signal is sent through pin (B) to the engine controller according to the position of the
decelerator pedal.
D155AX-6
D155AX-6
SEN00610-03
SEN00610-03
Monitor system
The monitor system monitors the machine condition with the sensors installed to various
parts of the machine and processes and displays the obtained information on the panel
quickly to notify the operator of the machine
condition.
The main display sections and functions of the
panel are as follows.
1) Monitor unit which turns on the alarm
when the machine has a trouble.
2) Gauge unit which constantly displays the
machine condition (coolant temperature,
torque converter oil temperature, fuel
level, etc.)
3) Function of displaying error codes.
4) Function of monitoring the current and
voltage of the sensors and solenoids,
The CPU (Central Processing Unit) in the monitor panel displays and outputs various information items processed by the power train
controller. The display unit is LCD (Liquid Crystal Display)
D155AX-6
SEN00610-03
Processing in machine monitor (Common to all specifications)

Display of machine monitor
Contents and conditions of processing
1. Display of travel direction and gear speed.
F1, R3, etc. are notified by CAN according to information of power train controller.
Method
Flow of signals
CAN
2. Display of gauges of fuel level, engine coolant temperature, 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
CAN.
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.
Each sensor/solenoid-controllermachine monitor
Display of monitoring condition

Method
1. The communication conditions of each sensor, each solenoid, and CAN are displayed.
The item Nos. and device conditions are notified to
CAN
the machine monitor by CAN.
The machine monitor displays the items and each
value.
Flow of signals
Each sensor-controller-machine
monitor
2. Each items is selected by using the cursor switches and

CAN
confirmation switch.
Other items
01
02
03
04
05
06
07
08
09
10
11
12
13
88
89

Monitoring
Trouble history
Maintenance history
Maintenance mode change
Telephone number set
Default
Adjustment
PM clinic
Reduced cylinders mode operation
No injection cranking
Fuel consumption display
Service message display

Screen adjustment a
Method
Flow of signals
See testing and adjusting, special functions of machine monitor.
D155AX-6
SEN00610-03
Machine monitor
Outline
q
The machine monitor has the functions to display various items and the functions to select
modes and electric parts.
q
The machine monitor has a CPU (Central Processing Unit) in it to process, display, and output the information.
q
The monitor display employs an LCD (Liquid
Crystal Display). The switches are flat sheet
switches.
Precautions on the machine monitor display

q
The liquid crystal display panel may have black
spots (which do not light up) or bright spots
(which stay on).
Products having 10 or less black or bright
spots conform the product specification; such
the condition is quite normal.
q
Battery voltage may suddenly drop at enginestart due to ambient temperature or the condition of the battery. The machine monitor display 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 reason, blue spots will not cause any problem
(since the liquid crystal lights up red, blue, and
green spots when displaying white).
D155AX-6
Input and output signals
Input/
output
1
Battery power (+24V constantly)
Input
2
Battery power (+24V constantly)
Input
3
Battery power GND
4
Battery power GND
Input/
5
Wake-up
Output
6
Relay output
Output
7
Chassis signal GND
8
Hydraulic oil pressure
9
Fuel level
Input
10
NC(*)
11
Charge amount
Input
12
Chassis analog signal GND
13
Light switch
Input
14
Key switch (ACC)
Input
15
Key switch (C)
Input
16
Preheating
Input
17
NC(*)
18
NC(*)
*: Never connect to NC or malfunctions or failures will

occur.
Signal name
CN-CM02
Input/
output
1
NC(*)
2
NC(*)
3
Coolant level sensor
Input
4
NC(*)
5
NC(*)
6
NC(*)
7
Chassis signal GND
8
CAN terminating resistance
Input/
9
CAN_H
Output
Input/
10
CAN_L
Output
11
NC(*)
12
NC(*)

occur.
Pin No.
CN-CM03
Pin No.
CN-CM01
Pin No.
SEN00610-03
Signal name
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Input/
output
RS232C CD for communication terminal Input
RS232C RXD for communication terminal Input
RS232C SG for communication terminal
Signal name
Signal GND for communication terminal
control
Communication terminal selection signal Input
RS232C RTS for communication terminal Output
RS232C TXD for communication terminal Output
RS232C DTR for communication terminal Output
RS232C DTR for communication terminal Input
RS232C CTS for communication terminal
RS232C RI for communication terminal
Power GND for communication terminal
Input CH1 for communication terminal
status
Output for communication terminal
power control
Output CH1 for communication terminal
control
Output CH2 for communication terminal
control
Input CH2 for communication terminal
status
Electric power supply for communication
terminal
Input
Input
Input
Output
Output
Output
Input
Output
CN-CM04
Input/
output
1
NC(*)
2
NC(*)
3
NC(*)
4
NC(*)
5
NC(*)
6
NC(*)
7
NC(*)
8
NC(*)
9
NC(*)
10
NC(*)
11
NC(*)
12
NC(*)

occur.
Pin No.
Signal name
CN-CM05
Pin No.
1
2
3
4
5
6
7
8
D155AX-6
Input/
output
Electric power supply for camera
Output
Camera NTSC signal input 1
Input
Input
Input
Electric power supply GND for camera
Camera signal GND1
Camera signal GND2
Camera signal GND3
Signal name
SEN00610-03
Monitor control, display portion
1.
2.
3.
4.
5.
6.
7.
8.
10
Gear shift mode selector switch

Buzzer cancel switch
Working mode selector switch
Engine coolant temperature
Multi gauge
Pilot display
Service meter, clock
Hydraulic mode display
9.
10.
11.
12.
13.
14.
15.
16.
Fuel level
Travel gear speed gear shift mode preset
Guidance icon
Function switch
Custom switch
Custom memory switch
Float mode switch
Air conditioner switch
D155AX-6
D155AX-6
SEN00610-03
11
SEN00610-03
Machine monitor display
Check
Display
category
Symbol
Display item
Displays when engine is stopped and

starting switch is ON
Display when normal: OFF
Display when abnormal: ON
Below low level
Engine oil pressure
When sensor is abnormal

or when wiring harness is
disconnected
Battery charge
Displays when starting switch is ON

and engine is running
When charge is defective Display when normal: OFF
CAUTION lamp flashes
Engine oil pressure
Below 49.0kPa
{0.5kg/cm2}
Radiator coolant level
Below low level
Caution
Torque converter oil temperature
Pilot
Display method
Radiator coolant level
12
Display range
When at highest level on

engine coolant
temperature gauge
Above 102C:
Symbol ON
Above 105C:
Symbol ON + buzzer
When at highest level on
engine coolant
temperature gauge
Above 120C:
Symbol ON
Above 130C:
Symbol ON + buzzer
Hydraulic oil temperature
Above 100C:
Symbol ON
Above 110C:
Symbol ON + buzzer
Maintenance
When replacement time

of filter or oil has been
passed
Preheating
When preheating
Displays when starting switch is ON

and engine is running
Alarm buzzer sounds
Lights according to required time

determined by engine controller
based.
It also lights at the time of manual preheat by setting starting switch at preheat position (turning it
counterclockwise).
D155AX-6
Display
category
Symbol
Display item
SEN00610-03
Display range
Display method
Engine coolant
temperature
Gauges
Torque converter oil

temperature
Indicative applicable temperature
Fuel level
Service meter
(Hours meter)
D155AX-6
Indicative applicable level
From 0 to 99999
Actuated when the engine is rotating
13
SEN00610-03
Gauge
The gauge pointer disappears when information on coolant temperature or hydraulic oil temperature cannot
be obtained due to disconnection of CAN.
Gauge
Engine coolant
temperature
(C)
Power train oil

temperature
(C)
Hydraulic oil
temperature
(C)
Fuel level (l)
14
Range
A1
A2
A3
A4
A5
A6
B1
B2
B3
B4
B5
B6
C1
C2
C3
C4
C5
C6
D1
D2
D3
D4
D5
D6
Temperature or volume
105
102
100
85
60
30
130
120
118
90
50
0
110
100
98
70
20
0
565
425
310
220
150
75
Indicator
Buzzer sound
Red
Red
Off
Off
Off
White
Red
Red
Off
Off
Off
White
Red
Red
Off
Off
Off
White
Off
Off
Off
Off
Off
Red
D155AX-6
Machine speed
1. 0 km/h
2. 5 km/h
SEN00610-03
Battery voltage
3. 10 km/h
4. 15 km/h
1. 0 V
2. 17 V
3. 20 V
Hydraulic, HSS pump oil pressure
Engine speed
1. 0 MPa
2. 10 MPa
3. 20 MPa
1. 500 rpm
2. 1,000 rpm
3. 1,500 rpm
4. 30 MPa
5. 40 MPa
6. 50 MPa
Engine oil pressure
1. 0.0 MPa
2. 0.2 MPa
3. 0.3 MPa
D155AX-6
4. 25 V
5. 30 V
6. 31 V
4. 2,000 rpm
5. 2,500 rpm
6. 3,000 rpm
Drawbar pull
4. 0.4 MPa
5. 0.5 MPa
6. 0.7 MPa
1. 0 W
2. 0.2 W
3. 0.4 W
4. 0.6 W
5. 0.8 W
6. 1.0 W
15
SEN00610-03
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
16
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.
F3
Select item
Selects item on left side (Selects right end item after left
end item).
F4
Select item
Selects item on right side (Selects left end item after right
end item).
F3
Select item
Selects item on lower side (Selects top item after bottom

item)/Resets holding of monitoring.
F4
Select item
Selects item on upper side (Selects bottom item after top

item)/Holds monitoring.
F1
Select item
Selects page on lower side (Selects top page after bottom

page).
F2
Select item
Selects page on upper side (Selects bottom page after top

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

adjustment of screen.)
F1
Start
Starts operation. (Used to start measurement of split fuel

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

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

(Only dual-tilt dozzer specification)
F2
Change multi gauge
Change of multi gauge items
D155AX-6
SEN00610-03
Air conditioner control switch

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

9a : Specifies airflow
9b : Specifies temperature
9c : AUTO
9d : A/C
9e : Switches among air blowing modes
9f : Switches between inside air and outside air
9g : OFF
9a to 9c : Enables entered information simultaneously with switching to the air conditioner 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.
Pressing F4 on the normal screen when the

service meter is displayed in the top center of
the screen switches the display to the time,
and doing so when the time is displayed
switches the display to the service meter.
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
SEN00610-03
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 normal screen.
No operation at least 30 sec. : Returns to the normal screen.
q
No.
F1 : Displays the next page.

Displays the top page when the last page is
displayed.
F2 : Displays the previous page.
Displays the last page when the top page is
displayed.
F3 : Selects (highlights) an item one down.
F4 : Selects (highlights) an item one up.
F5 : Returns to the normal screen.
F6 : Switches to the maintenance time reset screen.
q
18
If the remaining time on the maintenance table

screen is less than 30 hours, the relevant items
are highlighted in yellow, and if 0 hours, they
are done in red.
On the maintenance time reset screen, reset
the remaining time for the selected item to
return to the default.
The table below shows the maintenance items

and replacement intervals. The time remaining
to maintenance is reduced as the machine is
operated.
Item
01 Engine oil
02 Engine oil filter
03 Fuel main filter
41 Fuel pre filter
04 Hydraulic filter
06 Corrosion resistor
07 Damper case oil
08 Final drive case oil
10 Hydraulic oil
19 P/L oil
20 P/L oil filter
*: If equipped (To be determined)
P/L: Power train
q
Replacement interval
(Hours)
500
500
1000
500
2000
1000(*)
2000
1000
2000
1000
500
The content of the caution display differs

according to the remaining time. The relationship is as shown in the table below.
Display
Condition
Remaining time for mainteNone
nance for all items is more
than 30 hours.
There is one or more items
Notice display (black symwith less than 30-hour
bol displayed on yellow
remaining time for maintebackground)
nance.
There is one or more items
Warning display (white
with less than 0-hour
symbol displayed on red
remaining time for maintebackground)
nance.
D155AX-6
To reset the maintenance time carelessly, it is

locked by the password.
SEN00610-03
User mode
q
q
q
q
Pressing F6 on the normal screen enters the

user mode, switching to the user menu screen.
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
The default password is 000000.

Enabling the password lock on an attachmentequipped machine locks the attachment setting screen at the same time.
For information on changing the maintenance
password, see Maintenance password change
function in the Testing and adjusting section.
F3 :
F4 :
F5 :
F6 :
Selects (highlights) an item one down.

Selects (highlights) an item one up.
Returns to the normal screen.
Switches to the setting screen for the selected
item.
(In user mode, no switch operation at least 30 sec.
returns to the previous screen.)
Utility screen select

q
D155AX-6
If utility screen select is selected with switch

F6, (1) Standard Display, (2) Load Display, or
(3) Body Pitch Display can be selected.
Select an item with switch F3 or F4 and confirm that item with switch F6.
19
SEN00610-03
Multi gauge select

On this screen, the gauges displayed at the
center can be selected.
Select an item with switch F3 or F4 and confirm that item with switch F6.
q
q
Standard display
q
The normal screen is selected.
Load display
q
The horizontal axis indicates the time and the
vertical axis indicates the traction force. The
operation should be carried out in the green
range.
q
The graph on the screen is updated and
scrolled to the left at intervals of several seconds.
The following items can be selected.
No.
Selected item
Remarks
Power train oil Temperature
With caution
HYD oil temperature
With caution
Vehicle Speed
HYD Pressure
ENG Oil Pressure
Battery Voltage
Engine Speed
Traction Force
Clock
With caution
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 seconds.
20
D155AX-6
Screen adjustment
q
q
q
Selecting the Screen adjustment from the user

menu and pressing F6 switches to the screen
adjustment screen.
From this menu, you can adjust the brightness,
contrast, and luminance of the machine monitor screen.
When the light switch is in Night mode ON, the
night mode screen is adjustable.
When the light switch is in Daytime mode ON
or OFF, the daytime mode screen is adjustable.
F2 : Returns all adjusted values to the defaults.

F3 : Decreases the value indicated by the indicator
one graduation left.
F4 : Increases the value indicated by the indicator
one graduation right.
F5 : Cancels changes you made before confirming
them with F6 to return to the menu screen.
F6 : Confirms the changes and moves to the next
item.
q
SEN00610-03
F6 : Moves to the setup items of the selected (highlighted) item.

q
q
The adjustment methods for the camera

screen and normal screen are the same.
The background when adjusting the camera
screen is the No. 1 camera image.

F6 : Moves to the setup items of the selected (highlighted) item.
Clock adjustment
q
Selecting the Clock adjustment from the user

menu and pressing F6 switches to the clock
adjustment screen.
On this screen, you can change the setting of
the time displayed on the normal screen.
For a camera-equipped machine, the brightness, contrast, and illuminance of the camera
screen are also adjustable.
For a camera-equipped machine, selecting
Sc reen adjus tment fro m the us er menu
switches to the screen for selecting a screen
you want to adjust.
1)

D155AX-6
Time setting
Set the clock time. If the time setting item
is not highlighted, press F6 to highlight it.
The time display part is highlighted.
F3 : Advances the clock one hour.
F4 : Sets the clock back one hour.
F5 : Cancels changes you made before
confirming them with F6 to return to
the user menu.
F6 : Confirms the changes and moves to
minute setting.
21
SEN00610-03
The minute display part is highlighted.

F3 : Advances the clock one min.
F4 : Set the clock back one min.
the use menu.
the 12/24 display mode.
2)
3)
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 : Moves to the item one right.
F4 : Moves to the item one left.
F5 : Cancels the changes to return to the
user menu.
summer time.
Summer time
Selecting ON for this sets the time forward
one hour. Setting OFF returns to the ordinary time.
F3 : Moves to the item one right.
F4 : Moves to the item one left.
the user menu screen.
the time setting.
a
F3 :
F4 :
F5 :
F6 :
Selects (highlights) an item one down.

Selects (highlights) an item one up.
Cancels the changes to return to the user menu.
Cancels the changes to return to the user menu.
Message display
q
q
q
For a KOMTRAX-equipped machine, you can

view notification from the sales representative.
When there is a message, the message monitor appears on the upper left of the normal
screen.
The lighting green monitor indicates that there
are messages to be read.
The lighting blue monitor appears when you
have not sent replies yet after opening messages which accept replies.
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
22
Selecting the Language from the user menu

screen and pressing F6 switches to the language setting screen.
From this menu, you can change the language
to be displayed on the monitor. Available languages are as follows.
English, Japanese, Chinese, French, Spanish,
Portuguese, Italian, German, Russian, and
Turkish
D155AX-6
Press F6 to enter user mode and select Message display and you can view (open) the
messages.
SEN00610-03
Fan reverse mode

q
q
q
q
In this mode, the fan is driven in reverse to

clean the radiator core.
While the starting switch is OFF, select an item
with switch F3 or F4 and confirm that item with
switch F6.
While screen (A) is displayed, press switch F6,
and the fan is ready to run in reverse.
While screen (B) is displayed, start the engine.
F6 : Returns to the user mode screen.

q
q
q
Under messages that accept replies, Value to

be entered with 10-key: [ ] appears.If it
appears, enter the selected item number provided in the message using the switches of the
machine monitor, and press F6.
Do you want to transmit the entered value?
appears under the message. Press F6 and the
entered value will be sent.
Messages will be deleted when their validity

expire or a new message is received.
When no message has not been received, No
message appears at the blue part of the top of
the screen.
Separately from the message display for users
above, the service menu is provided with message display for service.
D155AX-6
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
the travel lock in the LOCK position.
q
While the fan is running in reverse, the
machine cannot travel.
q
When resetting the reverse running,
turn the starting switch OFF to stop the
engine.
q
When using this mode, warm up the
engine sufficiently. If the engine is not
warmed up, air may not be supplied
sufficiently.
23
SEN00610-03
Service meter check function

q
If you continuously pressing auto-deceleration

switch (1) and buzzer cancel switch (2) at the
same time when setting the starting switch to
the OFF position, the service meter will appear
on the screen in 3 to 5 sec.
When these switches are released, the LCD

goes out.
Continuous operation of the machine monitor
may display blue bright spots on this screen; it
is quite normal.
24
Display LCD check function

q
Continuously pressing the buzzer cancel

switch (1) and F2 at the same time on the
password input screen or normal screen
causes the entire LCD to light in white.
Release F2 and buzzer cancel switch in order.
If any part of the display is black, the LCD is
broken.
Pressing any function switch returns to the previous screen.
D155AX-6
SEN00610-03
Sensors
Type of sensor
1
Sensor method
When normal
When abnormal
Contact
OFF
ON
Resistance
Torque converter oil temperature
Resistance
Resistance
Contact
ON
OFF
Fuel level
Resistance
Engine oil pressure

Coolant level
Engine speed sensor
Resistance
Resistance
Pitch angle sensor
Resistance
Engine oil pressure sensor
1.
2.
3.
Plug
Contact ring
Contact
4.
5.
6.
Diaphragm
Spring
Terminal
4.
5.
6.
Tube
Wire
Connector
Engine coolant temperature sensor

Torque converter oil temperature sensor
Hydraulic oil temperature sensor
1.
2.
3.
Thermistor
Body
Tube
D155AX-6
25
SEN00610-03
Coolant level sensor
1.
2.
3.
Float
Sensor
Tube
4.
5.
Wire
Connector
Fuel level sensor
1.
2.
3.
4.
5.
6.
7.
26
Connector
Float
Arm
Body
Spring
Contact
Spacer
Function
q
The fuel sensor is installed to the side face of
the fuel tank. The float moves up and down
according go the fuel level. This movement of
the float is transmitted by the arm and actuates
a variable resistance. This sends a signal to
the monitor panel to indicate the remaining fuel
level.
D155AX-6
SEN00610-03
Engine speed sensor

1.
2.
3.
Magnet
Terminal
Case
4.
5.
Boots
Connector
3.
4.
Wire
Connector
Pitch angle sensor
1.
2.
Body
Tube
D155AX-6
27
SEN00610-03
Palm command control system
1.
2.
3.
4.
5.
6.
7.
8.
28
Machine monitor (Multi-information)

Preset mode switch
Engine throttle controller
Engine speed sensor
Transmission control valve
Steering control valve
Transmission output shaft speed sensor
D155AX-6
SEN00610-03
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 gearshift 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 according 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 automatically.
Gear shift operation

q
Set a gear by pressing (a) or (b) of the steering/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 gearshift mode)
4. Mark of Dozing (which indicates auto
gearshift mode)
B: Manual gearshift mode
5. Gear speed used currently
6. Preset (gear speed at start)
7. Mark of Ripping (which indicates manual
gearshift mode)
D155AX-6
29
SEN00610-03
Setting preset with shift switches in neutral

q
Set the preset (gear speed at start) and the
maximum gear speed during travel (for only
the auto gearshift mode) with the gearshift
switches in neutral.
2. Setting preset (gear speed at start) and
maximum gear speed during travel)
Changing gear speed with gearshift switches

during travel
q
The maximum gear speed during travel (in the
auto gearshift mode) or the gear speed used
during travel (in the manual gearshift mode)
can be changed with the gearshift switches
while the machine is traveling.
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.

6. Setting preset (gear speed at start)

5. 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
heightened to the next range.
Shift-down switch: Each time this switch is
lowered to the next range.
30
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.
D155AX-6
KOMTRAX system
SEN00610-03
The KOMTRAX system consists of a KOMTRAX

terminal, communication antenna, machine
monitor, and GPS antenna.
This system transmits various kinds of
machine information wirelessly. Persons to
operate the KOMTRAX can refer to the information at office to provide various kinds of services for customers.
Information transmittable from the KOMTRAX
system includes the following.
1. Operation map
2. Service meter
3. Position information
4. Error history
and others.
To provide the services, you need to make an
arrangement for starting the KOMTRAX service separately.
D155AX-6
31
SEN00610-03
KOMTRAX terminal
TH300
For japan / For other countries

Using satellite wave
1.
2.
3.
Communication antenna connection

Connector A (14 poles)
Connector B (10 poles)
Outline
The KOMTRAX terminal is a wireless communication device to transmit various kinds of
machine information or GPS position information the monitor obtains from network signals
or input signals in the machine. The terminal
can transmit information via the communication antenna.
q
Use of KOMTRAX terminal must be limited for
the countries in which such communication is
allowed.
q
When using TH300 in Japan or in other countries, the satellite communication company to
contract is different. So, part numbers of
TH300 are different in Japan or in other countries. Also, when using TH300 in countries
other than Japan, you must notify the name of
the country.
q
Input and output signals

Connector A
Pin No.
A-1
A-2
A-3
A-4
A-5
A-6
A-7
A-8
A-9
A-10
A-11
A-12
A-13
A-14
Signal name
Power (12V)
NC(*1)
NC(*1)
Electric power supply switching
NC(*1)
NC(*1)
GND
GND
NC(*1)
NC(*1)
NC(*1)
NC(*1)
NC(*1)
NC(*1)
Input/
output
Input
Output
Connector B
Input/
output
B-1
Serial signal DCD
Output
B-2
Serial signal RXD
Output
B-3
Serial signal TXD
Input
B-4
Serial signal DTR
Input
B-5
Serial signal SGND
B-6
Serial signal DSR
Output
B-7
NC(*1)
B-8
NC(*1)
B-9
NC(*1)
B-10 NC(*1)
*1: Never connect to NC or malfunctions or failures

will occur.
Pin No.
32
Signal name
D155AX-6
D155AX-6
SEN00610-03
33
SEN00610-03
D155AX-6 Bulldozer
2009 KOMATSU
All Rights Reserved
34
D155AX-6
SEN00678-03
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up

Standard value table for engine ...................................................................................................................... 2
Standard value table for machine ................................................................................................................... 3
D155AX-6
SEN00678-03
Standard value table for engine
Category
Item
Speed
Machine model
D155AX-6
Engine
SAA6D140E-5
Unit
Standard value for

new machine
Service limit value
High idle
rpm
2,100 (0/-50)
2,100 (0/-50)
Low idle
rpm
740 (+20/0)
740 (+20/0)
Rated speed
rpm
1,900
1,900
kPa
{mmHg}
Min. 117
{Min. 880}
100
{750}
660
700
Max. 25
(Max. 2.5)
35
{3.5}
Max. 1.0
2.0
Measurement condition
Engine coolant
temperature: Within
operating range
Engine coolant temperature: Within

operating range
Intake air pressure
Power train oil temperature: Within
(Boost pressure)
operating range
Torque converter: Stalled
Exhaust
Whole speed range
temperature
(Outside temperature: 20C)
Exhaust gas color
Engine
Valve clearance
Engine coolant
temperature: Within
operating range
Blow-by pressure
High idle
Intake valve
mm
0.35
Exhaust valve
mm
0.57
Min. 1.43
{Min. 14.6}
Min. 1.43
{Min. 14.6}
Min. 1.18
{Min. 12}
Min. 1.18
{Min. 12}
Min. 4.1
{Min. 42}
2.8
{29}
200 250
200 250
Max. 2.94
{Max. 300}
3.92
{400}
MPa
{kg/cm2}
Min. 0.34
{Min. 3.5}
0.21
{2.1}
MPa
{kg/cm2}
Min. 0.10
{Min. 1.0}
0.08
{0.8}
90 110
120
mm
13 16
13 16
mm
Approx. 10
Approx. 10
MPa
{kg/cm2}
MPa
Low idle
{kg/cm2}
Compression MPa
Engine oil
pressure
{kg/cm2}
temperature:
40 60C Engine
rpm
speed
operating range
kPa
{mmH2O}
operating range
Torque converter: Stalled
High idle
SAE0W30EOS,
SAE5W40EOS,
High idle
SAE10W30DH,
Engine oil pressure
SAE15W40DH
SAE30DH Oil
Engine oil temperature: Low idle
Min. 80 C
Oil temperature
Whole speed range (In oil pan)
Between water pump pulley

alternator pulley
Deflection under finger pressure of
98 N {10 kg}
Between compressor pulley fan
Air compressor belt
pulley
tension
Deflection under finger pressure of
59 N {6 kg}
Alternator belt
tension
%
(Bosch
index)
(Bosch
index)
Normal temperature
EGR valve and

Engine coolant
bypass valve drive
temperature: Within
oil pressure
operating range
Compression
pressure
At sharp
acceleration
D155AX-6
SEN00678-03
Standard value table for machine
Machine model
Category
Item
Cooling fan
Engine speed
Decelerator pedal
speed
Auto deceleration
speed
D155AX-6
Unit
Standard value for

new machine
Service limit value
rpm
875 50
875 50
rpm
1,875 50
1,875 50
rpm
1,610 50
1,450
rpm
1,550 50
1,395
rpm
1,250 50
1,250 50
mm
30 5
30 5
mm
30 5
30 5
N o Left
mm
40 5
40 5
N o Right
mm
40 5
40 5
mm
50 10
50 10
All stroke
mm
79 10
79 10
Stroke to 0 of
oil pressure
mm
54 4
54 4
operating range
operating range
Hydraulic oil temperature: Within
operating range
Engine: High idle
Decelerator pedal speed:
Press pedal
Auto deceleration speed:
Set all levers in neutral

operating range
Torque converter
stall speed
operating range
operating range
Engine: High idle
Torque converter
Select P mode
stall speed + Work Torque converter stall speed: F3
equipment relief
Torque converter stall speed + Work
speed
equipment relief speed: F3 + Ripper
raise
Fan motor speed
Hydraulic oil
temperature: Within
operating range
Fan: Set in 100%
mode
Engine: High idle
Max. speed
PCCS lever
Stroke of control lever/pedal
No
Forward/
Reverse travel
No
Stop engine
Center of lever grip
Forward
Reverse
Steering
Decelerator pedal
Stop engine
Center of pedal
Brake pedal
Engine: Low idle

Center of pedal
D155AX-6
SEN00678-03
Machine model
Item
Blade control lever
Unit
Standard value for

new machine
Service limit value
N o Raise
mm
72 10
72 10
N o Lower
mm
72 10
72 10
N o Left tilt
mm
53 10
53 10
mm
53 10
53 10
N o Raise
mm
75 10
75 10
N o Lower
mm
75 10
75 10
N o In
mm
80 10
80 10
N o Out
mm
80 10
80 10
No
N
{kg}
N
{kg}
N
{kg}
N
{kg}
N
{kg}
N
{kg}
N
{kg}
N
{kg}
N
{kg}
N
{kg}
56.9 6.9
{5.8 0.7}
50.1 6.9
{5.2 0.7}
24.5 4.9
{2.5 0.5}
27.5 4.9
{2.8 0.5}
49.0 9.8
{5.0 1.0}
411.6 78.4
{42.0 8.0}
39.2 5.9
{4.0 0.6}
39.2 9.8
{4.0 1.0}
9.8 4.9
{1.0 0.5}
29.4 5.9
{3.0 0.6}
56.9 6.9
{5.8 0.7}
50.1 6.9
{5.2 0.7}
24.5 4.9
{2.5 0.5}
27.5 4.9
{2.8 0.5}
49.0 9.8
{5.0 1.0}
411.6 78.4
{42.0 8.0}
39.2 5.9
{4.0 0.6}
39.2 9.8
{4.0 1.0}
9.8 4.9
{1.0 0.5}
29.4 5.9
{3.0 0.6}
N
{kg}
29.4 5.9
{3.0 0.6}
29.4 5.9
{3.0 0.6}
N
{kg}
N
{kg}
N
{kg}
N
{kg}
19.6 4.9
{2.0 0.5}
19.6 4.9
{2.0 0.5}
24.5 4.9
{2.5 0.5}
24.5 4.9
{2.5 0.5}
19.6 4.9
{2.0 0.5}
19.6 4.9
{2.0 0.5}
24.5 4.9
{2.5 0.5}
24.5 4.9
{2.5 0.5}
Stop engine
Center of lever knob
No
PCCS lever
Stroke of control lever/pedal
Category
D155AX-6
Stop engine
Forward/
Reverse travel
No
Stop engine
Center of lever grip
Right tilt
Forward
Reverse
N o Left
Steering
Operating effort of control lever/pedal
N o Right
Decelerator pedal
Brake pedal
Stop engine
Center of pedal
Engine: Low idle
Center of pedal
N o Raise
N o Lower
Stop engine
Lower o
Blade control lever/
Float
switch
Lower o Float: Switch
N o Left tilt
No
Right tilt
N o Raise
Stop engine
N o Lower
N o In
N o Out
D155AX-6
SEN00678-03
Machine model
Category
Item
Torque converter
inlet pressure
Torque converter
outlet pressure
Transmission main
relief pressure
Torque converter
lockup clutch
Power train oil pressure
Transmission 2nd
clutch pressure
0.05 0.49
{0.5 5.0}
Max. 1.0
{Max. 10.0}
0.05 0.49
{0.5 5.0}
Max. 1.0
{Max. 10.0}
0.05 0.29
{0.5 3.0}
0.05 0.29
{0.5 3.0}
0.29 0.69
{3.0 7.0}
2.81 3.11
{28.7 31.7}
0.29 0.69
{3.0 7.0}
Min. 2.62
{Min. 26.7}
3.04 3.33
{31.0 34.0}
Min. 2.84
{Min. 29.0}
1.32 0.20
{13.5 2.0}
1.32 0.20
{13.5 2.0}
1.32 0.20
{13.5 2.0}
2.65 0.20
{27.0 2.0}
1.32 0.20
{13.5 2.0}
2.65 0.20
{27.0 2.0}
2.65 0.20
{27.0 2.0}
2.65 0.20
{27.0 2.0}
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
2.45 2.75
{25.0 28.0}
2.60 2.89
{26.5 29.5}
Min. 2.26
{Min. 23.0}
Min. 2.40
{Min. 24.5}
2.65 2.94
{27.0 30.0}
Min. 2.45
{Min. 25.0}
2.79 3.09
{28.5 31.5}
2.81 3.11
{28.7 31.7}
Min. 2.60
{Min. 26.5}
Min. 2.62
{Min. 26.7}
3.04 3.33
{31.0 34.0}
Min. 2.84
{Min. 29.0}
2.60 2.89
{26.5 29.5}
2.75 3.04
{28.0 31.0}
Min. 2.40
{Min. 24.5}
Min. 2.55
{Min. 26.0}
2.81 3.11
{28.7 31.7}
Min. 2.62
{Min. 26.7}
3.04 3.33
{31.0 34.0}
Min. 2.84
{Min. 29.0}
High idle
MPa
{kg/cm2}
0.05 0.29
{0.5 3.0}
0.05 0.29
{0.5 3.0}
Low idle
MPa
{kg/cm2}
2.75 0.29
{28.0 3.0}
2.75 0.29
{28.0 3.0}
2.16
{22.0}
2.16
{22.0}
2.75 0.29
{28.0 3.0}
2.16
{22.0}
2.75 0.29
{28.0 3.0}
2.16
{22.0}
Power train oil temperature: Within operating High idle

range
PCCS lever: Neutral
Low idle
Display by monitoring
High idle
Power train oil temperature: Within operating
range
PCCS lever: Neutral
(Main relief pressure)
(Stator clutch pressure)
Brake pedal: Press
(Other than above)
Low idle
High idle
Low idle
High idle
Low idle
High idle
Low idle
High idle
Low idle
Power train oil temperature: Within operating High idle

range
Low idle
PCCS lever: Neutral
(Main relief pressure)
(Stator clutch pressure) High idle
Brake pedal: Press
(Other than above)
Low idle
Transmission 3rd
clutch pressure
Transmission lubricating oil pressure
(Reference)
Steering right brake
Power train oil
pressure
temperature: Within
operating range
PCCS lever: Neutral
Steering left brake Brake pedal: Release
pressure
D155AX-6
Service limit value
Low idle
Transmission F
clutch pressure
Transmission 1st
clutch pressure
Standard value for

new machine
Torque converter
stator clutch
pressure
Transmission R
clutch pressure
D155AX-6
High idle
Low idle
High idle
High idle
Low idle
High idle
Unit
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
MPa
{kg/cm2}
SEN00678-03
Machine model
Power train performance
Category
Item
Travel speed
Unit
Standard value for

new machine
Service limit value
F1
km/h
3.8 0.2
3.8 0.2
F2
km/h
7.5 0.4
7.5 0.4
F3L
km/h
7.5 0.4
7.5 0.4
F3
km/h
11.6 0.6
11.6 0.6
R1
km/h
4.6 0.2
4.6 0.2
R2
km/h
6.8 0.4
6.8 0.4
R3L
km/h
9.2 0.5
9.2 0.5
R3
km/h
14.0 0.7
14.0 0.7
MPa
{kg/cm2}
2.45 (+1.37/0)
2.45 (+1.37/0)
{25 (+14/0)}
{25 (+14/0)}
27.5 1.5
{280 15}
27.5 1.5
{280 15}
27.5 1.5
{280 15}
27.5 1.5
{280 15}
27.5 1.5
{280 15}
27.5 1.5
{280 15}
27.5 1.5
{280 15}
27.5 1.5
{280 15}
25.0 0.98
{255 10}
25.0 0.98
{255 10}
38.2 41.7
{390 425}
38.2 41.7
{390 425}
36.2 38.1
{369 389}
36.2 38.1
{369 389}
MPa
{kg/cm2}
3.97 (+0.49/0)
3.78 4.46
{40.5 (+5/0)}
{38.5 45.5}
MPa
{kg/cm2}
3.82 4.12
{39 42}
3.53
{36}
sec
3.0 4.0
3.0 4.0
sec
1.0 1.7
1.0 1.7
Flat ground
Engine coolant
temperature: Within
operating range
Power train oil
temperature: Within
operating range
Select manual
gearshift mode
Engine: High idle
Approach run:
10 30 m
Measuring distance:
20 m
(Converted into km/h)
Hydraulic oil temperaLow idle

ture: Within operating
range
All levers:
High idle
Set in neutral
MPa
{kg/cm2}
Blade lift relief

pressure
Blade tilt relief
pressure
MPa
{kg/cm2}
MPa
{kg/cm2}
operating range
Ripper lift relief
MPa
Engine: High idle
pressure
{kg/cm2}
Cylinder of measured circuit:
Ripper tilt relief
MPa
Stroke end
pressure
{kg/cm2}
Work equipment LS
MPa
relief pressure
{kg/cm2}
HSS relief pressure
HSS LS relief
pressure

MPa
operating range
{kg/cm2}
Engine: High idle
MPa
Steering of measured circuit:
Press brake pedal {kg/cm2}
Control circuit basic

pressure
Control valve EPC

valve output
pressure
(Reference)
Work equipment speed
Work equipment
Work equipment/HSS oil pressure
Unload pressure
D155AX-6
Blade lift

operating range
Engine: High idle
All levers: Set in neutral
operating range
Engine: High idle
Lever of measured circuit: Stroke
end
Hydraulic oil temperature: Within operating

range
Raise
Engine: High idle
Select P mode
Apply no load to blade.
Measure time required
to move blade from
ground level to raise
Lower
stroke end
For measuring posture,
see Fig. 1
D155AX-6
SEN00678-03
Machine model
Category
Item
Work equipment
Blade tilt
Ripper lift
Ripper tilt
Time lag
Blade
Ripper
D155AX-6
Hydraulic oil
temperature: Within
Left tilt
operating range
Engine: High idle
Select P mode
Apply no load to blade
to move blade from left
tilt end to right tilt end Right tilt
see Fig. 2
Hydraulic oil
temperature: Within
operating range
Raise
Engine: High idle
Select P mode
Apply no load to ripper
(Shank hole: Lowest)
to move ripper from
ground level to raise
Lower
end
see Fig. 3
Hydraulic oil temperature: Within operating
range
Tilt in
Engine: High idle
Select P mode
Apply no load to ripper
to move ripper from tilt
in end to tilt back end Tilt back
see Fig. 4
operating range
Engine: Low idle
Select P mode.
Blade control lever: Set to stroke end
Lower blade from max. rising position
and measure time after blade comes
in contact with ground until idler is
lifted
operating range
Engine: Low idle
Select P mode
Ripper control lever: Set to stroke
end
Lower ripper from max. rising position and measure time after ripper
comes in contact with ground until
sprocket is lifted
D155AX-6
Unit
Standard value for

new machine
Service limit value
sec
1.8 2.8
3.1
sec
1.8 2.8
3.1
sec
2.0 3.0
4.0
sec
1.5 2.5
3.5
sec
4.5 5.5
6.2
sec
3.7 4.7
6.1
sec
Max. 1.7
2.5
sec
Max. 1.5
1.5
SEN00678-03
Machine model
Category
Item
Hydraulic drift of work equipment

Leakage from cylinder
Work equipment
Hydraulic drift
of lifted blade
Hydraulic drift
of machine
lifted by blade
Hydraulic drift
of machine
tilted by blade
operating range
Stop engine
Measure reduction of blade bottom
height h in 15 minutes
For measuring posture, see Fig. 5
operating range
Stop engine
Measure reduction of idler center
operating range
Stop engine
Measure reduction of track shoe
bottom height h in 5 minutes

operating range
Hydraulic drift
Stop engine
of machine
Measure reduction of sprocket center
lifted by ripper
Blade lift
cylinder
Ripper lift
cylinder
Ripper tilt
cylinder

operating range
Engine: High idle
Measure leakage from relieved
cylinder in 1 minute
D155AX-6
Unit
Standard value for

new machine
Service limit value
mm
Max. 50/15 minutes
200/15 minutes
mm
Max. 50/5 minutes
70/5 minutes
mm
Max. 50/5 minutes
70/5 minutes
mm
Max. 50/5 minutes
70/5 minutes
cc/min
Max. 3.0
12
cc/min
Max. 2.7
11
cc/min
Max. 2.7
11
D155AX-6
SEN00678-03
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
SEN00678-03
Fig. 7: Hydraulic drift of machine tilted by blade
Fig. 8: Hydraulic drift of machine lifted by ripper
10
D155AX-6
D155AX-6
SEN00678-03
11
SEN00678-03
D155AX-6 Bulldozer
2010 KOMATSU
All Rights Reserved
12
D155AX-6
SEN00679-05
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up

Tools for testing, adjusting, and troubleshooting............................................................................................. 3
Measuring engine speed................................................................................................................................. 7
Measuring intake air pressure (boost pressure) ............................................................................................. 9
Measuring exhaust temperature ................................................................................................................... 10
Measuring exhaust gas color ........................................................................................................................ 12
Adjusting valve clearance ............................................................................................................................. 13
Measuring compression pressure................................................................................................................. 14
Measuring blow-by pressure......................................................................................................................... 16
Measuring engine oil pressure...................................................................................................................... 17
Testing EGR valve and bypass valve drive oil pressure ............................................................................... 18
Handling fuel system parts............................................................................................................................ 19
Releasing residual pressure from fuel system .............................................................................................. 19
Measuring fuel pressure ............................................................................................................................... 20
Measuring fuel return rate and fuel leakage ................................................................................................. 21
Bleeding air from fuel circuit.......................................................................................................................... 25
Measuring fuel circuit for leakage ................................................................................................................. 27
D155AX-6
SEN00679-05
Testing and adjusting alternator belt tension................................................................................................. 28

Testing and adjusting air conditioner compressor belt tension...................................................................... 29
Measuring fan speed..................................................................................................................................... 30
Measuring fan circuit oil pressure ................................................................................................................. 31
Bleeding air from fan pump ........................................................................................................................... 32
Adjusting fuel control dial and decelerator pedal .......................................................................................... 33
D155AX-6
SEN00679-05
Testing and adjusting item
Symbol
Measuring intake air pressure (boost pressure)
Measuring exhaust
temperature
Measuring exhaust gas

color
Part No.
Part name
Adjusting valve clearance
Measuring blow-by
pressure
799-101-1502 Digital thermometer
1 99.9 1,299C
Commercially
Smoke meter
available
Commercially
Thickness gauge
available
6
Measuring fan speed
795-471-1450
07005-00812
6151-51-8490
6206-71-1770
Commercially
available
Commercially
available
Hose
1 5 mm 2 3 m
Hose
1 15 mm 2 3 m
Commercially
Measuring cylinder
available
Commercially
Stopwatch
available
799-205-1100 Tachometer kit
799-101-5002 Hydraulic tester
790-261-1204 Digital hydraulic tester

2 799-401-3400 Adapter
799-101-5220 Nipple
3
07002-11023 O-ring
D155AX-6
Pressure gauge: 60 MPa

{600 kg/cm2}
Pressure gauge: 1.0 MPa
1
{10 kg/cm2}
1
Adapter
Gasket
Spacer
Joint
1
Measuring fan circuit
pressure
Pressure gauge:
2.5, 6, 40, 60 MPa
{25, 60, 400, 600 kg/cm2}
Pressure gauge:
2.5, 6, 40, 60 MPa
{25, 60, 400, 600 kg/cm2}
1
{600 kg/cm2}
Pressure gauge: 1.0 MPa
1
{10 kg/cm2}
1
8 1.25 mm o R1/8
1
1 Inside diameter: 14 mm
1 Inside diameter of joint: 10 mm
2 799-401-2320 Hydraulic tester
Air intake: 0.35 mm,

Exhaust: 0.57 mm
Measuring fuel return rate

J 4
and fuel leakage
Bosch index: 0 9
1 0 5 kPa {0 500 mmH2O}
799-201-1504 Blow-by checker
1
2
795-471-1330 Adapter
6261-71-6150 Gasket
1 0 6.9 MPa {0 70 kg/cm2}

1
For 140E-5 engine
1
Testing engine oil pres1

sure
Testing EGR valve and G
bypass valve drive oil
pressure
2 799-401-2320 Hydraulic tester
Measuring fuel pressure
Remarks
799-401-2220 Hose
1 795-502-1590 Compression gauge

Measuring compression
pressure
101 200 kPa

{ 760 1,500 mmHg}
1 Straight type quick coupler
799-201-2202 Boost gauge kit
1 799-201-9001 Handy smoke checker

C
Q'ty
Tools for testing, adjusting, and troubleshooting
1
1
1 6.0 99999.9 rpm
Pressure gauge:
2.5, 6, 40, 60 MPa
1
{25, 60, 400, 600 kg/cm2}
1
{600 kg/cm2}
1 Size: 05
1 Size: 10 1.25 mm
Measuring power train oil

pressure
Symbol
Part No.
Part name

M
Adjusting brake pedal

Emergency escape
method when power train
has trouble
79A-264-0091
19M-06-32820
1
P
17A-06-41410
2 790-190-1601
799-101-5002
1
Measuring and adjusting
work equipment and HSS Q
790-261-1204
oil pressure
799-101-5220
2
07002-11023
Push-pull scale
Switch assembly
Wiring harness
Pump assembly
Hydraulic tester
Digital hydraulic tester
Nipple
O-ring

Measuring control circuit
basic pressure

2 799-401-3200 Adapter

Testing work equipment
1
lock solenoid valve output S
pressure
2 799-401-3200 Adapter
Emergency operation
when work equipment has
trouble
17A-06-41421 Wiring harness
T-adapter assembly
T-adapter assembly
T-adapter
T-adapter
T-adapter
Socket
T-adapter
T-adapter
Socket
1
1
1
1
1
1
1
795-799-5530 Socket
Pressure gauge:
2.5, 6, 40, 60 MPa
{25, 60, 400, 600 kg/cm2}
1
{600 kg/cm2}
1 0 490 N {0 50 kg}
1
1
1
Pressure gauge:
2.5, 6, 40, 60 MPa
1
{25, 60, 400, 600 kg/cm2}
1
{600 kg/cm2}
2
Size: 10 1.25 mm
2
Pressure gauge:
2.5, 6, 40, 60 MPa
1
{25, 60, 400, 600 kg/cm2}
1
{600 kg/cm2}
1 Size: 03
Pressure gauge:
2.5, 6, 40, 60 MPa
1
{25, 60, 400, 600 kg/cm2}
1
{600 kg/cm2}
1 Size: 03
1
Adapter
Measuring ripper pin puller

1
solenoid valve output
U
pressure
Troubleshooting for
engine
Controller/sensors/actuators
Remarks
Pressure gauge:
2.5, 6, 40, 60 MPa
{25, 60, 400, 600 kg/cm2}
1
{600 kg/cm2}
1 Size: 03
2 799-401-3200
799-601-9000
or
799-601-9300
799-601-4101
or
799-601-4201
799-601-4130
799-601-4150
799-601-4211
799-601-4220
799-601-4240
799-601-4260
799-601-4330
Q'ty
SEN00679-05
Ne sensor
For oil pressure sensor
Engine controller
Engine controller
For ambient pressure sensor
Engine controller
G (Bkup) sensor
Coolant, fuel and oil temperature
1
sensor
D155AX-6

Troubleshooting for
engine
Controller/sensors/actuators
Symbol
SEN00679-05
Q'ty
Remarks
Socket
T-adapter
T-adapter
Socket
1
1
1
1
Boost and intake temperature sensor

For injector
Common rail pressure
For supply pump PCV
T-adapter assembly
T-box
1 For ECONO
T-adapter assembly
T-adapter
1 For DT2P
For DT3P
1 (Does not include 799-601-4101 and
799-601-4201)
1 For DT4P
For DT6P
799-601-4201)
For DT8PB (Black)
799-601-4201)
DT12PGR (Gray)
799-601-4201)
For DT12PB (Black)
799-601-4201)
For DT12PG (Green)
799-601-4201)
Part No.
795-799-5540
799-601-9020
799-601-9420
799-601-9430
799-601-2500
or
799-601-2800
or
799-601-7100
or
799-601-7400
or
799-601-8000
799-601-2600
799-601-4101
or
799-601-4201
or
799-601-9000
or
799-601-9200
799-601-9020
Part name
799-601-9030 T-adapter
799-601-9040 T-adapter
799-601-9050 T-adapter
Troubleshooting for
chassis
Sensors/wiring harnesses
799-601-9070 T-adapter
799-601-9110 T-adapter
799-601-9120 T-adapter
799-601-9130 T-adapter
799-601-7000
or
799-601-7100
or
T-adapter assembly
799-601-7400
or
799-601-8000
799-601-7050 T-adapter
799-601-7110
799-601-9000
or
799-601-9100
799-601-9280
799-601-9290
799-601-9300
799-601-9350
D155AX-6
T-adapter
For SWP6P
(Does not include 799-601-8000)
1 For M3P
T-adapter assembly
T-adapter
T-adapter
T-adapter assembly
T-adapter
1 For HD30-23
1 For HD30-31
1
1 For DRC-401
Symbol
Troubleshooting for
chassis
Sensors/wiring harnesses
Part No.
Part name
Q'ty
SEN00679-05
Remarks
799-601-9360 T-adapter
799-601-7360 T-adapter
799-601-9890 Adapter for multiple
1 For DRC-24
1 For REL-5P
1 For DT2-4 and DTM2
Removal and installation

of boost pressure and
temperature sensors
Commercially
Torque wrench
available

of engine oil pressure sensor
795-799-6210 Deep socket
1 27 mm deep socket
Commercially
Socket
available
795T-981-1010 Socket

of engine coolant temperature sensor
Measuring internal leakage of work equipment
cylinder
Measuring coolant
temperature and oil
temperature
3.26 mm torque wrench

(KTC Q4T15 or equivalent)
21mm deep socket

1 (MITOLOY 4ML 21 or equivalent)
Applied engine: 530056 534132
19 mm deep socket
1
Applied engine: 534133
Commercially
Measuring cylinder
available
799-101-1502 Digital thermometer
1 99.9 1,299C
Testing operating effort

and pressing force
79A-264-0021 Push-pull scale

1 0 300 N {0 30 kg}
1 0 500 N {0 50 kg}
Measuring stroke and

hydraulic drift
Measuring work equipment speed

Measuring voltage and
resistance
Commercially
Ruler
available
Commercially
Stopwatch
available
Commercially
Circuit tester
available
1
1
1
For the model names and part Nos. of the T-boxes and T-adapters used for troubleshooting for the
machine monitor, controllers, sensors, actuators, electrical equipment, and wiring harnesses, see Troubleshooting (Information related to troubleshooting), List of T-boxes and T-adapters.
: Socket
D155AX-6
Measuring engine speed

k
1.
SEN00679-05
Stop the machine on level ground, lower

the work equipment to the ground, stop the
engine, and set the parking brake lever and
work equipment lock lever in the lock position.
Measure the engine speed under the following
conditions.
q
Engine coolant temperature: Within operating range
q
Power train oil temperature: Within operating range
q
Hydraulic oil temperature: Within operating range
q
Working mode: P mode
q
Gearshift mode: Either Auto or Manual
Preparation work
Measure the engine speed with the Adjustment
function in the service mode of the machine
monitor.
a For the operating method of the machine
monitor, see Special functions of machine
monitor (EMMS).
1) Measuring low idle speed, decelerator
pedal speed, auto-deceleration speed,
torque converter stall speed, and torque
converter stall speed + work equipment
relief speed (full stall speed):
q
Adjustment code: 0530 (Stall mode)
a When stalling the torque converter for
a purpose other than measuring the
engine speed, be sure to use this
adjustment code, too.
2)
Measuring high idle speed:

q
Adjustment code: 0007 (Reset engine
deceleration)
a Only when this code is selected, the
engine can be operated and tested
with the auto-decelerator reset.
D155AX-6
2.
Measuring low idle speed

1) Start the engine and set the fuel control
dial in the low idle (MIN) position.
2) Set the PCCS lever, blade control lever,
and ripper control lever in neutral and
measure the engine speed.
a The parking brake lever and work
equipment lock lever may be kept in
the LOCK position.
3.
Measuring high idle speed

dial in the high idle (MAX) position.
the LOCK position.
a When measuring the high idle speed,
be sure to select adjustment code
[0007] (If adjustment code [0530] is
selected, the auto-deceleration speed
is measured).
4.
Measuring decelerator pedal speed

and ripper control lever in neutral, press
the decelerator pedal to the stroke end,
and measure the engine speed.
the LOCK position.
5.
Measuring auto-deceleration speed

SEN00679-05
a
6.
7.

a
The parking brake lever and work

the LOCK position.
Measuring torque converter stall speed

2) Operate the shiftup (UP) switch of the
PCCS lever and set the preset mode display section to [F3-R3].
a The preset mode display section (at
the right bottom of the screen) can be
set to [F3-R3] only while the Adjustment function is selected.
3) While pressing the brake pedal securely,
set the parking brake lever in the free
position and set the direction of PCCS
lever in the forward position.
a Before going to the next step, check
that [F3] is displayed in the gear
speed display section (at the right
bottom of the screen).
a Keep the steering system in neutral.
4) Press the decelerator pedal and set the
fuel control dial in the high idle (MAX)
position.
5) Return the decelerator pedal slowly to stall
the torque converter 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.
6) Just after the power train oil temperature
gauge (T/C TEMPERATURE) indicates
118 120 C, return the direction of PCCS
lever to neutral.
a The top of the green range of the
power train oil temperature gauge
indicates about 118 120 C.
7) Repeat above steps 3) 6) 3 times.
8) Perform steps 3) 5) again and measure
the engine speed about 5 seconds after
the power train oil temperature gauge (T/C
TEMPERATURE) indicates 118 120 C.
a Immediately after finishing measurement, return the direction of PCCS
lever to neutral and lower the power
train oil temperature with the engine
at high idle.
3)
4)
5)
6)
k
7)
8)
9)
The preset mode display section (at

Set the work equipment lock lever in the
free position and operate the ripper control
lever to set the ripper lift cylinder to the
raise stroke end.
While pressing the brake pedal securely,
Press the decelerator pedal and set the
position.
Return the decelerator pedal slowly to stall
the torque converter with the engine at
high idle.
Keep pressing the brake pedal securely and keep your right foot on the
decelerator pedal for safety until the
work is finished.
Just after the power train oil temperature
gauge (T/C TEMPERATURE) indicates
118 120 C, return the direction of PCCS
lever to neutral.
a The top of the green range of the
power train oil temperature gauge
indicates about 118 120 C.
Repeat above steps 4) 7) 3 times.
Perform steps 4) 6) again, operate the
ripper control lever to relieve the ripper
raise system, and measure the engine
speed about 5 seconds after the power
train oil temperature gauge (T/C TEMPERATURE) indicates 118 120 C.
a Immediately after finishing measurement, return the direction of PCCS
lever to neutral and lower the power
train oil temperature with the engine
at high idle.
Measuring torque converter stall + work

equipment relief speed (Full stall speed)
2) Operate the shiftup (UP) switch of the
D155AX-6
Measuring intake air pressure

(boost pressure)
a
SEN00679-05
Run the engine at a medium or higher speed

and drain the oil from the test hose.
a Insert the connecting parts of the gauge
and hose about a half and open the selfseal on the hose side repeatedly, and the
oil will be drained.
a If Pm kit (A) is available, you may drain
the oil by using the oil draining coupling
(790-261-1130) in that kit.
a If oil is left in the hose, the gauge does not
work. Accordingly, be sure to drain the oil.
5.
Turn the starting switch ON and set the

machine monitor to Adjustment function of the
service mode.
q
a For the operating method, see Special
functions of machine monitor (EMMS).
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 converter.
7.
After finishing measurement, remove the measuring instruments and return the removed parts.
Measuring instruments for intake air pressure

(boost pressure)
Symbol
A
k
Part No.
799-201-2202
799-401-2220
Part name
Boost gauge kit
Hose

Be careful not to touch any hot part of the
engine when removing or installing the
measuring tools.
Measure the intake air pressure (boost pressure) under the following conditions.
q
q
q
1.
Open the engine left side cover.
2.
Remove intake air pressure pickup plug (1)

from the rear of the air intake connector.
3.
4.
Install nipple [1] of boost gauge kit A and connect gauge [2].
D155AX-6
SEN00679-05
Measuring exhaust temperature 1

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

Install and remove the measuring instruments after the exhaust manifold is cooled.
Measure the exhaust temperature under the
following conditions.
q
q
q
1.
Open the engine right side cover and right

mudguard.
2.
Remove 1 exhaust temperature pickup plug (1)

from the exhaust manifold.
a You may measure the exhaust temperature at either front or rear plug.
3.
10
Install sensor [1] of digital thermometer B and

connect them to meter [2].
a Clamp the wiring harness of the digital
thermometer so that it will not touch a hot
part during measurement.
4.
When measuring maximum exhaust temperature for troubleshooting

Operate the machine actually and measure the
maximum exhaust temperature.
a Use the PEAK mode of the thermometer.
a The exhaust temperature largely depends
on the outside air temperature (intake air
temperature of the engine). Accordingly, if
any abnormal value is obtained, correct it
by the following calculation.
q
Corrected value [C] = Measured
value + 2 (20 Outside air temperature)
5.
Procedure for measuring exhaust temperature

periodically for preventive maintenance (Pm
clinic)
a If the torque converter is stalled simply,
the torque converter oil is overheated
before the exhaust temperature is stabilized. 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.
q
a For the operating method, see Special functions of machine monitor
(EMMS).
D155AX-6
2)
3)
4)
5)
6)
7)
SEN00679-05
Start the engine and set the fuel control

Operate the shiftup (UP) switch of the
a The preset mode display section (at
Set the work equipment lock lever in the
free position and operate the ripper control
lever to set the ripper lift cylinder to the
raise stroke end.
While pressing the brake pedal securely,
Press the decelerator pedal and set the
position.
Return the decelerator pedal slowly to stall
the torque converter and relieve the ripper
raise system to raise the exhaust temperature to about 650 C (Condition (a) in the
figure) with the engine at high idle.
k
8)
9)
Just after the power train oil temperature (T/C TEMPERATURE)

reaches about 120 C, return the
direction of PCCS lever to neutral
and lower the power train oil temperature with the engine at high
idle.
The border between the green range
and red range of the power train oil
temperature gauge indicates about
120 C.
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
Under the condition of step 7), stop relieving the ripper raise system and lower the
exhaust temperature by only stalling the
torque converter (Condition (b) in the figure).
a If the exhaust temperature does not
lower but rises, set the temperature
high in step 7).
After the exhaust temperature is lowered
and stabilized, measure the exhaust temperature (Condition (c) in the figure).
After finishing measurement, remove the measuring instruments and return the removed
parts.
11
SEN00679-05
Measuring exhaust gas color

a
Measuring instruments for exhaust gas color
Symbol
C
k
1.
Part No.
Part name
799-201-9001
Handy smoke checker
Commercially
available
Smoke meter

Be careful not to touch any hot part of the
engine when removing or installing the
measuring tools.
If an air source and an electric power source
are not available in the field, use handy smoke
checker C1. When recording official data, use
smoke meter C2.
Measure the exhaust gas color under the following condition.
q
Measuring with handy smoke checker C1
1) Stick a sheet of filter paper to smoke
checker C1.
2) Insert the exhaust gas intake pipe in
exhaust pipe (1).
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.
2)
3)
4)
5)
6)
7)
5)
6)
2.
12
Remove the filter paper and compare it

with the attached scale.
After finishing measurement, remove the
measuring instrument and return the
removed parts.
Measuring with smoke meter C2

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.
8)
9)
Connect the probe hose, receptacle of the

accelerator switch, and air hose to smoke
meter C2.
a Limit the supplied air pressure to 1.5
MPa {15 kg/cm}.
Connect the power cable to a receptacle
of AC 100 V.
a Before connecting the cable, check
that the power switch of the smoke
meter is turned OFF.
Loosen the cap nut of the suction pump
and fit the filter paper.
a Fit the filter paper securely so that the
exhaust gas will not leak.
Turn power switch of smoke meter C2
ON.
Start the engine.

Accelerate the engine suddenly or run it at
high idle and press the pedal of smoke
meter C2 and collect the exhaust gas into
the filter paper.
Place the contaminated filter paper on the
clean filter paper (at least 10 sheets) in the
filter paper holder and read the indicated
value.
removed parts.
D155AX-6
SEN00679-05
Adjusting valve clearance

a
Measuring instruments for valve clearance
Symbol
Part No.
Commercially
available
1.
Part name
Thickness gauge

Adjust the valve clearance under the following
condition.
q
Engine coolant temperature: Normal temperature
Remove the engine hood assembly and air
cleaner together.
4
2.
5.
6.
Engine hood assembly: 170 kg
Remove all cylinder head covers (1).
7.
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 compression top dead center, the rocker arm of the
No. 1 cylinder can be moved by the valve
clearance with the hand. If the rocker arm
cannot be moved, the No. 1 cylinder is not
at the compression top dead center. In
this case, rotate the crankshaft one more
turn.
a Eliminate the slack of the injector wiring
harness and press it against the injector
body so that it will not interfere with the
rocker arm.
D155AX-6
8.
9.
While fixing adjustment screw (3), loosen locknut (4).

a After setting the No. 1 cylinder to the compression top dead center, adjust the valve
clearance of the No. 1 cylinder.
Insert thickness gauge D in the clearance
between rocker arm (5) and cross head (6) and
adjust the valve clearance with adjustment
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
While fixing adjustment screw (3), tighten locknut (4).
3 Locknut:
45.1 51.0 Nm {4.6 5.2 kgm}
a After tightening the locknut, check the
valve clearance again.
After adjusting the No. 1 cylinder, rotate the

crankshaft forward by 120 to set the stamped
TOP line of each cylinder to pointer (2) according to the firing order and adjust the valve
clearance.
q
Firing order: 153624
After finishing adjustment, return the removed
parts.
3 Cylinder head cover mounting bolt:
29.4 34.3 Nm {3.0 3.5 kgm}
13
SEN00679-05
Measuring compression
pressure
a
1.
Part No.
Part name
795-502-1590
Compression gauge
795-471-1330
Adapter
6261-71-6150
Gasket
5.
Install adapter E2 to the mounting hole on the

injector and connect compression gauge E1.
a Be sure to fit the gasket to the injector
end.
a Fix the adapter with the injector holder.
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.
Remove the engine hood assembly and air

cleaner together.
Engine hood assembly: 170 kg
Remove cylinder head cover (1) of the cylinder

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

injector wiring harness (4) and remove injector
(5) and wiring harness.
14
Disconnect the terminal of the injector wiring harness on the injector side and the
bracket on the rocker housing side and
remove the injector wiring harness
(Loosen the 2 terminal nuts alternately).
Pass a wire under the fuel path projected
sideways and pull up the injector (Do not
pry the injector top up).

When measuring the compression pressure,
take care not to burn yourself on the exhaust
manifold, muffler, etc. or get caught in a rotating part.
Measure the compression pressure under the
following conditions.
q
Engine oil temperature: 40 60 C
2.
Measuring tools for compression pressure
Symbol
E
D155AX-6
7.
Disconnect power supply connector EGC3 (6)

of the engine controller.
k
If this connector is not disconnected,

the engine will start during measurement and will be dangerous. Accordi 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
connector.
Cover the controller side and wiring
harness side with vinyl sheets, etc. to
prevent electric leakage and ground
fault.
SEN00679-05
a
a
1)
2)
3)
4)
5)
8.

machine monitor to Monitoring function of the
service mode.
q
Monitoring code: 01002 Engine Speed
a
1)
2)
3)
4)
a
9.
Rotate the engine with the starting motor and

measure the compression pressure.
a Read the pressure gauge pointer when it
is stabilized.
a When measuring the compression pressure, check that the engine speed is in the
range of the measurement condition.
Install the injector and fuel high-pressure

tube according to the following procedure.
Before installing the injector, replace the
copper gasket and O-ring with new ones.
Push in injector (11) with the hand to
assemble holder (12) temporarily.
Tighten bolt (13) and washer (14) temporarily.
2 Spherical part of washer:
Engine oil
Tighten sleeve nut (15) of the fuel highpressure tube temporarily.
Tighten bolt (13) permanently.
3 Bolt: 58.8 73.5 Nm {6 7.5 kgm}
Tighten sleeve nut (15) permanently.
3 Sleeve nut:
39.2 49.0 Nm {4 5 kgm}
Install the injector wiring harness according to the following procedure.

Install the injector wiring harness to the
rocker arm housing and fix the connector
side with the plate.
Fix the intermediate clamp with the clip.
Tighten the nut on the injector side.
3 Nut: 2 0.2 Nm {0.2 0.02 kgm}
Secure the clamp and spacer with the
bolt.
3 Rocker arm assembly mounting
bolt: 93 103 Nm {9.5 10.5 kgm}
Adjust the valve clearance. For details,
see Adjusting valve clearance.
3 Cylinder head cover mounting bolt:
29.4 34.3 kgm {3.0 3.5 kgm}
10. After finishing measurement, remove the measuring instruments and return the removed
parts.
D155AX-6
15
SEN00679-05
Measuring blow-by pressure

a
Part No.
799-201-1504
Part name
Blow-by checker

Measure the blow-by pressure under the following conditions.
q
q
q
1.
Open the engine left side cover and left mudguard.
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
16
value is judged abnormal, check for

increase of oil consumption, bad exhaust
gas color, deterioration of oil, high deterioration speed of oil, etc. which are related
to the abnormal blow-by pressure.
Measuring instrument for blow-by pressure
Symbol
4.
parts.
D155AX-6
SEN00679-05
Measuring engine oil pressure

a
1
2
4.
Run the engine at low idle and high idle and

measure the engine oil pressure.
5.
parts.
Measuring instruments for engine oil pressure
Symbol
G
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-401-2320
Hydraulic tester

Measure the engine oil pressure under the following condition.
q
1.
Open the engine left side cover and left mudguard.
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
17
SEN00679-05
Testing EGR valve and bypass

valve drive oil pressure
a
G
k
Part No.
4.
Start the engine and measure the oil pressure

at low idle and high idle.
5.
After finishing measurement , remove the measuring instruments and return the removed
parts.
q
Remove the gasket sealant remaining on
the threads of the removed plug with a wire
brush and apply new adhesive or gasket
sealant to the plug before installing.
2 Plug: LT2 or LG-5
3 Plug:
9.8 19.6 Nm {1.0 2.0 kgm}
Part name
799-101-5002
Hydraulic tester
790-261-1204

1.
Remove oil pressure pickup plug (2) from the

left side of timing gear cover (1).
2.
Install nipple [1] of hydraulic tester G1 to the

hole from which the oil pressure pickup plug
was removed.
18
Connect hydraulic tester [2] and [3] (Component part of tool G1) to the nipple [1].
Testing instrument for EGR valve and bypass

valve drive oil pressure
Symbol
3.
D155AX-6
Handling fuel system parts

a
SEN00679-05
Precautions for testing and maintaining fuel

system
The common rail fuel injection system (CRI)
consists of more precise parts than the conventional fuel injection pump and nozzle. If foreign matter enters this system, it can cause a
trouble.
When testing and maintaining the fuel system,
take care more than the past. If dust, etc.
sticks to any part, wash that part thoroughly
with clean fuel.
Precautions for replacing fuel filter cartridge
Be sure to use the Komatsu genuine fuel filter
cartridge.
Since the common rail fuel injection system
(CRI) consists of more precise parts than the
conventional fuel injection pump and nozzle, it
employs a high-efficiency special filter to prevent foreign matter from entering it. If a filter
other than the genuine one is used, the fuel
system may have a trouble. Accordingly,
never use such a filter.
D155AX-6
Releasing residual pressure from

fuel system
1
a
Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running.
Low-pressure circuit:
Feed pump Fuel filter Supply pump
High-pressure circuit:
Supply pump Common rail Injector
The pressure in both low-pressure circuit and
high-pressure circuit lowers to a safety level
automatically 30 seconds after the engine is
stopped.
Before the fuel circuit is tested and its parts are
removed, the residual pressure in the fuel circuit must be released completely. Accordingly,
observe the following.
Before testing the fuel system or removing
its parts, wait at for least 30 seconds after
stopping the engine until the residual pressure in the fuel circuit is released. (Do not
start the work just after stopping the engine
since there is residual pressure.)
19
SEN00679-05
Measuring fuel pressure

a
1
2
3
k
a
k
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-401-2320
Hydraulic tester
795-471-1450
Adapter
07005-00812
Gasket
Run the engine at high idle and measure the

fuel pressure.
a If the fuel pressure is in the following
range, it is normal.
Engine speed
Fuel pressure
High idle
0.15 0.3 MPa

{1.5 3 kg/cm}

Test only the fuel pressure in the low-pressure
circuit from the feed pump through the fuel filter to the supply pump.
Since the pressure in the high-pressure circuit 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
the fuel filter.
2.
Install adapter H3 and elbow [1] and nipple [2]

of hydraulic tester H1 and connect them to
hydraulic tester H2.
20
3.
Measuring instruments for fuel pressure
Symbol
4.
parts.
3 Plug: 7.84 9.8 Nm {0.8 1.0 kgm}
D155AX-6
SEN00679-05
Measuring fuel return rate and fuel leakage
Measuring instruments for return rate and fuel

leakage
Symbol
a
k
Part No.
Part name
6151-51-8490
Spacer
6206-71-1770
Joint
Commercially available Hose
Commercially available Hose
Commercially available Measuring cylinder
Commercially available Stopwatch
Prepare an oil pan of about 20 l to receive the

fuel flowing out during the test.
D155AX-6
21
SEN00679-05
1.
Preparation work
1) Open the engine left side cover and left
mudguard.
2) Remove tube (3) between supply pump
(1) and common rail (2).
a In the figure, 1 oil filter is removed
temporarily from the common rail
side.
a Disconnect both ends of the tube,
loosen the clamp, and move the tube
to the opposite side of the cylinder
block.
5)
2.
22
3)
Insert spacer J1 on supply pump (1) side

and tighten the removed joint bolt again.
a Connect the return pipe to the fuel
tank again, too.
a Be sure to fit the gaskets to both ends
of the spacer.
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.
Connect test hose J3 to the end of joint

J2.
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
a The above is the preparation work for
measuring the leakage from the pressure limiter.
Testing leakage from pressure limiter

1) Lay test hose J3 so that it will not slacken
and put its end in the oil pan.
machine monitor to Monitoring function of
the service mode.
q
Monitoring code:
01002 Engine Speed
a For the operating method, see "Special functions of machine monitor
(EMMS)".
D155AX-6
3)
4)
3.
SEN00679-05
Run the engine at high idle and stall the

torque converter. After the engine speed
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 limiter is in the following range, it is normal.
Engine speed
Leakage
(cc/min)
Torque converter
stall
Max. 10
2)
Lay test hose J4 so that it will not slacken

and put its end in the oil pan.
3)
Turn the starting switch ON set the

machine monitor to Adjusting function of
the service mode.
q
(EMMS)".
After finishing measurement, stop the

engine.
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.
D155AX-6
23
SEN00679-05
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 injector is in the following range, it is normal.
Torque converter
stall speed (rpm)
5)
4.
24
Limit of return rate

(spill) (cc/min)
1,600
960
1,700
1,020
1,800
1,080
1,900
1,140
2,000
1.200
After finishing measurement, stop the

engine.
Work after finishing measurement

After finishing all measurement, remove the
measuring instruments and return the removed
parts.
D155AX-6
SEN00679-05
Bleeding air from fuel circuit
If fuel is used up or if a fuel circuit part is removed and installed, bleed air from the fuel circuit according to the following procedure.
1.
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,
remove the cap from part (a).
a If clean fuel is not available, do not
remove the prefilter but fill it with the fuel
by operating priming pump (4).
a Do not add fuel to fuel main filter (2) from
outside.
D155AX-6
3.
Install fuel prefilter (1) to the filter head.

a Apply engine oil thinly over the packing on
the fuel prefilter side.
a After the packing of the fuel prefilter
touches the sealing face of the filter head,
tighten the fuel prefilter 3/4 turns.
25
SEN00679-05
7.
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}
26
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.
D155AX-6
Measuring fuel circuit for

leakage
k
a
a
SEN00679-05
9.
Very high pressure is generated in the highpressure circuit of the fuel system. If fuel
leaks while the engine is running, it is dangerous since it can catch fire.
After testing the fuel system or removing and
installing its parts, test it for fuel leakage
according to the following procedure.
Clean and degrease the engine and the parts
around it in advance so that you can test it easily for fuel leakage.
1.
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 leakage.

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.
5.

for fuel leakage.
6.
Run the engine at high idle.
7.

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

a Relieve the ripper circuit by raising the ripper.
D155AX-6

for fuel leakage.
a If no fuel leakage is detected, inspection is
completed.
27
SEN00679-05
Testing and adjusting alternator

belt tension
1
k
6.
Install belt cover (1) with the 2 mounting bolts.

a Check for breakage of the pulleys, wear of
the V-grooves, contact of the belts and Vgrooves, 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.
a After tightening the bolts, check that the
belt tension is normal according to the
above procedure.
7.
After testing and adjusting, return the removed

parts.

Testing
1. Open the engine right side cover and remove
the inspection plate on the right of the radiator
guard.
2.
Press the intermediate point of the belt

between alternator pulley and water pump pulley 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
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 replacing 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).
28
D155AX-6
Testing and adjusting air

conditioner compressor belt
tension
k
SEN00679-05
a
After tightening the bolts, check that the

belt tension is normal according to the
above procedure.

Testing
1. Open the engine left side cover and left mudguard.
2.
Press the intermediate point of the belt

between the supply pump pulley and compressor pulley with a finger and measure deflection
(a) of the belt.
a Pressing force:
Approx. 59 N {Approx. 6 kg}
a Deflection (a): 10 mm
5.
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.
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 Vgrooves, 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.
D155AX-6
29
SEN00679-05
Measuring fan speed

a
Measuring instrument for fan speed
Symbol
Part No.
799-205-1100
Part name
Tachometer kit
Open the radiator mask and remove the fan

net.
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
4.
5.
Hydraulic oil
temperature [C]
Engine speed
[rpm]
Standard value of
fan speed [rpm]
57 2 C
or
77 2 C
Low idle
500 50
High idle
(1675 25)
1250(+50/0)

Measure the fan motor speed under the following condition.
q
1.
1) Set the fuel control dial to the HIGH IDLE

position, check the engine speed by the
monitoring code (ID: 01002), and fix the
decelerator pedal so that the engine
speed is 1675 25 [rpm].
2) Enter the fan 100% speed mode (ID: 1005)
of the adjustment mode and check the fan
100% speed. If the fan 100% speed is out
of the standard range, adjust it.
(Set the actual speed within the standard
range by changing the adjustment value
(offset).)
3) If the fan 100% speed does not increase
into the standard range, see [Fan speed
abnormal] of troubleshooting H mode.
4) Check the fan 100% speed at high idle and
low idle.
Take care that the probe will not interfere with the fan.
Rotate the fan with the hand and check
that the probe can sense the rotation of
the reflection tape.
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.
Check the fan speed in the fan 100% speed

mode (ID: 1005) at each engine speed according to following procedures.
6.
30
For the operation method in the adjustment mode, see "Special functions of
machine monitor (EMMS)".
parts.
D155AX-6
SEN00679-05
Measuring fan circuit oil pressure1

a
Measuring instruments for fan circuit oil pressure
Symbol
1
L
2
3
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-401-3400
Adapter (05)
799-101-5220
Nipple (10 x 1.25 mm)
07002-11023
O-ring

Measure the fan circuit oil pressure under the
following condition.
q
1.
Open the radiator mask and remove the fan

net.
2.
Disconnect supply hose (1) of the fan motor.
3.
Install adapter L2 and connect the disconnected 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}.
D155AX-6
5.
6.
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.
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)".
a If this adjustment code is displayed, the
fan speed is kept at 100% speed in accordance with the engine speed, regardless
of the state of the machine.
31
SEN00679-05
7.
While running the engine at high idle, measure

the fan circuit oil pressure.
Bleeding air from fan pump

a
8.
32
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
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 minutes.
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}
parts.
D155AX-6
SEN00679-05
Adjusting fuel control dial and decelerator pedal
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 signal
3) 3rd throttle signal (Power train controller)
q
The engine controller controls the fuel
control system of the engine (CRI system)
according to the one of the above input
signals which indicates the lowest engine
speed.
q
Adjust the decelerator pedal speed and
high idle speed with the decelerator pedal
linkage.
D155AX-6
DIAL: Fuel control dial

PEDAL: Decelerator pedal
ROD: Decelerator pedal rod
POTENTIO: Decelerator pedal potentiometer
ENG-ECU: Engine controller
P/T-ECU: Power train controller
ENGINE: Engine unit (CRI devices)
[KOMNET]: KOMNET communication circuit (3rd
throttle signal)
33
SEN00679-05
2.
Preparation work
1) Remove the right cover of the dashboard
and the right foot rest as a unit.
2) Start the engine and set the machine monitor to Adjusting function of the service
mode.
q
Adjustment code:
0007 (Engine decelerator cut)
(EMMS)".
3.
Adjusting decelerator pedal speed

With the fuel control dial in the high idle position (MAX), press decelerator pedal (1) to stopper 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 abnormal, adjust installed dimension (a) of stopper 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 position (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
q
When the engine speed is above 1,950
rpm:
Lower the engine speed below 1,900 rpm
temporarily with stopper bolt (3) to eliminate 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 stopper bolt: 34.8 mm
34
5.
Work after adjustment

After finishing all adjustment, return the
removed parts.
D155AX-6
D155AX-6
SEN00679-05
35
SEN00679-05
D155AX-6 Bulldozer
2011 KOMATSU
All Rights Reserved
36
D155AX-6
SEN00680-02
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up

Testing and adjusting, Part 2........................................................................................................................... 3
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
SEN00680-02
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
D155AX-6
SEN00680-02

Measuring power train oil
pressure
a
Measuring instruments for power train oil pressure
Symbol
M
k
Part No.
1
2
3
4
5
6
7
8
9
10
Part name
799-101-5002
Hydraulic tester
790-261-1204

work equipment lock lever in the LOCK
position.
Measure the power train oil pressure under the
following condition.
q
Power train oil temperature:
Within operating range
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.
Since the inlet pressure and outlet pressure of

the torque converter are measured with the
Monitoring function of the service mode of the
machine monitor, there are not oil pressure
pickup plugs for them in the centralized pressure pickup section.
Pressure pickup plugs and gauges to be

used
No. Stamp
11
Oil pressure to be
measured
Transmission main relief

pressure
Torque converter lockup
LU
clutch pressure
Torque converter stator
SC
clutch pressure
Transmission forward
F
clutch pressure
Transmission reverse
R
clutch pressure
Transmission 1st clutch
1ST
pressure
Transmission 2nd clutch
2ND
pressure
Transmission 3rd clutch
3RD
pressure
Steering right brake
RB
pressure
Steering left brake presLB
sure
Torque converter inlet
pressure
Torque converter outlet
pressure
TM
D155AX-6
Oil pressure
gauge
(MPa {kg/cm})
6.0 {60}
2.5 {25}
6.0 {60}
6.0 {60}
6.0 {60}
6.0 {60}
6.0 {60}
6.0 {60}
6.0 {60}
6.0 {60}
Machine
monitor
Machine
monitor
SEN00680-02
1.
Measuring transmission main relief pressure (TM)

1) Connect oil pressure gauge [1] of hydraulic tester M to oil pressure pickup plug (1).
a When using an analog oil pressure
gauge, use one of 6.0 MPa {60 kg/
cm}.
2)
3)
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.
While running the engine at low idle and
high idle, measure the main relief pressure.
2.
Measuring torque converter lockup clutch

pressure (LU)
cm}.
2)
3)
4)

measuring instruments and return the
removed parts.
4)
Start the engine and raise the machine

with the blade and ripper to a height where
you can run the track shoe idle.
After raising the machine, set the
work equipment lock lever in the
LOCK position.
Set the gearshift mode and preset range

as follows with the gearshift mode selector
switch and shiftup or shiftdown switch.
q
Gearshift mode:
Auto gearshift (Dozing)
q
Preset range: F1-R1
Set the machine monitor to Monitoring
function of the service mode.
q
Monitoring code:
31520 T/M Fill Sw Input 2
(EMMS).
D155AX-6
SEN00680-02
3.
5)
Measuring torque converter stator clutch

pressure (SC)
cm}.
Set the PCCS lever in the forward position

to run the track shoe idle.
k
6)
Take care not to get caught in a

rotating part of the track shoe during measurement.
While running the engine at high idle,
when L/U Fill Sw in the monitoring item is
turned ON, measure the lockup clutch
pressure.
2)
3)
7)

the LOCK position.
high idle, measure the stator clutch pressure.

removed parts.
4)
D155AX-6

removed parts.
SEN00680-02
4.
Measuring transmission forward clutch

pressure (F)
cm}.
2)
3)
4)
5)
Start the engine and set the parking brake

lever in the FREE position.
q
Gearshift mode:
Manual gearshift (Ripping)
q
Preset range: F2-R2
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.
measure the forward 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)
5.

removed parts.
Measuring transmission reverse clutch

pressure (R)
cm}.
2)
3)
4)
5)

q
Gearshift mode:
q
Preset range: F2-R2
direction of PCCS lever in the reverse
q
Keep the steering system in neutral.
q
Check that [R3] is displayed in the
measure the reverse clutch pressure.
k

D155AX-6
SEN00680-02
k
6)
6.

removed parts.
Measuring transmission 1st clutch pressure (1ST)

cm}.
2)
3)
4)
5)

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

q
Gearshift mode:
q
Preset range: F1-R1
position.
While running the engine at low idle, measure the 1st clutch pressure.
D155AX-6
6)
7.

removed parts.
Measuring transmission 2nd clutch pressure (2ND)

cm}.
2)
3)
4)

q
Gearshift mode:
q
Preset range: F2-R2
position.
SEN00680-02
a
a
5)

Check that [F2] is displayed in the
While running the engine at low idle, measure the 2nd clutch pressure.
k

Preset range: F2-R2
While running the engine at low idle, measure the 3rd clutch pressure.
q
4)
5)
6)
8.
Measuring transmission 3rd clutch pressure (3RD)

cm}.
2)
3)

removed parts.
6)


removed parts.

q
Gearshift mode:
D155AX-6
9.
Measuring steering right brake pressure

(RB)
cm}.
2)
3)

high idle, measure the right brake pressure.
a During measurement, check that the
oil pressure lowers to 0 when the
brake pedal is pressed or the parking
brake lever is set in the LOCK position.
SEN00680-02
10. Measuring steering left brake pressure (LB)

1) Connect oil pressure gauge [1] of hydraulic tester M to oil pressure pickup plug
(10).
cm}.
2)
3)
4)
4)

removed parts.
D155AX-6

high idle, measure the left brake pressure.
a During measurement, check that the
oil pressure lowers to 0 when the
brake pedal is pressed or the parking
brake lever is set in the LOCK position.

removed parts.
SEN00680-02
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)
3)
10

the LOCK position.
high idle, measure the inlet pressure and
outlet pressure of the torque converter.
D155AX-6
Adjusting transmission output

shaft speed sensor
k
1.
SEN00680-02
Remove the fuel tank and transmission output

shaft speed sensor (1).
a
Fuel tank: 950 kg (when full)
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

parts.
6.
Start the engine, set the machine monitor to

Monitoring function of the service mode, and
check that the transmission speed is indicated
normally.
a Monitoring code: 31400 T/M Out Speed
a To rotate the transmission output shaft,
drive the machine actually or run the track
idle.

position.
5.
11
SEN00680-02
Simple test procedure for brake

performance
1
k

position.
Carry out the simple performance test of the
brake under the following condition.
q
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 follows with the gearshift mode selector switch
and shiftup or shiftdown switch.
q
Gearshift mode:
q
Preset range: F2-R2
4.
While pressing the brake pedal, set the direction of PCCS lever in the forward position.
k
a
a
5.
12
6.
Return the decelerator pedal slowly and check

that the machine does not start when the
engine speed reaches the high idle speed.
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.
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.
Check that [F2] is displayed in the gear
speed display section.
Press the decelerator pedal and set the fuel

control dial in the high idle (MAX) position.
D155AX-6
SEN00680-02
Adjusting brake pedal
Adjusting tool for brake pedal
Symbol
N
k
a
a
1.
Part No.
Part name

position.
Tighten the locknut of the rod securely and
bend the cotter pin securely.
When adjusting the brake pedal, remove the
left cover of the dashboard and left foot rest as
a unit.
Adjusting brake potentiometer
machine monitor to Adjusting function of
the service mode.
a Adjustment code: 0005
(Brake pedal potentiometer initial correction)
(EMMS)".
D155AX-6
2)
3)
4)
Adjust installed dimension (b) of stopper

(2) so that dimension (a) will be 80 mm.
q
Dimension (b) = 35.5 mm (Reference
value)
Adjust installed dimension (b) of stopper
(2) so that the brake pedal potentiometer
voltage will be the specified voltage when
brake pedal (1) is released.
q
Brake pedal voltage: 2,500 50 mV
Referring to "Special functions of machine
monitor (EMMS), Service mode 07, Adjustment (Adjustment ID: 0005)", perform initial
correction of the brake pedal potentiometer.
13
SEN00680-02
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 following 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

parts.
14
D155AX-6
SEN00680-02
Adjusting parking brake lever
a
a

position.
When adjusting the parking brake lever,
remove the battery cover.
4
Brake oil pressure (At high idle)

Parking brake lever
Oil pressure
FREE position
2.75 0.29 MPa

{28.0 3.0 kg/cm}
LOCK position
0 MPa {0 kg/cm}
Battery cover: 65 kg
1.
Assembly and installation of lever assembly

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
SEN00680-02
3.
Checking limit switch

the service mode.
a Monitoring code:
40905 T/M Sw Input 1
(EMMS)".
2)
16
Check that the limit switch signal is input

normally when parking brake lever (3) is
set in the FREE position and LOCK position.
q
FREE position:
Travel lock NC OFF, Travel lock NO
ON
q
LOCK position:
Travel lock NC ON, Travel lock NO
OFF
D155AX-6
SEN00680-02
Emergency escape method when

power train has trouble
1
a
Tools for emergency escape
Symbol
P
1
2
1.
Part No.
Part name
19M-06-32820 Switch assembly

790-190-1601
Pump assembly
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
power train control unit (travel direction,
gear speed, steering), escape according
to the following procedure.
a The engine must be startable for the following procedure.
a If the engine cannot be started, see Emergency escape method with brake releasing device (Using P2).
k Do not turn the starting switch ON or
start the engine before preparing the
switch assembly and wiring harness
P1 completely.
1) Connect wiring harness [2] to switch
assembly [1] of emergency escape device
P1.
k
2)
Set the all gear speed switches of

switch assembly [1] in the OFF
position and set the directional
switch in the P position to prevent
the machine from starting suddenly.
3)
Disconnect neutral safety relay NSF (2)

and connect pins No. 3 and No. 5 of the
connector on the wiring harness side.
a Direct coupling circuit: NSF (female)
No. 3 io No. 5
a If connector PL1 is disconnected, a
model selection error is made and
neutral safety relay NSF is not driven.
The above operation is performed to
prevent this.
k If the engine is started by this
method, the neutral safety function
d o e s n o t w o r k . A c c o r d i n g l y,
before starting the engine, set the
parking brake lever in the LOCK
position and set the PCCS lever in
k Start the engine by this method
only in an emergency. If the engine
does not start in another case, be
sure to carry out troubleshooting
and repair the trouble.
Open the left fender inspection cover and

connect wiring harness [2] to connector
PL1 (1).
a The male housing and female housing of connector PL1 are fixed with
screws.
a Connect the wiring harness to both
male side and female side of connector PL1.
D155AX-6
17
SEN00680-02
4)
5)
6)
2.
18

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.
2)
Install volume pump [3] of pump assembly

P2 to the outside of the operator's cab.
3)
Remove the fuel tank undercover and disconnect supply hose (3) of the pin puller
solenoid valve.
4)
Connect end hose [4] of pump assembly

P2 to the hose side.
a Since the hose on the machine side is
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
5)

parking brake lever in the FREE position.
After moving the machine, remove the

instruments used and return the removed
parts.
a Check that the seal at the joint of connector 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}
Escape method with brake releasing device

(Using P2)
a If the engine cannot be started and the
parking brake cannot be released, escape
1) Assemble pump assembly P2.
D155AX-6
6)
7)
SEN00680-02
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 operated 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.
Tow the machine to a safe place.
a The brake releasing oil pressure lowers 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
SEN00680-02
Adjusting idler clearance
1.
20
If the idler runs out or tilts because of wear of

the right and left side guide plates or upper and
lower guide plates, and guide plate, adjust
position.
Adjusting in lateral direction
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.
2.
Adjusting in vertical direction

1) Measure clearance (b) between guide
plates (5) and (6) at 2 places.
2) The idler cannot be adjusted vertically. If
clearance (b) is more than 8 mm, replace
the upper and lower guide plates (5), (6),
(7) and (8) with new ones.
a Guide plates (5), (7) and (8) are
welded.
3) After finishing measurement, return the
removed parts.
D155AX-6
SEN00680-02
Testing and adjusting track shoe

tension
1
k

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

and front carrier roller and measure maximum
clearance (a) between the bottom of the steel
bar and shoe grouser.
a For the above measurement, use an Lshaped steel which will be deflected less.
q
Standard max. clearance (a): 20 30 mm
4.

parts.
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
3.
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}
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
SEN00680-02
Measuring and adjusting work

equipment and HSS oil pressure 1
a
Measuring and adjusting instruments for work

equipment and HSS oil pressure
Symbol
1
Q
2
k
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-101-5220
Nipple (10 x 1.25 mm)
07002-11023
O-ring

position.
When measuring and adjusting the work
equipment and HSS oil pressure, remove the
control valve cover.
4
3)
Run the engine at high idle and set the

blade control lever and ripper control lever in
neutral and measure the unload pressure.
a The work equipment lock lever may
be set in the LOCK position.
k Do not operate the work equipment
or steer the machine with the oil
pressure gauge of 6.0 MPa {60 kg/
cm} installed. If you do so, the oil
pressure gauge will be broken.
4)

removed parts.
Control valve cover: 25 kg
Measuring
a Measure the work equipment and HSS oil
pressure under the following condition.
q
a The unload pressure, work equipment oil pressure, and HSS oil pressure can be checked
with the monitoring function of the service
mode of the machine monitor (See 4).
1.
Measuring unload pressure

1) Remove P oil pressure pickup plug (1)
from the control valve.
2.
2)
22
Measuring work equipment oil pressure

1) Remove P oil pressure pickup plug (1)
and LS oil pressure pickup plug (2) from
the control valve.
Install nipple Q2 and connect it to oil pressure gauge [1] of hydraulic tester Q1.
cm}.
D155AX-6
2)
Install nipples Q2 and connect them to oil

pressure gauges [1] of hydraulic tester
Q1.
a When using analog oil pressure
gauges, use ones of 40 MPa {400 kg/
cm}.
3)
Start the engine and set the work equipment lock lever in the FREE position.
Run the engine at high idle, operate the
blade control lever and ripper control lever
to relieve each cylinder at a stroke end,
and measure the work equipment relief
pressure and work equipment LS relief
pressure.
a The work equipment relief pressure is
measured on the P-stamp side and
the work equipment LS relief pressure is measured on the LS-stamp
side.
k Do not steer the machine with the
oil pressure gauge of 40 MPa {400
kg/cm} installed. If you do so, the
oil pressure gauge will be broken.
4)
5)
SEN00680-02
3.
Measuring HSS oil pressure

1) Install the measuring instruments to the
control valve.
a Measuring points of the HSS oil pressure are the same as those of the
work equipment oil pressure.
a When using analog oil pressure
gauges, use ones of 60 MPa {600 kg/
cm}.
2)
3)
Start the engine, set the parking brake

lever in the FREE position, and keep
pressing the brake pedal.
Run the engine at high idle, set the PCCS
lever in the right or left steering position to
relief the steering circuit, and measure the
HSS relief pressure and HSS LS relief
pressure.
k
Since the steering circuit is relieved, keep pressing the brake

The HSS relief pressure is measured
on the P-stamp side and the HSS LS
relief pressure is measured on the
LS-stamp side.

removed parts.
4)
D155AX-6

removed parts.
23
SEN00680-02
4.
Measuring with machine monitor

the service mode.
q
Monitoring code:
70700 Hydraulic Pump Pressure 1
(EMMS).
2)
Start the engine and measure each oil

pressure.
a The measuring condition of each oil
pressure is the same with 1 3
above.
a Only the oil pressures on the P-stamp
side (unload pressure, work equipment relief pressure, and HSS relief
pressure) can be measured with the
monitoring function. The oil pressures on the LS-stamp side (work
equipment LS relief pressure and
HSS LS relief pressure) cannot be
measured.
Adjusting
1. Adjusting unload pressure
a The unload pressure cannot be adjusted.
2.
Adjusting work equipment oil pressure

a If the work equipment oil pressure is
abnormal, adjust it with work equipment
LS relief valve (3) according to the following procedure.
a The 5-spool valve of the single tilt specification is shown in the figure (The dual tilt
machine has the 6-spool valve).
1)
2)
3)
4)
24
While fixing adjustment nut (4), loosen

locknut (5).
Adjust the pressure by rotating adjustment
nut (4).
a If the adjustment nut 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
adjustment nut: Approx. 19.6 MPa
{Approx. 200 kg/cm}
While fixing adjustment nut (4), tighten
locknut (5).
3 Locknut: 39 49 Nm {4 5 kgm}
After finishing measurement, check the

work equipment oil pressure according to
the above measuring method.
D155AX-6
3.
SEN00680-02
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 specification is shown in the figure (The dual tilt
machine has the 6-spool valve).
1)
2)
3)
4)
While fixing adjustment screw (7), loosen

locknut (8).
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 adjustment screw:
Approx. 15.1 MPa
{Approx. 154 kg/cm}
While fixing adjustment screw (7), tighten
locknut (8).
3 Locknut:
68.6 78.5 Nm {7 8 kgm}
After finishing measurement, check the

HSS oil pressure according to the above
measuring method.
D155AX-6
25
SEN00680-02
Measuring control circuit basic

pressure
1
a
Measuring instruments for control circuit basic

pressure
Symbol
R
1
2
1.
Part No.
Part name
799-101-5002
Hydraulic tester
709-261-1204
799-401-3200
Adapter (03)
The control circuit basic pressure is the pressure lowered by the self-pressure reducing
valve of the fan circuit. It is used commonly for
the EPC valves of the control valve (steering,
blade, and ripper), HSS circuit charge, fan
pump control, and blade lift cylinder quick drop
EPC valve.
position.
Measure the control circuit basic pressure
under the following condition.
q
Run the engine at high idle, set the blade control lever and ripper control lever in neutral,
and measure the control circuit basic pressure.
a The work equipment lock lever may be set
in the LOCK position.
5.
After finishing measurement, remove the measuring instrument and return the removed
parts.
The control circuit basic pressure cannot be

adjusted.
Remove the control valve cover and disconnect accumulator inlet hose (1).
4
2.
Install adapter R2 and connect the disconnected hose again.
3.
Install nipple [1] of hydraulic tester R1 and connect it to oil pressure gauge [2].
26
4.
D155AX-6
SEN00680-02
Measuring work equipment lock

solenoid valve output pressure 1
a
Measuring instruments for work equipment

lock solenoid valve output pressure
Symbol
S
1
2
1.
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-401-3200
Adapter (03)

position.
Measure the work equipment lock solenoid
valve output pressure under the following condition.
q
4.
Remove the control valve cover and disconnect control valve inlet hose (1).
4
2.
Install adapter S2 and connect the disconnected hose again.
3.
Install nipple [1] of hydraulic tester S1 and connect it oil pressure gauge [2].
D155AX-6
5.
Run the engine at high idle, set the work equipment lock lever in the LOCK position and
FREE position, and measure the solenoid
valve output.
a If the output pressure is as follows, the
operation of the work equipment lock solenoid valve is normal.
Work equipment
lock lever
Output pressure
LOCK position
0 MPa {0 kg/cm}
FREE position
Same as control circuit

basic pressure (See standard value table)
parts.
27
SEN00680-02
Emergency operation method

when work equipment has trouble1
a
Tools for emergency operation
Symbol
T
a
k
1.
2.
Part No.
Disconnect connector WLK of the work equipment lock solenoid valve and connect it to the
male side of wiring harness T.
Part name
If the blade or ripper cannot be moved because of a trouble in the work equipment control s ystem, oper ate it ac cording to the
The engine must be startable for the following
procedure.
Do not turn the starting switch ON or start
the engine before preparing wiring harness
T completely.
Install wiring harness T in the operator's cab
and check where to connect each connector.
q
WLK: To work equipment lock solenoid
under floor
q
WEPW: To power supply connector
above control valve
q
WEPX: To EPC solenoid above control
valve
q
WEPY: To EPC solenoid above control
valve
4.
Connector on machine side to be connected

Connector on
machine side
Connector on wiring
harness T side
WLK (male)
WLK
Remove the control valve cover.

4
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.
Remove the floor cover from the front of the

operator's seat.
4
28
3.
Floor cover: 20 kg
Connector to be connected
Connector on machine
side
Connector on wiring
harness T side
WEPW (female)
WEPW
D155AX-6
6.
SEN00680-02
Disconnect EPC solenoid connectors EWP1

WEPA above the control valve and connect
connectors WEPX and WEPY of wiring harness T to the male side.
a Disconnect only the pair (2 pieces) of the
connector of the control valve spool (cylinder) to be moved and connect the connectors 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).
7.
k
k
8.
Start the engine and operate switch [1] of wiring harness T to move the work equipment.
Before starting the engine, check that
the switch is in neutral.
Since the work equipment cannot be
controlled finely with the switch, keep
the engine speed as low as possible.
After finishing operation of the work equipment, remove the tools used and return the
removed parts.
Connectors to be connected (The following table is for the dual tilt specification.
WEP5 and WEP6 are not connected to
the single tilt specification.)
Connectors on machine side
Device/Operating direction
Blade lift
Blade tilt left
Blade tilt right
Ripper lift
Ripper tilt
No.
Band color
Raise
WEP1
Green
Lower
WEP2
Green/Black
Retract
WEP3
Brown
Extend
WEP4
Brown/Black
Retract
WEP5
Blue
Extend
WEP6
Blue/Black
Raise
WEP7
Yellow
Lower
WEP8
Yellow/Black
In
WEP9
Red
Back
WEPA
Red/Black
Connectors on wiring harness T side

Device/Operating direction
LIFT
D155AX-6
No.
Band color
UP
WEPX
DOWN
WEPY
29
SEN00680-02
Measuring ripper pin puller

solenoid valve output pressure 1
a
Measuring instruments for ripper pin puller

solenoid valve output pressure
Symbol
U
1
2
1.
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-401-3200
Adapter (03)

position.
Measure the ripper pin puller solenoid valve
output pressure under the following condition.
q
4.
Remove the undercover of the fuel tank and

disconnect ripper pin puller solenoid valve
hose (1) or (2).
q
Hose (1): Pin puller cylinder head side
q
Hose (2): Pin puller cylinder bottom side
Run the engine at high idle, set the pin puller

switch in the pull-out position and push-in position, and measure the solenoid valve output
pressure at each position.
a If the output pressure is as follows, the
operation of the ripper pin puller solenoid
valve is normal.
Tested Pin puller
hose
switch
(1)
(2)
2.
Install adapter U2 and connect the disconnected hose again.
3.
Install nipple [1] of hydraulic tester U1 and connect oil pressure gauge [2].
30
5.
Output pressure
Pull-out
Same as transmission
main relief pressure
(See standard value table)
Push-in
0 MPa {0 kg/cm}
Pull-out
0 MPa {0 kg/cm}
Push-in
Same as transmission
main relief pressure
(See standard value table)
parts.
D155AX-6
SEN00680-02
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 following 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
extend it to the stroke end.
2)
Blade tilt cylinder

Extract the tilt cylinder to the stroke end
and brace the blade to push up the left
side of the machine body.
3)

Brace the ripper to push up the rear side
of the machine body.
D155AX-6
2.
Turn the starting switch ON and set the work

equipment lock lever in the FREE position.
3.
Extend the cylinder to be tested with the corresponding lever and check its movement.
q
If the lowering speed is increased, the cylinder packing is defective.
q
If the lowering speed does not change, the
control valve is defective.
a If the pressure in the accumulator is lost,
run the engine for about 10 seconds to
heighten the pressure in the accumulator.
[Reference]
Reason why the lowering speed is increased when
the cylinder packing is the cause of the hydraulic
drift:
1. If the machine is set in the above position
(where the holding pressure is applied to the
bottom side), the oil leaks from the bottom side
to the head side. Since the volume on the
head side is less than that on the bottom side
by the volume of the rod, the pressure in the
head side is increased by the oil flowing in
from the bottom side.
2. As the pressure in the head side is increased,
it is balanced at a certain level (which depends
on the leakage), then the lowering speed is
lowered.
3. If the circuit on the head side is opened to the
drain circuit by the above operation of the lever
(the bottom side is closed by the check valve
at this time), the oil on the head side flows in
the drain circuit. As a result, the pressure is
unbalanced and the lowering speed is
increased.
31
SEN00680-02
Measuring internal leakage of

work equipment cylinder
a
Measuring instruments for internal leakage of

Symbol
Part No.
Commercially
available
a
a
1.
2.
32
Hose (2): Ripper lift cylinder

Hose (3): Ripper tilt cylinder
Head: 07378-11000 (Size #10)
O-ring: 07000-13032 (Size #10)
Part name
Measuring cylinder

position.
Since the blade lift cylinder is equipped with a
piston valve, its internal leakage cannot be
measured.
Measure the internal leakage of work equipment cylinder under the following condition.
q
Extend the cylinder to be measured to the
stroke end and set the machine in the measuring position.
1) Blade tilt cylinder
Tilt the blade to the left end.
2) Ripper lift cylinder
Pull out the shank pin and lower the ripper
to the end.
3) Ripper tilt cylinder
Tilt the ripper forward (in) to the end.
k Release the residual pressure from the
cylinder circuit. For details, see Releasing residual pressure from work
equipment cylinder.
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
Plug: 07376-70422 (Size #04)
O-ring: 02896-11012 (Size #04)
3.
Run the engine at high idle and apply the relief

pressure to the cylinder bottom side.
q
Blade tilt cylinder:
Operate to tilt blade to left.
q
Ripper lift cylinder:
Operate to lower ripper.
q
Ripper Tilt cylinder:
Operate to tilt ripper forward (in).
4.
After 30 second, measure leakage in 1 minute

with measuring cylinder V.
5.
After finishing measurement, return the removed parts.

a Bleed air from the cylinder circuit. For details, see Bleeding air from work equipment cylinder.
D155AX-6
SEN00680-02
Releasing residual pressure from

1
Bleeding air from work equipment

cylinder
1
1.
When disconnecting the piping between the

control valve and work equipment cylinder,
release the residual pressure from the circuit
position.
a
1.
Run the engine at low idle for about 5 minutes.
2.
While running the engine at low idle, extend

and retract the cylinder to be bled 4 5 times.
a Move the piston rod to about 100 mm
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.
Loosen oil filler cap (1) of the hydraulic tank

gradually to release the residual pressure from
the tank.
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 seconds to increase the pressure in the accumulator, then stop it.
5.
Repeat steps 2 4 above 2 3 times.
D155AX-6
If the work equipment cylinder is removed and

installed or its piping is disconnected and connected, bleed air from its circuit according to
Before performing the following operation,
check that the hydraulic oil level is normal.
33
SEN00680-02
Adjusting work equipment lock lever
a
a
a
a

position.
When adjusting the work equipment lock lever,
remove the control valve cover.
4
Monitoring code: 70300 Blade Sw Input

For the operating method, see Special
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
sliding surface. Do not move it.
3.
Set work equipment lock lever (1) in the FREE

position and check that limit switch (2) operates normally.
q
Stroke of limit switch: 2.5 3 mm
4.

machine monitor to Monitoring function of the
service mode.
34
5.
Check that the limit switch signal is input normally when work equipment lock lever (1) is
set in the FREE position and LOCK position.
q
FREE position:
Work equipment lock NC OFF, Work
equipment lock NO ON
q
LOCK position:
Work equipment lock NC ON, Work equipment lock NO OFF
D155AX-6
SEN00680-02
Adjusting blade
a
a
1.
If the blade is removed and installed or disassembled and reassemble, adjust it according
The above figure shows the blade of the dual
tilt specification.
Adjusting shims for assembly
1) Adjust the shim of tilting section (1) (1
place).
a After reassembling the tilting section,
supply grease to it.
2 Tilting section: Grease (G2-LI)
Adjusted
point
Adjusted
clearance
Standard
clearance
Standard shim
thickness
See note.
4 mm
D155AX-6
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.
35
SEN00680-02
2)
Adjust the shim of center section (2) (2

places).
a After reassembling the center section,
supply grease to it.
2 Center section: Grease (G2-LI)
Adjusted
point
Adjusted
clearance
Standard
clearance
Standard shim
thickness
See note.
4 mm
3)
Adjusting blade tilt distance (Single tilt

specification)
1) Adjust installed dimension (d) of brace (4)
with the handle.
Dimension
d
2)
Adjust the shim so that the play of the
ball in the axial direction will be less
than 1 mm and the ball can rotate
smoothly.
Dimension
blade
1,292 mm
Semi-U blade
Full-U blade
1,372 mm
1,372 mm
Measure right and left tilt distances (e1)

and (e2).
blade
Semi-U blade
Full-U blade
e1
565 mm
570 mm
583 mm
e2
565 mm
570 mm
583 mm
Adjust the shim of lifting section (3) (2

places).
Adjusted
point
Adjusted
clearance
Standard
clearance
Standard shim
thickness
Max. 1 mm
4 mm
36
2.
3)
If both tilt distances are not the same,

adjust installed dimension (d) of brace (4)
q
e1 > e2:
Increase installed dimension (d)
slightly.
q
e1 < e2:
Decrease installed dimension (d)
slightly.
D155AX-6
Adjusting operator's cab
SEN00680-02
If the operator's cab is removed and installed

or disassembled and transported and assembled 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
changeover switch:
EXTERNAL position
q
Air conditioner fan switch: High (FULL)
1) Prepare a transparent vinyl hose.
q
Outside diameter: 6 mm, Length:
3,000 mm
2) Secure the inside end of the hose to the
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.
4)
5)
6)
Seal the clearance between the hole of

bolt (1) and hose [1] with tape (3).
Pour water in the hose up to about half
and bend the hose in a U-shape.
Secure hose [1] to the outside of the cab
and set the water level in the vinyl hose
out of the cab to that in the cab.
D155AX-6
2.
7)
Start the engine and set the machine monitor to Adjusting function of the service
mode.
a Adjustment code:
1005 (Fan 100% mode)
(EMMS).
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 pressure of cab)
a If the measured value (internal pressure of the cab) is lower than the
standard value, check the seals of the
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
optional parts in the cab.
Checking searing performance

1) Close all the openings (doors and windows) 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.
37
SEN00680-02
4)
Check around the dashboard carefully for

water leakage.
a If water leaks, caulk the leaking part
and check again.
4)
5)
3.
Testing and adjusting door lock (damper

rubber)
a Close the door and check the relationship
between the operator's cab and door
(damper rubber portions). If there is any
abnormality, adjust it.
1) Stick adhesive tape [2] to the contact face
of damper rubber (6) of door (5).
a Check both sides, 2 places on each
side.
2) Open and close door (5) 2 3 times.
3) Check the contact portions of adhesive
tape [2] and operator's cab.
q
Normal:
When the door is closed, the damper
rubber comes in contact lightly (No
adjustment is required).
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 (Adjustment is required).
4.
Testing and adjusting door lock (latch and

striker)
a Close the door and check the relationship
between the operator's cab and door
(latch and striker). If there is any abnormality, adjust it.
1) Move door (5) in the closing direction and
check the engaging condition of latch (8)
and striker (9).
a Check quantity of misalignment (f)
between center of latch (d) and center
of striker (e) from the direction of A.
q
Normal: Quantity of misalignment (f)
is 0.5 mm or less.
2)
3)
4)
38
Loosen the mounting bolts of damper rubber (6).

a You can remove and install the shims
without removing the mounting bolts.
Increase or decrease shims (7) under
damper rubber (6) to adjust the height of
damper rubber (6) properly.
Tighten the mounting bolts of striker (9)

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

is locked and unlocked smoothly.
a If the door is not locked or unlocked
smoothly (the operating effort of the
knob is large), repeat adjustment
from the first.
a Operating effort of door knob:
49 19.6 N {5 2 kg}
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)
SEN00680-02
2)
3)
4)
5)
5.
Check that striker (10) is not leaning

against or from center (g) of latch (11).
Check that striker (10) is aligned with center (h) of latch (11).
q
Normal: Quantity of misalignment is
0.5 mm or less.
Loosen the mounting bolts of striker (10).

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

striker)
a Check the relationship between the operator'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 direction and check the engagement of the
latch and striker.
D155AX-6
39
SEN00680-02
6.
Testing and adjusting open lock (stopper

rubber)
a Check the relationship between the operator'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 forward 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 eliminated.
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.
While fixing stopper rubbers (12) and (13),
tighten the locknuts.
6)
40
D155AX-6
D155AX-6
SEN00680-02
41
SEN00680-02
D155AX-6 Bulldozer
2009 KOMATSU
All Rights Reserved
42
D155AX-6
SEN00681-04
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up

Special functions of machine monitor (EMMS) ............................................................................................... 2
D155AX-6
SEN00681-04
Special functions of machine monitor (EMMS)
Air conditioner specification
D155AX-6
Heater specification
SEN00681-04
Upper section of machine monitor (Display section)

(a): Multi-display
a The figure shows an example of display of symbols and gauges in the ordinary display mode
(The contents of display depend on the condition of the machine and operating method).
a When the engine is started, the battery voltage
may lower suddenly, depending on the ambient temperature and the condition of the battery. In this case, the machine monitor goes off
for a moment. This phenomenon is not a failure, however.
Upper section of machine monitor (Switch section)
[F1]: F1 function switch
a The function of each function switch is indicated 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 section)
[1]: Numeral 1 input switch/Operation mode selector switch
[2]: Numeral 2 input switch/Gearshift mode selector 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 heater 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 effective, according to the display condition of multidisplay (a).
a The difference between the air conditioner
specification and heater specification is only
the functions of the switches in this section.
D155AX-6
SEN00681-04
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 others 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.
Operator mode (Outline)
Page
Service mode
5p
5p
16 p
01 Monitoring
17 p
Mechanical system "Abnormality
Record"
A Display of screen to input password
6p
A Display of check before starting
6p
A Display of warning after check before starting
6p
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
B Operation of customize memory
8p
Setting of ECO display
44 p
B Selection of float mode
8p
B Operation to cancel alarm buzzer
8p
B Operation of air conditioner/heater
9p
B Selection of dual tilt (Dual tilt specification)
9p
Special operations
A Display of KOMATSU logo
Page
Operation to display camera mode

B
(if camera is installed)
10 p
B Operation to display clock and service meter
10 p
Terminal Status
75 p
B Check of maintenance information
11 p
11 p
12 KOMTRAX GPS & Communication Status

Settings
Modem S/N
76 p
Setting and display of user mode

B
(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
02 Abnormal- Electrical system "Abnormality

ity Record Record"
24 p
25 p
Air conditioner "Abnormality Record"/

35 p
Heater "Abnormality Record"
07 Adjustment
45 p
08 PM CLINIC
71 p
09 Cylinder Cut-Out
72 p
10 No Injection
73 p
11 Fuel Consumption
74 p
77 p
O (Special operations)
Function of checking display of LCD
D
(Liquid Crystal Display)
14 p
D Function of checking service meter
14 p
D Function of changing maintenance password
15 p
Classification of operator mode

A: Display/Function from time when starting switch is turned ON to time when screen changes to ordinary 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
D155AX-6

t
a
SEN00681-04
Operator mode (Outline)

Only outline of the operator mode is described
in this section. For details of contents/operation of each function/display, see "the Structure, function and maintenance standard, or
Operation and Maintenance Manual".
The following are the displays or functions of
the operator mode explained in this section
(including some items which need special
operations).
Display pattern of operator mode

The contents of display from the time when
starting switch is turned ON to the time when
screen changes to ordinary screen depends on
the setting and condition of the machine.
a: When engine start lock is set effective
b: When engine start lock is set ineffective
c: When there is abnormal item in checkbefore-starting items
d: When there is maintenance item which is
not maintained after specified interval
Display pattern
a
Display of KOMATSU logo
Display of screen to input password
Display of check before starting
Display of warning after check before

starting
Display of ending of maintenance inter

val
Display of check of preset
Display of ordinary screen
Display of KOMATSU logo

When the starting switch is turned ON, the
KOMATSU logo is displayed for 2 seconds.
After the KOMATSU logo is displayed for 2 seconds, the screen changes to "Display of screen to
input password" or "Display of check before starting".
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
Operation of air conditioner/heater
Selection of dual tilt (Dual tilt specification)

Operation to display camera mode
(if camera is installed)
Operation to display clock and service meter
The following screen may be displayed instead

of the above "Display of screen to input password screen".
If this screen is displayed, call the person
responsible to operation of KOMTRAX in your
Komatsu distributor and ask for remedy.
Check of maintenance information

Display of caution monitor
Display of action code and failure code
O (Special operations)
Function of checking display of LCD (Liquid Crystal Display)
Function of checking service meter
Function of changing maintenance password
D155AX-6
SEN00681-04
Display of screen to input password

After the KOMATSU logo is displayed, the screen
to input the engine start lock password is displayed.
a This screen is displayed only when the engine
start lock function is set effective.
a If the password is input normally, the screen
changes to "Display of check before starting".
a The machine monitor has some password
functions other than the engine start lock.
Those functions are independent from one
another.
Display of check before starting

When the screen changes to the check-beforestarting screen, the check before starting is carried
out for 2 seconds.
a If any abnormality is detected by the check
before starting, the screen changes to "Display
of warning after check before starting" or "Display of ending of maintenance interval".
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.
Display of warning after check before starting

If any abnormality is detected by the check before
starting, the warning monitor is displayed on the
screen.
a The following figure shows that the radiator
coolant level monitor (a) is warning of low radiator coolant level.
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
30 seconds to urge the operator to maintenance.
a This screen is displayed only when the maintenance function is effective. The color of the
maintenance monitor (yellow or red) indicates
the length of the time after the maintenance
interval.
a Set or change the maintenance function in the
service mode.
D155AX-6
Display of check of preset

If the check before starting is finished normally, the
screen to check the preset (gear speed at start) is
displayed for 2 seconds.
a After display of check of preset is finished, the
scree n cha nges to "Disp la y of ordinary
screen".
Display of ordinary screen

If the machine monitor starts normally, the ordinary
screen is displayed.
a Service meter (a) or a clock is displayed at the
center upper section of the screen (The service meter or clock is selected with [F4]).
a Power train oil temperature gauge (b) is displayed 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 service mode).
D155AX-6
SEN00681-04
Display of end screen

When the starting switch is turned OFF, the end
screen is displayed for 5 seconds.
a Another message may be displayed on the
end screen, depending on the message display function of KOMTRAX.
Selection of operation mode

While the ordinary screen is displayed, press the
operation mode selector switch, and the operation
mode monitor (a) changes.
a Each time the switch is pressed, the operation
mode changes between [P (Power)] and [E
(Economy)].
SEN00681-04
Selection of gearshift mode

gearshift mode selector switch, and the gearshift
mode monitor (a) in the gear speed display section
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.
Customizing operation
customize switch, and you can change the setting
of the machine.
a If the customize memory switch is operated
while the above screen is displayed, up to 5
settings can be saved.
Operation of customize memory

customize memory switch, and you can select the
recorded setting of customization.
Selection of float mode

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
[OFF (Float is ineffective)].
a If the float mode is turned ON, float mode monitor (a) is displayed. If the former is turned
OFF, the latter is put out.
a The float mode switch sets the float button of
the blade control lever effective or ineffective.
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.
D155AX-6
Operation of air conditioner/heater

While the ordinary screen is displayed, press the air
conditioner switch or heater switch, and the Airconditioner Adjustment screen or Heater Adjustment screen is displayed.
a While the Air-conditioner Adjustment screen or
Heater Adjustment screen is displayed, if you
do not touch any switch for 5 seconds, the
screen changes to the ordinary screen.
a Air conditioner specification
SEN00681-04
Selection of dual tilt (Dual tilt specification)

While the ordinary screen is displayed, press [F1],
and the dual tilt monitor (a) changes.
a Each time [F1] is pressed, the dual tilt mode
changes between [ON (Dual)] and [OFF (Single)].
a If the dual tilt mode is turned ON, dual tilt mode
monitor (a) is displayed. If the former is turned
OFF, the latter is put out.
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.
D155AX-6
SEN00681-04
Operation to display camera mode (if camera is

installed)
When a camera is installed, if [F3] is pressed, the
multi-display changes to the camera image.
a Set the connection of the camera in the service
mode.
a
a
a
a
10
Up to 3 cameras can be connected. If the

camera mode is selected, however, only the
image of camera 1 is always displayed.
Operation to display clock and service meter

and section (a) changes to the service meter and
clock alternately.
a When the clock is selected, adjust the time, set
12-hour or 24-hour display, and set the summer time with the user mode function.
a Display of service meter
Display of clock
If a caution is generated in the camera mode,

the caution monitor is displayed at the left
upper of the screen.
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 ordinary screen and displays the error information.
When 2 or more cameras are connected, the
image of one of them or the images of 2 of
them can be displayed.
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 displayed on the right side. The image of camera
3 is displayed only singly.
If the images of 2 cameras are displayed
simultaneously, images are displayed at intervals of 1 second on the right and left screen.
D155AX-6
SEN00681-04
Check of maintenance information

While the maintenance monitor or ordinary screen
is displayed, press [F5], and the maintenance table

and the user menu screen is displayed.
To reset the time left after finishing maintenance, more operations are necessary.
There are following items in the user menu.

Utility Screen Select
Multi Gage Select
Screen Adjustment
Clock Adjustment
Language
Message display
Hydraulic fan reversing
[KOMTRAX message]
q
There are 2 types of KOMTRAX message; one
is for the user and the other is for the service.
q
For user:
A message transmitted from the KOMTRAX
base station for the user. If it is received, the
message monitor is displayed on the ordinary
screen. To see the contents of the message,
operate "Message display" in the above user
menu.
D155AX-6
11
SEN00681-04
For service:
A message transmitted from the KOMTRAX
base station for the service. Even if it is
received, nothing is displayed on the ordinary
screen. To see the contents of the message,
operate "KOMTRAX message display" in the
service menu.
Display of caution monitor

If an abnormality which displays a caution monitor
occurs on the ordinary screen or camera mode
screen, the caution monitor is displayed large for a
moment and then displayed at (a) in the screen.
a On the camera mode screen, the caution monitor blinks at the left upper of the screen when
the caution is generated.
12
Display of action code and failure code

If an abnormality which displays an action code and
a failure code occurs on the ordinary screen or
camera mode screen, all the information of the
abnormality is displayed.
(a) : Action code (3 digits)
(b) : Failure code (5 or 6 digits)
(c) : Telephone mark
(d) : Telephone No.
a This screen is displayed only when an abnormality (failure code) for which an action code is
set occurs.
a The telephone mark and telephone No. are
displayed only when the telephone No. is registered in the service mode.
a If multiple abnormalities occur simultaneously,
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 service mode, check the details in the service
mode.
D155AX-6

a
SEN00681-04
Remedies given by displayed action codes to operator to take (The following table is an excerpt from the
Operation and Maintenance Manual)
Action
code
Method of indicating trouble
Examples of trouble
Remedy given to operator to take
E01
Action code and failure code are Backup alarm does not sound.
displayed.
Fan speed is kept at maximum.
Although all or a part of automatic

function stops, machine can be
operated.
Ask your Komatsu distributor for
repair.
E02
Gear is not shifted up or down.

Action code and failure code are Engine boost pressure is abnormal.
displayed.
Exhaust gas color is bad when
Alarm buzzer sounds.
temperature is low.
If operator stops and restarts

engine, machine can be operated
without limiting any function.
Operator must take care, however.
repair.
E03
Engine coolant temperature sensor 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
Telephone No. is displayed (if
maximum.
set).
repair.
Gearshift shock is increased.
Steering performance lowers.
Braking shock is increased.
E04
Action code and failure code are

Engine cannot be controlled.
displayed.
Machine cannot travel.
Telephone No. is displayed (if
set).
Machine stops.
D155AX-6
Stop machine immediately.

repair.
13
SEN00681-04
Function of checking display of LCD (Liquid

Crystal Display)
While the ordinary screen is displayed, if the following numeral input switch and function switch are
operated as follows, all the LCD (Liquid Crystal Display) lights up in white.
q
Operation of switches (simultaneous): [4] +
[F2]
a When finishing the operation of the switches,
release [F2] first.
a If there is a display error in the LCD, only that
part is indicated in black.
a The LCD panel sometimes has black points
(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 function switch.
14
Function of checking service meter

To check the service meter while the starting switch
is turned OFF, operate the numeral input switches
as follows. At this time, only the service meter section displays.
q
Operation of switches (simultaneous): [4] + [1]
a Since there is some time lag in start of the
LCD, hold down the switches until the LCD displays normally.
a After the machine monitor is used continuously, blue points (points which do not go off)
may be seen on this screen. This phenomenon does not indicate a failure or a defect.
D155AX-6
SEN00681-04
Function of changing maintenance password

When changing the maintenance password used
for the maintenance setting function, follow these
procedures.
1.
2.
3.
While the ordinary 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] + [5] o [5] o [5]
a This operation of the switches is not accepted until 10 minutes pass after the
starting switch is turned on.
Set a new password of 4 6 digits (If it

has only 3 or less digits or has 7 or more
digits, it is not accepted).
[F5]: Delete input numeral/Return to ordinary screen
[F6]: Confirm input numeral
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
q
a If a password different from the password
input before is input, the message to input
again is displayed.
5.
If the screen to notify completion of setting is

displayed and then the ordinary screen is displayed, the password is changed successfully.
After the "Password" screen is displayed, input

the current password with the numeral input
switches and confirm it with the function
switch.
q
q
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 message to input the password again is displayed.
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
SEN00681-04
t Service mode
To change the operator mode to the service mode,
perform the following operation.
This operation is always required when you use the
service mode.
1.
Check of display of screen and operation of

switches
While the ordinary 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 This operation of the switches is accepted
only while the ordinary screen is displayed.

a
The items which can be selected in the

service menu are as follows.
01 Monitoring
Mechanical system "Abnormality
Record"
02 Abnormality
Record
Electrical system "Abnormality

Record"
Air conditioner "Abnormality Record"/
Heater "Abnormality Record"
03 Maintenance Record
04 Maintenance Mode Change
05 Phone Number Entry
Key-OFF Mode
Setting of unit
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
Settings
GPS & Communication Status

Modem S/N
2.
16
Selection of service menu

When the "Service Menu" screen is displayed,
the service mode is selected. Select a service
menu you use with the function switches or
numeral input switches.
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].
13 Service Message
Items with 2-digit codes are the menus displayed on the Service menu screen. The items
on their right are the menus on the next hierarchy.
D155AX-6
SEN00681-04
Monitoring
The machine monitor can monitor the condition of
the machine in real time by receiving signals from
various switches, sensors, and actuators installed
to many parts of the machine and the information
from the controllers which are controlling switches,
etc.
1.
Selecting menu
Select "01 Monitoring" on the "Service Menu"
screen.
3.
2.
Selecting monitoring items

After the "Monitoring" screen is displayed,
select items to be monitored with the function
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 service menu screen
q
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
Deciding monitoring items

After selecting monitoring items, execute monitoring with the function switch or numeral input
switch.
a Execution with function switch: Doubleclick 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 example, select them and confirm with [F6]. If
[F6] is pressed once more at this time,
monitoring is executed.
a If monitoring items are selected up to the
limit number, monitoring is executed automatically.
17
SEN00681-04
4.
Executing monitoring
After the "Monitoring" screen is displayed, perform the necessary operation of the machine
and check the monitoring information.
a Monitoring information is indicated by
value, ON/OFF, or special display.
a The unit of display can be set to SI unit,
metric unit, or inch unit with the Default
function in the service mode.
5.
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
6.
Changing machine setting mode

To change the setting of the "P/E Mode", "Fan
Rev." mode, or "Working" mode during monitoring, operate the corresponding switch under
the current condition, and the mode setting
While this screen is displayed, if the corresponding switch is operated further, the corresponding 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.
D155AX-6
SEN00681-04
Monitoring items list

Code
No.
Monitoring item
(Display on screen)
Unit (Initial setting: ISO)

ISO
meter
inch
Component
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
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
32900 Pitch Angle
BL (Left brake fill sw)
ON OFF
P/T
CL (Left clutch fill sw)
ON OFF
P/T
CR (Right clutch fill sw)
ON OFF
P/T
BR (Right brake fill sw)
ON OFF
P/T
Remarks
31521 S/T Fill Sw Input
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
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
km/h
km/h
MP/h
P/T
P/T
30100 T/C Oil Temperature
40001 Vehicle Speed

60000 Traction
D155AX-6
19
SEN00681-04
Monitoring item
(Display on screen)

ISO
meter
inch
Component
in charge
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
r/min
rpm
rpm
P/T
Code
No.
10000 Fan Speed
40905 T/M Sw Input 1
T/M Fill Sw
40906
Input 1
31520
T/M Fill Sw
Input 2
40909 T/M Output 1
SUNC (Gear shift up sw)
ON OFF
P/T
SUNO (Gear shift up sw)
ON OFF
P/T
SDNC
(Gear shift down sw)
ON OFF
P/T
SDNO
(Gear shift down sw)
ON OFF
P/T
PNC
(Parking brake lever sw)
ON OFF
P/T
PNO
(Parking brake lever sw)
ON OFF
P/T
F (F clutch fill sw)
ON OFF
P/T
R (R clutch fill sw)
ON OFF
P/T
1st (1st clutch fill sw)
ON OFF
P/T
2nd (2nd clutch fill sw)
ON OFF
P/T
3rd (3rd clutch fill sw)
ON OFF
P/T
L/U( Lock-up clutch fill sw)
ON OFF
P/T
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
Fres
(Fan reverse solenoid)
ON OFF
P/T
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
Remarks
D155AX-6
Monitoring item
(Display on screen)
SEN00681-04

ISO
meter
inch
Component
in charge
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
Code
No.
FLNC (Blade float sw)
ON OFF
W/E
FLNO (Blade float sw)
ON OFF
W/E
BPNC (Blade pitch sw)
ON OFF
W/E
BPNO (Blade pitch sw)
ON OFF
W/E
WLNC
(Work equipment lock sw)
ON OFF
W/E
WLNO
(Work equipment lock sw)
ON OFF
W/E
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
70300 Blade Sw Input
04200 Fuel Level Sensor Volt
MON
04300 Battery Charge Volt
MON
04401 Hyd Oil Temperature
MON
04002 Hyd Temp Sens Volt
MON
18900 ECM Internal Temp
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
mV
mV
mV
ENG
03001 Throttle Pos Sens Volt

17500 Engine Power Mode
D155AX-6
Remarks
ENG
21
SEN00681-04
Monitoring item
(Display on screen)

ISO
meter
inch
Component
in charge
MPa
kg/cm
psi
ENG
ENG
MPa
kg/cm
psi
ENG
CA
CA
CA
ENG
04107 Coolant Temperature
ENG
01405 Coolant Temp Sens Volt
ENG
kPa
kg/cm
psi
ENG
ENG
kPa
kg/cm
psi
ENG
36501 Charge Press Sens Volt
ENG
03203 Battery Power Supply
ENG
37300 Fuel Rate
l/h
l/h
gal/h
ENG
31706 Final Throttle Position
ENG
18500 Charge Temperature
ENG
18501 Charge Temp Sens Volt
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
ENG
14200 Fuel Temperature
ENG
14201 Fuel Temp Sens Volt
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
Code
No.
36400 Rail Pressure

36401 Rail Pressure Sens Volt
36200 Rail Press Command
36300 Injection Timing Command
37400 Ambient Pressure

37401 Ambient Press Sens Volt
36500 Charge Pressure-Abs
40912 P/T Sw Input
a
a
22
R-sig
ON OFF
P/T
Acc
ON OFF
P/T
Eng S
ON OFF
P/T
Eng L
ON OFF
P/T
Eng Sd
ON OFF
P/T
Remarks
Indication by absolute value (including

ambient pressure)
Entry order of items in table

The items are entered in the order of display on the monitoring selection menu screen.
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.
Components in charge
D155AX-6
MON
ENG
P/T
W/E
D155AX-6
SEN00681-04
: The machine monitor is in charge of detection of monitoring information.

: The engine controller is in charge of detection of monitoring information.
: The power train controller is in charge of detection of monitoring information.
: The work equipment controller is in charge of detection of monitoring information.
23
SEN00681-04
"Abnormality Record" (Mechanical system

"Abnormality Record")
The machine monitor classifies and records the
abnormality which occurred in the past or which are
occurring at present into the mechanical system
abnormality, electrical system abnormality, and air
conditioner abnormality or heater abnormality.
To check the mechanical system "Abnormality
Record", perform the following procedures.
1.
Selecting menu
Select "02 Abnormality Record" on the "Service Menu" screen.
2.
Selecting sub menu

After the "Abnormality Record" screen is displayed, select "01 Mechanical Systems" with
the function switches or numeral input
switches.
q
[F3]: Move to lower record
q
[F4]: Move to upper record
q
[F5]: Return to service menu screen
q
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.
24
3.
Information displayed on "Abnormality Record"

screen
On the "Mechanical Systems" screen, the following information is displayed.
(a): Occurrence order of abnormality from latest one/Total number of records
(b): Failure code
(c): Contents of trouble
(d): Number of occurrence time
(e): Service meter reading at first occurrence
(f): Service meter reach at last occurrence
q
[F1]: Move to next page (screen) (if displayed)
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
table in "Abnormality Record (Electrical
system Abnormality Record)".
4.
Deleting "Abnormality Record"

The contents of the mechanical system
"Abnormality Record" cannot be deleted.
D155AX-6
"Abnormality Record" (Electrical system "Abnormality Record")

To check the electrical system "Abnormality
Record", perform the following procedures.
1.
Selecting menu
Select "02 Abnormality Record" on the "Service Menu" screen.
2.
Selecting sub menu

After the "Abnormality Record" screen is displayed, select "02 Electrical Systems" with the
function switches or numeral input switches.
q
q
q
q
[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.
D155AX-6
SEN00681-04
3.

screen
On the "Electrical Systems" screen, the following information is displayed.
(a):Occurrence order of abnormality from latest one/Total number of records
(b):Failure code
(c): Contents of trouble
(d):Number of occurrence time
(e):Service meter reading at first occurrence
(f): Service meter reach at last occurrence
q
[F1]: Move to next page (screen) (if displayed)
q
[F2]: Move to previous page (screen) (if
displayed)
q
q
q
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
table.
4.

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.
25
SEN00681-04

a
2)
3)
26
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].
q
[F2]: Delete all items
q
q
q
[F5]: Return to "Abnormality Record"
screen
q
[F6]: Delete selected item
a To delete items one by one: Select
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 failure code, the deleting operation is
accepted but the information is not
deleted.
4)
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).
If the screen to notify completion of deletion is displayed and then the "Electrical
Sys. Error Reset" (delete mode) screen is
displayed, the deletion of the "Abnormality
Record" is completed.
a After a while, the screen returns to
the "Electrical Sys. Error Reset"
screen.
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
D155AX-6
SEN00681-04
Failure codes table

Action
code
Failure
code
Component
in charge
Category of history
E03
1500L0
Transmission clutch: Abnormal
P/T
Electrical system
E03
15SAL1
Forward clutch: Fill high
P/T
Electrical system
E03
15SALH
Forward clutch: Fill Low
P/T
Electrical system
E03
15SBL1
Reverse clutch: Fill high
P/T
Electrical system
E03
15SBLH
Reverse clutch: Fill Low
P/T
Electrical system
E03
15SEL1
Speed 1st clutch: Fill high
P/T
Electrical system
E03
15SELH
Speed 1st clutch: Fill Low
P/T
Electrical system
E03
15SFL1
Speed 2nd clutch: Fill high
P/T
Electrical system
E03
15SFLH
Speed 2nd clutch: Fill Low
P/T
Electrical system
E03
15SGL1
Speed 3rd clutch: Fill high
P/T
Electrical system
E03
15SGLH
Speed 3rd clutch: Fill Low
P/T
Electrical system
E02
15SJL1
L/U : Fill high
P/T
Electrical system
E02
15SJLH
L/U : Fill low
P/T
Electrical system
E04
2301L1
Right brake: Fill high
P/T
Electrical system
E04
2301LH
Right brake: Fill low
P/T
Electrical system
E04
2302L1
Left brake: Fill high
P/T
Electrical system
E04
2302LH
Left brake: Fill low
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
ENG
Mechanical system
B@BCNS
Eng Water Overheat
ENG
Mechanical system
B@BCZK
Eng Water Level Low
MON
Mechanical system
B@CENS
T/C Oil Overheat
P/T
Mechanical system
B@HANS
Hyd Oil Overheat
MON
Mechanical system
E04
CA111
EMC Critical Internal Failure
ENG
Electrical system
E04
CA115
Eng Ne and Bkup Speed Sens Error
ENG
Electrical system
E03
CA122
Chg Air Press Sensor High Error
ENG
Electrical system
E03
CA123
Chg Air Press Sensor Low Error
ENG
Electrical system
E03
CA131
Throttle Sensor High Error
ENG
Electrical system
E03
CA132
Throttle Sensor Low Error
ENG
Electrical system
E02
CA135
Eng Oil Press Sensor High Error
ENG
Electrical system
E02
CA141
Eng Oil Press Sensor Low Error
ENG
Electrical system
E02
CA144
Coolant Temp Sens High Error
ENG
Electrical system
E02
CA145
Coolant Temp Sens Low Error
ENG
Electrical system
E01
CA153
Chg Air Temp Sensor High Error
ENG
Electrical system
D155AX-6
Trouble (Displayed on screen)
27
SEN00681-04
Action
code
Failure
code
E01
CA154
E03
Component
in charge
Category of history
Chg Air Temp Sensor Low Error
ENG
Electrical system
CA187
Sens Supply 2 Volt Low Error
ENG
Electrical system
E03
CA221
Ambient Press Sens High Error
ENG
Electrical system
E03
CA222
Ambient Press Sens Low Error
ENG
Electrical system
E03
CA227
Sens Supply 2 Volt High Error
ENG
Electrical system
E03
CA234
Eng Overspeed
ENG
Electrical system
E03
CA238
Ne Speed Sens Supply Volt Error
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
ENG
Electrical system
E03
CA272
PCV1 Open Error
ENG
Electrical system
E03
CA273
PCV2 Short Error
ENG
Electrical system
E03
CA274
PCV2 Open Error
ENG
Electrical system
E03
CA322
Inj #1 (L#1) Open/Short Error
ENG
Electrical system
E03
CA323
ENG
Electrical system
E03
CA324
ENG
Electrical system
E03
CA325
ENG
Electrical system
E03
CA331
ENG
Electrical system
E03
CA332
ENG
Electrical system
E04
CA342
Calibration Code Incompatibility
ENG
Electrical system
E03
CA351
Injectors Drive Circuit Error
ENG
Electrical system
E03
CA352
ENG
Electrical system
E03
CA386
ENG
Electrical system
E04
CA441
Battery Voltage Low Error
ENG
Electrical system
E04
CA442
Battery Voltage High Error
ENG
Electrical system
E03
CA449
Rail Press Very High Error
ENG
Electrical system
E03
CA451
Rail Press Sensor High Error
ENG
Electrical system
E03
CA452
Rail Press Sensor Low Error
ENG
Electrical system
E02
CA553
Rail Press High Error
ENG
Electrical system
E03
CA554
Rail Press Sensor In Range Error
ENG
Electrical system
E02
CA559
Rail Press Low Error
ENG
Electrical system
E03
CA689
Eng Ne Speed Sensor Error
ENG
Electrical system
E03
CA731
Eng Bkup Speed Sens Phase Error
ENG
Electrical system
E04
CA757
All Continuous Data Lost Error
ENG
Electrical system
E03
CA778
Eng Bkup Speed Sensor Error
ENG
Electrical system
E02
CA1228
EGR Valve Servo Error 1
ENG
Electrical system
E03
CA1625
ENG
Electrical system
28
D155AX-6
Action
code
Failure
code
E03
CA1626
E03
SEN00681-04
Component
in charge
Category of history
BP Valve Sol Current High Error
ENG
Electrical system
CA1627
BP Valve Sol Current Low Error
ENG
Electrical system
E02
CA1628
Bypass Valve Servo Error 1
ENG
Electrical system
E03
CA1629
ENG
Electrical system
E03
CA1631
BP Valve Pos Sens High Error
ENG
Electrical system
E03
CA1632
BP Valve Pos Sens Low Error
ENG
Electrical system
E03
CA1633
KOMNET Datalink Timeout Error
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
ENG
Electrical system
E03
CA2186
Throt Sens Sup Volt Low Error
ENG
Electrical system
E03
CA2249
Rail Press Very Low Error
ENG
Electrical system
E03
CA2271
EGR Valve Pos Sens High Error
ENG
Electrical system
E03
C2272
EGR Valve Pos Sens Low Error
ENG
Electrical system
E03
CA2351
EGR Valve Sol Current High Error
ENG
Electrical system
E03
CA2352
EGR Valve Sol Current Low Error
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
P/T
Electrical system
E02
D130KB
Neutral relay: Short circuit
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
P/T
Electrical system
E03
DAFRKR
CAN Disconnection
MON
Electrical system
E03
DB2RKR
CAN Disconnection
ENG
Electrical system
E04
DB90KK
WE controller: Source voltage reduction
W/E
Electrical system
E03
DB90KR
PT controller: Can communication lost
P/T
Electrical system
E01
DB90KT
WE controller: Abnormality in controller
W/E
Electrical system
E03
DB95KK
W/E
Electrical system
E03
DB97KK
W/E
Electrical system
E04
DB99KQ
WE controller: Type select signal
W/E
Electrical system
E03
DB9RKR
WE controller: Can communication lost
W/E
Electrical system
E03
DBE0KK
PT controller: Source voltage reduction
P/T
Electrical system
D155AX-6
29
SEN00681-04
Action
code
Failure
code
E01
DBE0KT
E02
Component
in charge
Category of history
PT controller: Abnormality in controller
P/T
Electrical system
DBE6KK
P/T
Electrical system
E02
DBE7KK
P/T
Electrical system
E04
DBE9KQ
PT controller: Type select signal
P/T
Electrical system
E02
DD12KA
Shift up Sw: Disconnection
P/T
Electrical system
E02
D12KB
Shift up Sw: Short circuit
P/T
Electrical system
E02
D13KA
Shift down Sw: Disconnection
P/T
Electrical system
E02
DD13KB
Shift down Sw: Short circuit
P/T
Electrical system
E03
DD14KA
Parking lever Sw: Disconnection
P/T
Electrical system
E03
DD14KB
Parking lever Sw: Short circuit
P/T
Electrical system
E02
DDDDKA
Back up brake Sw: Disconnection
P/T
Electrical system
E02
DDDDKB
Back up brake Sw: Short circuit
P/T
Electrical system
E02
DDDDKX
Back up brake Sw: Signal mismatch
P/T
Electrical system
E02
DDN7KA
WEQ Knob Sw(down): Disconnection
W/E
Electrical system
E02
DDN7KB
WEQ Knob Sw(down): Short circuit
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
W/E
Electrical system
E03
DDNLKB
Weq lock Sw: Short circuit
W/E
Electrical system
E02
DDTSL1
S/C: Fill high
P/T
Electrical system
E02
DDTSLH
S/C: Fill low
W/E
Electrical system
E03
DFA4KX
BL lever 1: Out of normal range
W/E
Electrical system
E03
DFA4KZ
BL lever: Disconnection or short circuit
W/E
Electrical system
E03
DFA4L8
BL lever: Signal mismatch
W/E
Electrical system
E03
DFA5KA
BL lever 1: Disconnection
W/E
Electrical system
E03
DFA5KB
BL lever 1: Short circuit
W/E
Electrical system
E03
DFA6KA
W/E
Electrical system
E03
DFA6KB
W/E
Electrical system
E03
DFA7KX
BT lever 1: Out of normal range
W/E
Electrical system
E03
DFA7KZ
BT lever: Disconnection or short circuit
W/E
Electrical system
E03
DFA7L8
BT lever: Signal mismatch
W/E
Electrical system
E03
DFA8KA
BT lever 1: Disconnection
W/E
Electrical system
E03
DFA8KB
BT lever 1: Short circuit
W/E
Electrical system
E03
DFA9KA
W/E
Electrical system
E03
DFA9KB
W/E
Electrical system
E03
DFAAKX
RL lever 1: Out of normal range
W/E
Electrical system
E03
DFAAKZ
RL lever: Disconnection or short circuit
W/E
Electrical system
30
D155AX-6
Action
code
Failure
code
E03
DFAAL8
E03
SEN00681-04
Component
in charge
Category of history
RL lever: Signal mismatch
W/E
Electrical system
DFABKA
RL lever 1: Disconnection
W/E
Electrical system
E03
DFABKB
RL lever 1: Short circuit
W/E
Electrical system
E03
DFACKA
W/E
Electrical system
E03
DFACKB
W/E
Electrical system
E03
DFADKX
RT lever 1: Out of normal range
W/E
Electrical system
E03
DFADKZ
RT lever: Disconnection or short circuit
W/E
Electrical system
E03
DFADL8
RT lever: Signal mismatch
W/E
Electrical system
E03
DFAEKA
RT lever 1: Disconnection
W/E
Electrical system
E03
DFAEKB
RT lever 1: Short circuit
W/E
Electrical system
E03
DFAFKA
RT lever 2: Disconnection
W/E
Electrical system
E03
DFAFKB
RT lever 2: Short circuit
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
P/T
Electrical system
E02
DHT5KB
T/C in-pressure sensor: Short circuit
P/T
Electrical system
E02
DHT7KA
T/C out-pressure sensor: Disconnection
P/T
Electrical system
E02
DHT7KB
T/C out-pressure sensor: Short circuit
P/T
Electrical system
E03
DK10KX
Fuel control Dial: Out of normal range
P/T
Electrical system
E03
DK30KA
ST lever 1: Disconnection
P/T
Electrical system
E03
DK30KB
ST lever 1: Short circuit
P/T
Electrical system
E04
DK30KX
ST lever 1: Out of normal range
P/T
Electrical system
E04
DK30KZ
ST lever: Disconnection or short circuit
P/T
Electrical system
E03
DK30L8
ST lever: Signal mismatch
P/T
Electrical system
E03
DK31KA
P/T
Electrical system
E03
DK31KB
P/T
Electrical system
E03
DK40KA
Brake potentiometer: Disconnection
P/T
Electrical system
E03
DK40KB
Brake potentiometer: Short circuit
P/T
Electrical system
E04
DK55KX
FR lever: Out of normal range
P/T
Electrical system
E04
DK55KZ
FR lever: Disconnection or short circuit
P/T
Electrical system
E03
DK55L8
FR lever: Signal mismatch
P/T
Electrical system
E03
DK56KA
FR lever 1: Disconnection
P/T
Electrical system
E03
DK56KB
FR lever 1: Short circuit
P/T
Electrical system
E03
DK57KA
P/T
Electrical system
E03
DK57KB
P/T
Electrical system
D155AX-6
31
SEN00681-04
Action
code
Failure
code
E03
DKH1KA
E03
Component
in charge
Category of history
Pitch angle sensor: Disconnection
P/T
Electrical system
DKH1KB
Pitch angle sensor: Short circuit
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
E03
DWN1KA
Hss EPC1: Disconnection
P/T
Electrical system
E03
DWN1KB
Hss EPC1: Short circuit
P/T
Electrical system
E03
DWN1KY
P/T
Electrical system
E03
DWN2KA
P/T
Electrical system
E03
DWN2KB
P/T
Electrical system
E03
DWN2KY
P/T
Electrical system
E04
DWN3KA
Ssp solenoid: Disconnection
P/T
Electrical system
E04
DWN3KB
Ssp solenoid: Short circuit
P/T
Electrical system
E04
DWN3KY
SSP solenoid: Short circuit
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
P/T
Electrical system
E02
DXH1KA
Lock-up ECMV: Disconnection
P/T
Electrical system
E02
DXH1KB
Lock-up ECMV: Short circuit
P/T
Electrical system
E03
DXH1KY
P/T
Electrical system
E03
DXH4KA
1st clutch ECMV: Disconnection
P/T
Electrical system
E03
DXH4KB
1st clutch ECMV: Short circuit
P/T
Electrical system
E03
DXH4KY
P/T
Electrical system
E03
DXH5KA
2nd clutch ECMV: Disconnection
P/T
Electrical system
E03
DXH5KB
2nd clutch ECMV: Short circuit
P/T
Electrical system
E03
DXH5KY
P/T
Electrical system
E03
DXH6KA
3rd clutch ECMV: Disconnection
P/T
Electrical system
E03
DXH6KB
3rd clutch ECMV: Short circuit
P/T
Electrical system
E03
DXH6KY
P/T
Electrical system
E03
DXH7KA
R clutch ECMV: Disconnection
P/T
Electrical system
E03
DXH7KB
R clutch ECMV: Short circuit
P/T
Electrical system
E04
DXH7KY
P/T
Electrical system
E03
DXH8KA
F clutch ECMV: Disconnection
P/T
Electrical system
E03
DXH8KB
F clutch ECMV: Short circuit
P/T
Electrical system
32
D155AX-6
Action
code
Failure
code
E04
DXH8KY
E04
SEN00681-04
Component
in charge
Category of history
P/T
Electrical system
DXHBKA
Right brake ECMV: Disconnection
P/T
Electrical system
E04
DXHBKB
Right brake ECMV: Short circuit
P/T
Electrical system
E04
DXHBKY
P/T
Electrical system
E04
DXHCKA
Left brake ECMV: Disconnection
P/T
Electrical system
E04
DXHCKB
Left brake ECMV: Short circuit
P/T
Electrical system
E04
DXHCKY
P/T
Electrical system
E03
DXHRKA
Blade up EPC: Disconnection
W/E
Electrical system
E03
DXHRKB
Blade up EPC: Short circuit
W/E
Electrical system
E03
DXHRKY
W/E
Electrical system
E03
DXHSKA
Blade down EPC: Disconnection
W/E
Electrical system
E03
DXHSKB
Blade down EPC: Short circuit
W/E
Electrical system
E03
DXHSKY
W/E
Electrical system
E03
DXHTKA
Blade left 1 EPC: Disconnection
W/E
Electrical system
E03
DXHTKB
Blade left 1 EPC: Short circuit
W/E
Electrical system
E03
DXHTKY
W/E
Electrical system
E03
DXHUKA
Blade right 1 EPC: Disconnection
W/E
Electrical system
E03
DXHUKB
Blade right 1 EPC: Short circuit
W/E
Electrical system
E03
DXHUKY
W/E
Electrical system
E03
DXHWKA
Ripper up EPC: Disconnection
W/E
Electrical system
E03
DXHWKB
Ripper up EPC: Short circuit
W/E
Electrical system
E03
DXHWKY
W/E
Electrical system
E03
DXHXKA
Ripper down EPC: Disconnection
W/E
Electrical system
E03
DXHXKB
Ripper down EPC: Short circuit
W/E
Electrical system
E03
DXHXKY
W/E
Electrical system
E03
DXHYKA
Ripper Tilt In EPC: Disconnection
W/E
Electrical system
E03
DXHYKB
Ripper Tilt In EPC: Short circuit
W/E
Electrical system
E03
DXHYKY
W/E
Electrical system
E03
DXHZKA
Ripper Tilt Back EPC: Disconnection
W/E
Electrical system
E03
DXHZKB
Ripper Tilt Back EPC: Short circuit
W/E
Electrical system
E03
DXHZKY
W/E
Electrical system
E03
DXJ4KA
WEQ lock Sol.: Disconnection
W/E
Electrical system
E03
DXJ4KB
WEQ lock Sol.: Short circuit
W/E
Electrical system
E03
DXJ8KA
W/E
Electrical system
E03
DXJ8KB
W/E
Electrical system
E03
DXJ8KY
W/E
Electrical system
E03
DXJ9KA
W/E
Electrical system
D155AX-6
33
SEN00681-04
Action
code
Failure
code
E03
DXJ9KB
E03
Component
in charge
Category of history
W/E
Electrical system
DXJ9KY
W/E
Electrical system
E01
DXJAKA
Q-drop EPC: Disconnection
W/E
Electrical system
E01
DXJAKB
Q-drop EPC: Short circuit
W/E
Electrical system
E01
DXJAKY
W/E
Electrical system
E02
DXJBKA
S/C ECMV: Disconnection
P/T
Electrical system
E02
DXJBKB
S/C ECMV: Short circuit
P/T
Electrical system
E02
DXJBKY
P/T
Electrical system
a
a
34
Entry order of items in table

The items are entered in the order of their failure codes (incremental order).
Action code
If the failure code is detected, the action code, failure code, and telephone No. (if regisAttached:
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.
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.
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" .
D155AX-6
"Abnormality Record" (Air conditioner "Abnormality Record"/Heater "Abnormality Record")

To check the air conditioner "Abnormality Record"
or heater "Abnormality Record", perform the following procedures.
a All the following figures show the air conditioner specification.
1.
Selecting menu
Select "02 Abnormality Record" on the Service
menu screen.
2.
Selecting sub menu

After the "Abnormality Record" screen is displayed, select "03 Air-conditioning System" or
"03 Heater Abnormality Record" with the function switches or numeral input switches.
q
q
q
q
[F6].
D155AX-6
SEN00681-04
3.

screen
On the air conditioner "Abnormality Record" or
heater "Abnormality Record" screen, the following information is displayed.
(a): System/Component name
(b): Number of occurrence time
(c): Condition (Normal or abnormal)
q
[F2]: Delete "Abnormality Record"
q
a If [E] is displayed on the left of a condition,
the abnormality is still occurring or resetting of it has not been confirmed.
a If "CAN Status" is displayed in Communication condition, communication cannot
be carried out normally. Accordingly, the
conditions of other items are turned OFF.
4.

While the "Abnormality Record" screen is displayed, press [F2], and the number of occurrence time of fault is deleted. If it is confirmed
at this time that the abnormality has been
reset, the display changes to Normal.
In the heater specification, the display of "Air
conditioner" is replaced with "Heater" and the
items which are not related to the heater are
not displayed.
35
SEN00681-04
Maintenance Record
The machine monitor records the maintenance
information of the filters, oils, etc., which the operator can display and check by the following operations. When maintenance is carried out, if the data
are reset in the operator mode, the number of the
times of maintenance is recorded in this section.
01 Engine Oil Change
1.
07 Check and addition of damper case oil
02 Eng Oil Filter Change

03 Fuel Main Filter Change
41 Fuel Pre Filter Change
04 Hyd Oil Filter Change
06 Corrosion Resistor Change
Selecting menu
Select "03 Maintenance Record" on the "Service Menu" screen.
08 Replacement interval of final drive case oil

10 Replacement of hydraulic oil
19 Replacement of power train oil
20 Replacement of power train oil filter
3.
2.
Selecting maintenance record item

After the "Maintenance Record" screen is displayed, select an item to be checked with the
q
q
q
q
q
numeral input switches to select the item
of that code.
36
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
The following items can be selected in the

maintenance record.
D155AX-6
SEN00681-04
Maintenance Mode Change

The operating condition for maintenance function in
the operation mode can be set and changed with
this menu.
q
Set function effective or ineffective
q
Change set change interval (by items)
q
Initialize all set change intervals
00 Maintenance Mode On/Off
1.
06 Replacement interval of corrosion resistor
Selecting menu
Select "04 Maintenance Mode Change" on the
Service menu screen.
01 Engine Oil Change Int

02 Eng Oil Filter Change Int
03 Fuel Main Filter Change Int
41 Fuel Pre Filter Change Int
04 Hyd Oil Filter Change Int
07 Check and replacement interval of damper case oil
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 Use Default Value
3.
2.
Selecting sub menu

After the "Maintenance Mode On/Off" screen is
displayed, select an item to be monitored with
the function switches or numeral input
switches.
q
q
q
q
q
q
numeral input switches to select the item
of that code and confirm it with [F6].
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
q
q
q
[F5]: Cancel selection and return to Maintenance 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.
The following items can be selected on

the "Maintenance Mode On/Off" screen.
D155AX-6
37
SEN00681-04
4.
Contents of setting of each maintenance item

After selecting each maintenance item, if the
screen is displayed, set the item with the function switches.
q
q
q
q
q
38
Default: Maintenance interval set in machine

monitor (Recommended by manufacturer
and not changeable).
Set: Maintenance interval which can be
set freely. Maintenance functions in operator mode operate on basis of this set time
(which is increased or decreased by 50
hours).
ON: Maintenance function of this item is
set effective in operator mode.
OFF: Maintenance function of this item is
set ineffective in operator mode.
[F3]: Select Reduce set value (Upper) or
OFF (Lower).
[F4]: Select Increase set value (Upper) or
ON (Lower).
[F5]: Cancel setting before confirmation
and return to Maintenance Mode
Change screen.
[F6]: Confirm setting of upper or lower line.
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 Use Default Value", if the
screen is displayed, set with the function
switches.
q
q
If this operation is executed, the set values of all the maintenance items are set to
default values.
[F5]: Return to Maintenance Mode Change
screen
[F6]: Execute default setting
A while after [F6] is pressed, the default
setting completion screen is displayed.
Then, if the "Maintenance Mode Change"
screen is displayed, default setting is completed.
The default setting of the corrosion resistor is "OFF".
D155AX-6
Phone Number Entry

The phone No. displayed when the action code/failure code is displayed in the operator mode can be
input and changed according to the following procedure.
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 "Service Menu" screen.
2.
Registering and changing telephone No.

After the "Phone Number Entry" screen is displayed, 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
a
SEN00681-04
a
If [F6] is pressed without inputting a digit,

there is not information of phone No.
Accordingly, no phone No. is displayed in
the operator mode.
Up to 14 digits can be input from the left.

Input nothing in the surplus positions.
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
SEN00681-04
Default setting (Key-on Mode)

Check or change various settings related to the
machine monitor and machine by default setting.
The function of Key-on Mode is used to set the initial mode displayed on the machine monitor when
the starting switch is turned ON.
1.
Selecting menu
Select "06 Default" on the "Service Menu"
screen.
2.
Selecting sub menu

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
3.
Selecting mode
After the "Key-on Mode" screen is displayed,
select the mode to be set with the function
switches.
q
Mode at previous key-OFF: Final mode in
previous operation is displayed when
starting switch is turned ON
q
Default Value (ALL OFF): Default setting
of all mode items (Power: E, other 3 items:
OFF) is displayed when starting switch is
turned ON
q
q
q
[F5]: Cancel selection and return to
default screen
q
[F6]: Confirm selection and return to
default screen
a When the machine is delivered, Default
Value (All OFF).
D155AX-6
SEN00681-04
Default setting (Setting of unit)

The unit selecting function is used to select the unit
of the data displayed for monitoring, etc.
1.
Selecting menu
screen.
2.
Selecting sub menu

"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
SEN00681-04
Default setting (Setting of maintenance password)

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.

screen
Selecting menu
screen.
2.
Selecting sub menu

"03 Maintenance Password" with the function
switches or numeral input switches.
Service menu screen.
3.
Selecting Enable/Disable
After the "Maintenance Password" screen is
displayed, select the setting with the function
switches.
q
Disable: Password screen is not displayed
q
Enable: Password screen is displayed
q
q
q
[F5]: Cancel selection and return to Initialization screen
42
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.
5.
Changing maintenance password

The password can be changed by operating
the switches specially in the operator mode.
a See "Function of changing maintenance
password" in the operator mode.
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.
D155AX-6
Default setting (Setting of camera)

The camera setting function is used to set default
setting and removal of a camera.
1.
SEN00681-04
q
q
q
q
Selecting menu
screen.
a
a
a
a
2.
Selecting sub menu

"04 Camera" with the function switches or
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 camera is displayed in original position (as in
mirror, used as back monitor)
q
Reverse image: Image of connected camera is displayed in reverse position (as
seen directly, used as front or side monitor)
D155AX-6
[F3]: Move to left item

[F4]: Move to right item
[F5]: Cancel setting before confirmation
and return to Default screen
[F6]: Confirm selection in each line
After "Camera" screen is displayed, camera 1 can be always set. When 2 or more
cameras are connected, if camera 1 is set,
the screen changes to setting of camera 2
automatically.
After confirming the setting of each line
with [F6], return to the Default screen with
[F5], and the setting is effective.
If a camera is connected but not set normally 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.
If 2 or more cameras are connected, be
sure to set the use of them from camera 1
in order.
The function of displaying 2 images simultaneously is effective when use of camera
1 and camera 2 is set.
When a camera is installed, check that the
displayed image is not inverted horizontally in the operator mode.
43
SEN00681-04
Default setting (Setting of ECO display)

machine monitor and machine by initialization.
The ECO display setting function is used to set the
display of the ECO gauge.
1.
If ECO display is turned ON, ECO is displayed when the screen changes to the
ordinary screen.
Display of ECO gauge (a)
Selecting menu
screen.
2.
Selecting sub menu

"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
screen
44
D155AX-6
SEN00681-04
Adjustment
The operator can adjust various items related to the
machine with the machine monitor.
When using an adjustment item, select it according
1.
Selecting menu
Select "07 Adjustment" on the "Service Menu"
screen.
3.
2.
Selecting adjustment item

After the "Adjustment" screen is displayed,
input the 4-digit adjustment ID of the adjustment item to be used with the numeral input
switches.
q
[F5]: Cancel adjustment and return to Service menu screen
q
[F6]: Confirm input adjustment ID and go
to Adjustment screen
a For the adjustment ID's and their adjustment items, see the adjustment items
table.
Displaying adjustment screen

After the "Adjustment" screen for the adjustment 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.
a For the method of operating each adjustment item, see the explanation of its
adjustment ID.
If the input adjustment ID is incorrect, the

message of "No ready Adjustment" is displayed 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
SEN00681-04
Adjustment items table

Adjustment
ID
46
Adjustment item
Remarks
0002
Power train controller initialization
0004
Work equipment specification setting
0005
Brake pedal potentiometer initial correction
0007
Engine decelerator cutting
0009
Pitch angle sensor initial correction
0010
Fan 70% mode
0031
Work equipment controller initialization
0530
Stall mode
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
6002
6003
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

Fine adjustment with blade fine control mode ON
Resetting auto-decelerating function
Recommended mode of torque converter stall
8022
Blade raising current correction (Fine control mode)
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
9996
Sudden stop prevent valve operation mode
9997
High idle cut mode
9998
Max. gear speed setting mode
Control brake: Brake ECMV (Right and left)
D155AX-6
Adjustment ID: 0002 (Power train controller initialization)
SEN00681-04
Adjustment ID: 0004 (Work equipment specification setting)
This adjustment code is used to initialize the

specification code recognized by the power
train controller and the set values of the memory in the controller.
After the power train controller is replaced, be
sure to carry out this adjustment once.
Functions of function switches

[F3]: Unused
[F4]: Unused
[F5]: Return to adjustment item selecting
screen (ID inputting screen)
[F6]: Save setting

[F3]: Increase specification value [CODE]
[F4]: Decrease specification value [CODE]
[F6]: Save setting
Operating method:
1) Press [F6] and check that the alarm
buzzer sounds.
2) Check that the displayed specification
code [CODE] has changed from [5x5] to
[555].
a If specification code [555] is not displayed,
the controller wiring harness or the controller unit may be defective.
a Even if this adjustment code is turned off,
the setting is effective.
Operating method:
1) Press [F3] or [F4] to select the specification value [CODE] of the work equipment
concerned.
This adjustment code is used to make the work

equipment controller recognize the type of the
work equipment.
After the work equipment controller is replaced, be sure to carry out this adjustment
once.
CODE
2)
k
D155AX-6
Type of work equipment
Dual tiltdozer
Single tiltdozer
Mechanical dozer
Press [F6] and check that the alarm buzzer sounds.

If the specification of the work equipment 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.
Even if this adjustment code is turned off,
47
SEN00681-04
Adjustment ID: 0005 (Brake pedal potentiometer

initial correction)
48
This adjustment code is used to make the

power train controller recognize the zero point
of the brake pedal potentiometer.
After the power train controller or brake pedal
potentiometer is replaced or the brake pedal
linkage is disconnected and connected, be
sure to carry out this adjustment once.
[F3]: Unused
[F4]: Unused
[F6]: Save corrected value
Operating method:
1) Check that the brake pedal is in the neutral position (it is not pressed at all) and
keep it in that position.
2) Press [F6] and check that the alarm buzzer sounds.
a Even if the adjustment is carried out, the
displayed value does not change.
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.
Adjustment ID: 0007

(Engine decelerator cutting)
a
a
This adjustment code is used to stop the autodeceleration function of the engine and check
the high idle speed of the engine unit.
The engine can be driven and tested with the
auto-deceleration reset only while this adjustment code is selected.
Use this adjustment code for testing, adjusting,
or troubleshooting when necessary.

[F3]: Unused
[F4]: Unused
[F6]: Unused
Operating method:
When this adjustment code is displayed, its
function is effective and the auto-deceleration
function is stopped.
a After this adjustment code is turned OFF,
its function is ineffective.
D155AX-6
Adjustment ID: 0009 (Pitch angle sensor initial correction)

power train controller recognize the zero point
of the pitch angle sensor and to correct the
installation error.
After the power train controller is replaced or
the pitch angle sensor is removed and installed
or replaced, be sure to carry out this adjustment once.
[F3]: Unused
[F4]: Unused
[F6]: Save corrected value
Operating method:
1) Check that the machine is level.
a If adjustment is carried out, displayed item
[BODY PITCH ANGLE] changes to [0.0 ]
(The other displayed items do not
change).
D155AX-6
SEN00681-04
Adjustment ID: 0010

(Fan 70% mode)
This adjustment code is used to set the cooling

fan speed to about 70% forcibly.

[F3]: Increase adjustment value [FAN 70%
SPEED MODE]
[F4]: Decrease adjustment value [FAN 70%
SPEED MODE]
[F6]: Unused
Operating method:
function is effective and the cooling fan speed
is controlled to about 70% of the maximum
speed.
49
SEN00681-04
Adjustment ID: 0031 (Work equipment controller

initialization)
This adjustment code is used to initialize the

specification code recognized by the work
equipment controller and the set values of the
memory in the controller.
After the work equipment controller is replaced, be sure to carry out this adjustment
once.
[F3]: Unused
[F4]: Unused
[F6]: Save setting
Operating method:
2) Check that the displayed specification
code [CODE] has changed from [6x6] to
[666].
a If specification code [666] is not displayed,
the controller wiring harness or the controller unit may be defective.
Adjustment ID: 0530

(Stall mode)
This adjustment code is used to set the fan

speed in the 100% mode automatically and
make it possible to set the preset (gear speed
at start) to [F3-R3] to stall the torque converter.
a The preset (gear speed at start) can be
set to [F3-R3] only while this adjustment
code is selected.
a Use this adjustment code for testing,
adjusting, or troubleshooting when necessary.

[F3]: Unused
[F4]: Unused
[F6]: Unused
Mode setting information within screen

[P-AUTO SFT MODE]:
Automatic gearshift in P mode
[E-AUTO SFT MODE]:
Automatic gearshift in E mode
[P-MANUAL SFT MODE]:
Manual gearshift in P mode
[E-MANUAL SFT MODE]:
Manual gearshift in E mode
Operating method:
function is effective and the preset (gear speed
at start) is set to [F3-R3].
k
50
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 Measuring engine speed).
After this adjustment code is turned OFF,
D155AX-6
Adjustment ID: 0910 (Load record check mode)
This adjustment code is used to check the load

on the machine, odometer, and reverse odometer.
[F3]: Unused
[F4]: Unused
[F6]: Unused
Mode setting information within screen
[1000 rpm SMR]: Time displayed by service
meter in which engine speed
was above 1,000 rpm
[ODO METER FORWARD]:
Total forward travel distance
[ODO METER REVERSE]:
Total reverse travel distance
Operating method:
function is effective and the load on the
machine, odometer, and reverse odometer are
displayed simultaneously.
a The data cannot be reset.
D155AX-6
SEN00681-04
Adjustment ID: 1005 (Fan 100% mode)
This adjustment code is used to set the cooling

fan speed to about 100% forcibly. It is also
used to set the adjustment value of the maximum speed. See "Testing and adjusting, Part 1
Measuring fan speed"

[F3]: Increase adjustment value [FAN 100%
SPEED MODE]
[F4]: Decrease adjustment value [FAN 100%
SPEED MODE]
[F6]: Save adjustment value
Operating method:
a When this adjustment code is displayed,
its function is effective and the cooling fan
speed is controlled to about 100% of the
maximum speed.
1) Increase or decrease the adjustment
value by pressing [F3] or [F4].
2) When confirming the adjustment value,
press [F6] and check that the alarm
buzzer sounds.
its function is ineffective but the set adjustment value is effective.
51
SEN00681-04
Adjustment ID: 1012 (Steering lever neutral position adjustment)
Adjustment ID: 1013 (Steering lever leftmost position adjustment)

power train controller recognize the neutral
position of the steering potentiometer of the
PCCS lever.
After the power train controller or PCCS lever
is replaced, be sure to carry out this adjustment once.

[F3]: Unused
[F4]: Unused

[F3]: Unused
[F4]: Unused
Operating method:
1) Check that the PCCS lever is in the neutral position of the steering direction and
buzzer sounds.
the adjustment is effective.
controller recognize the neutral position of
the potentiometer. It is not used to adjust
the steering force.
Operating method:
1) Operate the PCCS lever to the left stroke
end of the steering direction and keep it in
that position.
buzzer sounds.
controller recognize the leftmost position
of the potentiometer. It is not used to
adjust the steering force.
52

power train controller recognize the leftmost
PCCS lever.
D155AX-6
Adjustment ID: 1014 (Steering lever rightmost position adjustment)

power train controller recognize the rightmost
PCCS lever.
[F3]: Unused
[F4]: Unused
Operating method:
1) Operate the PCCS lever to the right stroke
end of the steering direction and keep it in
that position.
buzzer sounds.
controller recognize the rightmost position
adjust the steering force.
D155AX-6
SEN00681-04
Adjustment ID: 1015 (Right brake oil pressure offset)
This adjustment code is used to adjust the right

brake oil pressure manually.
Use this adjustment code for work when necessary.

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

The offset oil pressure is displayed and the
adjustment value is increased or decreased by
0.1 kg/cm (The value displayed on the screen
is multiplied by 100).
a The default adjustment value is 0 kg/cm.
a The adjustment range is -3 3 kg/cm.
Operating method:
1) Increase or decrease the adjustment value by pressing [F3] or [F4].
a If the oil pressure has been adjusted, it is
displayed. It can be adjusted again within
the adjustment range, however.
a It is not necessary to operate the brake
during adjustment. After finishing adjustment, however, operate the brake and
check that there is not a problem in the
actual brake performance.
53
SEN00681-04
Adjustment ID: 1016

(Left brake oil pressure offset)
54
This adjustment code is used to adjust the left

brake oil pressure manually.
The offset oil pressure is displayed and the
adjustment value is increased or decreased by
0.1 kg/cm (The value displayed on the screen
is multiplied by 100).
a The default adjustment value is 0 kg/cm.
a The adjustment range is -3 3 kg/cm.
Operating method
a It is not necessary to operate the brake
during adjustment. After finishing adjustment, 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.
Adjustment ID: 2021 (Power train controller voltage

check mode)
This adjustment code is used to check the constant power supply voltage and switch power
supply voltage applied to the power train controller.

[F3]: Unused
[F4]: Unused
[F6]: Unused

[PT CONTROLLER UNSWITCH POWER]:
Constant power supply voltage
[PT CONTROLLER ACC POWER]:
Switch power supply voltage
Operating method:
function is effective and the constant power
supply voltage and switch power supply voltage are displayed simultaneously.
D155AX-6
Adjustment ID: 2022 (Work equipment controller

voltage check mode)
SEN00681-04
Adjustment ID: 2222 (HSS min. current setting

mode)
This adjustment code is used to check the constant power supply voltage and switch power
supply voltage applied to the work equipment
controller.

[F3]: Unused
[F4]: Unused
[F6]: Unused

[F3]: Unused
[F4]: Unused

[WE CONTROLLER UNSWITCH POWER]:
Constant power supply voltage
[WE CONTROLLER ACC POWER]:
Switch power supply voltage
Operating method:
function is effective and the constant power
supply voltage and switch power supply voltage are displayed simultaneously.
Operating method
1) Set the parking brake lever in the free
position.
2) Tilt the PCCS lever to a right or left position at which the current to be set is indicated and hold it at that position.
q
If the lever is tilted to the left, the current becomes negative.
q
If the lever is tilted to the right, the
current becomes positive.
a The current (mA) varies in the range from
-350 (left end) to 350 (right end).
a As the set current is increased in the positive or negative direction, the turning
radius to start steering is reduced more
(the machine is steered more quickly).
a It is not necessary to steer the machine
during adjustment. After finishing adjustment, however, steer the machine and
actual steering feel.
a The following figure shows an example of
reducing the set current for the left steering to increase the turning radius.
D155AX-6
This adjustment code is used to adjust the

turning radius to start steering the machine
when the steering feel is different by the steering direction.
55
SEN00681-04
Adjustment ID: 6001 (R1 reverse slow set speed)
Even if this adjustment code is turned off, the

adjustment is effective.
56

engine speed applied to travel at gear speed
R1 with the reverse slow mode ON.


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 multiplied by 1/10).
a The default adjustment value is 300 rpm
(Displayed value: 30).
(Default setting: 2,050 300 = 1,850 rpm)
Operating method
a If the engine speed has been adjusted, it
is displayed. It can be adjusted again
within the adjustment range, however.
a It is not necessary to drive the machine
during adjustment. After finishing adjustment, however, drive the machine at R1
with the reverse slow mode ON and check
that there is not a problem in the actual
travel speed.
D155AX-6
SEN00681-04





Operating method
buzzer sounds.
travel speed.
Operating method
travel speed.
D155AX-6

57
SEN00681-04
Adjustment ID: 7842 (Transmission clutch IP automatic initial correction)
Adjustment ID: 7843 (Transmission clutch IP manual initial correction)

power train controller recognize the mechanical condition of the transmission.
After the power train controller or transmission

[F3]: Unused
[F4]: Unused
Conditions for correction work

1) [ENGINE SPEED]: 1,700 1,950 rpm
2) [T/C TEMPERATURE]: 65 85 C
3) Parking brake lever: LOCK position
a When using this adjustment code, keep
the above cond itions (In pa rticular,
increase the power train oil temperature
sufficiently before starting adjustment).

a If [F2] is pressed while [F1] is pressed, all
the correction values are set to 0.
Functions of shift-up and shift-down switches

You can select a clutch to be corrected manually with the shift-up and shift-down switches.
Conditions for correction work

Same as the conditions for IP automatic correction (Adjustment ID: 7842).
Operating method:
1) Start the engine and keep its speed in the
specified range of condition with the fuel
control dial.
2) Select a clutch to be corrected manually
with the shift-up or shift-down switches.
buzzer sounds.
a The machine does not move during the
correction work.
58
Operating method:
1) Start the engine and keep its speed in the
specified range of condition with the fuel
control dial.
2) Press [F6] and start the correction work
and check that [1ST CLUTCH] is displayed newly on the screen.
3) If [END OF TEACHING] is displayed on
the screen, press [F6]. If the alarm buzzer
sounds at this time, correction work is
completed.
a The machine does not move during the
correction work.
This adjustment code is used to carry out correction manually when the correction is not
carried out normally by the operation of IP
automatic correction (Adjustment ID: 7842).
Use this adjustment code after the IP correction work, if necessary.
D155AX-6
Adjustment ID: 7845 (Transmission clutch IP learning display)
SEN00681-04
Adjustment ID: 8000 (Blade lift lever neutral position adjustment)
This adjustment code is used to check the

information of correction made by the operation of IP automatic correction (Adjustment ID:
7842) or IP manual correction (Adjustment ID:
7843).

[F3]: Change display
[F4]: Change display
[F6]: Unused

[F3]: Unused
[F4]: Unused
Operating method
function is effective and the correction information is displayed.
Operating method
1) Check that the blade control lever is in the
neutral position of the lifting direction and
buzzer sounds.
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

equipment controller recognize the neutral
position of the lift potentiometer of the blade
control lever.
After the work equipment controller or blade
control lever is replaced, be sure to carry out
this adjustment once.
59
SEN00681-04
Adjustment ID: 8001 (Blade lift lever max. raising

position adjustment)
Adjustment ID: 8002 (Blade lift lever max. lowering


equipment controller recognize the maximum
raising position of the lift potentiometer of the
blade control lever.

[F3]: Unused
[F4]: Unused

[F3]: Unused
[F4]: Unused
Operating method
1) Operate the blade control lever to the raising stroke end of the lifting direction and
buzzer sounds.
controller recognize the maximum raising
position of the potentiometer. It is not
used to adjust the sensitivity of the blade
control lever (For adjustment of the sensitivity of the blade control lever in the lifting
direction, carry out adjustment codes
8020 8023).
Operating method
1) Operate the blade control lever to the lowering stroke end of the lifting direction and
buzzer sounds.
controller recognize the maximum lowering position of the potentiometer. It is not
used to adjust the sensitivity of the blade
control lever (For adjustment of the sensitivity of the blade control lever in the lifting
direction, carry out adjustment codes
8020 8023).
60

lowering position of the lift potentiometer of the
blade control lever.
D155AX-6
Adjustment ID: 8003 (Blade tilt lever neutral position adjustment)
SEN00681-04
Adjustment ID: 8004 (Blade tilt lever rightmost


position of the tilt potentiometer of the blade
control lever.

[F3]: Unused
[F4]: Unused

[F3]: Unused
[F4]: Unused
Operating method
1) Check that the blade control lever is in the
neutral position of the tilting direction and
buzzer sounds.
the sensitivity of the blade control lever
(For adjustment of the sensitivity of the
blade control lever in the tilting direction,
carry out adjustment codes 8024 and
8025).
Operating method
1) Operate the blade control lever to the right
stroke end of the tilting direction and keep
it in that position.
buzzer sounds.
controller recognize the rightmost position
adjust the sensitivity of the blade control
lever (For adjustment of the sensitivity of
the blade control lever in the tilting direction, carry out adjustment codes 8024 and
8025).
D155AX-6

equipment controller recognize the rightmost
control lever.
61
SEN00681-04
Adjustment ID: 8005 (Blade tilt lever leftmost position adjustment)
Adjustment ID: 8006 (Ripper lift lever neutral position adjustment)

equipment controller recognize the leftmost
control lever.

[F3]: Unused
[F4]: Unused

[F3]: Unused
[F4]: Unused
Operating method
1) Operate the blade control lever to the left
buzzer sounds.
controller recognize the leftmost position
adjust the sensitivity of the blade control
lever (For adjustment of the sensitivity of
the blade control lever in the tilting direction, carry out adjustment codes 8024 and
8025).
Operating method
1) Check that the ripper control lever is in the
neutral position of the lifting direction and
buzzer sounds.
the sensitivity of the ripper control lever.
62

position of the lift potentiometer of the ripper
control lever.
After the work equipment controller or ripper
D155AX-6
Adjustment ID: 8007 (Ripper lift lever max. raising

SEN00681-04
Adjustment ID: 8008 (Ripper lift lever max. lowering position adjustment)

raising position of the lift potentiometer of the
ripper control lever.

[F3]: Unused
[F4]: Unused

[F3]: Unused
[F4]: Unused
Operating method
1) Operate the ripper control lever to the raising stroke end of the lifting direction and
buzzer sounds.
controller recognize the maximum raising
used to adjust the sensitivity of the ripper
control lever.
Operating method
1) Operate the ripper control lever to the lowering stroke end of the lifting direction and
buzzer sounds.
controller recognize the maximum lowering position of the potentiometer. It is not
control lever.
D155AX-6

lowering position of the lift potentiometer of the
63
SEN00681-04
Adjustment ID: 8009 (Ripper tilt lever neutral position adjustment)
Adjustment ID: 8010 (Ripper tilt lever max. IN position adjustment)

position of the tilt potentiometer of the ripper
control lever.

[F3]: Unused
[F4]: Unused

[F3]: Unused
[F4]: Unused
Operating method
1) Check that the ripper control lever is in the
neutral position of the tilting direction and
buzzer sounds.
the sensitivity of the ripper control lever.
Operating method
1) Operate the ripper control lever to the IN
buzzer sounds.
controller recognize the maximum IN position of the potentiometer. It is not used to
adjust the sensitivity of the ripper control
lever.
64

IN position of the tilt potentiometer of the ripper
control lever.
D155AX-6
Adjustment ID: 8011 (Ripper tilt lever max. BACK


BACK position of the tilt potentiometer of the

[F3]: Unused
[F4]: Unused
Operating method
1) Operate the ripper control lever to the
BACK stroke end of the tilting direction
and keep it in that position.
buzzer sounds.
controller recognize the maximum BACK
control lever.
D155AX-6
SEN00681-04
Adjustment ID: 8020 (Blade raising current correction)
This adjustment code is used to adjust the sensitivity of start of blade when the blade control
lever is moved in the raising position with the
blade fine mode OFF.

[F3]: Increase adjustment value [Current offset]
[F4]: Decrease adjustment value [Current offset]
Operating method
is displayed. It can be adjusted repeatedly, however.
a It is not necessary to move the blade during adjustment. After finishing adjustment, however, raise the blade and check
operation feel (Check with the blade fine
control mode OFF).
65
SEN00681-04
Adjustment ID: 8021 (Blade lowering current correction)
Adjustment ID: 8022 (Blade raising current correction (Fine control mode))
lever is moved in the lowering position with the
blade fine mode OFF.


Operating method
a It is not necessary to move the blade during adjustment. After finishing adjustment, however, lower the blade and check
control mode OFF).
Operating method
a It is not necessary to move the blade during adjustment. After finishing adjustment, however, raise the blade and check
control mode ON).
66
lever is moved in the raising position with the
blade fine mode ON.
D155AX-6
Adjustment ID: 8023 (Blade lowering current correction (Fine control mode))
lever is moved in the lowering position with the
blade fine mode ON.

Operating method
a It is not necessary to move the blade during adjustment. After finishing adjustment, however, lower the blade and check
control mode ON).
D155AX-6
SEN00681-04
Adjustment ID: 8024 (Blade tilting left current correction)
lever is moved in the tilting left position.

Operating method
a It is not necessary to move the blade during adjustment. After finishing adjustment, however, tilt the blade to the left and
actual operation feel.
67
SEN00681-04
Adjustment ID: 8025 (Blade tilting right current correction)
68
lever is moved in the tilting right position.
Operating method
a It is not necessary to move the blade during adjustment. After finishing adjustment, however, tilt the blade to the right
and check that there is not a problem in
the actual operation feel.
Adjustment ID: 9995

(Control brake release mode)
This adjustment code is used to release the

control brake (right and left brake ECMV) to
check the operation of the backup brake
(brake pedal solenoid valve).

[F3]: Unused
[F4]: Unused
[F6]: Unused
Operating method
function is effective and the control brake (right
and left brake ECMV) is kept released.
D155AX-6
Adjustment ID: 9996 (Sudden stop prevent valve

operation mode)
This adjustment code is used to stop the sudden stop prevent solenoid valve and right and
left brake ECMV to check the operation of the
sudden stop prevent valve.

[F3]: Unused
[F4]: Unused
[F6]: Unused
Operating method
function is effective and the sudden stop prevent solenoid valve and right and left brake
ECMV are kept stopped.
D155AX-6
SEN00681-04
Adjustment ID: 9997

(High idle cut mode)
This adjustment code is used to limit the high

idle speed.

[F3]: Increase adjustment value [HIGH IDLE
RPM SET MODE]
[F4]: Decrease adjustment value [HIGH IDLE
RPM SET MODE]
Operating method
a When resetting the limitation of the high
idle speed, set the adjustment value to the
original high idle speed (2,050 rpm).
69
SEN00681-04
Adjustment ID: 9998 (Max. gear speed setting mode)
q
q
This adjustment code is used to limit the maximum transmission gear speed.
The limited gear speed is applied in both automatic gearshift mode and manual gearshift
mode.

[F3]: Increase adjustment value [MAX SHIFT]
[F4]: Decrease adjustment value [MAX SHIFT]
Operating method
a When resetting the limitation of the maximum gear speed, set the adjustment
value to the maximum gear speed (3RD).
70
D155AX-6
SEN00681-04
Pm Clinic
The machine monitor can check the condition of the
machine without connecting testing tools to assist
the Pm Clinic and other periodic inspections.
1.
2nd screen
[F1]: Change screen

[F2]: Change screen
[F3]: Reset holding
[F4]: Hold (displayed data)
Selecting menu
Select "08 PM CLINIC" on the Service menu
screen.
q
q
q
q
3.
2.
Information displayed on Pm Clinic screen

The Pm Clinic function displays the following
information on 2 pages.
q
1st screen
D155AX-6
Holding displayed information

The displayed information can be held and
released with [F3] and [F4].
71
SEN00681-04
Cylinder Cut-Out operation

The operator can perform Cylinder Cut-Out operation with the machine monitor.
Reduced cylinder mode operation means to run the
engine with 1 or more fuel injectors disabled electrically to reduce the number of effective cylinders.
This operation is used to find out a cylinder which
does not output power normally (combustion in it is
abnormal).
1.
2.
3.
Resetting disabled cylinder

When changing a cylinder to be disabled or
when reduced cylinder mode operation is finished, select a disabled cylinder to be reset
with the function switches.
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 light
blue, the cylinder is reset.
a If the machine monitor rests a disabled
cylinder but the engine controller cannot
reset that disabled cylinder, the background of the cylinder No. becomes red.
a The reduced cylinder mode operation is
not automatically reset after the screen
returns to the operator mode. Accordingly, 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
pressed, the holding function is reset.
a The holding function is effective, regardless of setting of the reduced cylinder
mode operation.
Selecting menu
Select "09 Cylinder Cut-Out" on the "Service
Menu" screen.
Selecting cylinder to be disabled

After the "Cylinder Cut-Out" screen is displayed, select a cylinder to be disabled with the
function switches.
q
[F1]: Move selection mark (R) to left
q
[F2]: Move selection mark (R) to right
q
[F3]: Reset holding
q
[F4]: Hold
q
q
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 cylinder No. becomes yellow.
a One or more cylinders can be disabled.
[Reference]
If a normally operating cylinder is disabled, the
following phenomena occur.
1) Lowering of engine speed
2) Increase of final injection rate command
(quantity)
q
If the engine is running near the high idle, however, the engine speed may not lower for the
reason of engine control.
q
In this case, lower the engine speed with the
fuel control dial and judge by increase of the
injection rate command.
q
72
D155AX-6
SEN00681-04
a
Display of No Injection
If the engine is operated after long storage of the
machine, it may be worn or damaged because of
insufficient lubrication with oil. To prevent this, the
function to lubricate the engine before starting it by
cranking it without injecting fuel is installed.
Set the No Injection while the engine is stopped.
1.
2.
3.
Limit the cranking time to 20 seconds to

protect the starting motor.
Selecting menu
Select "10 No Injection" on the "Service Menu"
screen.
Displaying check screen

If the "No Injection" screen is displayed, the
machine monitor asks the operator if no-injection 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 following screen, the screen of "Communication
between controllers is being checked" is
displayed.
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.
5.
Prohibiting no-injection cranking

If the operator tries to perform the no-injection
cranking while the engine is running, the message 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 message of "Engine is running" is displayed
on the screen.
Starting no-injection cranking

If no-injection cranking (Fuel injection in no cylinders) 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 following screen, the screen of "Setting is being
prepared" is displayed.
D155AX-6
73
SEN00681-04
Display of Fuel Consumption

This function calculates the hourly fuel consumption from the actual fuel consumption in a measuring period and indicates it.
1.
Selecting menu
Select "11 Fuel Consumption" on the "Service
Menu" screen.
2.
Starting measurement
After the screen of "Fuel Consumption" is displayed, start measurement with the function
switches.
q
[F1]: Start
q
[F2]: Clear
q
[F5]: Return to Service menu screen
a When the screen of "Fuel Consumption" is
displayed, if a data is indicated, it is the
data of the previous measurement. This
data is not an obstacle to new measurement and can be deleted by pressing [F2].
a If [F1] is pressed, the data is displayed on
the starting date and time side and measurement starts.
a The display unit of the fuel changes
according to the unit set with the initialization (unit setting) function.
SI and meter: l/h,
inch: gal/h
74
3.
Display and function during measurement

Clock mark (a) flashes during measurement.
a While the fuel consumption is being measured, the operator can work with the
operator mode and other functions. Measurement is not finished until this screen is
displayed again and [F1] is pressed (Even
if the starting switch is turned OFF, this
function is kept effective, although fuel
consumption is measured only while the
engine is running).
4.
Finishing measurement
Press [F1], and measurement is finished and
the data are displayed on the finishing date
and time side.
5.
Displaying fuel consumption

If the measurement is finished, the hourly fuel
consumption calculated from the fuel consumption calculated by the engine controller
and the elapsed time are displayed.
D155AX-6
Display of KOMTRAX Settings (Terminal Status)

The setting condition and operating condition of
KOMTRAX can be checked with "KOMTRAX Settings".
Terminal Status is used to check the setting condition of the KOMTRAX terminal.
1.
Selecting menu
Select "12 KOMTRAX Settings" on the "Service Menu" screen.
2.
Selecting sub menu

After the "KOMTRAX Settings" screen is displayed, 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 condition of KOMTRAX communication
q
GMT time: Greenwich Meant Time (+ 9
hours in Japan)
D155AX-6
SEN00681-04
[F5]: Return to KOMTRAX Settings screen
75
SEN00681-04
Display of KOMTRAX Settings (GPS & Communication Status)

KOMTRAX can be checked with KOMTRAX Settings.
Condition of positioning and communication is used
to check the condition of positioning and communication of the KOMTRAX terminal.
1.
Selecting menu
2.
Selecting sub menu

After the Display of "KOMTRAX Settings"
screen is displayed, select "02 GPS & Communication Status" with the function switches or
76
3.
Contents of display of condition of positioning

and communication
On the screen of "GPS & Communication Status", the following items are displayed.
q
Positioning: Positioning condition of GPS
q
Communication: Communication environment of communication MODEM and connecting condition of communication
MODEM
q
Number of message not yet sent: Number
of mails in machine monitor not yet sent
q
D155AX-6
SEN00681-04
Display of KOMTRAX Settings

KOMTRAX can be checked with KOMTRAX Settings.
MODEM S/N is used to check the serial No. of the
KOMTRAX communication MODEM.
1.
Selecting menu
2.
Selecting sub menu

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
D155AX-6
77
SEN00681-04
Display of Service Message

Special messages for the serviceman sent from the
KOMTRAX base station (a distributor, etc.) can be
checked with this function.
If there is setting in a message, a return mail can be
sent by using numeral input switches.
1.
Operation to display menu

Select "13 Service Message" on the "Service
Menu" screen.
2.
Display of message (Read-only)

If there is a message, its contents are displayed. If there is not a message, "No message" is displayed.
q
a This message is different from a message
transmitted to the operator in the operator
mode.
a Since this message is special for the serviceman, the message monitor is not displayed 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.
q
78
a
a
[F6]: Confirm and return input value

This message is different from a message
transmitted to the operator in the operator
mode.
Since this message is special for the serviceman, the message monitor is not displayed when it is received as in the
operator mode.
D155AX-6
D155AX-6
SEN00681-04
79
SEN00681-04
D155AX-6 Bulldozer
2010 KOMATSU
All Rights Reserved
80
D155AX-6
SEN00682-02
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up

Testing and adjusting, Part 4........................................................................................................................... 2
Handling of power supply circuit of engine controller........................................................................... 2
Preparation work for troubleshooting of electrical system.................................................................... 3
Pm Clinic .............................................................................................................................................. 5
D155AX-6
SEN00682-02

Handling of power supply circuit
of engine controller
1
1.
Before disconnecting or connecting a connector 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.
D155AX-6
Preparation work for

troubleshooting of electrical
system
SEN00682-02
2.
When carrying out troubleshooting of an electric circuit related to the machine monitor,
engine controller, power train controller, or work
equipment controller, expose the related connectors according to the following procedure.
1.
Machine monitor
1) Remove the 4 mounting bolts each from
covers (1) and (2) and remove those covers.
2) Remove the 4 mounting bolts each from
covers (3) and (4) and remove those covers together with the foot rest.
a The 2 bolts on the front window side of the
foot rest are used as the cover mounting
bolts, too.
3) Remove the 4 mounting bolts of machine
monitor (5) and pull out machine monitor
(5) and switch cover together toward the
operator's seat.
4)
Engine controller
1) Open the left engine side cover and left
mudguard.
2) Remove the mounting bolts and cover (6).
3)
Insert or connect troubleshooting T-adapters in or to connectors EGC1, EGC2, and

EGC3 of engine controller (7).
a Since connectors EGC1 and EGC2
are fixed with screws, loosen those
screws before disconnecting.
a When returning connectors EGC1
and EGC2, tighten the screws to the
specified torque.
3 Screw: 3 1 Nm {0.3 0.1 kgm}
Insert or connect troubleshooting T-adapters 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
SEN00682-02
3.

1) Remove the inside lower cover of the left
console.
a This cover is installed on the opposite
side of the work equipment controller.
2) Insert or connect troubleshooting T-adapters in or to connectors STC1, STC2, and
STC3 of power train controller (8).
a Since the connectors are fixed with
screws, loosen those screws before
disconnecting.
a When returning the connectors, tighten 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.
2)
Insert or connect troubleshooting T-adapters in or to connectors WEC1, WEC2, and

WEC3 of work equipment controller (10).
a Since the connectors are fixed with
screws, loosen those screws before
disconnecting.
a When returning the connectors, tighten the screws to the specified torque.
3 Screw: 2.83 0.28 Nm
{0.288 0.028 kgm}
D155AX-6
SEN00682-02
Pm Clinic
Machine model
Serial No.
Service meter
D155AX-6
User's name
Date of execution
/
Inspector
Specifications
Blade
Rear attachment
T blade
T Semi-U blade
T Full-U blade
T
T Multi-shank ripper
T Variable giant ripper
T Counterweight (
T
Shoe width
T 560 mm
T 610 mm
T 660 mm
T 710 mm
kg)
Working condition
Quarry/Mining
Construction
Type of soil (Specific gravity:
T Construction/Civil engineering T Rock
T Road
T Gravel
T Tunnel
T Sand
T
T Clay
T Coal
T Gold
T Limestone
T
) Contents of work
T Dozing
T Side cutting
T Ripping
T Travel
%
%
%
%
Check of oil and coolant levels
T Engine coolant level

T Engine oil level
T Hydraulic oil level
When necessary
T Damper case oil level
T Power train oil level
Power train oil temperature
Max. range:
Max. range:
Following figure (Left)
Following figure (Right)
Operator's opinion
T Final drive oil level

T
Ambient temperature
Max.
C/Min.
Altitude
Result of visual inspection
Fault history of mechanical system
Fault history of electrical system
AA10NX
times/1st time
h/last
times/1st time
h/last
AB00MA
times/1st time
h/last
times/1st time
h/last
B@BAZG
times/1st time
h/last
times/1st time
h/last
B@BCNS
times/1st time
h/last
times/1st time
h/last
B@BCZK
times/1st time
h/last
times/1st time
h/last
B@CENS
times/1st time
h/last
times/1st time
h/last
B@HANS
times/1st time
h/last
times/1st time
h/last
CA234
times/1st time
h/last
times/1st time
h/last
D155AX-6
SEN00682-02
Check positions/Method 1
D155AX-6
SEN00682-02
D155AX-6
SEN00682-02
D155AX-6
SEN00682-02
Pm Clinic check sheet

Machine model
Serial No.
Service meter
User's name
Date of execution
Inspector
D155AX-6
Unit
Low idling
Boost
pressure
Exhaust
temperature
2.
715 765
715 765
rpm
F3 stall
1,560 1,660
1,450
F3 stall + Ripper raise relieve
1,500 1,600
1,395
Min. 117
{Min. 880}
100
{750}
660
700
Max. 2.94
{Max. 300}
3.92
{400}
Min. 034
{Min. 3.5}
0.21
{2.1}
Min. 010
{Min. 1.0}
0.08
{0.8}
Standard
value for new
machine
Service limit
value
kPa
{mmHg}
Ambient temperature
F3 stall
C
kPa
{mmH2O}
High idle
Low idle
1,825 1,925 1,825 1,925

825 925
F3 stall
Measurement result
2,000 2,100 2,000 2,100
825 925
Blow-by presF3 stall

sure
Engine oil
pressure
Service limit
value
MPa
{kg/cm}
Cooling fan
Item
Unit
Low idle
Fan
Speed
Circuit
pressure
D155AX-6
Adjustment: High idle

1005
High idle
Measurement result
Rejected
Engine
Without deceleration
High (Adjustment: 0007)
Engine speed idle Normal (Deceleration)
Decelerator pedal
Standard
value for new
machine
Rejected
Item
Accepted
Engine
Accepted
1.
rpm
1,200 1,300 1,200 1,300
MPa
{kg/cm}
SEN00682-02
Transmission
Item
High idle
Max. 1.0
{Max. 10.0}
Max. 1.0
{Max. 10.0}
Low idle
0.05 0.29
{0.5 3.0}
0.05 0.29
{0.5 3.0}
0.29 0.69
{3.0 7.0}
0.29 0.69
{3.0 7.0}
1.12 1.52
{11.5 15.5}
1.12 1.52
{11.5 15.5}
1.12 1.52
{11.5 15.5}
1.12 1.52
{11.5 15.5}
Low idle
2.45 2.85
{25.0 29.0}
2.45 2.85
{25.0 29.0}
High idle
2.45 2.85
{25.0 29.0}
2.45 2.85
{25.0 29.0}
Standard
value for new
machine
Service limit
value
Low idle
2.81 3.11
{28.7 31.7}
Min. 2.62
{Min. 26.7}
High idle
3.04 3.33
{31.0 34.0}
Min. 2.84
{Min. 29.0}
2.45 2.75
{25.0 28.0}
Min. 2.26
{Min. 23.0}
2.65 2.94
{27.0 30.0}
Min. 2.45
{Min. 25.0}
Monitoring: 32601
Monitoring: 32603
High idle
MPa
{kg/cm}
Gear speed: P/N
Unit
Gear speed: P/N
F clutch
pressure
Gear speed: F3
Brake: Applied
Low idle
R clutch
pressure
Gear speed: R3
Brake: Applied
Low idle
1st clutch
pressure
Gear speed: F1
Brake: Applied
Low idle
2.81 3.11
{28.7 31.7}
Min. 2.62
{Min. 26.7}
2nd clutch
pressure
Gear speed: F2
Brake: Applied
Low idle
2.60 2.89
{26.5 29.5}
Min. 2.40
{Min. 24.5}
3rd clutch
pressure
Gear speed: F3
Brake: Applied
Low idle
2.81 3.11
{28.7 31.7}
Min. 2.62
{Min. 26.7}
Standard
value for new
machine
Service limit
value
Low idle
2.46 3.04
{25.0 31.0}
2.16
{22.0}
High idle
2.46 3.04
{25.0 31.0}
2.16
{22.0}
2.46 3.04
{25.0 31.0}
2.16
{22.0}
2.46 3.04
{25.0 31.0}
2.16
{22.0}
Right brake
pressure
Gear speed: N
Brake: Released
Left brake
pressure
Gear speed: N
Brake: Released
Brake
F2 stall, high idle
performance
Low idle
High idle
MPa
{kg/cm}
Unit
MPa
{kg/cm}
Rejected
0.05 0.49
{0.5 5.0}
Main relief
pressure
Item
Brake
0.05 0.49
{0.5 5.0}
Automatic gearLow idle

Lockup clutch shift mode
pressure
Gear speed: F1
Travel with no load High idle
Stator clutch
pressure
10
Low idle
Measurement result
Measurement result
Rejected
Outlet
pressure
Service limit
value
Unit
Measurement result
Rejected
Torque converter
Inlet
pressure
Standard
value for new
machine
Accepted
Item
Accepted
Power train oil pressure

k Measure each transmission clutch pressure only while the engine is running at low speed
for safety.
Accepted
3.
Machine must not move.
D155AX-6
Item
Unload
pressure
Work equipment
control lever: All
levers in neutral
Work equipment relief

pressure
Cylinder stroke
Work equip- end relief
ment LS relief
pressure
2.45 3.82
{25 39}
2.45 3.82
{25 39}
High idle
26.0 29.0
{265 295}
26.0 29.0
{265 295}
24.0 26.0
{245 265}
24.0 26.0
{245 265}
38.2 41.5
{390 425}
38.2 41.5
{390 425}
36.2 38.1
{369 389}
36.2 38.1
{369 389}
3.97 4.46
{40.5 45.5}
3.97 4.46
{40.5 45.5}
Standard
value for new
machine
Service limit
value
3.0 4.0
3.0 4.0
High idle
MPa
{kg/cm}
High idle
Brake: Applied
HSS LS relief Steering: Relieved
High idle
pressure
Control
circuit basic
pressure
Work equipment
control lever: All
levers in neutral
High idle
Measurement result
Work
equipment
speed
Blade raise
Unit
High idle
Blade left tilt
High idle
Ripper lower
High idle
Ripper tilt in
High idle
1.8 2.8
3.1
1.5 2.5
3.5
4.5 5.5
6.2
Unit
Standard
value for new
machine
Service limit
value
mm
Max. 150
200
mm
Max. 50
70
Unit
Standard
value for new
machine
Service limit
value
sec
Measurement result
Rejected
Accepted
Hydraulic
drift
Hydraulic oil
temperature
Hydraulic drift
of blade lift
Engine: Stopped
Blade lift: 15 minutes
Ripper lift: 5 minutes
Hydraulic drift
of ripper lift
Measurement result
Rejected
Accepted
Hydraulic drift of work equipment

Item
Final drive
Item
FD
Final drive
D155AX-6
Engine: Stopped
Measurement result
Rejected
7.
High idle
HSS relief
pressure
Item
6.
Service limit
value
Unit
Accepted
5.
Standard
value for new
machine
Rejected

Accepted
4.
SEN00682-02
There must not abnormally

much metal dust.
11
SEN00682-02
8.
Repair record (Must be filled in)

Date
12
Service meter
Repair record
Date
Service meter
Repair record
D155AX-6
SEN00682-02
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 result
Accepted Rejected
Under- Bushing
Measure just Left side of machine
carriage temperature after work.
Right side of machine
Left side of machine
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
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
Item
Unit
Undercarriage
Left side of
machine
Opening of
track link
Measure
dimension (a).
Clearance
limit
Pin No.
Measurement result
Rejected
Accepted
SEN00682-02
1.4
(Each side)
mm
Right side of
machine
1.4
(Each side)
Opening of track link (a)
14
D155AX-6
D155AX-6
SEN00682-02
15
SEN00682-02
D155AX-6 Bulldozer
2010KOMATSU
All Rights Reserved
16
D155AX-6
SEN04628-02
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
40 Troubleshooting

Failure codes table.......................................................................................................................................... 2
Fuse locations................................................................................................................................................. 9
Information in troubleshooting table .............................................................................................................. 13
D155AX-6
SEN04628-02
40 Troubleshooting
Failure codes table

Action
code
Failure
code
E03
1500L0
E03
1
Component
in charge
Category of
history
P/T
Electrical system
15SAL1 Forward clutch: Fill high
P/T
Electrical system
E03
15SALH Forward clutch: Fill low
P/T
Electrical system
E03
15SBL1 Reverse clutch: Fill high
P/T
Electrical system
E03
15SBLH Reverse clutch: Fill low
P/T
Electrical system
E03
15SEL1 Speed 1st clutch: Fill high
P/T
Electrical system
E03
15SELH Speed 1st clutch: Fill low
P/T
Electrical system
E03
15SFL1 Speed 2nd clutch: Fill high
P/T
Electrical system
E03
15SFLH Speed 2nd clutch: Fill low
P/T
Electrical system
E03
15SGL1 Speed 3rd clutch: Fill high
P/T
Electrical system
E03
15SGLH Speed 3rd clutch: Fill low
P/T
Electrical system
E02
15SJL1
P/T
Electrical system
E02
15SJLH L/U: Fill low
P/T
Electrical system
E04
2301L1
P/T
Electrical system
E04
2301LH Right brake: Fill low
P/T
Electrical system
E04
2302L1
P/T
Electrical system
E04
2302LH Left brake: Fill low
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
ENG
Mechanical system
B@BCNS Eng Water Overheat
ENG
Mechanical system
B@BCZK Eng Water Level Low
MON
Mechanical system
B@CENS T/C Oil Overheat
P/T
Mechanical system
B@HANS Hyd Oil Overheat
MON
Mechanical system

L/U: Fill high
E04
CA111
ENG
Electrical system
E04
CA115
ENG
Electrical system
E03
CA122
ENG
Electrical system
E03
CA123
ENG
Electrical system
E03
CA131
ENG
Electrical system
E03
CA132
ENG
Electrical system
E02
CA135
ENG
Electrical system
E02
CA141
ENG
Electrical system
E02
CA144
ENG
Electrical system
E02
CA145
ENG
Electrical system
E01
CA153
ENG
Electrical system
E01
CA154
ENG
Electrical system
E03
CA187
ENG
Electrical system
E03
CA221
ENG
Electrical system
Reference
manual
Troubleshooting
by failure code,
Part 1
SEN00716-02
Troubleshooting
by failure code,
Part 2
SEN00717-02
D155AX-6
40 Troubleshooting
Action
code
Failure
code
E03
CA222
E03
SEN04628-02
Component
in charge
Category of
history
ENG
Electrical system
CA227
ENG
Electrical system
E00
CA234
Eng Overspeed
ENG
Mechanical system
E03
CA238
ENG
Electrical system
E01
CA263
ENG
Electrical system
E01
CA265
ENG
Electrical system
E03
CA271
PCV1 Short Error
ENG
Electrical system
E03
CA272
PCV1 Open Error
ENG
Electrical system
E03
CA273
PCV2 Short Error
ENG
Electrical system
E03
CA274
PCV2 Open Error
ENG
Electrical system
E03
CA322
ENG
Electrical system
E03
CA323
ENG
Electrical system
E03
CA324
ENG
Electrical system
E03
CA325
ENG
Electrical system
E03
CA331
ENG
Electrical system
E03
CA332
ENG
Electrical system
E04
CA342
ENG
Electrical system
E03
CA351
ENG
Electrical system
E03
CA352
ENG
Electrical system
E03
CA386
ENG
Electrical system
E04
CA441
ENG
Electrical system
E04
CA442
ENG
Electrical system
E03
CA449
ENG
Electrical system
E03
CA451
ENG
Electrical system
E03
CA452
ENG
Electrical system
E02
CA553
ENG
Electrical system
E03
CA554
ENG
Electrical system
E02
CA559
ENG
Electrical system
E03
CA689
ENG
Electrical system
E03
CA731
ENG
Electrical system
E04
CA757
ENG
Electrical system
E03
CA778
ENG
Electrical system
E02
CA1228 EGR Valve Servo Error 1
ENG
Electrical system
E03
CA1625 EGR Valve Servo Error 2
ENG
Electrical system
E03
CA1626 BP Valve Sol Current High Error
ENG
Electrical system
E03
CA1627 BP Valve Sol Current Low Error
ENG
Electrical system
E02
CA1628 Bypass Valve Servo Error 1
ENG
Electrical system
E03
CA1629 Bypass Valve Servo Error 2
ENG
Electrical system
E03
CA1631 BP Valve Pos Sens High Error
ENG
Electrical system
E03
CA1632 BP Valve Pos Sens Low Error
ENG
Electrical system
E03
CA1633 KOMNET Datalink Timeout Error
ENG
Electrical system
D155AX-6
Reference
manual
Troubleshooting
by failure code,
Part 2
SEN00717-02
Troubleshooting
by failure code,
Part 3
SEN00718-03
SEN04628-02
Action
code
Failure
code
40 Troubleshooting
Component
in charge
Category of
history
E01
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
ENG
Electrical system
E03
CA2186 Throt Sens Sup Volt Low Error
ENG
Electrical system
E03
CA2249 Rail Press Very Low Error
ENG
Electrical system
E03
CA2271 EGR Valve Pos Sens High Error
ENG
Electrical system
E03
CA2272 EGR Valve Pos Sens Low Error
ENG
Electrical system
E03
CA2351 EGR Valve Sol Current High Error
ENG
Electrical system
E03
CA2352 EGR Valve Sol Current Low Error
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
P/T
Electrical system
E02
D130KB Neutral relay: Short circuit
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
P/T
Electrical system
E03
DAFRKR CAN Disconnection
MON
Electrical system
E03
DB2RKR CAN Disconnection
ENG
Electrical system
E04
DB90KK WE controller: Source voltage reduction
W/E
Electrical system
E03
DB90KR PT controller: Can communication lost
P/T
Electrical system
E01
DB90KT WE controller: Abnormality in controller
W/E
Electrical system
E03
W/E
Electrical system
E03
W/E
Electrical system
E04
DB99KQ WE controller: Type select signal
W/E
Electrical system
E03
DB9RKR WE controller: Can communication lost
W/E
Electrical system
E03
DBE0KK PT controller: Source voltage reduction
P/T
Electrical system
E01
DBE0KT PT controller: Abnormality in controller
P/T
Electrical system
E02
P/T
Electrical system
E02
P/T
Electrical system
E04
DBE9KQ PT controller: Type select signal
P/T
Electrical system
E02
DD12KA Shift up Sw: Disconnection
P/T
Electrical system
E02
DD12KB Shift up Sw: Short circuit
P/T
Electrical system
E02
DD13KA Shift down Sw: Disconnection
P/T
Electrical system
E02
DD13KB Shift down Sw: Short circuit
P/T
Electrical system
E03
DD14KA Parking lever Sw: Disconnection
P/T
Electrical system
E03
DD14KB Parking lever Sw: Short circuit
P/T
Electrical system
E02
DDDDKA Back up brake Sw: Disconnection
P/T
Electrical system
Reference
manual
Troubleshooting
by failure code,
Part 3
SEN00718-03
Troubleshooting
by failure code,
Part 4
SEN00719-01
D155AX-6
40 Troubleshooting
Action
code
Failure
code
SEN04628-02
Component
in charge
Category of
history
E02
DDDDKB Back up brake Sw: Short circuit
P/T
Electrical system
E02
DDDDKX Back up brake Sw: Signal mismatch
P/T
Electrical system
E02
DDN7KA WEQ Knob Sw (down): Disconnection
W/E
Electrical system
E02
DDN7KB WEQ Knob Sw (down): Short circuit
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
W/E
Electrical system
E03
DDNLKB Weq lock Sw: Short circuit
W/E
Electrical system
E02
DDTSL1 S/C: Fill high
P/T
Electrical system
E02
DDTSLH S/C: Fill low
P/T
Electrical system
E03
DFA4KX BL lever 1: Out of normal range
W/E
Electrical system
E03
DFA4KZ BL lever: Disconnection or short circuit
W/E
Electrical system
E03
DFA4L8 BL lever: Signal mismatch
W/E
Electrical system
E03
DFA5KA BL lever 1: Disconnection
W/E
Electrical system
E03
DFA5KB BL lever 1: Short circuit
W/E
Electrical system
E03
DFA6KA BL lever 2: Disconnection
W/E
Electrical system
E03
DFA6KB BL lever 2: Short circuit
W/E
Electrical system
E03
DFA7KX BT lever 1: Out of normal range
W/E
Electrical system
E03
DFA7KZ BT lever: Disconnection or short circuit
W/E
Electrical system
E03
DFA7L8 BT lever: Signal mismatch
W/E
Electrical system
E03
DFA8KA BT lever 1: Disconnection
W/E
Electrical system
E03
DFA8KB BT lever 1: Short circuit
W/E
Electrical system
E03
DFA9KA BT lever 2: Disconnection
W/E
Electrical system
E03
DFA9KB BT lever 2: Short circuit
W/E
Electrical system
E03
DFAAKX RL lever 1: Out of normal range
W/E
Electrical system
E03
DFAAKZ RL lever: Disconnection or short circuit
W/E
Electrical system
E03
DFAAL8 RL lever: Signal mismatch
W/E
Electrical system
E03
DFABKA RL lever 1: Disconnection
W/E
Electrical system
E03
DFABKB RL lever 1: Short circuit
W/E
Electrical system
E03
DFACKA RL lever 2: Disconnection
W/E
Electrical system
E03
DFACKB RL lever 2: Short circuit
W/E
Electrical system
E03
DFADKX RT lever 1: Out of normal range
W/E
Electrical system
E03
DFADKZ RT lever: Disconnection or short circuit
W/E
Electrical system
E03
DFADL8 RT lever: Signal mismatch
W/E
Electrical system
E03
DFAEKA RT lever 1: Disconnection
W/E
Electrical system
E03
DFAEKB RT lever 1: Short circuit
W/E
Electrical system
E03
DFAFKA RT lever 2: Disconnection
W/E
Electrical system
E03
DFAFKB RT lever 2: Short circuit
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
D155AX-6
Reference
manual
Troubleshooting
by failure code,
Part 4
SEN00719-01
Troubleshooting
by failure code,
Part 5
SEN00720-02
SEN04628-02
Action
code
Failure
code
40 Troubleshooting
Component
in charge
Category of
history
DH21KB WEQ pressure sensor: Short circuit
W/E
Electrical system
E02
DHT5KA T/C in-pressure sensor: Disconnection
P/T
Electrical system
E02
DHT5KB T/C in-pressure sensor: Short circuit
P/T
Electrical system
E02
DHT7KA T/C out-pressure sensor: Disconnection
P/T
Electrical system
E02
DHT7KB T/C out-pressure sensor: Short circuit
P/T
Electrical system
E03
DK10KX Fuel control Dial: Out of normal range
ENG
Electrical system
E03
DK30KA ST lever 1: Disconnection
P/T
Electrical system
E03
DK30KB ST lever 1: Short circuit
P/T
Electrical system
E04
DK30KX ST lever 1: Out of normal range
P/T
Electrical system
E04
DK30KZ ST lever: Disconnection or short circuit
P/T
Electrical system
E03
DK30L8 ST lever: Signal mismatch
P/T
Electrical system
E03
DK31KA ST lever 2: Disconnection
P/T
Electrical system
E03
DK31KB ST lever 2: Short circuit
P/T
Electrical system
E03
DK40KA Brake potentiometer: Disconnection
P/T
Electrical system
E03
DK40KB Brake potentiometer: Short circuit
P/T
Electrical system
E04
DK55KX FR lever: Out of normal range
P/T
Electrical system
E04
DK55KZ FR lever: Disconnection or short circuit
P/T
Electrical system
E03
DK55L8 FR lever: Signal mismatch
P/T
Electrical system
E03
DK56KA FR lever 1: Disconnection
P/T
Electrical system
E03
DK56KB FR lever 1: Short circuit
P/T
Electrical system
E03
DK57KA FR lever 2: Disconnection
P/T
Electrical system
E03
DK57KB FR lever 2: Short circuit
P/T
Electrical system
E03
DKH1KA Pitch angle sensor: Disconnection
P/T
Electrical system
E03
DKH1KB Pitch angle sensor: Short circuit
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
E03
DWN1KA Hss EPC1: Disconnection
P/T
Electrical system
E03
DWN1KB Hss EPC1: Short circuit
P/T
Electrical system
E03
DWN1KY Hss EPC1: Short circuit
P/T
Electrical system
E03
DWN2KA Hss EPC2: Disconnection
P/T
Electrical system
E03
DWN2KB Hss EPC2: Short circuit
P/T
Electrical system
E03
DWN2KY Hss EPC2: Short circuit
P/T
Electrical system
E04
DWN3KA Ssp solenoid: Disconnection
P/T
Electrical system
E04
DWN3KB Ssp solenoid: Short circuit
P/T
Electrical system
E04
DWN3KY Ssp solenoid: Short circuit
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
E01
DXA0KB TVC Sol.: Short circuit
W/E
Electrical system
Reference
manual
Troubleshooting
by failure code,
Part 5
SEN00720-02
Troubleshooting
by failure code,
Part 6
SEN00721-03
D155AX-6
40 Troubleshooting
Action
code
Failure
code
SEN04628-02
Component
in charge
Category of
history
E01
DXA0KY TVC Sol.: Short circuit
W/E
Electrical system
E02
DXH1KA Lock-up ECMV: Disconnection
P/T
Electrical system
E02
DXH1KB Lock-up ECMV: Short circuit
P/T
Electrical system
E03
DXH1KY Lock-up ECMV: Short circuit
P/T
Electrical system
E03
DXH4KA 1st clutch ECMV: Disconnection
P/T
Electrical system
E03
DXH4KB 1st clutch ECMV: Short circuit
P/T
Electrical system
E03
DXH4KY 1st clutch ECMV: Short circuit
P/T
Electrical system
E03
DXH5KA 2nd clutch ECMV: Disconnection
P/T
Electrical system
E03
DXH5KB 2nd clutch ECMV: Short circuit
P/T
Electrical system
E03
DXH5KY 2nd clutch ECMV: Short circuit
P/T
Electrical system
E03
DXH6KA 3rd clutch ECMV: Disconnection
P/T
Electrical system
E03
DXH6KB 3rd clutch ECMV: Short circuit
P/T
Electrical system
E03
DXH6KY 3rd clutch ECMV: Short circuit
P/T
Electrical system
E03
DXH7KA R clutch ECMV: Disconnection
P/T
Electrical system
E03
DXH7KB R clutch ECMV: Short circuit
P/T
Electrical system
E04
DXH7KY R clutch ECMV: Short circuit
P/T
Electrical system
E03
DXH8KA F clutch ECMV: Disconnection
P/T
Electrical system
E03
DXH8KB F clutch ECMV: Short circuit
P/T
Electrical system
E04
DXH8KY F clutch ECMV: Short circuit
P/T
Electrical system
E04
DXHBKA Right brake ECMV: Disconnection
P/T
Electrical system
E04
DXHBKB Right brake ECMV: Short circuit
P/T
Electrical system
E04
DXHBKY Right brake ECMV: Short circuit
P/T
Electrical system
E04
DXHCKA Left brake ECMV: Disconnection
P/T
Electrical system
E04
DXHCKB Left brake ECMV: Short circuit
P/T
Electrical system
E04
DXHCKY Left brake ECMV: Short circuit
P/T
Electrical system
E03
DXHRKA Blade up EPC: Disconnection
W/E
Electrical system
E03
DXHRKB Blade up EPC: Short circuit
W/E
Electrical system
E03
DXHRKY Blade up EPC: Short circuit
W/E
Electrical system
E03
DXHSKA Blade down EPC: Disconnection
W/E
Electrical system
E03
DXHSKB Blade down EPC: Short circuit
W/E
Electrical system
E03
DXHSKY Blade down EPC: Short circuit
W/E
Electrical system
E03
DXHTKA Blade left 1 EPC: Disconnection
W/E
Electrical system
E03
DXHTKB Blade left 1 EPC: Short circuit
W/E
Electrical system
E03
DXHTKY Blade left 1 EPC: Short circuit
W/E
Electrical system
E03
DXHUKA Blade right 1 EPC: Disconnection
W/E
Electrical system
E03
DXHUKB Blade right 1 EPC: Short circuit
W/E
Electrical system
E03
DXHUKY Blade right 1 EPC: Short circuit
W/E
Electrical system
E03
DXHWKA Ripper up EPC: Disconnection
W/E
Electrical system
E03
DXHWKB Ripper up EPC: Short circuit
W/E
Electrical system
E03
DXHWKY Ripper up EPC: Short circuit
W/E
Electrical system
E03
DXHXKA Ripper down EPC: Disconnection
W/E
Electrical system
D155AX-6
Reference
manual
Troubleshooting
by failure code,
Part 6
SEN00721-03
Troubleshooting
by failure code,
Part 7
SEN00722-01
SEN04628-02
Action
code
Failure
code
40 Troubleshooting
Component
in charge
Category of
history
E03
DXHXKB Ripper down EPC: Short circuit
W/E
Electrical system
E03
DXHXKY Ripper down EPC: Short circuit
W/E
Electrical system
E03
DXHYKA Ripper Tilt In EPC: Disconnection
W/E
Electrical system
E03
DXHYKB Ripper Tilt In EPC: Short circuit
W/E
Electrical system
E03
DXHYKY Ripper Tilt In EPC: Short circuit
W/E
Electrical system
E03
DXHZKA Ripper Tilt Back EPC: Disconnection
W/E
Electrical system
E03
DXHZKB Ripper Tilt Back EPC: Short circuit
W/E
Electrical system
E03
DXHZKY Ripper Tilt Back EPC: Short circuit
W/E
Electrical system
E03
DXJ4KA WEQ lock Sol.: Disconnection
W/E
Electrical system
E03
DXJ4KB WEQ lock Sol.: Short circuit
W/E
Electrical system
E03
DXJ8KA Blade left 2 EPC: Disconnection
W/E
Electrical system
E03
DXJ8KB Blade left 2 EPC: Short circuit
W/E
Electrical system
E03
DXJ8KY Blade left 2 EPC: Short circuit
W/E
Electrical system
E03
DXJ9KA Blade right 2 EPC: Disconnection
W/E
Electrical system
E03
DXJ9KB Blade right 2 EPC: Short circuit
W/E
Electrical system
E03
DXJ9KY Blade right 2 EPC: Short circuit
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
P/T
Electrical system
E02
DXJBKB S/C ECMV: Short circuit
P/T
Electrical system
E02
DXJBKY S/C ECMV: Short circuit
P/T
Electrical system
Reference
manual
Troubleshooting
by failure code,
Part 7
SEN00722-01
Troubleshooting
by failure code,
Part 8
SEN00723-01
a Entry order of items in table

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 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
40 Troubleshooting
SEN04628-02
Fuse locations
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
Power circuit breaker
Circuit
(Type of power supply) breaker No.
CB105
(Accessory power
supply)
CB30
(Unswitched power
supply)
Circuit
breaker
capacity
Destination of power
CB9
20A
Optional power supply
CB1
20A
CB2
20A
CB3
20A
Air conditioner unit, blower motor, and compressor electromagnetic clutch
CB4
20A
Headlamp, additional headlamp
CB5
20A
Rear lamp, additional rear lamp, ripper point lamp
CB6
20A
CB7
20A

Emergency power supply (For power train switch box)
Emergency power supply (For work equipment switch box)
Starting switch
Engine hold relay
Machine monitor
CB8
30A

(Type of power supply)
Fuse No.
Fuel
capacity
CB30
(Unswitched power
supply)
20A
Operator's cab power supply (To connection table of fuse box
5A
Backup alarm, backup alarm relay
20A
20A
5A
Engine controller (Signal ACC)
CB105H
(Unswitched power
supply)
Engine controller
Engine electrical intake air heater
Fuse box FS1
CB105
(Accessory power
supply)
Starting switch (ACC)
D155AX-6
SEN04628-02
40 Troubleshooting
Fuse box FS2

Fuse No.
Fuel
capacity
CB30
(Unswitched power
supply)
5A
Pedal brake solenoid valve
5A
CB105
(Accessory power
supply)
Starting switch (ACC)
10
Engine electrical intake air heater

3
20A
Ripper pin puller solenoid valve
5A
Horn
20A
Optional power supply
Pneumatic suspension seat
D155AX-6
40 Troubleshooting
SEN04628-02
Locations of circuit breakers CB30, CB105, and CB105H (In battery room)
Locations of circuit breakers CB1 CB9 and fuse boxes FS1 and FS2 (In battery room)
D155AX-6
11
SEN04628-02
40 Troubleshooting
Fuse box
Power circuit fuse
FS1-1
(Unswitched power
supply)
FS1-3
(Accessory power
supply)
Fuse No.
Fuel
capacity
Radio
10A
12V accessory connector (Via DC converter)

12V accessory socket (Via DC converter)
20A
20A
Additional light relay, additional light

Rotary lamp
12V accessory connector (Via DC converter)
12V accessory socket (Via DC converter)
Radio
FS1-4
(Accessory power
supply)
Location of fuse box
12
Room lamp
20A
10A
Front wiper, rear wiper
10A
Left wiper, right wiper
Cigarette lighter
Windshield wiper (Via intermittent relay)
(In operator's cab)
D155AX-6
40 Troubleshooting
SEN04628-02
Information in troubleshooting table
a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully.
Action code
Failure code
Display on
Display on machine
machine monimonitor
tor
Contents of
trouble
Trouble
Trouble name displayed in fault history of machine monitor
Contents of trouble detected by machine monitor or controller
Action of
Action taken by machine monitor or controller to protect system or devices when they detect
machine monitrouble
tor or controller
Problem that
appears on
machine
Problem that appears on machine as result of action taken by machine monitor or controller
(shown above)
Related information
Information related to detected trouble or troubleshooting
Cause
Standard value in normal state/Remarks on troubleshooting

<Contents of description>
Standard value in normal state to judge possible causes
Remarks on judgment
Possible causes
and standard
value in normal
state
D155AX-6
<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
V) circuit is in contact with power source (24 V) circuit.
Short circuit
Independent wiring harnesses are in contact with each
other abnormally.
Possible causes of trouble

(Given numbers are refer<Precautions for troubleshooting>
ence numbers, which do not
(1) Method of indicating connector No. and handling of Tindicate priority)
adapter
Insert or connect T-adapter as explained below for troubleshooting, unless otherwise specified.
If connector No. has no marks of "male" and "female",
3
disconnect connector and insert T-adapters in both male
side and female side.
If connector No. has marks of "male" and "female", disconnect 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.
Connect positive (+) lead to pin No. or wiring harness
4
entered on front side.
Connect negative () lead to pin No. or harness entered
on rear side.
13
SEN04628-02
40 Troubleshooting
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 (i
o): Roughly shows the location on the machine.
14
D155AX-6
40 Troubleshooting
D155AX-6
SEN04628-02
15
SEN04628-02
40 Troubleshooting
D155AX-6 Bulldozer
2011 KOMATSU
All Rights Reserved
16
D155AX-6
SEN00851-02
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
40 Troubleshooting

Points to remember when troubleshooting ..................................................................................................... 2
Sequence of events in troubleshooting........................................................................................................... 3
Check before troubleshooting ......................................................................................................................... 4
Classification and procedures for troubleshooting .......................................................................................... 5
Connection table for connector pin numbers .................................................................................................. 8
T- branch box and T- branch adapter table ................................................................................................... 44
D155AX-6
SEN00851-02
40 Troubleshooting
Points to remember when troubleshooting

k
k
k
k
k
k
Stop the machine in a level ground, and check that the lock pin, blocks, and parking brake are
securely fitted.
When carrying out the operation with two or more workers, keep strictly to the agreed signals,
and do not allow any unauthorized person to come near.
If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative () terminal of the battery first.
When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and function.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1.
2.
3.
When carrying out troubleshooting, do not

hurry to disassemble the components.
If components are disassembled immediately
any failure occurs:
q
Parts that have no connection with the failure or other unnecessary parts will be disassembled.
q
It will become impossible to find the cause
of the failure.
It will also cause a waste of manhours, parts,
or oil or grease, and at the same time, will also
lose the confidence of the user or operator.
For this reason, when carrying out troubleshooting, it is necessary to carry out thorough
prior investigation and to carry out troubleshooting in accordance with the fixed procedure.
Points to ask user or operator
1) Have any other problems occurred apart
from the problem that has been reported?
2) Was there anything strange about the
machine before the failure occurred?
3) Did the failure occur suddenly, or were
there problems with the machine condition
before this?
4) Under what conditions did the failure
occur?
5) Had any repairs been carried out before
the failure?
When were these repairs carried out?
6) Has the same kind of failure occurred
before?
Check before troubleshooting
1) Check the oil level
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3)
4)
5)
Check the travel of the control levers.

Check the stroke of the control valve
spool.
Other maintenance items can be checked
externally, so check any item that is considered to be necessary.
4.
Confirming failure
q
Confirm the extent of the failure yourself,
and judge whether to handle it as a real
failure or as a problem with the method of
operation, etc.
a When operating the machine to reenact the troubleshooting symptoms, do
not carry out any investigation or
measurement that may make the
problem worse.
5.
Troubleshooting
q
Use the results of the investigation and
inspection in Items 2 4 to narrow down
the causes of failure, then use the troubleshooting flowchart to locate the position of
the failure exactly.
a The basic procedure for troubleshooting is as follows.
1) Start from the simple points.
2) Start from the most likely points.
3) Investigate other related parts or
information.
6.
Measures to remove root cause of failure

q
Even if the failure is repaired, if the root
cause of the failure is not repaired, the
same failure will occur again.
To prevent this, always investigate why
the problem occurred. Then, remove the
root cause.
D155AX-6
40 Troubleshooting
SEN00851-02
Sequence of events in troubleshooting
D155AX-6
SEN00851-02
40 Troubleshooting
Check before troubleshooting

Item
1. Check of level and type of fuel
2. Check of fuel for foreign matter
Lubricating
oil/Coolant
Hydraulic/
Mechanical
equipment
Criterion
Remedy
Add fuel
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
5. Check of power train oil level
Between H L
Add oil
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
1. Check for abnormal noise/smell
Repair
2. Check for oil leakage
Repair
3. Bleeding air
Bleed air
1. Check of battery terminals and wiring for looseness and corrosion
Retighten or replace
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
Between H L
Add or replace
6. Check of wires for discoloration, burn, and

removal of cover
Repair or replace
7. Check for released wire clamp and drooping wire
Repair
8. Check of wires for wetness (Check connectors

and terminals for wetness, in particular)
Dry
9. Check circuit breaker for turning OFF and fuse

for disconnection and corrosion
Replace
10. Check of alternator voltage

(while engine speed is at middle or higher)
After operating for several

minutes: 27.5 29.5 V
Replace
11. Check of battery relay for operating sound

(when starting switch is turned ON or OFF)
Replace
5. Check of electrolyte level

Electrical
equipment
D155AX-6
40 Troubleshooting
SEN00851-02
Classification and procedures for troubleshooting
Classification for troubleshooting

Type
Display of code
Contents
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 history:
If a action code and a failure code are not displayed on the machine monitor, check for a mechanical
system failure code and an electrical system failure code with the fault history function of the machine
monitor.
If a failure code is recorded, carry out troubleshooting for the corresponding "Display of code" according to that code.
a If an electrical system failure code is recorded, delete all the codes and reproduce them, and then
see if the trouble is still detected.
a A failure code of the mechanical system cannot be deleted.
a If a trouble is displayed in the air conditioner fault history or heater fault history by the fault history
function, carry out the corresponding troubleshooting in "E mode".
3.
When action code or failure code is not displayed and no failure code is recorded in fault
history:
If a action code or a failure code is not displayed on the machine monitor and no failure code is recorded
in the fault history, a trouble that the machine cannot find out by itself may have occurred in the electrical
system or hydraulic and mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from
the table of "Phenomena looking like troubles and troubleshooting Nos.", and then carry out troubleshooting corresponding to that phenomenon in the "E mode", "H mode", or "S mode".
D155AX-6
SEN00851-02
40 Troubleshooting
Phenomena looking like troubles and troubleshooting Nos.

Troubleshooting
No.
Phenomena looking like troubles
Display
of code
E mode
H mode
S mode
Phenomena related to action code/failure code

1 Action code and failure code are displayed on machine monitor
2
When fault history is checked, failure code is displayed in mechanical

system fault history
When fault history is checked, failure code is displayed in electrical

system fault history
When fault history is checked, failure code is displayed in air conditioner

or heater fault history
According to displayed
code
E-20
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
D155AX-6
40 Troubleshooting
SEN00851-02
Troubleshooting
No.
Phenomena looking like troubles
Display
of code
E mode
H mode
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
S mode
Phenomena related to machine monitor

44 When starting switch turned ON, machine monitor displays nothing
45
When starting switch turned ON (before starting engine), basic check

item (radiator coolant level) lights up
E-1
E-2
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

normally
E-9
51 Hydraulic temperature gauge (multi-gauge) does not indicate normally
E-10
Contents of display by machine monitor are different from applicable

52
machine
E-11
53 Machine monitor does not display some items
E-12
50
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
D155AX-6
E-27
SEN00851-02
Connection table for connector pin numbers
40 Troubleshooting
(Rev. 2009.04)
The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
D155AX-6
40 Troubleshooting
D155AX-6
SEN00851-02
SEN00851-02
10
40 Troubleshooting
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40 Troubleshooting
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11
SEN00851-02
12
40 Troubleshooting
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13
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14
40 Troubleshooting
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16
40 Troubleshooting
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40 Troubleshooting
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SEN00851-02
18
40 Troubleshooting
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28
40 Troubleshooting
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40 Troubleshooting
D155AX-6
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29
SEN00851-02
30
40 Troubleshooting
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40 Troubleshooting
D155AX-6
SEN00851-02
31
SEN00851-02
32
40 Troubleshooting
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40 Troubleshooting
D155AX-6
SEN00851-02
33
SEN00851-02
34
40 Troubleshooting
D155AX-6
40 Troubleshooting
D155AX-6
SEN00851-02
35
SEN00851-02
36
40 Troubleshooting
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40 Troubleshooting
D155AX-6
SEN00851-02
37
SEN00851-02
38
40 Troubleshooting
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40 Troubleshooting
D155AX-6
SEN00851-02
39
SEN00851-02
40
40 Troubleshooting
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40 Troubleshooting
D155AX-6
SEN00851-02
41
SEN00851-02
42
40 Troubleshooting
D155AX-6
40 Troubleshooting
D155AX-6
SEN00851-02
43
SEN00851-02
40 Troubleshooting
T- branch box and T- branch adapter table

a
(Rev. 2009.03)
1
q q
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-2800
Identification
symbol
799-601-2700
Part name
T-adapter kit
799-601-2500
Part No.
Number of pins
The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
799-601-2600 T-box (for ECONO)
21
799-601-3100 T-box (for MS)
37
799-601-3200 T-box (for MS)
37
q
q
799-601-3380 Plate for MS (14-pin)

799-601-3410 Adapter for BENDIX (MS)
24
MS-24P
24
MS-24P
17
MS-17P
17
MS-17P
q
q
MS-5P
10
MS-10P
MS-5P
17
MS-17P
19
MS-19P
14
MS-14P
q
q
799-601-3470 Case
799-601-2710 Adapter for MIC
MIC-5P
q q
13
MIC-13P
q q
17
MIC-17P
q q q
21
MIC-21P
q q q
MIC-9P
799-601-2750 Adapter for ECONO
ECONO2P
q q
ECONO3P
q q
ECONO4P
q q
ECONO8P
q q
12 ECONO12P q q
799-601-2810 Adapter for DLI
DLI-8P
q q
12
DLI-12P
q q
16
DLI-16P
q q
799-601-2840 Extension cable (ECONO type)
12 ECONO12P q q
q
q q
q q
q q q
799-601-2850 Case
799-601-4350 T-box (for DRC 60, ECONO)
60
799-601-4360 Case
799-601-7010 Adapter for X (T-adapter)
799-601-7020 Adapter for X
X2P
q q q
X3P
q q q
X4P
q q q
799-601-7050 Adapter for SWP
SW6P
q q q
SW8P
q q q
12
SW12P
q
M2P
q q q
M3P
q q q
14
SW14P
16
SW16P
799-601-7080 Adapter for M (T-adapter)
799-601-7090 Adapter for M
44
q
q
D155AX-6
40 Troubleshooting
SEN00851-02
799-601-7150 Adapter for S (White)
10
S10P
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
Out of kit
799-601-4201
q q q
799-601-4101
S8P
799-601-9300
799-601-9200
799-601-7140 Adapter for S
799-601-9100
M8P
799-601-9000
799-601-8000
q
799-601-7500
q q q
799-601-7400
q q q
M6P
799-601-7100
M4P
799-601-7000
799-601-2800
Part name
799-601-2700
Identification
symbol
Part No.
799-601-2500
Number of pins
T-adapter kit
q
q
16
S16PW
12
S12PW
799-601-7180 Adapter for AMP040
A8P
12
A12P
16
A16P
q q q
20
A20P
q q q
799-601-7230 Short connector for X
q q q
q q
799-601-7240 Case
799-601-7270 Case
799-601-7510 Adapter for 070
10
07-10
799-601-7520 Adapter for 070
12
07-12
799-601-7530 Adapter for 070
14
07-14
799-601-7540 Adapter for 070
18
07-18
799-601-7550 Adapter for 070
20
07-20
799-601-7360 Adapter for relay
REL-5P
799-601-7370 Adapter for relay
REL-6P
799-601-7380 Adapter for JFC
799-601-9010 Adapter for DTM
DTM2
799-601-9020 Adapter for DT
DT2
DT3
DT4
DT6
799-601-9060 Adapter for DT (Gray)
DT8GR
799-601-9070 Adapter for DT (Black)
DT8B
799-601-9080 Adapter for DT (Green)
DT8G
799-601-9090 Adapter for DT (Brown)
DT8BR
799-601-9110 Adapter for DT (Gray)
12
DT12GR
799-601-9120 Adapter for DT (Black)
12
DT12B
799-601-9130 Adapter for DT (Green)
12
DT12G
799-601-9140 Adapter for DT (Brown)
12
DT12BR
799-601-9210 Adapter for HD30-18
D18-8
q q
799-601-9220 Adapter for HD30-18
14
D18-14
q q
799-601-9230 Adapter for HD30-18
20
D18-20
q q
799-601-9240 Adapter for HD30-18
21
D18-21
q q
799-601-9250 Adapter for HD30-24
D24-9
q q
799-601-9260 Adapter for HD30-24
16
D24-16
q q
799-601-9270 Adapter for HD30-24
21
D24-21
q q
799-601-9280 Adapter for HD30-24
23
D24-23
q q
799-601-9290 Adapter for HD30-24
31
D24-31
q q
799-601-9310 Plate for HD30 (24-pin)

799-601-9320 T-box (for ECONO)
D155AX-6
24
q q
q q
q q
q q
45
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-2800
Identification
symbol
799-601-2700
Part name
T-adapter kit
799-601-2500
Part No.
40 Troubleshooting
Number of pins
SEN00851-02
799-601-9330 Case
799-601-9340 Case
799-601-9350 Adapter for DRC
40
DRC-40
799-601-9360 Adapter for DRC
24
DRC-24
799-601-9410* Socket for engine (CRI-T2)
Adapter for engine (CRI-T2)

799-601-9420 Adapter for engine (CRI-T3) PFUEL
Oil pressure sensor
A3
q q
q q
1,2,3
795-799-5520* Socket for engine (HPI-T2)
Socket for engine (HPI-T2)

Temperature sensor
q q
q q
799-601-9430*
795-799-5540*
Socket for engine (CRI-T2)

Socket for engine (CRI-T3) PCV
Socket for engine (HPI-T2)

Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2)
q
q
799-601-4110 Adapter for engine (140-T3) PIM
ITT3N
q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM
FCIN
q q
FCIG
q q
799-601-4150 Adapter for engine (CRI-T3) POIL
FCIB
q q

799-601-4160
Oil pressure switch
4160
q q
799-601-4180 Adapter for engine (CRI-T3) PEVA
4180
q q

799-601-4190*
Commonrail pressure
1,2,3L
q q
1,2,3,4C
q q
799-601-4240* Socket for engine (CRI-T3) PAMB
1,2,3A
q q
799-601-4250* Socket for engine (CRI-T3) PIM
1,2,3B
q q
799-601-4330* Socket for engine (CRI-T3) G
1,2,3,G
q q

799-601-4340*
Pump actuator
2,PA
q q
1,2,3,4T
799-601-4260 Adapter for controller (ENG)
DTP4
799-601-4140
799-601-4230*
799-601-4380*

Atomosphere pressure

Air intake pressure/temperature
Socket for engine (CRI-T3)(95)

Air intake pressure/temperature
q
q q
50
DRC50
60
DRC60
799-601-4390* Socket for controller (95 ENG)
60
799-601-4280* Box for controller (PUMP)
121
799-601-9720 Adapter for controller (HST)
16
HST16A
16
HST16B
26
HST26A
2,
3,
4,
799-601-9890
Multi-adapter for
DT2 4 and DTM2
* Shows not T-adapter but socket.
46
D155AX-6
SEN00851-02
40 Troubleshooting
47
D155AX-6
SEN00851-02
40 Troubleshooting
D155AX-6 Bulldozer
2009 KOMATSU
All Rights Reserved
48
D155AX-6
SEN00716-02
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
40 Troubleshooting
Troubleshooting by failure and error

codes, Part 1
Failure code [1500L0] Transmission clutch: Abnormal ................................................................................... 3
Failure code [15SAL1] Forward clutch: Fill high ............................................................................................. 4
Failure code [15SALH] Forward clutch: Fill low .............................................................................................. 5
Failure code [15SBL1] Reverse clutch: Fill high ............................................................................................. 6
Failure code [15SBLH] Reverse clutch: Fill low .............................................................................................. 7
Failure code [15SEL1] Speed 1st clutch: Fill high........................................................................................... 8
Failure code [15SELH] Speed 1st clutch: Fill low ........................................................................................... 9
Failure code [15SFL1] Speed 2nd clutch: Fill high........................................................................................ 10
Failure code [15SFLH] Speed 2nd clutch: Fill low .........................................................................................11
Failure code [15SGL1] Speed 3rd clutch: Fill high........................................................................................ 12
Failure code [15SGLH] Speed 3rd clutch: Fill low......................................................................................... 13
Failure code [15SJL1] L/U: Fill high .............................................................................................................. 14
Failure code [15SJLH] L/U: Fill low............................................................................................................... 16
Failure code [2301L1] Right brake: Fill high ................................................................................................. 18
D155AX-6
SEN00716-02
40 Troubleshooting
Failure code [2301LH] Right brake: Fill low .................................................................................................. 19

Failure code [2302L1] Left brake: Fill high .................................................................................................... 20
Failure code [2302LH] Left brake: Fill low..................................................................................................... 21
Failure code [7RFAKA] ECM HOLD RELAY: Disconnection......................................................................... 22
Failure code [AA10NX] Air Cleaner Clogging ............................................................................................... 24
Failure code [AB00MA] Battery Charge Abnormal........................................................................................ 26
Failure code [B@BAZG] Eng Oil Press Low ................................................................................................. 28
Failure code [B@BCNS] Eng Water Overheat.............................................................................................. 28
Failure code [B@BCZK] Eng Water Level Low............................................................................................. 29
Failure code [B@CENS] T/C Oil Overheat ................................................................................................... 29
Failure code [B@HANS] Hyd Oil Overheat................................................................................................... 30
D155AX-6
40 Troubleshooting
SEN00716-02
Failure code [1500L0] Transmission clutch: Abnormal

Action code
E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Failure code
1500L0
Trouble

(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]
Among failure codes related to transmission clutch, following combinations of failure codes
occurred similarly.
1) [15SAL1] and [15SBL1]
2) [15SALH] and [15SBLH]
3) 2 or all of [15SEL1], [15SFL1], and [15SGL1]
4) 2 or all of [15SELH], [15SFLH], and [15SGLH]
Limits operation of engine and transmission.
Auto-shift-down function does not operate.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to specific gear speed.
Method of reproducing failure code: Start engine + Travel.
Cause
Possible causes
and standard If other failure codes are displayed, carry out troubleshooting for them.
value in normal [15SAL1], [15SALH], [15SBL1], [15SBLH], [15SEL1], [15SELH], [15SFL1], [15SFLH],
state
[15SGL1], [15SGLH], [DXH4KA], [DXH4KB], [DXH5KA], [DXH5KB], [DXH6KA], [DXH6KB]
D155AX-6
SEN00716-02
40 Troubleshooting
Failure code [15SAL1] Forward clutch: Fill high

Action code
Failure code
E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
15SAL1
Trouble
Forward clutch: Fill high

When output to transmission F clutch ECMV solenoid circuit is turned OFF, fill switch signal is
turned ON.
Sets transmission in neutral when operator sets it in reverse position (Prevention of double engagement).
Once machine is stopped, travel is limited to F1.
State of F clutch ECMV fill switch signal can be checked with monitoring function.
(Code: 40906 T/M Fill Sw Input 1)
Method of reproducing failure code: Start engine + Set transmission in neutral.
Cause

a Prepare with starting switch OFF, then start engine and carry
out troubleshooting.
Defective F clutch ECMV fill

switch (Internal short circuit)
FFT (male)
Between (1) chassis ground
Possible causes
and standard
value in normal
state
Ground fault in wiring har2 ness

(Contact with GND circuit)
PCCS lever
(Travel gear speed)
Resistance
Min. 1 Mz
F1, F2, F3
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between STC2 (female) (35)
FFT (female) (1) and chassis ground
Resistance
Min. 1 Mz
3
Defective power train controller
STC2
4 Defective hydraulic system
PCCS lever
(Travel gear speed)
Voltage
5 11 V
F1, F2, F3
Max. 1 V
If causes 1 3 are not detected in electrical system, hydraulic system may be defective. Carry out related troubleshooting (H mode).
Circuit diagram related to transmission F clutch ECMV
D155AX-6
40 Troubleshooting
SEN00716-02
Failure code [15SALH] Forward clutch: Fill low

Action code
Failure code
E03
15SALH
Trouble
Forward clutch: Fill low

Contents of
trouble
When output to transmission F clutch ECMV solenoid circuit is turned ON, fill switch signal is turned
OFF.
Action of
controller
Sets transmission in neutral when operator sets it in forward position (Prevention of double engagement).
Problem that
appears on
machine
Related
information

Once machine is stopped, travel is limited to R1.
State of F clutch ECMV fill switch signal can be checked with monitoring function.
Method of reproducing failure code: Start engine + Set transmission in forward position.
Cause

Defective F clutch ECMV fill

1 switch (Internal disconnection)
Possible causes
and standard
value in normal
state
FFT (male)
PCCS lever
(Travel gear speed)
Resistance
Min. 1 Mz
F1, F2, F3
Max. 1 z
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
ness (Disconnection in wiring
2
or defective contact in con- Wiring harness between STC2 (female) (35)
ResisMax. 1 z
nector)
FFT (female) (1)
tance
3
STC2
PCCS lever
(Travel gear speed)
Voltage
5 11 V
F1, F2, F3
Max. 1 V
D155AX-6
SEN00716-02
40 Troubleshooting
Failure code [15SBL1] Reverse clutch: Fill high

Action code
Failure code
E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
15SBL1
Trouble
Reverse clutch: Fill high

When output to transmission R clutch ECMV solenoid circuit is turned OFF, fill switch signal is
turned ON.
Sets transmission in neutral when operator sets it in forward position (Prevention of double engagement).
State of R clutch ECMV fill switch signal can be checked with monitoring function.
Cause

Defective R clutch ECMV fill

FRT (male)
Possible causes
and standard
value in normal
state
PCCS lever
(Travel gear speed)
Resistance
Min. 1 Mz
R1, R2, R3
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshootGround fault in wiring haring without turning starting switch ON.
2 ness (Contact with GND cirWiring harness between STC2 (female) (25)
Resiscuit)
Min. 1 Mz
FRT (female) (1) and chassis ground
tance
3
STC2
PCCS lever
(Travel gear speed)
Voltage
5 11 V
R1, R2, R3
Max. 1 V
Circuit diagram related to transmission R clutch ECMV
D155AX-6
40 Troubleshooting
SEN00716-02
Failure code [15SBLH] Reverse clutch: Fill low

Action code
Failure code
E03
15SBLH
Trouble
Reverse clutch: Fill low

Contents of
trouble
When output to transmission R clutch ECMV solenoid circuit is turned ON, fill switch signal is turned
OFF.
Action of
controller
Sets transmission in neutral when operator sets it in reverse position (Prevention of double engagement).
Problem that
appears on
machine
Related
information

State of R clutch ECMV fill switch signal can be checked with monitoring function.
Method of reproducing failure code: Start engine + Set transmission in reverse position.
Cause

Defective R clutch ECMV fill

Possible causes
and standard
value in normal
state
FRT (male)
PCCS lever
(Travel gear speed)
Resistance
Min. 1 Mz
R1, R2, R3
Max. 1 z
2
ResisMax. 1 z
nector)
FRT (female) (1)
tance
3
STC2
PCCS lever
(Travel gear speed)
Voltage
5 11 V
R1, R2, R3
Max. 1 V
D155AX-6
SEN00716-02
40 Troubleshooting
Failure code [15SEL1] Speed 1st clutch: Fill high

Action code
Failure code
E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
15SEL1
Trouble
Speed 1st clutch: Fill high

When output to transmission 1st clutch ECMV solenoid circuit is turned OFF, fill switch signal is
turned ON.
Once machine is stopped, travel is limited to F1 and R1.
State of 1st clutch ECMV fill switch signal can be checked with monitoring function.
Cause

a Prepare with starting switch OFF, then start engine, select
manual gearshift mode, and carry out troubleshooting.
Defective 1st clutch ECMV

1 fill switch (Internal short circuit)
Possible causes
and standard
value in normal
state
F1T (male)
PCCS lever
(Travel gear speed)
Resistance
Other than F1, N, or

R1
Min. 1 Mz
F1, R1
Max. 1 z
Resiscuit)
Min. 1 Mz
F1T (female) (1) and chassis ground
tance
3
STC3
PCCS lever
(Travel gear speed)
Voltage

R1
5 11 V
F1, R1
Max. 1 V
Circuit diagram related to transmission 1st clutch ECMV
D155AX-6
40 Troubleshooting
SEN00716-02
Failure code [15SELH] Speed 1st clutch: Fill low

Action code
Failure code
E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
15SELH
Trouble
Speed 1st clutch: Fill low

When output to transmission 1st clutch ECMV solenoid circuit is turned ON, fill switch signal is
turned OFF.
State of 1st clutch ECMV fill switch signal can be checked with monitoring function.
Method of reproducing failure code: Start engine + Set transmission in F1 or R1 position (in manual
gearshift mode).
Cause


1 fill switch (Internal disconnection)
Possible causes
and standard
value in normal
state
F1T (male)
PCCS lever
(Travel gear speed)
Resistance

R1
Min. 1 Mz
F1, R1
Max. 1 z
2
ResisMax. 1 z
nector)
F1T (female) (1)
tance
3
STC3
PCCS lever
(Travel gear speed)
Voltage

R1
5 11 V
F1, R1
Max. 1 V
D155AX-6
SEN00716-02
40 Troubleshooting
Failure code [15SFL1] Speed 2nd clutch: Fill high

Action code
Failure code
E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
15SFL1
Trouble
Speed 2nd clutch: Fill high

When output to transmission 2nd clutch ECMV solenoid circuit is turned OFF, fill switch signal is
turned ON.
State of 2nd clutch ECMV fill switch signal can be checked with monitoring function.
Cause

Defective 2nd clutch ECMV

Possible causes
and standard
value in normal
state
F2T (male)
PCCS lever
(Travel gear speed)
Resistance

R2
Min. 1 Mz
F2, R2
Max. 1 z
Resiscuit)
Min. 1 Mz
tance
3
STC3
PCCS lever
(Travel gear speed)
Voltage

R2
5 11 V
F2, R2
Max. 1 V
Circuit diagram related to transmission 2nd clutch ECMV
10
D155AX-6
40 Troubleshooting
SEN00716-02
Failure code [15SFLH] Speed 2nd clutch: Fill low

Action code
Failure code
E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
15SFLH
Trouble
Speed 2nd clutch: Fill low

When output to transmission 2nd clutch ECMV solenoid circuit is turned ON, fill switch signal is
turned OFF.
State of 2nd clutch ECMV fill switch signal can be checked with monitoring function.
gearshift mode).
Cause


Possible causes
and standard
value in normal
state
F2T (male)
PCCS lever
(Travel gear speed)
Resistance

R2
Min. 1 Mz
F2, R2
Max. 1 z
2
ResisMax. 1 z
nector)
F2T (female) (1)
tance
3
STC3
PCCS lever
(Travel gear speed)
Voltage

R2
5 11 V
F2, R2
Max. 1 V
D155AX-6
11
SEN00716-02
40 Troubleshooting
Failure code [15SGL1] Speed 3rd clutch: Fill high

Action code
Failure code
E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
15SGL1
Trouble
Speed 3rd clutch: Fill high

When output to transmission 3rd clutch ECMV solenoid circuit is turned OFF, fill switch signal is
turned ON.
State of 3rd clutch ECMV fill switch signal can be checked with monitoring function.
Cause

Defective 3rd clutch ECMV

Possible causes
and standard
value in normal
state
F3T (male)
PCCS lever
(Travel gear speed)
Resistance

R3
Min. 1 Mz
F3, R3
Max. 1 z
Resiscuit)
Min. 1 Mz
tance
3
STC3
PCCS lever
(Travel gear speed)
Voltage

R3
5 11 V
F3, R3
Max. 1 V
Circuit diagram related to transmission 3rd clutch ECMV
12
D155AX-6
40 Troubleshooting
SEN00716-02
Failure code [15SGLH] Speed 3rd clutch: Fill low

Action code
Failure code
E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
15SGLH
Trouble
Speed 3rd clutch: Fill low

When output to transmission 3rd clutch ECMV solenoid circuit is turned ON, fill switch signal is
turned OFF.
State of 3rd clutch ECMV fill switch signal can be checked with monitoring function.
gearshift mode).
Cause


Possible causes
and standard
value in normal
state
F3T (male)
PCCS lever
(Travel gear speed)
Resistance

R3
Min. 1 Mz
F3, R3
Max. 1 z
2
ResisMax. 1 z
nector)
F3T (female) (1)
tance
3
STC3
PCCS lever
(Travel gear speed)
Voltage

R3
5 11 V
F3, R3
Max. 1 V
If causes 1 - 3 are not detected in electrical system, hydraulic system may be defective. Carry out related troubleshooting (H mode).
D155AX-6
13
SEN00716-02
40 Troubleshooting
Failure code [15SJL1] L/U: Fill high

Action code
Failure code
E02
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
15SJL1
Trouble
L/U: Fill high

When output to torque converter lockup clutch ECMV solenoid circuit is turned OFF, fill switch signal is turned ON.
None in particular.
Engine may stall during travel.
State of lockup clutch ECMV fill switch signal can be checked with monitoring function.
Method of reproducing failure code: Start engine + Set transmission in forward position (in automatic gearshift mode).
Cause

automatic gearshift mode, and carry out troubleshooting.
Defective lockup clutch

1 ECMV fill switch (Internal
short circuit)
Possible causes
and standard
value in normal
state
FLUC (male)
PCCS lever
(Travel gear speed)
Resistance
Min. 1 Mz
Locked up at F1, F2,

or F3
Max. 1 z
Resiscuit)
Min. 1 Mz
FLUC (female) (1) and chassis ground
tance
3
14
STC2
PCCS lever
(Travel gear speed)
N
Between (36) chasLocked up at F1, F2,
sis ground
or F3
Voltage
5 11 V
Max. 1 V
D155AX-6
40 Troubleshooting
SEN00716-02
Circuit diagram related to torque converter lockup clutch ECMV
D155AX-6
15
SEN00716-02
40 Troubleshooting
Failure code [15SJLH] L/U: Fill low

Action code
Failure code
E02
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
15SJLH
Trouble
L/U: Fill low

When output to torque converter lockup clutch ECMV solenoid circuit is turned ON, fill switch signal
is turned OFF.
None in particular.
State of lockup clutch ECMV fill switch signal can be checked with monitoring function.
Method of reproducing failure code: Start engine + Set transmission in forward position (in automatic gearshift mode).
Cause


1 ECMV fill switch (Internal disconnection)
Possible causes
and standard
value in normal
state
FLUC (male)
PCCS lever
(Travel gear speed)
Resistance
Min. 1 Mz
Locked up at F1, F2,

or F3
Max. 1 z
2
ResisMax. 1 z
nector)
FLUC (female) (1)
tance
3
16
STC2
PCCS lever
(Travel gear speed)
N
sis ground
or F3
Voltage
5 11 V
Max. 1 V
D155AX-6
40 Troubleshooting
SEN00716-02
D155AX-6
17
SEN00716-02
40 Troubleshooting
Failure code [2301L1] Right brake: Fill high

Action code
Failure code
E04
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
2301L1
Trouble

When output to steering case right brake ECMV solenoid circuit is turned OFF, fill switch signal is
turned ON.
Limits operation of engine, transmission, and brake.
Applies brake lightly during travel.
Once machine is stopped, machine cannot travel at all.
State of right brake ECMV fill switch signal can be checked with monitoring function.
(Code: 31521 S/T Fill Sw Input)
Method of reproducing failure code: Start engine + Operate parking brake lever (Free) + Operate
brake pedal (Press).
Cause
Defective right brake ECMV
Possible causes
and standard
value in normal
state

a Prepare with starting switch OFF, then start engine, set parking
brake lever in Free position, and carry out troubleshooting.
FBRR (male)
Brake pedal
Resistance
Released
Max. 1 z
Pressed
Min. 1 Mz
2 ness (Contact with GND cirWiring
harness between STC2 (female) (38)
Resiscuit)
Min. 1 Mz
FBRR (female) (1) and chassis ground
tance
3
STC2
Brake pedal
Voltage
Released
Max. 1 V
Pressed
5 11V
Circuit diagram related to steering case right brake ECMV
18
D155AX-6
40 Troubleshooting
SEN00716-02
Failure code [2301LH] Right brake: Fill low

Action code
Failure code
E04
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
2301LH
Trouble
Right brake: Fill low

When output to steering case right brake ECMV solenoid circuit is turned ON, fill switch signal is
turned OFF.
State of right brake ECMV fill switch signal can be checked with monitoring function.
Cause
Possible causes
and standard
value in normal
state

FBRR (male)
Brake pedal
Resistance
Released
Max. 1 z
Pressed
Min. 1 Mz
2
ResisMax. 1 z
nector)
FBRR (female) (1)
tance
3
STC2
Brake pedal
Voltage
Released
Max. 1 V
Pressed
5 11 V
D155AX-6
19
SEN00716-02
40 Troubleshooting
Failure code [2302L1] Left brake: Fill high

Action code
Failure code
E04
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
2302L1
Trouble

When output to steering case left brake ECMV solenoid circuit is turned OFF, fill switch signal is
turned ON.
State of left brake ECMV fill switch signal can be checked with monitoring function.
Cause

Possible causes
and standard
value in normal
state
Defective left brake ECMV fill

FBRL (male)
Brake pedal
Resistance
Released
Max. 1 z
Pressed
Min. 1 Mz
Resiscuit)
Min. 1 Mz
FBRL (female) (1) and chassis ground
tance
3
STC2
Brake pedal
Voltage
Released
Max. 1 V
Pressed
5 11 V
Circuit diagram related to steering case left brake ECMV
20
D155AX-6
40 Troubleshooting
SEN00716-02
Failure code [2302LH] Left brake: Fill low

Action code
Failure code
E04
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
2302LH
Trouble
Left brake: Fill low

When output to steering case left brake ECMV solenoid circuit is turned ON, fill switch signal is
turned OFF.
State of left brake ECMV fill switch signal can be checked with monitoring function.
Cause

Possible causes
and standard
value in normal
state
Defective left brake ECMV fill

FBRL (male)
Brake pedal
Resistance
Released
Max. 1 z
Pressed
Min. 1 Mz
2
ResisMax. 1 z
nector)
FBRL (female) (1)
tance
3
STC2
Brake pedal
Voltage
Released
Max. 1 V
Pressed
5 11 V
D155AX-6
21
SEN00716-02
40 Troubleshooting
Failure code [7RFAKA] ECM HOLD RELAY: Disconnection

Action code
Failure code
7RFAKA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
ECM HOLD RELAY: Disconnection

When ground circuit of engine cut relay circuit is disconnected to turn output ON, no current flows.
None in particular.
When engine cut mechanism is installed, engine cannot be cut (stopped).
State of engine cut relay circuit signal can be checked with monitoring function.
(Code: 40912 P/T Sw Input)
Method of reproducing failure code: Start engine.
This failure code detects abnormality on primary side (coil side) of engine cut relay but does not
detect abnormality on secondary side (contact side).
Cause
Defective engine cut relay

(Internal disconnection)

ACT (male)
Resistance
Between (1) (2)
200 400 z
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between STC2 (female) (19)
2
or defective contact in con- ACT (female) (2)
nector)
Wiring harness between ACT (female) (1)
terminal 270.
Max. 1 z
Resistance
Max. 1 z
Short circuit in wiring harWiring harness between STC2 (female) (19)
3 ness (Contact with GND cir- ACT (female) (2) and chassis ground
cuit)
Wiring harness between ACT (female) (1),
(3) terminal 270, circuit branch end and
chassis ground.
Defective power train con4
troller
22
Resistance
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON

and carry out troubleshooting.
STC2
Voltage
20 30 V
D155AX-6
40 Troubleshooting
SEN00716-02
Circuit diagram related to engine cut relay
D155AX-6
23
SEN00716-02
40 Troubleshooting
Failure code [AA10NX] Air Cleaner Clogging

Action code
Failure code
Contents of
trouble
AA10NX
Trouble
Air Cleaner Clogging

(Machine monitor system)
While engine was running, air cleaner clogging switch signal circuit detected clogging of air cleaner
(opening of sensor contact).
Action of
None in particular.
machine monitor
Problem that
appears on
machine
Related
information
If machine is used as it is, engine may be damaged.

Cause
1
Clogged air cleaner

(When system is normal)

a Air cleaner may be clogged. Check and clean or replace it.
Defective air cleaner clog2 ging switch (Internal disconnection)
Possible causes
and standard
value in normal
state
AF1 (male)
Between (1) (2)
Air cleaner
Resistance
Normal (Intake air

resistance: *1)
Max. 1 z
Clogged (Intake air

resistance: *2)
Min. 1 Mz
Disconnection in wiring harness (Disconnection in wiring Wiring harness between CM02 (female) (4)
3
or defective contact in con- AF1 (female) (1)
nector)
Wiring harness between CM01 (female) (7),
CM02 (female) (7) AF1 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
troller
CM02
Between (4) (7)
Air cleaner
Voltage
Normal (Intake air

resistance: *1)
Max. 1 V
Clogged (Intake air

resistance: *2)
20 30 V
*1: Max. -3,430 Pa {-350 mmH2O}

*2: -7,470 490Pa {-762 50 mmH2O}
24
D155AX-6
40 Troubleshooting
SEN00716-02
Circuit diagram related to air cleaner clogging switch
D155AX-6
25
SEN00716-02
40 Troubleshooting
Failure code [AB00MA] Battery Charge Abnormal

Action code
Failure code
AB00MA
Contents of
trouble
Trouble
Battery Charge Abnormal

While engine was running, alternator signal circuit detected that battery charge voltage was low.
Action of
Displays charge level monitor red on machine monitor.
machine monitor
Problem that
appears on
machine
Related
information
If machine is used as it is, battery may not be charged.

Battery voltage can be checked with monitoring function.
(Code: 03203 Battery Power Supply)
Cause
Possible causes
and standard
value in normal
state
26
Defective charge by alternator (When system is normal)

CM01
Engine
Voltage
Above medium
speed
27.5 29.5 V
If cause 1 is not detected, charge level monitor system may be

Defective charge level monidefective. Carry out "E-5 Caution item lights up while engine is
tor system
running" in E mode.
D155AX-6
40 Troubleshooting
SEN00716-02
Circuit diagram related to preheating/starting/charging of engine
D155AX-6
27
SEN00716-02
40 Troubleshooting
Failure code [B@BAZG] Eng Oil Press Low

Action code
Failure code
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
B@BAZG
Trouble
Eng Oil Press Low

(Engine controller system)
While engine was running, engine oil pressure sensor signal circuit detected that engine oil pressure was abnormally low.
Displays engine oil pressure monitor red on machine monitor.
If machine is used as it is, engine may be seized.
Engine oil pressure sensor signal is input to engine controller and then transmitted to machine monitor through communication system.
Engine oil pressure can be checked with monitoring function.
(Code: 37200 Engine Oil Pressure)
Cause
Possible causes
and standard
value in normal
state
Low engine oil pressure

If cause 1 is not detected, engine oil pressure sensor may be

Defective engine oil pressure
defective. Carry out troubleshooting for failure codes [CA135] and
sensor system
[CA141].
Check engine oil pressure. If it is low, remove cause.
Failure code [B@BCNS] Eng Water Overheat

Action code
Failure code
B@BCNS
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
28
Eng Water Overheat

While engine was running, engine coolant temperature sensor signal circuit detected that engine
coolant was overheated.
Displays engine coolant temperature monitor red on machine monitor.
If machine is used as it is, engine may be seized.
Engine coolant temperature sensor signal is input to engine controller and then transmitted to
machine monitor through communication system.
Engine coolant temperature can be checked with monitoring function.
(Code: 04107 Coolant Temperature)
Cause
Possible causes
and standard
value in normal
state
Overheated engine coolant

Check engine coolant for overheating. If it is overheated, remove

cause.
Defective engine coolant

temperature sensor system
If cause 1 is not detected, engine coolant temperature sensor may

be defective. Carry out troubleshooting for failure codes [CA144]
and [CA145].
D155AX-6
40 Troubleshooting
SEN00716-02
Failure code [B@BCZK] Eng Water Level Low

Action code
Failure code
Contents of
trouble
B@BCZK
Trouble
Eng Water Level Low

(Machine controller system)
While starting switch was ON (and engine was stopped) or engine was running, radiator coolant
level switch signal circuit detected that radiator coolant level was low (sensor contact was open).
Action of
Displays radiator coolant level monitor red on machine monitor.
machine monitor
Problem that
appears on
machine
Related
information
If machine is used as it is, engine may be overheated.

Cause
Possible causes
and standard
value in normal
state
Low coolant level

Check radiator sub tank for lowering of coolant level. If coolant

level is low, add coolant.
Defective radiator coolant

level monitor system
If cause 1 is not detected, radiator coolant level monitor may be

defective. Carry out "E-2 Caution item lights up while starting
switch is ON (and engine is stopped)" in E mode.
Failure code [B@CENS] T/C Oil Overheat

Action code
Failure code
B@CENS
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
D155AX-6
T/C Oil Overheat

While engine was running, torque converter oil temperature sensor signal circuit detected that
power train oil was overheated.
Displays torque converter oil temperature monitor red on machine monitor.
If machine is used as it is, power train components may be damaged.
Torque converter oil temperature sensor signal is input to power train controller and then transmitted to machine monitor through communication system.
Power train oil temperature can be checked with monitoring function.
(Code: 30100 T/C Oil Temperature)
Cause
Possible causes
and standard
value in normal
state
Overheated power train oil

1
Check power train oil for overheating. If it is overheated, remove

cause.
Defective torque converter

2 oil temperature sensor system
If cause 1 is not detected, torque converter oil temperature sensor

system may be defective. Carry out troubleshooting for failure
code [DGT1KA] or [DGT1KX].
29
SEN00716-02
40 Troubleshooting
Failure code [B@HANS] Hyd Oil Overheat

Action code
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Failure code
B@HANS
Trouble
30
Hyd Oil Overheat

While engine was running, hydraulic oil temperature sensor signal circuit detected that hydraulic oil
was overheated.
Displays hydraulic oil temperature monitor red on machine monitor.
If machine is used as it is, work equipment and HSS circuit components may be damaged.
Hydraulic oil temperature can be checked with monitoring function.
(Code: 04401 Hyd Oil Temperature)
Cause
Possible causes
and standard
value in normal
state
Overheated hydraulic oil

1
Check hydraulic oil for overheating. If it is overheated, remove

cause.
Defective hydraulic oil tem2

perature gauge system
If cause 1 is not detected, hydraulic oil temperature gauge system

may be defective. Carry out troubleshooting for "E-10 Hydraulic oil
temperature gauge (Multi-gauge) does not indicated normally" in E
mode.
D155AX-6
40 Troubleshooting
D155AX-6
SEN00716-02
31
SEN00716-02
40 Troubleshooting
D155AX-6 Bulldozer
2008 KOMATSU
All Rights Reserved
32
D155AX-6
SEN00717-03
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
40 Troubleshooting

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
Failure code [CA221] Ambient Press Sens High Error ................................................................................. 28
D155AX-6
SEN00717-03
40 Troubleshooting
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...................................................................................... 40
Failure code [CA271] PCV1 Short Error ....................................................................................................... 41
Failure code [CA272] PCV1 Open Error ....................................................................................................... 42
Failure code [CA273] PCV2 Short Error ....................................................................................................... 43
Failure code [CA274] PCV2 Open Error ....................................................................................................... 44
Failure code [CA322] Inj #1 (L#1) Open/Short Error..................................................................................... 46
Failure code [CA342] Calibration Code Incompatibility ................................................................................. 58
Failure code [CA351] Injectors Drive Circuit Error ........................................................................................ 60
Failure code [CA352] Sens Supply 1 Volt Low Error..................................................................................... 62
Failure code [CA386] Sens Supply 1 Volt High Error.................................................................................... 64
Failure code [CA441] Battery Voltage Low Error .......................................................................................... 66
Failure code [CA442] Battery Voltage High Error.......................................................................................... 66
Failure code [CA449] Rail Press Very High Error ......................................................................................... 67
Failure code [CA451] Rail Press Sensor High Error ..................................................................................... 68
Failure code [CA452] Rail Press Sensor Low Error ...................................................................................... 70
Failure code [CA553] Rail Press High Error.................................................................................................. 70
Failure code [CA554] Rail Press Sensor In Range Error .............................................................................. 71
Failure code [CA559] Rail Press Low Error .................................................................................................. 72
Failure code [CA689] Eng Ne Speed Sensor Error....................................................................................... 76
D155AX-6
40 Troubleshooting
D155AX-6
SEN00717-03
SEN00717-03
40 Troubleshooting
Failure code [CA111] EMC Critical Internal Failure

Action code
Failure code
E04
CA111
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

Trouble occurred in engine controller.

None in particular.
Engine runs normally but may stop during operation or may not be able to start.
Source voltage of engine controller can be checked with monitoring function.
Cause
1
Defective circuit breaker

(CB30 or CB8)

If circuit breaker is turned OFF, circuit probably has ground fault.
(See cause 3.)
Disconnection in wiring harness (Disconnection in wiring

2
or defective contact in connector)
Wiring harness between EGC3 (female) (3),

(4) CB8 (2)
Resistance
Max. 1 z
Wiring harness between CB8 (1) CB30

(B30S)
Resistance
Max. 1 z
Wiring harness between CB30 (B30L) terminal BRB
Resistance
Max. 1 z

(2) chassis ground (GND20)
Resistance
Max. 1 z
Possible causes
and standard
value in normal
state

(4) CB8 (2) and chassis ground
Ground fault in wiring har(B30S), circuit branch end and chassis
3 ness (Contact with GND cirground
cuit)
Wiring harness between CB30 (B30L) terminal BRB and chassis ground
(2) chassis ground (GND20) and chassis
ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

4 Defective engine controller
EGC3
Starting switch
Voltage
Between (3), (4)

(1), (2)
ON
20 30 V
D155AX-6
40 Troubleshooting
SEN00717-03
Circuit diagram related to engine controller power supply
D155AX-6
SEN00717-03
40 Troubleshooting
Failure code [CA115] Eng Ne and Bkup Speed Sens Error

Action code
Failure code
E04
CA115
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

Trouble occurred in Ne speed sensor circuit and Bkup speed sensor circuit simultaneously.
None in particular.
Engine cannot be started (if engine has been stopped).
Engine stops (if engine has been running).
Related
information
Cause
Possible causes
and standard
value in normal
state
Defective Ne speed sensor

system
Ne speed sensor system may be defective. Carry out troubleshooting for code [CA689].
Defective Bkup speed sensor system
Bkup speed sensor system may be defective. Carry out troubleshooting for code [CA778].
Defective mount of Ne speed Check mount of Ne speed sensor directly for defect (defective
sensor
installation of sensor, internal trouble of flywheel, etc.)
Defective mount of Bkup

speed sensor
Defective connection (Wrong Check Ne speed sensor and Bkup speed sensor directly for defecconnection) of sensor
tive connection (wrong connection).
Check mount of Bkup speed sensor directly for defect (defective

installation of sensor, internal trouble of supply pump, etc.)
If causes 1 5 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried
out.)
D155AX-6
40 Troubleshooting
D155AX-6
SEN00717-03
SEN00717-03
40 Troubleshooting
Failure code [CA122] Chg Air Press Sensor High Error

Action code
Failure code
E03
CA122
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

Signal voltage in charge pressure sensor circuit is abnormally high.

Fixes charge pressure (400 kPa {4.08 kg/cm2}) and continues operation.
Acceleration performance of engine lowers or black smoke is produced more during acceleration.
State of charge pressure sensor can be checked with monitoring function.
(Code: 36500 Charge Pressure-Abs)
Cause
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.
2
Defective charge pressure

sensor (Internal trouble)
PIM
Between (1) (2)
Voltage
Power supply
4.75 5.25 V
Pressure sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness
and controller, too, for another cause of trouble, and then judge.
3
Possible causes
and standard
value in normal
state
Wiring harness between ENG (female) (37)

PIM (female) (1)
Resistance
Max. 1 z

PIM (female) (2)
Resistance
Max. 1 z

PIM (female) (3)
Resistance
Max. 1 z
Ground fault in wiring har PIM (female) (1) and chassis ground
4 ness (Contact with GND cirWiring harness between ENG (female) (47)
cuit)
PIM (female) (2) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

PIM (female) (3) and chassis ground
Resistance
Min. 1 Mz
Short circuit in wiring har5 ness (with another wiring

harness)

PIM (female) (1) and between ENG
(female) (47) PIM (female) (2)
Resistance
Min. 1 Mz

PIM (female) (1) and between ENG
Resistance
Min. 1 Mz
Chassis ground between ENG (female)

(47) PIM (female) (2) and between ENG
Resistance
Min. 1 Mz

ENG
Between (37) (47)
Voltage
Power supply
4.75 5.25 V
D155AX-6
40 Troubleshooting
SEN00717-03
Circuit diagram related to charge pressure sensor
D155AX-6
SEN00717-03
40 Troubleshooting
Failure code [CA123] Chg Air Press Sensor Low Error

Action code
Failure code
E03
CA123
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
10
Trouble

Signal voltage in charge pressure sensor circuit is abnormally low.

Fixes charge pressure (400 kPa {4.08 kg/cm2}) and continues operation.
Acceleration performance of engine lowers or black smoke is produced more during acceleration.
State of charge pressure sensor can be checked with monitoring function.
(Code: 36500 Charge Pressure-Abs)
Cause

Carry out troubleshooting for failure code [CA122].
D155AX-6
40 Troubleshooting
D155AX-6
SEN00717-03
11
SEN00717-03
40 Troubleshooting
Failure code [CA131] Throttle Sensor High Error

Action code
Failure code
E03
CA131
Contents of
trouble
Action of
controller
Trouble

Signal voltage in decelerator pedal potentiometer circuit is abnormally high.

Sets throttle position with fuel control dial signal and continues operation.
Problem that
appears on
machine
Related
information
State of decelerator pedal optimum operation range signal can be checked with monitoring function.
(Code: 03001 Throttle Pos Sens Volt)
Cause
1
Defective sensor power sup- If code [CA2185] or [CA2186] is indicated, carry out troubleshootply system
ing for it first.
Defective fuel control dial

(Internal trouble)
DCL (male)
Resistance
Between (B) (C)
1.5 2.5 kz
Between (A) (B)
0 3 kz
Between (A) (C)
0 3 kz
Possible causes
and standard
value in normal
state

3
Wiring harness between EGC2 (female) (9)

DCL (female) (A)
Resistance
Max. 1 z
Wiring harness between EGC2 (female)

(22) DCL (female) (B)
Resistance
Max. 1 z

(23) DCL (female) (C)
Resistance
Max. 1 z
Wiring harness between EGC2 (female) (9)
Ground fault in wiring har DCL (female) (A) and chassis ground
4 ness (Contact with GND cirWiring harness between EGC2 (female)
cuit)
(22) DCL (female) (B) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

(23) DCL (female) (C) and chassis ground
Resistance
Min. 1 Mz

12
EGC2
Voltage
Between (22) (23)
Power supply
4.75 5.25 V
Between (9) (23)
Signal
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00717-03
Circuit diagram related to decelerator pedal potentiometer
D155AX-6
13
SEN00717-03
40 Troubleshooting
Failure code [CA132] Throttle Sensor Low Error

Action code
Failure code
E03
CA132
Trouble

Contents of
trouble
Signal voltage in decelerator pedal potentiometer circuit is abnormally low.
Action of
controller
Sets throttle position with fuel control dial signal and continues operation.
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
14
State of decelerator pedal optimum operation range signal can be checked with monitoring function.
(Code: 03001 Throttle Pos Sens Volt)
Cause

D155AX-6
40 Troubleshooting
D155AX-6
SEN00717-03
15
SEN00717-03
40 Troubleshooting
Failure code [CA135] Eng Oil Press Sensor High Error

Action code
Failure code
E02
CA135
Contents of
trouble
Action of
controller
Trouble

Signal voltage in engine oil pressure sensor circuit is abnormally high.

Sets engine oil pressure to default value (250 kPa {2.55 kg/cm2}) and continues operation.
Problem that
appears on
machine
Related
information
State of engine oil pressure sensor can be checked with monitoring function.
(Code: 37201 Eng Oil Press Sens Volt)
Cause
1
ply system
for it first.

POIL
Between (1) (2)
Voltage
Power supply
4.75 5.25 V
Sensor voltage is measured with wiring harness connected.

Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge.
3
Possible causes
and standard
value in normal
state

POIL (female) (1)
Resistance
Max. 1 z

POIL (female) (2)
Resistance
Max. 1 z

POIL (female) (3)
Resistance
Max. 1 z
Ground fault in wiring har POIL (female) (1) and chassis ground
cuit)
POIL (female) (2) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

POIL (female) (3) and chassis ground
Resistance
Min. 1 Mz

harness)

POIL (female) (1) and between ENG
(female) (47) POIL (female) (2)
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

ENG
Between (37) (47)
16
Voltage
Power supply
4.75 5.25 V
D155AX-6
40 Troubleshooting
SEN00717-03
Circuit diagram related to engine oil pressure sensor
D155AX-6
17
SEN00717-03
40 Troubleshooting
Failure code [CA141] Eng Oil Press Sensor Low Error

Action code
Failure code
E02
CA141
Contents of
trouble
Action of
controller
Trouble

Signal voltage in engine oil pressure sensor circuit is abnormally low.

Sets engine oil pressure to default value (250 kPa {2.55 kg/cm2}) and continues operation.
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
18
State of engine oil pressure sensor can be checked with monitoring function.
(Code: 37201 Eng Oil Press Sens Volt)
Cause

D155AX-6
40 Troubleshooting
D155AX-6
SEN00717-03
19
SEN00717-03
40 Troubleshooting
Failure code [CA144] Coolant Temp Sens High Error

Action code
Failure code
E02
CA144
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

Signal voltage in engine coolant temperature sensor circuit is abnormally high.

Fixes engine coolant temperature (90C) and continues operation.
Startability of engine lowers at low temperature.

State of engine coolant temperature sensor can be checked with monitoring function.
(Code: 04105 Coolant Temp Sens Volt)
Cause

TWTR (male)

1 temperature sensor (Internal
trouble)
Between (A) (B)
Possible causes
and standard
value in normal
state
Coolant temperature
Resistance
0C
30 37 kz
25C
9.3 10.7 kz
50C
3.2 3.8 kz
80C
1.0 1.3 kz
95C
700 800 z
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female) (15)
Resis2
Max. 1 z
or defective contact in con- TWTR (female) (A)
tance
nector)
ResisMax. 1 z
TWTR (female) (B)
tance
Resiscuit)
Min. 1 Mz
TWTR (female) (A) and chassis ground
tance
ENG (female)
Between (15) (38)
20
Coolant temperature
Resistance
0C
30 37 kz
25C
9.3 10.7 kz
50C
3.2 3.8 kz
80C
1.0 1.3 kz
95C
700 800 z
D155AX-6
40 Troubleshooting
SEN00717-03
Circuit diagram related to engine coolant temperature sensor
D155AX-6
21
SEN00717-03
40 Troubleshooting
Failure code [CA145] Coolant Temp Sens Low Error

Action code
Failure code
E02
CA145
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
22
Trouble

Signal voltage in engine coolant temperature sensor circuit is abnormally low.

Fixes engine coolant temperature (90C) and continues operation.

State of engine coolant temperature sensor can be checked with monitoring function.
(Code: 04105 Coolant Temp Sens Volt)
Cause

D155AX-6
40 Troubleshooting
D155AX-6
SEN00717-03
23
SEN00717-03
40 Troubleshooting
Failure code [CA153] Chg Air Temp Sensor High Error

Action code
Failure code
E01
CA153
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

Signal voltage in charge temperature sensor circuit is abnormally high.

Fixes charge temperature (intake air temperature) (70C) and continues operation.

State of charge temperature sensor signal can be checked with monitoring function.
(Code: 18501 Charge Temp Sens Volt)
Cause

TIM (male)
Defective charge temperature sensor (Internal trouble)
Between (A) (B)
Between (A) chassis ground
Intake air
temperature
Resistance
0C
29 36 kz
25C
9 11 kz
40C
4.9 5.8 kz
100C
600 700 z
All range
Min. 1 Mz
Possible causes
and standard
value in normal
state
2
or defective contact in con- TIM (female) (A)
nector)
TIM (female) (B)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resiscuit)
Min. 1 Mz
TIM (female) (A) and chassis ground
tance
ENG (female)
Between (23) (47)
24
Intake air
temperature
Resistance
0C
29 36 kz
25C
9 11 kz
40C
4.9 5.8 kz
100C
600 700 z
D155AX-6
40 Troubleshooting
SEN00717-03
Circuit diagram related to charge temperature sensor
D155AX-6
25
SEN00717-03
40 Troubleshooting
Failure code [CA154] Chg Air Temp Sensor Low Error

Action code
Failure code
E01
CA154
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

Signal voltage in charge temperature sensor circuit is abnormally low.

Fixes charge temperature (intake air temperature) (70C) and continues operation.

State of charge temperature sensor signal can be checked with monitoring function.
(Code: 18501 Charge Temp Sens Volt)
Possible causes
and standard
value in normal
state
Cause

Failure code [CA187] Sens Supply 2 Volt Low Error

Action code
Failure code
E03
CA187
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

Signal voltage in sensor power supply 2 (5 V) circuit is abnormally low.
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.
Fixes charge pressure sensor value (400 kPa {4.08 kg/cm2}) and continues operation.
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.
Engine output drops.
Related
information
Possible causes
and standard
value in normal
state
26
Cause

D155AX-6
40 Troubleshooting
D155AX-6
SEN00717-03
27
SEN00717-03
40 Troubleshooting
Failure code [CA221] Ambient Press Sens High Error

Action code
Failure code
E03
CA221
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

Signal voltage in ambient pressure sensor circuit is abnormally high.

Sets ambient pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.
State of ambient pressure sensor signal can be checked with monitoring function.
(Code: 37401 Ambient Press Sens Volt)
Cause
1
ply system
for it first.
PAMB
2
Defective ambient pressure

Voltage
Between (1) (2)
Power supply
Between (3) (2)
Signal
4.75 5.25 V

3
Possible causes
and standard
value in normal
state

PAMB (female) (1)
Resistance
Max. 1 z

PAMB (female) (2)
Resistance
Max. 1 z

PAMB (female) (3)
Resistance
Max. 1 z
Ground fault in wiring har PAMB (female) (1) and chassis ground
cuit)
PAMB (female) (2) and chassis ground
PAMB (female) (3) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

harness)

PAMB (female) (1) and between ENG
(female) (38) - PAMB (female) (2)
Resistance
Min. 1 Mz

(female) (3) PAMB (female) (3)
Resistance
Min. 1 Mz

(female) (3) PAMB (female) (3)
Resistance
Min. 1 Mz
a repare with starting switch OFF, then turn starting switch ON or

start engine and carry out troubleshooting.
ENG
Voltage
Between (33) (38)
4.75 5.25 V
Between (3) (38)
28
D155AX-6
40 Troubleshooting
SEN00717-03
Circuit diagram related to ambient pressure sensor
D155AX-6
29
SEN00717-03
40 Troubleshooting
Failure code [CA222] Ambient Press Sens Low Error

Action code
Failure code
E03
CA222
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
30
Trouble

Signal voltage in ambient pressure sensor circuit is abnormally low.


State of ambient pressure sensor signal can be checked with monitoring function.
(Code: 37401 Ambient Press Sens Volt)
Cause

D155AX-6
40 Troubleshooting
D155AX-6
SEN00717-03
31
SEN00717-03
40 Troubleshooting
Failure code [CA227] Sens Supply 2 Volt High Error

Action code
Failure code
E03
CA227
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

Signal voltage in sensor power supply 2 (5 V) circuit is abnormally high.
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.
Fixes charge pressure sensor value (400 kPa [4.08 kg/cm2}) and continues operation.
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.
Related
information
Cause
1 Defective related system

If another failure code is indicated, carry out troubleshooting for it.
Defective sensor (Internal

2
trouble)
Possible causes
and standard
value in normal
state
Disconnect devices
at right in order. If
"E" of failure code
disappears when a
device is disconnected, that device
has trouble in it.
Bkup speed sensor
G connector
Oil pressure sensor
POIL connector
Ambient pressure
sensor
PAMB connector
Charge pressure
sensor
PIM connector
EGR inlet pressure

sensor
PEVA connector
EGR valve lift sensor
SEGR connector
Bypass valve lift sensor
SBP connector
Resis3
Max. 1 z
or defective contact in con- each sensor (female)
tance
nector)
ResisMax. 1 z
each sensor (female)
tance
Ground fault in wiring harWiring harness between ENG (female) (37)
4 ness (Contact with GND cir each sensor (female) and chassis ground
cuit)
each sensor (female) and chassis ground
harness)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
each sensor (female) and between ENG
(female) (47) each sensor (female)
Resistance
Min. 1 Mz

32
ENG
Voltage
Between (37) (47)
4.75 5.25 V
D155AX-6
40 Troubleshooting
SEN00717-03
Circuit diagram related to engine controller sensor power supply 2 (5 V)
D155AX-6
33
SEN00717-03
40 Troubleshooting
Failure code [CA234] Eng Overspeed

Action code
Failure code
CA234
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
34
Eng Overspeed
Engine speed is above operating range.

Limits fuel injection rate until engine speed lowers to operating range.
Engine speed fluctuates.

Engine speed can be checked with monitoring function.
(Code: 01002 Engine Speed)
Cause
Possible causes
and standard
value in normal
state
2 Improper way of use
Way of use of machine may be improper. Teach proper way of use

to operator.
out.)
D155AX-6
40 Troubleshooting
D155AX-6
SEN00717-03
35
SEN00717-03
40 Troubleshooting
Failure code [CA238] Ne Speed Sens Supply Volt Error

Action code
Failure code
E03
CA238
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

Trouble occurred in Ne speed sensor power supply (5 V) circuit.

Controls Ne speed sensor with signals of Bkup speed sensor.
Running engine stops (when Bkup speed sensor is also abnormal).
Stopped engine cannot be started (when Bkup speed sensor is also abnormal).
Related
information
Cause

Defective Ne speed sensor

(Internal trouble)
Disconnect devices
"E" of failure code
disappears when a
has trouble in it.
Engine Ne speed
sensor
NE connector
Possible causes
and standard
value in normal
state
2
or defective contact in con- NE (female) (1)
nector)
NE (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
3 ness (Contact with GND cir NE (female) (1) and chassis ground
cuit)
NE (female) (2) and chassis ground
harness)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
NE (female) (1) and between ENG
(female) (48) NE (female) (2)
Resistance
Min. 1 Mz

36
ENG
Voltage
Between (16) (48)
4.75 5.25 V
D155AX-6
40 Troubleshooting
SEN00717-03
Circuit diagram related to engine NE speed sensor
D155AX-6
37
SEN00717-03
40 Troubleshooting
Failure code [CA263] Fuel Temp Sensor High Error

Action code
Failure code
E01
CA263
Contents of
trouble
Action of
controller
Trouble

Signal voltage in fuel temperature sensor circuit is abnormally high.

Fixes fuel temperature (90 C) and continues operation.
Problem that
appears on
machine
Related
information
State of fuel temperature sensor signal can be checked with monitoring function.
(Code: 14201 Fuel Temp Sens Volt)
Cause

TFUEL (male)
Defective fuel temperature

Between (A) (B)
Possible causes
and standard
value in normal
state
Fuel temperature
Resistance
0C
30 37 kz
25C
9.3 10.7 kz
50C
3.2 3.8 kz
80C
1.0 1.3 kz
95C
700 800 z
Resis2
Max. 1 z
or defective contact in con- TFUEL (female) (A)
tance
nector)
ResisMax. 1 z
TFUEL (female) (B)
tance
Resiscuit)
Min. 1 Mz
TFUEL (female) (A) and chassis ground
tance
ENG (female)
Between (30) (47)
38
Fuel temperature
Resistance
0C
30 37 kz
25C
9.3 10.7 kz
50C
3.2 3.8 kz
80C
1.0 1.3 kz
95C
700 800 z
D155AX-6
40 Troubleshooting
SEN00717-03
Circuit diagram related to fuel temperature sensor
D155AX-6
39
SEN00717-03
40 Troubleshooting
Failure code [CA265] Fuel Temp Sensor Low Error

Action code
Failure code
E01
CA265
Contents of
trouble
Action of
controller
Trouble

Signal voltage in fuel temperature sensor circuit is abnormally low.

Fixes fuel temperature (90C) and continues operation.
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
40
Cause

D155AX-6
40 Troubleshooting
SEN00717-03
Failure code [CA271] PCV1 Short Error

Action code
Failure code
E03
CA271
Contents of
trouble
Action of
controller
Trouble
PCV1 Short Error

There is short circuit in PCV1 circuit of supply pump.

None in particular.
Problem that
appears on
machine
Related
information
Cause

Defective supply pump

PCV1 (Internal short circuit)
PCV1 (male)
Resistance
Between (1) (2)
2.3 5.3 z
Between (1), (2) chassis

ground
Min. 1 Mz
Possible causes
and standard
value in normal
state

2 ness (Contact with GND cir PCV1 (female) (1) and chassis ground
cuit)
PCV1 (female) (2) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

3
Hot short (Short circuit with Wiring harness between ENG (female) (4)
24V circuit) in wiring harness PCV1 (female) (1) and chassis ground
Voltage
Max. 1 V

Voltage
Max. 1 V
ENG (female)
Resistance
Between (4) (5)
2.3 5.3 z

ground
Min. 1 Mz
Circuit diagram related to supply pump PCV1
D155AX-6
41
SEN00717-03
40 Troubleshooting
Failure code [CA272] PCV1 Open Error

Action code
Failure code
E03
CA272
Contents of
trouble
Action of
controller
Trouble
PCV1 Open Error

There is disconnection in PCV1 circuit of supply pump.

None in particular.
Problem that
appears on
machine
Related
information
Cause


1 PCV1 (Internal disconnection)
PCV1 (male)
Resistance
Between (1) (2)
2.3 5.3 z

ground
Min. 1 Mz
Possible causes
and standard
value in normal
state
2
or defective contact in con- PCV1 (female) (1)
nector)
PCV1 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
cuit)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
ENG (female)
Resistance
Between (4) (5)
2.3 5.3 z

ground
Min. 1 Mz
42
D155AX-6
40 Troubleshooting
SEN00717-03
Failure code [CA273] PCV2 Short Error

Action code
Failure code
E03
CA273
Contents of
trouble
Action of
controller
Trouble
PCV2 Short Error

There is short circuit in PCV2 circuit of supply pump.

None in particular.
Problem that
appears on
machine
Related
information
Cause


PCV2 (Internal short circuit)
PCV2 (male)
Resistance
Between (1) (2)
2.3 5.3 z

ground
Min. 1 Mz
Possible causes
and standard
value in normal
state

cuit)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

3
24V circuit) in wiring harness PCV2 (female) (1) and chassis ground
Voltage
Max. 1 V
Voltage
Max. 1 V
ENG (female)
Resistance
Between (9) (10)
2.3 5.3 z

ground
Min. 1 Mz
D155AX-6
43
SEN00717-03
40 Troubleshooting
Failure code [CA274] PCV2 Open Error

Action code
Failure code
E03
CA274
Contents of
trouble
Action of
controller
Trouble
PCV2 Open Error

There is disconnection in PCV2 circuit of supply pump.

None in particular.
Problem that
appears on
machine
Related
information
Cause


1 PCV2 (Internal disconnection)
PCV2 (male)
Resistance
Between (1) (2)
2.3 5.3 z

ground
Min. 1 Mz
Possible causes
and standard
value in normal
state
2
or defective contact in con- PCV2 (female) (1)
nector)
PCV2 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
cuit)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
ENG (female)
Resistance
Between (9) (10)
2.3 5.3 z

ground
Min. 1 Mz
44
D155AX-6
40 Troubleshooting
SEN00717-03
D155AX-6
45
SEN00717-03
40 Troubleshooting
Failure code [CA322] Inj #1 (L#1) Open/Short Error

Action code
Failure code
E03
CA322
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

There is disconnection or short circuit in injector #1 circuit.

None in particular.
Output drops.
Rotation is unstable.
Related
information
Cause

Defective injector #1 (Internal trouble)
CN1 (male)
Resistance
Between (1) (2)
0.4 1.1 z

ground
Min. 1 Mz
Possible causes
and standard
value in normal
state
2
or defective contact in con- CN1 (female) (1)
nector)
CN1 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
3 ness (Contact with GND cir CN1 (female) (1) and chassis ground
cuit)
CN1 (female) (2) and chassis ground
4
Defective another cylinder

injector or wiring harness
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
If mutiple failure codes are displayed for injector malfunction, carry

out troubleshooting for them, too.
46
ENG (female)
Resistance
Between (45) (53)
0.4 1.1 z

ground
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00717-03
Circuit diagram related to injector #1
D155AX-6
47
SEN00717-03
40 Troubleshooting

Action code
Failure code
E03
CA323
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble


None in particular.
Output drops.
Related
information
Cause

CN5 (male)
Resistance
Between (1) (2)
0.4 1.1 z

ground
Min. 1 Mz
Possible causes
and standard
value in normal
state
2
nector)
CN5 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
cuit)
4

Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

48
ENG (female)
Resistance
Between (46) (60)
0.4 1.1 z

ground
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00717-03
D155AX-6
49
SEN00717-03
40 Troubleshooting

Action code
Failure code
E03
CA324
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble


None in particular.
Output drops.
Related
information
Cause

CN3 (male)
Resistance
Between (1) (2)
0.4 1.1 z

ground
Min. 1 Mz
Possible causes
and standard
value in normal
state
2
nector)
CN3 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
cuit)
4

Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

50
ENG (female)
Resistance
Between (55) (52)
0.4 1.1 z

ground
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00717-03
D155AX-6
51
SEN00717-03
40 Troubleshooting

Action code
Failure code
E03
CA325
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble


None in particular.
Output drops.
Related
information
Cause

CN6 (male)
Resistance
Between (1) (2)
0.4 1.1 z

ground
Min. 1 Mz
Possible causes
and standard
value in normal
state
2
nector)
CN6 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
cuit)
4

Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

52
ENG (female)
Resistance
Between (57) (59)
0.4 1.1 z

ground
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00717-03
D155AX-6
53
SEN00717-03
40 Troubleshooting

Action code
Failure code
E03
CA331
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble


None in particular.
Output drops.
Related
information
Cause

CN2 (male)
Resistance
Between (1) (2)
0.4 1.1 z

ground
Min. 1 Mz
Possible causes
and standard
value in normal
state
2
nector)
CN2 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
cuit)
4

Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

54
ENG (female)
Resistance
Between (54) (51)
0.4 1.1 z

ground
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00717-03
D155AX-6
55
SEN00717-03
40 Troubleshooting

Action code
Failure code
E03
CA332
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble


None in particular.
Output drops.
Related
information
Cause

CN4 (male)
Resistance
Between (1) (2)
0.4 1.1 z

ground
Min. 1 Mz
Possible causes
and standard
value in normal
state
2
nector)
CN4 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
cuit)
4

Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

56
ENG (female)
Resistance
Between (56) (58)
0.4 1.1 z

ground
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00717-03
D155AX-6
57
SEN00717-03
40 Troubleshooting
Failure code [CA342] Calibration Code Incompatibility

Action code
Failure code
E04
CA342
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

Incompatibility occurred in engine controller data.

None in particular.
Engine continues operation normally, but it may stop during operation or may not be able to start.
Related
information
Possible causes
and standard
value in normal
state
58
Cause

D155AX-6
40 Troubleshooting
D155AX-6
SEN00717-03
59
SEN00717-03
40 Troubleshooting
Failure code [CA351] Injectors Drive Circuit Error

Action code
Failure code
E03
CA351
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

Trouble occurred in injector drive circuit.

Limits engine output and continues operation (Limits common rail pressure).

Cause
2

(CB30 or CB8)

If another failure code (failure code of trouble in injector system) is
indicated, carry out troubleshooting for it.
If circuit breaker is turned OFF, circuit probably has ground fault
(See cause 4).
(4) CB8 (2)
Disconnection in wiring harness (Disconnection in wiring Wiring harness between CB8 (1) CB30
3
or defective contact in con- (B30S)
nector)
Wiring harness between CB30 (B30L) terminal BRB
Possible causes
and standard
value in normal
state
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
(4) CB8 (2) and chassis ground
Ground fault in wiring har(B30S) or circuit branch end and chassis
cuit)
Wiring harness between CB30 (B30L) terminal BRB and chassis ground
(2) chassis ground (GND20) and chassis
ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

60
EGC3
Voltage
Between (3), (4) (1), (2)
20 30 V
D155AX-6
40 Troubleshooting
SEN00717-03
Circuit diagram related to engine controller power supply
D155AX-6
61
SEN00717-03
40 Troubleshooting
Failure code [CA352] Sens Supply 1 Volt Low Error

Action code
Failure code
E03
CA352
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

Signal voltage in sensor power supply 1 (5 V) circuit of engine controller is abnormally low.
Limits common rail pressure sensor output and continues operation (Limits common rail pressure).
Related
information
Possible causes
and standard
value in normal
state
62
Cause

D155AX-6
40 Troubleshooting
D155AX-6
SEN00717-03
63
SEN00717-03
40 Troubleshooting
Failure code [CA386] Sens Supply 1 Volt High Error

Action code
Failure code
E03
CA386
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

Signal voltage in sensor power supply (5 V) circuit is abnormally high.

Limits common rail pressure sensor output and continues operation (Limits common rail pressure).
Related
information
Cause

Defective sensor (Internal

2
trouble)
Disconnect devices
"E" of failure code
disappears when a
has trouble in it.
Common rail pressure sensor
PFUEL connector
Possible causes
and standard
value in normal
state
3
or defective contact in con- PFUEL (female) (1)
nector)
PFUEL (female) (3)
Resistance
Max. 1 z
Resistance
Max. 1 z
4 ness (Contact with GND cir PFUEL (female) (1) and chassis ground
cuit)
PFUEL (female) (3) and chassis ground
harness)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
PFUEL (female) (1) and between ENG
(female) (47) PFUEL (female) (3)
Resistance
Min. 1 Mz

64
ENG
Voltage
Between (33) (47)
4.75 5.25 z
D155AX-6
40 Troubleshooting
SEN00717-03
Circuit diagram related to engine controller sensor power supply 1 (5 V)
D155AX-6
65
SEN00717-03
40 Troubleshooting
Failure code [CA441] Battery Voltage Low Error

Action code
Failure code
E04
CA441
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Trouble

Power supply circuit voltage of engine controller is abnormally low.

None in particular.
Cause

Failure code [CA442] Battery Voltage High Error

Action code
Failure code
E04
CA442
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
66
Trouble

Power supply circuit voltage of engine controller is abnormally low.

None in particular.
Cause

D155AX-6
40 Troubleshooting
SEN00717-03
Failure code [CA449] Rail Press Very High Error

Action code
Failure code
E03
CA449
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
D155AX-6
Trouble

Common rail pressure sensor circuit detected abnormally high pressure (level 2).

Common rail pressure can be checked with monitoring function.
(Code: 36400 Rail Pressure)
Cause

67
SEN00717-03
40 Troubleshooting
Failure code [CA451] Rail Press Sensor High Error

Action code
Failure code
E03
CA451
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

Signal voltage in common rail pressure sensor circuit is abnormally high.


State of common rail pressure sensor signal can be checked with monitoring function.
(Code: 36401 Rail Pressure Sens Volt)
Cause
1
ply system
for it first.
PFUEL
Defective common rail pres2

sure sensor (Internal trouble)
Voltage
Between (1) (3)
Power supply
4.75 5.25 V
Between (2) (3)
Signal
0.26 4.6 V

3
Possible causes
and standard
value in normal
state

PFUEL (female) (1)
Resistance
Max. 1 z

PFUEL (female) (2)
Resistance
Max. 1 z

PFUEL (female) (3)
Resistance
Max. 1 z
Ground fault in wiring har PFUEL (female) (1) and chassis ground
cuit)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

harness)
68

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00717-03
Cause
Possible causes
and standard
value in normal
state

ENG
Voltage
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
69
SEN00717-03
40 Troubleshooting
Failure code [CA452] Rail Press Sensor Low Error

Action code
Failure code
E03
CA452
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

Signal voltage in common rail pressure sensor circuit is abnormally low.


Possible causes
and standard
value in normal
state
Cause

Failure code [CA553] Rail Press High Error

Action code
Failure code
E02
CA553
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
70

Common rail pressure sensor circuit detected abnormally high pressure (level 1).
None in particular.

Cause
Possible causes
and standard
value in normal
state
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
common rail pressure sensor troubleshooting for failure code [CA451].
Defective mechanical system

4 of common rail pressure sen- Check mechanical system of common rail pressure sensor directly.
sor
5 Defective overflow valve
Check overflow valve directly for broken spring, worn seat, and
stuck ball.
6 Clogging of overflow piping
Check overflow piping directly for clogging.
7 Defective pressure limiter
Check pressure limiter directly for mechanical defect.
D155AX-6
40 Troubleshooting
SEN00717-03
Failure code [CA554] Rail Press Sensor In Range Error

Action code
Failure code
E03
CA554
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
D155AX-6
Trouble

In-range error occurred in common rail pressure sensor circuit.


Cause

Carry out troubleshooting for Failure code [CA451].
71
SEN00717-03
40 Troubleshooting
Failure code [CA559] Rail Press Low Error

Action code
Failure code
E02
CA559
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

Supply pump does not feed fuel (level 1).

Limits common rail pressure.

Cause
2 Use of improper fuel
Check fuel used directly for improper quality.
Defective low-pressure circuit device
4 Clogging of filter/strainer
Possible causes
and standard
value in normal
state
a For contents of troubleshooting, see Note 1. For check of pressure in fuel low-pressure circuit, see Testing and adjusting,
Testing fuel pressure.
Pressure in fuel low-pressure circuit (At high idle or under the
load equivalent to rating (Stalling))
Min. 0.15 MPa

{Min. 1.5 kg/cm2}
a For contents of troubleshooting, see Note 2.
Defective electrical system of Supply pump PCV may have electric trouble. Carry out troublesupply pump PCV
shooting for following codes; [CA271], [CA272], [CA273], [CA274].
Defective common rail pres- Common rail pressure sensor may be defective. Check wiring harsure sensor
ness for damage.
a For testing of leakage from pressure limiter, see Testing and
adjusting, Measuring fuel return rate and fuel leakage.
7 Defective pressure limiter
Leakage from pressure limiter

(Operation equivalent to rated
operation (under stall load))
Max. 10 cc/min
a For measuring of return (spill) limit from injector, see Testing

and adjusting, Measuring fuel return rate and fuel leakage.
8 Defective injector
9 Defective supply pump
Speed in rated operation

(stall load)
Return (Spill) limit from 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
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".
72
D155AX-6
40 Troubleshooting
SEN00717-03
Note 1: Check the low-pressure circuit parts for the following items.
1) Fuel level
2) Clogging of fuel tank breather
3) Sticking and wear of feed pump and clogging of filter
4) Leakage through and clogging of low-pressure fuel piping
5) Defective operation of bypass valve and installation of wrong part (See Fig. 1)
6) Clogging of fuel filter
7) Fuel in oil pan (Fuel leakage inside head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
Overflow valve (1): Spring is seen through both holes.
Bypass valve (2): Spring is seen through hole on nut side.
Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
D155AX-6
73
SEN00717-03
40 Troubleshooting
Check sheet for rail pressure low error

Model
Machine serial No.
Work No.
SAA6D140E-5
Service meter
Date of check
Engine
Engine serial No.
D155AX-6
/
h
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

Code
Displayed item
01002 Engine speed
31706
Final accelerator
position
Final fuel injection

18600 rate command
(by weight)
ISO unit
Standard value
(Reference value)
Low idle
r/min
715 765
High idle
r/min
1,825 1,925
Torque converter stall
r/min
1,560 1,660
Low idle
High idle
100
mg/st
Checking condition
Measured
value
Good NG
36200
Final common rail

pressure command
MPa
36400
Common rail pressure
MPa
Low idle
CA
Final injection tim36300

ing command
High idle
CA
CA
kPa
ISO unit
Standard value
(Reference value)
No. 1 cylinder
r/min
No. 2 cylinder
Reduce No. 3 cylinder
each
cylinder No. 4 cylinder
No. 5 cylinder
r/min
r/min
r/min
r/min
No. 6 cylinder
r/min
36500 Boost pressure

04107
Engine coolant temLow idle

perature
14200 Fuel temperature
Low idle
Check of reduced cylinder mode operation (Engine speed)

Setting
74
Reduced cylinder
Checking condition
Measured
value
Good NG
D155AX-6
40 Troubleshooting
C. Check of fuel circuit pressure
Fuel low-pressure circuit

pressure
SEN00717-03
Checking condition
At high idle or under the
load equivalent to rating
(Stalling)
Unit
Standard value
(Reference value)
MPa
{kg/cm2}
Min. 0.15
{Min. 1.5}
Measured
value
D. Check of strainers and filters
Good NG
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

return rate
11
Leakage through pressure

limiter
12 Return rate from injector
D155AX-6
Unit
Standard value
(Reference value)
Torque converter stal
cc/min
Max. 10

1,600 rpm
cc/min
960

1,700 rpm
cc/min
1,020

1,800 rpm
cc/min
1,080

1,900 rpm
cc/min
1,140

2,000 rpm
cc/min
1,200
Checking condition
Measured
value
Good NG
Speed:
Leakage
75
SEN00717-03
40 Troubleshooting
Failure code [CA689] Eng Ne Speed Sensor Error

Action code
Failure code
E03
CA689
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

Trouble occurred in engine Ne speed sensor circuit.

Operates with signals of Bkup speed sensor.
Running engine stops (when Bkup speed sensor is also abnormal).
Stopped engine cannot be started (when Bkup speed sensor is also abnormal).
Related
information
Cause
1
Defective sensor power supIf code [CA238] is indicated, carry out troubleshooting for it first.
ply system

2

NE (female) (1)
Resistance
Max. 1 z

NE (female) (2)
Resistance
Max. 1 z

NE (female) (3)
Resistance
Max. 1 z
Ground fault in wiring har NE (female) (1) and chassis ground
cuit)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
Possible causes
and standard
value in normal
state

harness)

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
Chassis ground between ENG (female)

(48) NE (female) (2) and between ENG
Resistance
Min. 1 Mz
Defective mount of sensor or Check Ne speed sensor directly for defective mount (defective
5 defective rotation sensing
clearance) or check rotation sensing part (flywheel) directly for
part
defect.
Defective engine Ne speed
sensor
If causes 1 5 are not detected, engine Ne speed sensor may be

defective. (Since trouble is in system, troubleshooting cannot be
carried out.)
out.)
76
D155AX-6
40 Troubleshooting
SEN00717-03
Circuit diagram related to engine Ne speed sensor
D155AX-6
77
SEN00717-03
40 Troubleshooting
D155AX-6 Bulldozer
2010 KOMATSU
All Rights Reserved
78
D155AX-6
SEN00718-04
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
40 Troubleshooting

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
Failure code [CA1653] EGR Inlet Press Sens High Error ............................................................................. 22
D155AX-6
SEN00718-04
40 Troubleshooting
Failure code [CA2185] Throt Sens Sup Volt High Error ................................................................................ 24
Failure code [CA2186] Throt Sens Sup Volt Low Error................................................................................. 26
Failure code [CA2249] Rail Press Very Low Error ........................................................................................ 26
Failure code [CA2271] EGR Valve Pos Sens High Error .............................................................................. 28
Failure code [CA2272] EGR Valve Pos Sens Low Error ............................................................................... 30
Failure code [CA2351] EGR Valve Sol Current High Error ........................................................................... 32
Failure code [CA2352] EGR Valve Sol Current Low Error ............................................................................ 34
Failure code [CA2555] Grid Htr Relay Volt Low Error ................................................................................... 35
Failure code [CA2556] Grid Htr Relay Volt High Error .................................................................................. 36
Failure code [D110KA] Battery relay: Disconnection .................................................................................... 38
Failure code [D110KB] Battery Relay: Drive Short Circuit ............................................................................ 40
Failure code [D130KA] Neutral relay: Disconnection .................................................................................... 42
Failure code [D130KB] Neutral relay: Short circuit........................................................................................ 44
Failure code [D161KA] Back-up alarm relay: Disconnection ........................................................................ 46
Failure code [D161KB] Back-up alarm relay: Short circuit ............................................................................ 48
Failure code [D190KA] ACC signal relay: Disconnection.............................................................................. 50
Failure code [D190KB] ACC signal relay: Short circuit ................................................................................. 52
Failure code [D5ZKKX] Throttle Dial: Out of normal range ........................................................................... 54
Failure code [DAFRKR] CAN Disconnection (Monitor) ................................................................................. 56
Failure code [DB2RKR] CAN Disconnection (Engine controller) .................................................................. 58
Failure code [DB90KK] WE controller: Source voltage reduction ................................................................. 60
Failure code [DB90KR] PT controller: Can communication lost.................................................................... 62
D155AX-6
40 Troubleshooting
SEN00718-04
Failure code [CA731] Eng Bkup Speed Sens Phase Error

Action code
Failure code
E03
CA731
Trouble

Contents of
trouble
Engine Bkup sensor circuit detected phase error.
Action of
controller
Controls with signals of engine Ne speed sensor.
Problem that
appears on
machine
Running engine stops (when Ne speed sensor is also abnormal).

Stopped engine cannot be started (when Ne speed sensor is also abnormal).
Related
information
Cause
Possible causes
and standard
value in normal
state
Defective engine Ne speed

sensor system
Engine Ne speed sensor may be defective. Carry out troubleshooting for failure code [CA689].
Defective engine Bkup

speed sensor system
Engine Bkup speed sensor may be defective. Carry out troubleshooting for failure code [CA778].
Failure code [CA757] All Continuous Data Lost Error

Action code
Failure code
E04
CA757
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

All data in engine controller are lost.

None in particular.
Related
information
Possible causes
and standard
value in normal
state
D155AX-6
Cause

SEN00718-04
40 Troubleshooting
Failure code [CA778] Eng Bkup Speed Sensor Error

Action code
Failure code
E03
CA778
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

Trouble occurred in engine Bkup speed sensor circuit.

Operates with signals of Ne speed sensor.
Running engine stops (when Ne speed sensor is also abnormal).
Stopped engine cannot be started (when Ne speed sensor is also abnormal).
Related
information
Cause
1
ply system
for it first.

2

G (female) (1)
Resistance
Max. 1 z

G (female) (2)
Resistance
Max. 1 z

G (female) (3)
Resistance
Max. 1 z
Ground fault in wiring har G (female) (1) and chassis ground
cuit)
G (female) (2) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

G (female) (3) and chassis ground
Resistance
Min. 1 Mz
Possible causes
and standard
value in normal
state

harness)

G (female) (1) and between ENG (female)
(47) G (female) (2)
Resistance
Min. 1 Mz

(26) G (female) (3)
Resistance
Min. 1 Mz
Chassis ground between ENG (female) (47)

(29) G (female) (3)
Resistance
Min. 1 Mz
Defective mount of sensor or Check Bkup speed sensor directly for defective mount (defective
5 defective rotation sensing
clearance) or check rotation sensing part (in supply pump) directly
part
for defect.
6
Defective engine Bkup

speed sensor
If causes 1 5 are not detected, engine Bkup speed sensor may

be defective. (Since trouble is in system, troubleshooting cannot
be carried out.)
out.)
D155AX-6
40 Troubleshooting
SEN00718-04
Circuit diagram related to engine Bkup speed sensor
D155AX-6
SEN00718-04
40 Troubleshooting
Failure code [CA1228] EGR Valve Servo Error 1

Action code
Failure code
E02
CA1228
Contents of
trouble
Action of
controller
Trouble

Trouble (level 1) occurred in EGR valve servo.

Performs open control.
Problem that
appears on
machine
Related
information
Operating condition of EGR valve can be checked with monitoring function.

(Code: 18100 EGR Valve Position)
Cause

a For measurement of EGR valve drive pressure, see Testing
and adjusting, "Measuring EGR valve and bypass valve drive
oil pressure"
Improper EGR valve drive

pressure
Engine speed
EGR valve drive pressure
Low idle
1.18 MPa {12 kg/cm2 }
High idle
1.43 MPa {14.6 kg/cm2 }
If EGR valve drive pressure is abnormal, check causes 3 and 4.

a For check of engine oil pressure, see Testing and adjusting,
Measuring engine oil pressure.
Possible causes
and standard
value in normal
state

3
system (main circuit)
Engine
Engine oil pressure
Low idle
0.08 MPa {0.8 kg/cm2 }
High idle
0.21 MPa {2.1 kg/cm2 }
If engine oil pressure is abnormal, carry out troubleshooting for "S12 Oil pressure lowers" in S mode.
Defective oil pump for EGR

valve
Check oil pump and relief valve for EGR valve circuit directly.
Defective oil feed piping for

EGR valve
Check oil feed piping for EGR valve circuit directly.
Defective oil return piping for

Check oil return piping for EGR valve circuit directly.
EGR valve
7 Defective EGR valve
Check mechanical section of EGR valve directly.
out.)
D155AX-6
40 Troubleshooting
SEN00718-04
Failure code [CA1625] EGR Valve Servo Error 2

Action code
Failure code
E03
CA1625
Trouble

Contents of
trouble
Trouble (level 2) occurred in EGR valve servo.
Action of
controller
Limits engine output and continues operation.

Closes EGR valve and bypass valve.
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
D155AX-6

Operating condition of EGR valve can be checked with monitoring function.
(Code: 18100 EGR Valve Position)
Cause

SEN00718-04
40 Troubleshooting
Failure code [CA1626] BP Valve Sol Current High Error

Action code
Failure code
E03
CA1626
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
BP Valve Sol Current High Error

There is short circuit in drive circuit of bypass valve solenoid.

Related
information
Cause
Defective bypass valve sole1
noid (Internal trouble)

BP (male)
Resistance
Between (1) (2)
10 21 z
Resis2
Max. 1 z
or defective contact in con- BP (female) (1)
tance
nector)
ResisMax. 1 z
BP (female) (2)
tance
Possible causes
and standard
value in normal
state
3 ness (Contact with GND cir BP (female) (1) and chassis ground
cuit)
BP (female) (2) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

4
24V circuit) in wiring harness - BP (female) (1) and chassis ground
Voltage
Max. 1 V

BP (female) (2) and chassis ground
Voltage
Max. 1 V
Prepare with starting switch OFF, then carry out troubleshooting

without turning starting switch ON.
ENG (female)
Resistance
Between (31) (11)
10 21 z
D155AX-6
40 Troubleshooting
SEN00718-04
Circuit diagram related to bypass valve solenoid & lift sensor
D155AX-6
SEN00718-04
40 Troubleshooting
Failure code [CA1627] BP Valve Sol Current Low Error

Action code
Failure code
E03
CA1627
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
BP Valve Sol Current Low Error

There is disconnection in drive circuit of bypass valve solenoid.

Related
information
Possible causes
and standard
value in normal
state
10
Cause

D155AX-6
40 Troubleshooting
SEN00718-04
Failure code [CA1628] Bypass Valve Servo Error 1

Action code
Failure code
E02
CA1628
Contents of
trouble
Action of
controller
Trouble

Trouble (level 1) occurred in bypass valve servo.

Performs open control.
Problem that
appears on
machine
Related
information
Operating condition of bypass valve can be checked with monitoring function.

(Code: 18200 BPS Valve Position)
Cause

a For measurement of EGR valve drive pressure, see Testing
and adjusting, "Measuring EGR valve and bypass valve drive
oil pressure"
Improper EGR valve drive

pressure
Engine speed
EGR valve drive pressure
Low idle
1.18 MPa {12 kg/cm2 }
High idle
1.43 MPa {14.6 kg/cm2 }
If EGR valve drive pressure is abnormal, check causes 3 and 4.

a For check of engine oil pressure, see Testing and adjusting,
Measuring engine oil pressure.
Possible causes
and standard
value in normal
state

3
system (main circuit)
Engine
Engine oil pressure
Low idle
0.08 MPa {0.8 kg/cm2 }
High idle
0.21 MPa {2.1 kg/cm2 }
If engine oil pressure is abnormal, carry out troubleshooting for "S

12 Oil pressure lowers" in S mode.
D155AX-6
Defective oil pump for

bypass valve
Check oil pump and relief valve for bypass valve circuit directly.
Defective oil feed piping for

bypass valve
Check oil feed piping for bypass valve circuit directly.
Defective oil return piping for

Check oil return piping for bypass valve circuit directly.
bypass valve
7 Defective bypass valve
Check mechanical section of bypass valve directly.
out.)
11
SEN00718-04
40 Troubleshooting
Failure code [CA1619] Bypass Valve Servo Error 2

Action code
Failure code
E03
CA1619
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
12
Trouble

Trouble (level 2) occurred in bypass valve servo.

Operating condition of bypass valve can be checked with monitoring function.
(Code: 18200 BPS Valve Position)
Cause

D155AX-6
40 Troubleshooting
D155AX-6
SEN00718-04
13
SEN00718-04
40 Troubleshooting
Failure code [CA1631] BP Valve Pos Sens High Error

Action code
Failure code
E03
CA1631
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
BP Valve Pos Sens High Error

Signal voltage in bypass valve lift sensor circuit is abnormally high.

State of bypass valve lift sensor signal can be checked with monitoring function.
(Code: 18201 BPS Valve Pos Sens Volt)
Cause
1
ply system
for it first.
Defective bypass valve lift

SBP
Between (1) (2)
Voltage
Power supply
4.75 5.25 V

3
Possible causes
and standard
value in normal
state

SBP (female) (1)
Resistance
Max. 1 z

SBP (female) (2)
Resistance
Max. 1 z

SBP (female) (3), (4)
Resistance
Max. 1 z
Ground fault in wiring har SBP (female) (1) and chassis ground
cuit)
SBP (female) (2) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

SBP (female) (3), (4) and chassis ground
Resistance
Min. 1 Mz

harness)
14

SBP (female) (1) and between ENG
(female) (38) SBP (female) (2)
Resistance
Min. 1 Mz

(female) (29) SBP (female) (3), (4)
Resistance
Min. 1 Mz

(female) (29) SBP (female) (3), (4)
Resistance
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00718-04
Cause
Possible causes
and standard
value in normal
state

Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
ENG
Voltage
Between (37) (38)
4.75 5.25 V
Circuit diagram related to bypass valve solenoid & lift sensor
D155AX-6
15
SEN00718-04
40 Troubleshooting
Failure code [CA1632] BP Valve Pos Sens Low Error

Action code
Failure code
E03
CA1632
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
16
Trouble
BP Valve Pos Sens Low Error

Signal voltage in bypass valve lift sensor circuit is abnormally low.

State of bypass valve lift sensor signal can be checked with monitoring function.
(Code: 18201 BPS Valve Pos Sens Volt)
Cause

D155AX-6
40 Troubleshooting
D155AX-6
SEN00718-04
17
SEN00718-04
40 Troubleshooting
Failure code [CA1633] KOMNET Datalink Timeout Error

Action code
E03
Contents of
trouble
Action of
controller
Failure code
CA1633
Trouble
KOMNET Datalink Timeout Error

Trouble occurred in KOMNET (CAN) communication circuit between engine controller and machine
monitor, power train controller, and work equipment controller.
Operates in default mode or maintains condition when abnormality occurs.
Problem that
appears on
machine
Related
information
Cause


1

(9) EGC2 (female) (46), STC2 (female)
(32) or WEC2 (female) (32)
Resistance
Max. 1 z
Wiring harness between CM02 (female)

Resistance
Max. 1 z
Possible causes
and standard
value in normal
state

(32), WEC2 (female) (32), ACCN (female)
Ground fault in wiring har(17), SRV (male) (3) or CA1 (female) (A)
2 ness (Contact with GND cirand chassis ground
cuit)
(18), SRV (male) (10) or CA1 (female) (B)
and chassis ground
Min. 1 Mz
Resistance
Min. 1 Mz

Hot short (Contact with GND (17), SRV (male) (3) or CA1 (female) (A)
3
circuit) in wiring harness
and chassis ground
and chassis ground
Defective CAN terminal
4 resistance (Internal disconnection or short circuit)
18
Resistance
Voltage
Max. 1 V
Voltage
Max. 1 V
Prepare with starting switch OFF, then carry out troubleshooting

CA1 (male)
Resistance
Between (A) (B)
Approx. 120 z
out.)
D155AX-6
40 Troubleshooting
SEN00718-04
Circuit diagram related to CAN communication
D155AX-6
19
SEN00718-04
40 Troubleshooting
Failure code [CA1642] EGR Inlet Press Sens Low Error

Action code
Failure code
E01
CA1642
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
20
Trouble
EGR Inlet Press Sens Low Error

Signal voltage in EGR inlet pressure sensor circuit is abnormally low.

Sets EGR inlet pressure to default value (102 kPa {1.04 kg/cm2}) and continues operation.
State of EGR valve inlet pressure sensor signal can be checked with monitoring function.
(Code: 18001 EGR In Press Sens Volt)
Cause

D155AX-6
40 Troubleshooting
D155AX-6
SEN00718-04
21
SEN00718-04
40 Troubleshooting
Failure code [CA1653] EGR Inlet Press Sens High Error

Action code
Failure code
E01
CA1653
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
EGR Inlet Press Sens High Error

Signal voltage in EGR inlet pressure sensor circuit is abnormally high.

Sets EGR inlet pressure to default value (102 kPa {1.04 kg/cm2}) and continues operation.
State of EGR valve inlet pressure sensor signal can be checked with monitoring function.
(Code: 18001 EGR In Press Sens Volt)
Cause
1
ply system
for it first.
2
Defective EGR inlet pressure

PEVA
Between (1) (2)
Voltage
Power supply
4.75 5.25 V

3
Possible causes
and standard
value in normal
state

PEVA (female) (1)
Resistance
Max. 1 z

PEVA (female) (2)
Resistance
Max. 1 z

PEVA (female) (3)
Resistance
Max. 1 z
Ground fault in wiring har PEVA (female) (1) and chassis ground
cuit)
PEVA (female) (2) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

PEVA (female) (3) and chassis ground
Resistance
Min. 1 Mz

harness)

PEVA (female) (1) and between ENG
(female) (47) PEVA (female) (2)
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

22
ENG
Voltage
Between (37) (47)
4.75 5.25 V
D155AX-6
40 Troubleshooting
SEN00718-04
Circuit diagram related to EGR inlet pressure sensor
D155AX-6
23
SEN00718-04
40 Troubleshooting
Failure code [CA2185] Throt Sens Sup Volt High Error

Action code
Failure code
E03
CA2185
Contents of
trouble
Action of
controller
Trouble
Throt Sens Sup Volt High Error

Signal voltage in throttle sensor power supply (5 V) circuit is abnormally high.

Sets throttle position with signal of fuel control dial and continues operation.
Problem that
appears on
machine
Related
information
Cause


(Internal trouble)
Disconnect devices
"E" of failure code
disappears when a
has trouble in it.
Decelerator pedal
potentiometer
DCL connector
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between EGC2 (female)
2
or defective contact in con- (22) DCL (female) (B)
nector)
(23) DCL (female) (C)
Resistance
Max. 1 z
Resistance
Max. 1 z
Ground fault in wiring harWiring harness between EGC2 (female)
3 ness (Contact with GND cir(22) DCL (female) (B) and chassis ground
cuit)
(23) DCL (female) (C) and chassis ground
harness)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
(22) DCL (female) (B) and between EGC2
(female) (23) DCL (female) (C)
Resistance
Min. 1 Mz

24
EGC2
Voltage
Between (22) (23)
4.75 5.25 V
D155AX-6
40 Troubleshooting
SEN00718-04
Circuit diagram related to throttle sensor power supply of engine controller
D155AX-6
25
SEN00718-04
40 Troubleshooting
Failure code [CA2186] Throt Sens Sup Volt Low Error

Action code
Failure code
E03
CA2186
Contents of
trouble
Action of
controller
Trouble
Throt Sens Sup Volt Low Error

Signal voltage in throttle sensor power supply (5 V) circuit of engine controller is abnormally low.
Sets throttle position with signal of fuel control dial and continues operation.
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Cause

Failure code [CA2249] Rail Press Very Low Error

Action code
Failure code
E03
CA2249
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Rail Press Very Low Error

Very low pressure error (level 2) occurred in supply pump.

Limits common rail pressure.
Related
information
Possible causes
and standard
value in normal
state
26
Cause

D155AX-6
40 Troubleshooting
D155AX-6
SEN00718-04
27
SEN00718-04
40 Troubleshooting
Failure code [CA2271] EGR Valve Pos Sens High Error

Action code
Failure code
E03
CA2271
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
EGR Valve Pos Sens High Error

Signal voltage in EGR valve lift sensor circuit is abnormally high.

State of EGR valve lift sensor signal can be checked with monitoring function.
(Code: 18101 EGR Valve Pos Sens Volt)
Cause
1
ply
for it first.
2
Defective EGR valve lift sensor (Internal trouble)
SEGR
Between (1) (2)
Voltage
Power supply
4.75 5.25 V

3
Possible causes
and standard
value in normal
state

SEGR (female) (1)
Resistance
Max. 1 z

SEGR (female) (2)
Resistance
Max. 1 z

SEGR (female) (3), (4)
Resistance
Max. 1 z
SEGR (female) (1) and chassis ground
Ground fault in wiring har4 ness (Contact with GND cir- Wiring harness between ENG (female) (47)
cuit)
SEGR (female) (2) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

SEGR (female) (3), (4) and chassis
ground
Resistance
Min. 1 Mz

harness)
28

SEGR (female) (1) and between ENG
(female) (47) SEGR (female) (2)
Resistance
Min. 1 Mz

(female) (19) SEGR (female) (3), (4)
Resistance
Min. 1 Mz

(female) (19) SEGR (female) (3), (4)
Resistance
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00718-04
Cause
Possible causes
and standard
value in normal
state

ENG
Voltage
Between (37) (47)
4.75 5.25 V
Circuit diagram related to EGR valve solenoid & lift sensor
D155AX-6
29
SEN00718-04
40 Troubleshooting
Failure code [CA2272] EGR Valve Pos Sens Low Error

Action code
Failure code
E03
CA2272
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
30
Trouble
EGR Valve Pos Sens Low Error

Signal voltage in EGR valve lift sensor circuit is abnormally low.

State of EGR valve lift sensor signal can be checked with monitoring function.
(Code: 18101 EGR Valve Pos Sens Volt)
Cause

D155AX-6
40 Troubleshooting
D155AX-6
SEN00718-04
31
SEN00718-04
40 Troubleshooting
Failure code [CA2351] EGR Valve Sol Current High Error

Action code
Failure code
E03
CA2351
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
EGR Valve Sol Current High Error

There is short circuit in EGR valve solenoid drive circuit.

Related
information
Cause
Defective EGR valve sole1
noid (Internal trouble)

EGR (male)
Resistance
Between (1) (2)
10 21 z
Resis2
Max. 1 z
or defective contact in con- EGR (female) (1)
tance
nector)
ResisMax. 1 z
EGR (female) (2)
tance
Possible causes
and standard
value in normal
state
3 ness (Contact with GND cir EGR (female) (1) and chassis ground
cuit)
EGR (female) (2) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

4
24V circuit) in wiring harness EGR (female) (1) and chassis ground
Voltage
Max. 1 V

EGR (female) (2) and chassis ground
Voltage
Max. 1 V
32
ENG (female)
Resistance
Between (22) (11)
10 21 z
D155AX-6
40 Troubleshooting
SEN00718-04
Circuit diagram related to EGR valve solenoid & lift sensor
D155AX-6
33
SEN00718-04
40 Troubleshooting
Failure code [CA2352] EGR Valve Sol Current Low Error

Action code
Failure code
E03
CA2352
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
EGR Valve Sol Current Low Error

There is disconnection in EGR valve solenoid drive circuit.

Related
information
Possible causes
and standard
value in normal
state
34
Cause

Carry out troubleshooting failure code [CA2351].
D155AX-6
40 Troubleshooting
SEN00718-04
Failure code [CA2555] Grid Htr Relay Volt Low Error

Action code
Failure code
E01
CA2555
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
D155AX-6
Trouble
Grid Htr Relay Volt Low Error

There is disconnection in intake air heater relay circuit.

None in particular.
Engine does not start easily at low temperature.

Cause

Carry out troubleshooting failure code [CA2556].
35
SEN00718-04
40 Troubleshooting
Failure code [CA2556] Grid Htr Relay Volt High Error

Action code
Failure code
E01
CA2556
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Grid Htr Relay Volt High Error

There is short circuit in intake air heater relay.

None in particular.
Engine does not start easily at low temperature.

Engine controller has automatic preheating function, which is turned ON when engine coolant temperature is below -5 C (for up to 30 seconds).
Cause
Defective intake air heater

relay (Internal trouble)

PHR (male)
Resistance
Between (1) (2)
200 400 z
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between EGC2 (female)
2
or defective contact in con- (40) PHR (female) (1)
nector)
Wiring harness between PHR (female) (2)
chassis ground (GND03)
Resistance
Max. 1 z
Resistance
Max. 1 z
3 ness (Contact with GND cirWiring harness between EGC2 (female)
Resiscuit)
Min. 1 Mz
(40) PHR (female) (1) and chassis ground
tance
36
EGC2
Coolant temperature
Voltage
-5 C or higher
Max. 1 V
Below -5 C
20 30 V
D155AX-6
40 Troubleshooting
SEN00718-04
Circuit diagram related to preheating/starting/charging of engine
D155AX-6
37
SEN00718-04
40 Troubleshooting
Failure code [D110KA] Battery relay: Disconnection

Action code
Failure code
D110KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Battery relay: Disconnection

Turns signal to battery relay holding circuit, no current flows.

Turns signal to battery relay holding circuit OFF.
Problem may occur in writing data into ROM (non-volatile memory) of each controller.
State of battery relay holding circuit signal can be checked with monitoring function.
(Code: 60600 BR Hold Relay)
Method of reproducing failure code: Turn starting switch ON o OFF.
Cause
Defective battery relay (Inter1
nal disconnection)
Battery relay
Continuity
Between terminals SW BRE
There is continuity
Possible causes
and standard
value in normal
state
2
or defective contact in con- terminal SW
nector)
Wiring harness between terminal BRE and
chassis ground
Resistance
Max. 1 z
Resistance
Max. 1 z

Hot short (Short circuit with

24V circuit) in wiring harness Wiring harness between STC3 (female) (4)
terminal SW, terminal 260, terminal AL/R
or circuit branch end and chassis ground
Voltage
Max. 1 V
4
38
STC3
Starting switch
Voltage
OFF
Max. 1 V
D155AX-6
40 Troubleshooting
SEN00718-04
Circuit diagram related to driving of battery relay
D155AX-6
39
SEN00718-04
40 Troubleshooting
Failure code [D110KB] Battery Relay: Drive Short Circuit

Action code
Failure code
D110KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Battery Relay: Drive Short Circuit

When signal was output to battery relay circuit, abnormal current flowed.
Turns signal to battery relay holding circuit OFF.
Problem may occur in writing data into ROM (non-volatile memory) of each controller.
State of battery relay holding circuit signal can be checked with monitoring function.
(Code: 60600 BR Hold Relay)
Method of reproducing failure code: Turn starting switch ON o OFF.
Cause

Possible causes
and standard
value in normal
state
Defective battery relay (Internal short circuit)
Battery relay
Continuity/Resistance
Between terminals SW BRE
There is continuity
Between terminal SW chassis

ground
Min. 1 Mz
Ground fault in wiring har2 ness (Contact with GND cir- Wiring harness between STC3 (female) (4)
Resiscuit)
terminal SW, terminal 260 or RSD
Min. 1 Mz
tance
(female) (1) and chassis ground
3
40
STC3
Starting switch
Voltage
ON
20 30 V
D155AX-6
40 Troubleshooting
SEN00718-04
Circuit diagram related to driving of battery relay
D155AX-6
41
SEN00718-04
40 Troubleshooting
Failure code [D130KA] Neutral relay: Disconnection

Action code
Failure code
E02
D130KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Neutral relay: Disconnection

When ground circuit of neutral safety relay circuit is disconnected, no current flows.
Turns output of neutral safety relay circuit OFF.
Engine cannot be started.

State of neutral safety relay circuit signal can be checked with monitoring function.
(Code: 59099 T/M Lock Relay)
Method of reproducing failure code: Turn starting switch ON + Operate parking brake lever (Free).
This failure code detects abnormality on primary side (coil side) of neutral safety relay but does not
Cause
1 Defective fuse (FS2-5)
Defective neutral safety relay
2
Possible causes
and standard
value in normal
state

If fuse is broken, circuit probably has ground fault (See cause 4).
NSF (male)
Resistance
Between (1) (2)
300 600 z
Resis3
Max. 1 z
or defective contact in con- NSF (female) (2)
tance
nector)
Wiring harness between NSF (female) (1)
ResisMax. 1 z
FS21 (5)
tance
Ground fault in wiring harWiring harness between STC2 (female) (8)
4 ness (Contact with GND cir- NSF (female) (2) and chassis ground
cuit)
FS21 (5) or circuit branch end and chassis
ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

5
42
STC2
Parking brake lever
Voltage
Lock
Max. 1 V
Free
20 30 V
D155AX-6
40 Troubleshooting
SEN00718-04
Circuit diagram related to neutral safety relay
D155AX-6
43
SEN00718-04
40 Troubleshooting
Failure code [D130KB] Neutral relay: Short circuit

Action code
Failure code
E02
D130KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Neutral relay: Short circuit

When ground circuit of neutral safety relay was disconnected, abnormal current flowed.
Turns output of neutral safety relay circuit OFF.
Engine cannot be started.

State of neutral safety relay circuit signal can be checked with monitoring function.
(Code: 59099 T/M Lock Relay)
This failure code detects abnormality on primary side (coil side) of neutral safety relay but does not
Cause
1
(Internal short circuit)
NSF (male)
Resistance
300 600 z
Between (1) (2)

Possible causes
and standard
value in normal
state

2
Voltage Max. 1 V
NSF (female) (2) and chassis ground
3
44
STC2
Parking brake lever
Voltage
Lock
Max. 1 V
Free
20 30 V
D155AX-6
40 Troubleshooting
SEN00718-04
Circuit diagram related to neutral safety relay
D155AX-6
45
SEN00718-04
40 Troubleshooting
Failure code [D161KA] Back-up alarm relay: Disconnection

Action code
Failure code
E01
D161KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Back-up alarm relay: Disconnection

When ground circuit of back-up alarm relay circuit is disconnected, no current flows.
Turns output of back-up alarm relay circuit OFF.
Back-up alarm does not sound

State of back-up alarm relay circuit signal can be checked with monitoring function.
(Code: 70400 Back Alarm Relay)
Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (R: Reverse).
This failure code detects abnormality on primary side (coil side) of back-up alarm relay but does not
Cause
Defective back-up alarm
2
relay (Internal disconnection)
Possible causes
and standard
value in normal
state

BKA (male)
Resistance
Between (1) (2)
300 600 z
Resis3
Max. 1 z
or defective contact in con- BKA (female) (2)
tance
nector)
Wiring harness between BKA (female) (1)
ResisMax. 1 z
FS12 (2)
tance
4 ness (Contact with GND cir- BKA (female) (2) or circuit branch end and
cuit)
chassis ground
Wiring harness between BKA (female) (1),
(3) FS12 (2) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

5
STC2
46
PCCS lever
(Directional)
Voltage
20 30 V
R (Reverse)
Max. 1 V
D155AX-6
40 Troubleshooting
SEN00718-04
Circuit diagram related to back-up alarm relay
D155AX-6
47
SEN00718-04
40 Troubleshooting
Failure code [D161KB] Back-up alarm relay: Short circuit

Action code
Failure code
E01
D161KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Back-up alarm relay: Short circuit

When ground circuit of back-up alarm relay was disconnected, abnormal current flowed.
Turns output of back-up alarm relay circuit OFF.
Back-up alarm does not sound.

State of back-up alarm relay circuit signal can be checked with monitoring function.
(Code: 70400 Back Alarm Relay)
Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (R: Reverse)
This failure code detects abnormality on primary side (coil side) of back-up alarm relay but does not
Cause
Possible causes
and standard
value in normal
state
Defective back-up alarm

relay (Internal short circuit)

BKA (male)
Resistance
Between (1) (2)
300 600 z


BKA (female) (2) or circuit branch end and
chassis ground
Voltage
Max. 1 V

3
STC2
48
PCCS lever
(Directional)
Voltage
20 30 V
R (Reverse)
Max. 1 V
D155AX-6
40 Troubleshooting
SEN00718-04
Circuit diagram related to back-up alarm relay
D155AX-6
49
SEN00718-04
40 Troubleshooting
Failure code [D190KA] ACC signal relay: Disconnection

Action code
Failure code
D190KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
ACC signal relay: Disconnection

When ground circuit of ACC signal drive relay circuit is disconnected, no current flows.
Turns signal to ACC signal drive relay circuit OFF.
Turbo-timer function does not operate (if turbo-timer is installed).
Machine is not affected particularly (if turbo-timer is not installed).
State of ACC signal drive relay circuit signal can be checked with monitoring function.
(Code: 60500 ENG Hold Relay)
Method of reproducing failure code: Turn starting switch ON o OFF (if turbo-timer is installed).
This failure code detects abnormality on primary side (coil side) of ACC signal drive relay but does
not detect abnormality on secondary side (contact side).
Cause
Defective ACC signal drive

relay (Internal disconnection)

EHL (male)
Resistance
Between (1) (2)
200 400 z
Possible causes
and standard
value in normal
state
2
or defective contact in con- EHL (female) (2)
nector)
Wiring harness between EHL (female) (1)
branch point (J)
50
Resistance
Max. 1 z
Resistance
Max. 1 z


EHL (female) (2) and chassis ground
Voltage
Max. 1 V
STC2 (female)
Resistance
200 400 z
D155AX-6
40 Troubleshooting
SEN00718-04
Circuit diagram related to ACC signal drive relay
D155AX-6
51
SEN00718-04
40 Troubleshooting
Failure code [D190KB] ACC signal relay: Short circuit

Action code
Failure code
D190KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Turns output of ACC signal drive relay circuit OFF.

Turbo-timer function does not operate (if turbo-timer is installed).
Machine is not affected particularly (if turbo-timer is not installed).
State of ACC signal drive relay circuit signal can be checked with monitoring function.
(Code: 60500 ENG Hold Relay)
Method of reproducing failure code: Turn starting switch ON o OFF (if turbo-timer is installed).
This failure code detects abnormality on primary side (coil side) of ACC signal drive relay but does
not detect abnormality on secondary side (contact side).
Defective ACC signal drive

relay (Short circuit)

EHL (male)
Resistance
Between (1) (2)
200 400 z
Resiscuit)
1 Mz
EHL (female) (2) and chassis ground
tance
52
ACC signal relay: Short circuit

When ground circuit of ACC signal drive relay was disconnected, abnormal current flowed.
Cause
Possible causes
and standard
value in normal
state
STC2 (female)
Resistance
200 400 z
D155AX-6
40 Troubleshooting
SEN00718-04
Circuit diagram related to ACC signal drive relay
D155AX-6
53
SEN00718-04
40 Troubleshooting
Failure code [D5ZKKX] Throttle Dial: Out of normal range

Action code
Failure code
E03
D5ZKKX
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Throttle Dial: Out of normal range

Signal voltage of fuel control dial is below 0.30 V or above 4.55 V.

Continues control with decelerator pedal potentiometer signal.
State of fuel control dial can be checked with monitoring function.
(Code: 03000 Fuel Dial Sensor)
Method of reproducing failure code: Turn starting switch ON.
Cause
Defective sensor 5V power

1
supply system
If failure code [DBE7KK] is also displayed, carry out troubleshooting for it first.

2 (Internal disconnection or
short circuit)
DIAL (male)
Resistance
Between (1) (3)
4.0 6.0 kz
Between (1) (2)
0.25 7.0 kz
Between (2) (3)
0.25 7.0 kz
Possible causes
and standard
value in normal
state
3
or defective contact in con- DIAL (female) (1)
nector)
DIAL (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resiscuit)
Min. 1 Mz
DIAL (female) (2) and chassis ground
tance
5 24 V circuit) in wiring harness
54

Voltage
Max. 1 V

STC1
Voltage
Between (1) (21)
0.30 4.33 V
D155AX-6
40 Troubleshooting
SEN00718-04
Circuit diagram related to fuel control dial
D155AX-6
55
SEN00718-04
40 Troubleshooting
Failure code [DAFRKR] CAN Disconnection (Monitor)

Action code
E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Failure code
DAFRKR
Trouble
CAN Disconnection (Monitor)

Machine monitor cannot recognize engine controller, power train controller, or work equipment controller in CAN communication circuit.
System may not operate normally.
Cause


1

Resistance
Max. 1 z

Resistance
Max. 1 z
Possible causes
and standard
value in normal
state

cuit)
and chassis ground
Min. 1 Mz
Resistance
Min. 1 Mz

Hot short (Short circuit with (17), SRV (male) (3) or CA1 (female) (A)
3
24V circuit) in wiring harness and chassis ground
Voltage
Max. 1 V

and chassis ground
Voltage
Max. 1 V

Defective machine monitor

5
or controller
56
Resistance
CA1 (male)
Resistance
Between (A) (B)
Approx. 120 z
If causes 1 4 are not detected, machine monitor, engine controller, power train controller or work equipment controller may be
carried out.)
D155AX-6
40 Troubleshooting
SEN00718-04
D155AX-6
57
SEN00718-04
40 Troubleshooting
Failure code [DB2RKR] CAN Disconnection (Engine controller)

Action code
Failure code
E03
DB2RKR
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
CAN Disconnection (Engine controller)

Power train controller cannot recognize engine controller in CAN communication circuit.
Cause


1

Resistance
Max. 1 z

Resistance
Max. 1 z
Possible causes
and standard
value in normal
state

cuit)
and chassis ground
Min. 1 Mz
Resistance
Min. 1 Mz



58
Resistance
Defective engine controller

or power train controller

(17), SRV (male) (3) or CA1 (female) (A)
and chassis ground
Voltage
Max. 1 V

and chassis ground
Voltage
Max. 1 V
CA1 (male)
Resistance
Between (A) (B)
Approx. 120 z
If causes 1 4 are not detected, engine controller or power train

controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
D155AX-6
40 Troubleshooting
SEN00718-04
D155AX-6
59
SEN00718-04
40 Troubleshooting
Failure code [DB90KK] WE controller: Source voltage reduction

Action code
Failure code
E04
DB90KK
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

(Work equipment controller system)
Source voltage of work equipment controller is below 17 V.

Machine monitor may not display normally.

Relays and solenoids may not be driven and system may not operate normally.
Once machine is stopped, it cannot travel at all.
Source voltage of work equipment controller can be checked with adjusting function. (Code: 2022)
Cause

1
(CB2, CB7, CB30 or CB105) (See cause 3).
Wiring harness between WEC3 (female) (1),
(11) CB7 (2)
Resistance
Max. 1 z

(B30S)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between CB105 (B105L)

terminal BRC
Resistance
Max. 1 z
Wiring harness between WEC3 (female)

(21), (31), (32), (33) chassis ground
(GND11)
Resistance
Max. 1 z
Wiring harness between CB30 (B30L) terDisconnection in wiring har- minal BRB
2
or defective contact in con- Wiring harness between WEC3 (female) (2),
(12), (22) CB2 (2)
nector)
(B105S)
Possible causes
and standard
value in normal
state
(11) CB7 (2) or circuit branch end and
chassis ground
Resistance
Min. 1 Mz

(B30S) or circuit branch end and chassis
ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

ground
Resistance
Min. 1 Mz

terminal BRC and chassis ground
Resistance
Min. 1 Mz
Ground fault in wiring harWiring harness between CB30 (B30L) ter3 ness (Contact with GND cirminal BRB and chassis ground
cuit)
(12), (22) CB2 (2) or WEPW (female) (A)
and chassis ground
60
D155AX-6
40 Troubleshooting
SEN00718-04
Cause

Possible causes
and standard
value in normal
state
Defective work equipment

4
controller
WEC3
Starting switch
Voltage
Between (1), (11)

(21), (31), (32), (33)
OFF
20 30 V
Between (2), (12),

(22) (21), (31), (32),
(33)
ON
20 30 V
Circuit diagram related to work equipment controller power supply
D155AX-6
61
SEN00718-04
40 Troubleshooting
Failure code [DB90KR] PT controller: Can communication lost

Action code
E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Failure code
DB90KR
Trouble
PT controller: Can communication lost

Power train controller cannot recognize machine monitor, engine controller or work equipment controller in CAN communication circuit.
Cause


1

Resistance
Max. 1 z

Resistance
Max. 1 z
Possible causes
and standard
value in normal
state

cuit)
and chassis ground
Min. 1 Mz
Resistance
Min. 1 Mz




5
or controller
62
Resistance

(17), SRV (male) (3) or CA1 (female) (A)
and chassis ground
Voltage
Max. 1 V

and chassis ground
Voltage
Max. 1 V
CA1 (male)
Resistance
Between (A) (B)
Approx. 120 z
carried out.)
D155AX-6
40 Troubleshooting
SEN00718-04
D155AX-6
63
SEN00718-04
40 Troubleshooting
D155AX-6 Bulldozer
2010 KOMATSU
All Rights Reserved
64
D155AX-6
SEN00719-01
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
40 Troubleshooting

codes, Part 4
Troubleshooting by failure and error codes, Part 4 ......................................................................................... 3
Failure code [DB90KT] WE controller: Abnormality in controller.......................................................... 3
Failure code [DB95KK] WE controller: Source voltage reduction ........................................................ 4
Failure code [DB97KK] WE controller: Source voltage reduction ........................................................ 6
Failure code [DB99KQ] WE controller: Type select signal ................................................................... 8
Failure code [DB9RKR] WE controller: Can communication lost....................................................... 10
Failure code [DBE0KK] PT controller: Source voltage reduction ....................................................... 12
Failure code [DBE0KT] PT controller: Abnormality in controller......................................................... 14
Failure code [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
SEN00719-01
40 Troubleshooting
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
D155AX-6
40 Troubleshooting
SEN00719-01
Failure code [DB90KT] WE controller: Abnormality in controller
Action code
Failure code
E01
DB90KT
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Information in ROM (non-volatile memory) of work equipment controller is abnormal.

Sets internal adjustment values to default values.
Operating feel of work equipment may become bad.
Adjusting function of machine monitor may not operate normally.
Cause
Possible causes
and standard
value in normal
state
Turn Adjustment function in service mode ON and perform operation of reproducing trouble. If "E" of failure code disappears at this
Defective adjustment of work
time, system is normal.
1
equipment controller
Adjustment code: 0031
(Initialization of work equipment controller)
2
D155AX-6
WE controller: Abnormality in controller


controller
Troubleshooting cannot be carried out since defect is in work

equipment controller. (If there is not any visible trouble in machine,
controller may be used as it is.)
SEN00719-01
40 Troubleshooting

Action code
Failure code
E03
DB95KK
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

Voltage of 5V power supply circuit for work equipment controller sensors is below 4.5 V or above
5.5 V.
Abnormal current flowed in 5V power supply circuit for work equipment controller sensors.
Turns output of 5V power supply circuit OFF, if abnormal current flows.
Cause


1 pump oil pressure sensor
(Internal trouble)
Possible causes
and standard
value in normal
state
Ground fault in wiring har2 ness (Contact with GND circuit)
Disconnect devices
"E" of failure code
disappears when a
has trouble in it.
Work equipment
pump oil pressure
sensor
Connector HHP
(34) HHP (female) (B) and chassis ground
Resistance
Min. 1 Mz

3
24V circuit) in wiring harness Wiring harness between WEC3 (female)
Voltage Max. 1 V
(34) HHP (female) (B) and chassis ground

controller

WEC1, WEC3
Voltage
Between WEC3 (34)

WEC1 (21)
4.5 5.5 V
D155AX-6
40 Troubleshooting
SEN00719-01
Circuit diagram related to work equipment controller 5V sensor power supply
D155AX-6
SEN00719-01
40 Troubleshooting

Action code
Failure code
E03
DB97KK
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

Voltage of 5V power supply circuit for work equipment controller sensors is below 4.5 V or above
5.5 V.
Abnormal current flowed in 5V power supply circuit for work equipment controller sensors.
Cause

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
1 or ripper control lever (Inter- of failure code disapnal trouble)
pears when a device
is disconnected, that
Ripper control
device has trouble in
lever
it.
Connector WLV1
Connector WLV2
Possible causes
and standard
value in normal
state

Ground fault in wiring har(22) WLV1 (female) (4), (8) and chassis
2 ness (Contact with GND cirground [Blade control lever system]
cuit)
(22) WLV2 (female) (4), (8) and chassis
ground [Ripper control lever system]
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

Hot short (Short circuit with (22) WLV1 (female) (4), (8) and chassis
3
24V circuit) in wiring harness ground [Blade control lever system]
Voltage
Max. 1 V

(22) WLV2 (female) (4), (8) and chassis
ground [Ripper control lever system]
Voltage
Max. 1 V

4
controller

WEC1
Voltage
Between WEC1(22) (21)
4.5 5.5 V
D155AX-6
40 Troubleshooting
SEN00719-01
Circuit diagram related to work equipment controller 5V sensor power supply
D155AX-6
SEN00719-01
40 Troubleshooting
Failure code [DB99KQ] WE controller: Type select signal

Action code
Failure code
E04
DB99KQ
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
WE controller: Type select signal

Specification setting in work equipment controller does not match to specification setting signal
(Work equipment controller cannot be recognized).
Turns all outputs of work equipment controller OFF.
Machine does not move at all.
Cause
Turn Adjustment function in service mode ON and perform

operation of reproducing trouble. If "E" of failure code disapDefective adjustment of work
pears at this time, system is normal.
1
equipment controller
Adjustment code: 0031
(Initialization of work equipment controller)
Possible causes
and standard
value in normal
state
2
or defective contact in con- Wiring harness between WEC3 (female)
ResisMax. 1 z
nector)
tance

controller

WEC3
Voltage
Wiring harness between (30) chassis

ground
Max. 1 V
Circuit diagram related to work equipment controller type select power supply
D155AX-6
SEN00719-01
40 Troubleshooting
Failure code [DB9RKR] WE controller: Can communication lost

Action code
Failure code
E03
DB9RKR
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
WE controller: Can communication lost

Work equipment controller cannot recognize machine monitor, engine controller or power train controller in CAN communication circuit.
Cause


1

Resistance
Max. 1 z

Resistance
Max. 1 z
Possible causes
and standard
value in normal
state

Ground fault in wiring har(17), SRV(male) (3) or CA1 (female) (A) and
2 ness (Contact with GND circhassis ground
cuit)
and chassis ground
Min. 1 Mz
Resistance
Min. 1 Mz

Hot short (Contact with GND (17), SRV (male) (3) or CA1 (female) (A)
3
circuit) in wiring harness
and chassis ground
and chassis ground

5
or controller
10
Resistance
Voltage
Max. 1 V
Voltage
Max. 1 V
CA1 (male)
Resistance
Between (A) (B)
Approx. 120 z
carried out.)
D155AX-6
40 Troubleshooting
SEN00719-01
D155AX-6
11
SEN00719-01
40 Troubleshooting
Failure code [DBE0KK] PT controller: Source voltage reduction

Action code
Failure code
E03
DBE0KK
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

Source voltage of work equipment controller is below 17 V.

Machine monitor may not display normally.

Relays and solenoids may not be driven and system may not operate normally.
Source voltage of power train controller can be checked with adjusting function. (Code: 2121)
Cause
1

(CB1, CB7, CB30 or CB105) (See cause 3).
Wiring harness between STC3 (female) (1),
(11) CB7 (2)
Resistance
Max. 1 z

(B30S)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z

terminal BRC
Resistance
Max. 1 z
Wiring harness between STC3 (female)

(21), (31), (32), (33) chassis ground
(GND11)
Resistance
Max. 1 z
Wiring harness between CB30 (B30L) terDisconnection in wiring har- minal BRB
2
or defective contact in con- Wiring harness between STC3 (female) (2),
(12), (22) CB1 (2)
nector)
(B105S)
Possible causes
and standard
value in normal
state
(11) CB7 (2) or circuit branch end and
chassis ground
Resistance
Min. 1 Mz

ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

ground
Resistance
Min. 1 Mz

terminal BRC and chassis ground
Resistance
Min. 1 Mz
Ground fault in wiring harWiring harness between CB30 (B30L) ter3 ness (Contact with GND cirminal BRB and chassis ground
cuit)
(12), (22) CB1 (2) or PL1 (female) (68)
and chassis ground
12
D155AX-6
40 Troubleshooting
SEN00719-01
Cause
Possible causes
and standard
value in normal
state


troller
STC3
Starting switch
Voltage
Between (1), (11)

(21), (31), (32), (33)
OFF
20 30 V
Between (2), (12),

(22) (21), (31), (32),
(33)
ON
20 30 V
Circuit diagram related to power train controller power supply
D155AX-6
13
SEN00719-01
40 Troubleshooting
Failure code [DBE0KT] PT controller: Abnormality in controller

Action code
Failure code
E01
DBE0KT
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Sets internal adjustment values to default values.

Shifting feel of transmission may become bad.
Adjusting function may not operate normally.
Defective adjustment of
1
power train controller
14
PT controller: Abnormality in controller

Information in ROM (non-volatile memory) of power train controller is abnormal.
Cause
Possible causes
and standard
value in normal
state

Adjustment code: 0002 (Initialization of power train controller)
Troubleshooting cannot be carried out since defect is in power train
controller. (If there is not any visible trouble in machine, controller
may be used as it is.)
D155AX-6
SEN00719-01
40 Troubleshooting

Action code
Failure code
E02
DBE6KK
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

Voltage of 24V power supply circuit for power train controller sensors is below 17 V or above 30 V.
Abnormal current flowed in 24V power supply circuit for power train controller sensors.
Cause

Disconnect devices
Defective pitch angle sensor at right in order. If
1 or torque converter pressure "E" of failure code
disappears when a
has trouble in it.
Possible causes
and standard
value in normal
state
Pitch angle sensor
Connector PT1
Torque converter
inlet pressure sensor
Connector TIP
Torque converter outlet pressure sensor
Connector TOP
PT1 (female) (C) [Pitch angle sensor system]
cuit)
PIT (female) (B) [Torque converter inlet
pressure sensor system]
TOP (female) (B) [Torque converter outlet
pressure sensor system]
troller
16
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

STC1
Voltage
Between (16) (21)
20 30 V
D155AX-6
40 Troubleshooting
SEN00719-01
Circuit diagram related to power train controller 24V sensor power supply
D155AX-6
17
SEN00719-01
40 Troubleshooting

Action code
Failure code
E02
DBE7KK
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

Voltage of 5V power supply circuit for power train controller sensors is below 4.5 V or above 5.5 V.
Abnormal current flowed in 5V power supply circuit for power train controller sensors.
Cause

Disconnect devices
Defective brake pedal poten- at right in order. If
1 tiometer, fuel control dial or "E" of failure code
PCCS lever (Internal trouble) disappears when a
has trouble in it.
Brake pedal
potentiometer
Connector BRK
Fuel control dial
Connector DIAL
PCCS lever
Connector TLV1
BRK (female) (C) and chassis ground
[Brake pedal potentiometer system]
Possible causes
and standard
value in normal
state
cuit)
[Fuel control dial system]
TLV1 (female) (4), (5) and chassis ground
[PCCS lever system]
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

BRK (female) (C) and chassis ground
[Brake pedal potentiometer system]
18
Voltage
Max. 1 V

[Fuel control dial system]
Voltage
Max. 1 V

TLV1 (female) (4), (5) and chassis ground
[PCCS lever system]
Voltage
Max. 1 V

STC1
Voltage
Between (22) (21)
4.5 5.5 V
D155AX-6
40 Troubleshooting
SEN00719-01
Circuit diagram related to power train controller 5V sensor power supply
D155AX-6
19
SEN00719-01
40 Troubleshooting
Failure code [DBE9KQ] PT controller: Type select signal

Action code
Failure code
E04
DBE9KQ
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
PT controller: Type select signal

Specification setting in power train controller does not match to specification setting signal
(Power train controller cannot be recognized).
Turns all outputs of power train controller OFF.
Machine does not move at all.
Possible causes
and standard
value in normal
state
Trouble
Cause
power train controller
Adjustment code: 0002 (Initialization of power train controller)
2
ResisMax. 1 z
nector)
tance

STC3
Voltage
Wiring harness between (30)

chassis ground
Max. 1 V
Circuit diagram related to work equipment controller type select power supply
20
D155AX-6
SEN00719-01
40 Troubleshooting
Failure code [DD12KA] Shift up Sw: Disconnection

Action code
Failure code
E02
DD12KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Shift up Sw: Disconnection

Signals of 2 systems of shift-up switch circuit are turned OFF (opened) simultaneously.
Recognizes that shift-up switch is not pressed.
Transmission gear cannot be shifted up.
Auto shift-down function does not operate.
"NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error.
State of shift-up switch signal can be checked with monitoring function.
(Code: 40905 T/M Sw Input 1)
Method of reproducing failure code: Turn starting switch ON + Operate shift-up switch.
Cause

Defective shift-up switch

SFTU (male)
Shift-up switch
OFF (Released)
ON (Pressed)
Resistance between
(3) (2)
Max. 1 z
Min. 1 Mz
Resistance between
(1) (2)
Min. 1 Mz
Max. 1 z
Possible causes
and standard
value in normal
state

2

SFTU (female) (1)
Resistance
Max. 1 z

SFTU (female) (2)
Resistance
Max. 1 z

SFTU (female) (3)
Resistance
Max. 1 z

3

24V circuit) in wiring harness SFTU (female) (1) and chassis ground
Voltage
Max. 1 V

SFTU (female) (3) and chassis ground
Voltage
Max. 1 V

STC1 ,STC3
4
22
Shift-up switch
OFF (Released)
ON (Pressed)
Voltage between
STC1 (12) STC1
(4)
Max. 1 V
5 11 V
Voltage between
STC3 (9) STC1 (4)
5 11 V
Max. 1 V
D155AX-6
40 Troubleshooting
SEN00719-01
Circuit diagram related to shift-up switch & shift-down switch
D155AX-6
23
SEN00719-01
40 Troubleshooting
Failure code [DD12KB] Shift up Sw: Short circuit

Action code
Failure code
E02
DD12KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Shift up Sw: Short circuit

Signals of 2 systems of shift-up switch circuit are turned ON (closed) simultaneously.

Recognizes that shift-up switch is not pressed.
Transmission gear cannot be shifted up.
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.
Cause

Possible causes
and standard
value in normal
state
Defective shift-up switch

SFTU (male)
Shift-up switch
OFF (Released)
ON (Pressed)
Resistance between
(3) (2)
Max. 1 z
Min. 1 Mz
Resistance between
(1) (2)
Min. 1 Mz
Max. 1 z

2 ness (Contact with GND cir SFTU (female) (1) and chassis ground
cuit)
SFTU (female) (3) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

24
STC1 ,STC3
Shift-up switch
OFF (Released)
ON (Pressed)
Voltage between
STC1 (12) STC1 (4)
Max. 1 V
5 11 V
Voltage between
STC3 (9) STC1 (4)
5 11 V
Max. 1 V
D155AX-6
40 Troubleshooting
SEN00719-01
D155AX-6
25
SEN00719-01
40 Troubleshooting
Failure code [DD13KA] Shift down Sw: Disconnection

Action code
Failure code
E02
DD13KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Shift down Sw: Disconnection

Signals of 2 systems of shift-down switch circuit are turned OFF (opened) simultaneously.
Recognizes that shift-down switch is not pressed.
Transmission gear cannot be shifted down.
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.
Cause

Defective shift-down switch

SFTD (female)
Shift-down switch
OFF (Released)
ON (Pressed)
Resistance between
(3) (2)
Max. 1 z
Min. 1 Mz
Resistance between
(1) (2)
Min. 1 Mz
Max. 1 z
Possible causes
and standard
value in normal
state

2

SFTD (female) (1)
Resistance
Max. 1 z

SFTD (female) (2)
Resistance
Max. 1 z

SFTD (female) (3)
Resistance
Max. 1 z

3
Hot short (Short circuit with Wiring harness between STC1 (female) (18)
24V circuit) in wiring harness SFTD (female) (1) and chassis ground
Voltage
Max. 1 V

SFTD (female) (3) and chassis ground
Voltage
Max. 1 V

26
STC1
Shift-down switch
OFF (Released)
ON (Pressed)
Voltage between
(24) - (4)
Max. 1 V
5 11 V
Voltage between
(18) (4)
5 11 V
Max. 1 V
D155AX-6
40 Troubleshooting
SEN00719-01
D155AX-6
27
SEN00719-01
40 Troubleshooting
Failure code [DD13KB] Shift down Sw: Short circuit

Action code
Failure code
E02
DD13KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Shift down Sw: Short circuit

Signals of 2 systems of shift-down switch circuit are turned ON (closed) simultaneously.

Recognizes that shift-down switch is not pressed.
Transmission gear cannot be shifted down.
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.
Cause

Possible causes
and standard
value in normal
state
Defective shift-down switch

SFTD (female)
Shift-down switch
OFF (Released)
ON (Pressed)
Resistance between
(3) (2)
Max. 1 z
Min. 1 Mz
Resistance between
(1) (2)
Min. 1 Mz
Max. 1 z

2 ness (Contact with GND cir SFTD (female) (1) and chassis ground
cuit)
SFTD (female) (3) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

28
STC1
Shift-down switch
OFF (Released)
ON (Pressed)
Voltage between
(24) (4)
Max. 1 V
5 11 V
Voltage between
(18) (4)
5 11 V
Max. 1 V
D155AX-6
40 Troubleshooting
SEN00719-01
D155AX-6
29
SEN00719-01
40 Troubleshooting
Failure code [DD14KA] Parking lever Sw: Disconnection

Action code
Failure code
E03
DD14KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Parking lever Sw: Disconnection

Signals of 2 systems of parking brake lever switch circuit are turned OFF (opened) simultaneously.
Recognizes that parking brake lever is in FREE position.
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.
Cause

PKSW (male)
Defective parking brake lever
2 switch (Internal disconnecResistance between
tion)
(A) (B)
Resistance between
(A) (C)
Parking brake lever

FREE position
LOCK position
Max. 1 z
Min. 1 Mz
Min. 1 Mz
Max. 1 z
Possible causes
and standard
value in normal
state

3
Wiring harness between FS22 (2) PKSW

(female) (A)
Resistance
Max. 1 z

PKSW (female) (B)
Resistance
Max. 1 z

PKSW (female) (C)
Resistance
Max. 1 z
Wiring harness between FS22 (2) PKSW
(female) (A) and chassis ground
cuit)
PKSW (female) (B) and chassis ground
PKSW (female) (C), PKS (female) (1) or
PKD (female) (1) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

troller
30
STC1
Parking brake lever

FREE position
LOCK position
Voltage between (23)

chassis ground
20 30 V
Max. 1 V

chassis ground
Max. 1 V
20 30 V
D155AX-6
40 Troubleshooting
SEN00719-01
Circuit diagram related to parking brake lever switch and solenoid valve
D155AX-6
31
SEN00719-01
40 Troubleshooting
Failure code [DD14KB] Parking lever Sw: Short circuit

Action code
Failure code
E03
DD14KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Parking lever Sw: Short circuit

Signals of 2 systems of parking brake lever switch circuit are turned ON (closed) simultaneously.
Recognizes that parking brake lever is in FREE position.
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.
Cause

PKSW (male)
Defective parking brake lever

switch (Internal short circuit) Resistance between
(A) (B)
Resistance between
(A) (C)
Possible causes
and standard
value in normal
state
Parking brake lever

FREE position
LOCK position
Max. 1 z
Min. 1 Mz
Min. 1 Mz
Max. 1 z
2

PKSW (female) (B) and chassis ground
24V circuit) in wiring harness
PKSW (female) (C), PKS (female) (1) or
PKD (female) (1) and chassis ground
Voltage
Max. 1 V
Voltage
Max. 1 V

32
STC1
Parking brake lever

FREE position
LOCK position

chassis ground
20 30 V
Max. 1 V

chassis ground
Max. 1 V
20 30 V
D155AX-6
40 Troubleshooting
SEN00719-01
Circuit diagram related to parking brake lever switch and solenoid valve
D155AX-6
33
SEN00719-01
40 Troubleshooting
Failure code [DDDDKA] Back up brake Sw: Disconnection

Action code
Failure code
E02
DDDDKA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Back up brake Sw: Disconnection

Signals of 2 systems of brake pedal switch circuit are turned OFF (opened) simultaneously.
Recognizes that brake pedal is not pressed.
State of brake pedal switch signal can be checked with monitoring function.
(Code: 40905 T/M Sw Input1)
Method of reproducing failure code: Turn starting switch ON + Operate brake pedal.
Cause

BKSW (male)
Defective brake pedal switch

Resistance between
(A) (B)
Resistance between
(A) (C)
Brake pedal
Released
Pressed
Max. 1 z
Min. 1 Mz
Min. 1 Mz
Max. 1 z
Possible causes
and standard
value in normal
state

3
Wiring harness between FS22 (1) BKSW

(female) (A)
Resistance
Max. 1 z

BKSW (female) (B)
Resistance
Max. 1 z

BKSW (female) (C)
Resistance
Max. 1 z
Wiring harness between FS22 (1) BKSW
(female) (A) and chassis ground
cuit)
BKSW (female) (B) and chassis ground
BKSW (female) (C), PBS (female) (1) or
PBD (female) (1) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

troller
34
STC1
Brake pedal
Released
Pressed

chassis ground
20 30 V
Max. 1 V
Voltage between (5)

chassis ground
Max. 1 V
20 30 V
D155AX-6
40 Troubleshooting
SEN00719-01
Circuit diagram related to brake pedal switch and solenoid valve
D155AX-6
35
SEN00719-01
40 Troubleshooting
Failure code [DDDDKB] Back up brake Sw: Short circuit

Action code
Failure code
E02
DDDDKB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Back up brake Sw: Short circuit

Signals of 2 systems of brake pedal switch circuit are turned ON (closed) simultaneously.
Recognizes that brake pedal is not pressed.
State of brake pedal switch signal can be checked with monitoring function.
Cause

BKSW (male)
Defective brake pedal switch

Resistance between
(A) (B)
Resistance between
(A) (C)
Possible causes
and standard
value in normal
state
Brake pedal
Released
Pressed
Max. 1 z
Min. 1 Mz
Min. 1 Mz
Max. 1 z
2

BKSW (female) (B) and chassis ground
BKSW (female) (C), PBS (female) (1), or
PBD (female) (1) and chassis ground
Voltage
Max. 1 V
Voltage
Max. 1 V

36
STC1
Brake pedal
Released
Pressed

chassis ground
20 30 V
Max. 1 V
Voltage between (5)

chassis ground
Max. 1 V
20 30 V
D155AX-6
40 Troubleshooting
SEN00719-01
Circuit diagram related to brake pedal switch and solenoid valve
D155AX-6
37
SEN00719-01
40 Troubleshooting
Failure code [DDDDKX] Back up brake Sw: Signal mismatch

Action code
Failure code
E02
DDDDKX
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
None in particular.
Backup brake may not operate.
State of brake pedal potentiometer signal can be checked with monitoring function.
(Code: 50400 Brake Pedal Potentio)
Defective brake pedal switch If failure code [DDDDKA] or [DDDDKB] is also displayed, carry out
system
troubleshooting for it first.
Adjust brake pedal and perform operation of reproducing trouble.

2 Defective brake pedal switch If "E" of failure code disappears at this time, system is normal.
Testing and adjusting item: Adjusting brake pedal
3
38
Back up brake Sw: Signal mismatch

Brake pedal potentiometer signal does not match to brake pedal switch signal.
Cause
Possible causes
and standard
value in normal
state
If causes 1 2 are not detected, power train controller may be

carried out.)
D155AX-6
SEN00719-01
40 Troubleshooting
Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection

Action code
Failure code
E02
DDN7KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
WEQ Knob Sw (down): Disconnection

Signals of 2 systems of blade pitch switch circuit are turned OFF (opened) simultaneously.
Recognizes that blade pitch switch is not pressed.
Blade pitch function does not operate.
State of blade pitch switch signal can be checked with monitoring function.
(Code: 70300 Blade Sw Input)
Method of reproducing failure code: Turn starting switch ON + Operate blade pitch switch.
Cause

Defective blade pitch switch

BNSL (female)
Blade pitch switch

OFF (Released)
ON (Pressed)
Resistance between
(3) (2)
Max. 1 z
Min. 1 Mz
Resistance between
(1) (2)
Min. 1 Mz
Max. 1 z
Possible causes
and standard
value in normal
state

2

(16) BNSL (female) (1)
Resistance
Max. 1 z
Wiring harness between WEC1 (female) (4)

BNSL (female) (2)
Resistance
Max. 1 z

BNSL (female) (3)
Resistance
Max. 1 z

3

(16) BNSL (female) (1) and chassis
ground
BNSL (female) (3) and chassis ground
Voltage
Max. 1 V
Voltage
Max. 1 V

WEC1, WEC2
4
40

controller
Blade pitch switch

OFF (Released)
ON (Pressed)
Voltage between
WEC2 (6) WEC1 (4)
Max. 1 V
5 11 V
Voltage between
WEC2 (16)
WEC1 (4)
5 11 V
Max. 1 V
D155AX-6
40 Troubleshooting
SEN00719-01
Circuit diagram related to blade float switch and blade pitch switch
D155AX-6
41
SEN00719-01
40 Troubleshooting
Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit

Action code
Failure code
E02
DDN7KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
WEQ Knob Sw (down): Short circuit

Signals of 2 systems of blade pitch switch circuit are turned ON (closed) simultaneously.
Recognizes that blade pitch switch is not pressed.
Blade pitch function does not operate.
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.
Cause

Possible causes
and standard
value in normal
state
Defective blade pitch switch

BNSL (female)
Blade pitch switch

OFF (Released)
ON (Pressed)
Resistance between
(3) (2)
Max. 1 z
Min. 1 Mz
Resistance between
(1) (2)
Min. 1 Mz
Max. 1 z
Ground fault in wiring harWiring harness between WEC2 (female)
2 ness (Contact with GND cir- (16) BNSL (female) (1) and chassis
cuit)
ground
BNSL (female) (3) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

WEC1, WEC2
3
42

controller
Blade pitch switch

OFF (Released)
ON (Pressed)
Voltage between
WEC2 (6) WEC1 (4)
Max. 1 V
5 11 V
Voltage between
WEC2 (16)
WEC1 (4)
5 11 V
Max. 1 V
D155AX-6
40 Troubleshooting
SEN00719-01
D155AX-6
43
SEN00719-01
40 Troubleshooting
Failure code [DDN9KA] WEQ Knob Sw (up): Disconnection

Action code
Failure code
E01
DDN9KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
WEQ Knob Sw (up): Disconnection

Signals of 2 systems of blade float switch circuit are turned OFF (opened) simultaneously.
Recognizes that blade float switch is not pressed.
Blade float function does not operate.
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.
Cause

Defective blade float switch

BNSU (male)
Blade float switch

OFF (Released)
ON (Pressed)
Resistance between
(3) (2)
Max. 1 z
Min. 1 Mz
Resistance between
(1) (2)
Min. 1 Mz
Max. 1 z
2
Possible causes
and standard
value in normal
state

(36) BNSU (female) (1)
Resistance
Max. 1 z

BNSU (female) (2)
Resistance
Max. 1 z

(26) BNSU (female) (3)
Resistance
Max. 1 z

Hot short (Short circuit with (36) BNSU (female) (1) and chassis
3
24V circuit) in wiring harness ground
Voltage
Max. 1 V

(26) BNSU (female) (3) and chassis
ground
Voltage
Max. 1 V

WEC1, WEC2
4
controller
44
Blade float switch

OFF (Released)
ON (Pressed)
Voltage between
WEC2 (26)
WEC1 (4)
Max. 1 V
5 11 V
Voltage between
WEC2 (36)
WEC1 (4)
5 11 V
Max. 1 V
D155AX-6
40 Troubleshooting
SEN00719-01
D155AX-6
45
SEN00719-01
40 Troubleshooting
Failure code [DDN9KB] WEQ Knob Sw (up): Short circuit

Action code
Failure code
E01
DDN9KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
WEQ Knob Sw (up): Short circuit

Signals of 2 systems of blade float switch circuit are turned ON (closed) simultaneously.
Recognizes that blade float switch is not pressed.
Blade float function does not operate.
Method of reproducing failure code: Turn starting switch ON + Operate blade float switch.
Cause

Defective blade float switch

BNSU (male)
Blade float switch

OFF (Released)
ON (Pressed)
Resistance between
(3) (2)
Max. 1 z
Min. 1 Mz
Resistance between
(1) (2)
Min. 1 Mz
Max. 1 z
Possible causes
and standard
value in normal
state

Ground fault in wiring har(36) BNSU (female) (1) and chassis
cuit)
(26) BNSU (female) (3) and chassis
ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

WEC1, WEC2
3
controller
46
Blade float switch

OFF (Released)
ON (Pressed)
Voltage between
WEC2 (26)
WEC1 (4)
Max. 1 V
5 11 V
Voltage between
WEC2 (36)
WEC1 (4)
5 11 V
Max. 1 V
D155AX-6
40 Troubleshooting
SEN00719-01
D155AX-6
47
SEN00719-01
40 Troubleshooting
Failure code [DDNLKA] Weq lock Sw: Disconnection

Action code
Failure code
E03
DDNLKA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Weq lock Sw: Disconnection

Signals of 2 systems of work equipment lock lever switch circuit are turned OFF (opened) simultaneously.
Recognizes that work equipment lock lever is in FREE position.
Method of reproducing failure code: Turn starting switch ON + Operate work equipment lock lever.
Cause


1 lock lever switch (Internal
disconnection)
WELK (male)

FREE position
LOCK position
Resistance between
(B) (A)
Max. 1 z
Min. 1 Mz
Resistance between
(C) (A)
Min. 1 Mz
Max. 1 z
2
Possible causes
and standard
value in normal
state

(10) WELK (female) (A)
Resistance
Max. 1 z

WELK (female) (B)
Resistance
Max. 1 z

(15) WELK (female) (C)
Resistance
Max. 1 z

3

WELK (female) (B) and chassis ground
(15) WELK (female) (C) and chassis
ground
Voltage
Max. 1 V
Voltage
Max. 1 V

WEC1, WEC2
4
controller
48

FREE position
LOCK position
Voltage between
WEC2 (5)
WEC1 (10)
Max. 1 V
5 11 V
Voltage between
WEC2 (15)
WEC1 (10)
5 11 V
Max. 1 V
D155AX-6
40 Troubleshooting
SEN00719-01
Circuit diagram related to work equipment lock lever switch
D155AX-6
49
SEN00719-01
40 Troubleshooting
Failure code [DDNLKB] Weq lock Sw: Short circuit

Action code
Failure code
E03
DDNLKB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Weq lock Sw: Short circuit

Signals of 2 systems of work equipment lock lever switch circuit are turned ON (closed) simultaneously.
Recognizes that work equipment lock lever is in FREE position.
Method of reproducing failure code: Turn starting switch ON + Operate work equipment lock lever.
Cause


1 lock lever switch (Internal
short circuit)
WELK (male)

FREE position
LOCK position
Resistance between
(B) (A)
Max. 1 z
Min. 1 Mz
Resistance between
(C) (A)
Min. 1 Mz
Max. 1 z
Possible causes
and standard
value in normal
state
Ground fault in wiring harWiring harness between WEC2 (female) (5)

2 ness (Contact with GND cir- WELK (female) (B) and chassis ground
cuit)
(15) WELK (female) (C) and chassis
ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

WEC1, WEC2
3
controller
50

FREE position
LOCK position
Voltage between
WEC2 (5)
WEC1 (10)
Max. 1 V
5 11 V
Voltage between
WEC2 (15)
WEC1 (10)
5 11 V
Max. 1 V
D155AX-6
40 Troubleshooting
SEN00719-01
Circuit diagram related to work equipment lock lever switch
D155AX-6
51
SEN00719-01
40 Troubleshooting
Failure code [DDTSL1] S/C: Fill high

Action code
Failure code
E02
DDTSL1
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
S/C: Fill high

When signal is not output to solenoid circuit of torque converter stator clutch ECMV, fill switch signal
is turned ON.
None in particular.
Travel torque may not be obtained sufficiently.
State of fill switch signal of stator clutch ECMV can be checked with monitoring function.
Method of reproducing failure code: Start engine + Set travel lever in N (Neutral).
Cause

Defective fill switch of stator

1 clutch ECMV (Internal short
circuit)
Possible causes
and standard
value in normal
state
FSTC (male)
PCCS lever
(Travel gear speed)
N
sis ground
or F3
Resistance
Max. 1 z
Min. 1 Mz
Resiscuit)
Min. 1 Mz
FSTC (female) (1) and chassis ground
tance
3
52
STC2
PCCS lever
(Travel gear speed)
N
Between (26) chasLocked
up
at F1, F2,
sis ground
or F3
Voltage
Max. 1 V
5 11 V
D155AX-6
40 Troubleshooting
SEN00719-01
Circuit diagram related to torque converter stator clutch ECMV
D155AX-6
53
SEN00719-01
40 Troubleshooting
Failure code [DDTSLH] S/C: Fill low

Action code
Failure code
E02
DDTSLH
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
S/C: Fill low

When signal is output to solenoid circuit of torque converter stator clutch ECMV, fill switch signal is
turned OFF.
None in particular.
Travel torque may not be obtained sufficiently.
State of fill switch signal of stator clutch ECMV can be checked with monitoring function.
Method of reproducing failure code: Start engine + Set travel lever in F (Forward) (Automatic gearshift mode).
Cause

Defective fill switch of stator

1 clutch ECMV (Internal disconnection)
Possible causes
and standard
value in normal
state
FSTC (male)
PCCS lever
(Travel gear speed)
N
sis ground
or F3
Resistance
Max. 1 z
Min. 1 Mz
2
ResisMax. 1 z
nector)
FSTC (female) (1)
tance
3
54
STC2
PCCS lever
(Travel gear speed)
N
sis ground
or F3
Voltage
Max. 1 V
5 11 V
D155AX-6
40 Troubleshooting
SEN00719-01
D155AX-6
55
SEN00719-01
40 Troubleshooting
D155AX-6 Bulldozer
2006 KOMATSU
All Rights Reserved
56
D155AX-6
SEN00720-02
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
40 Troubleshooting

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
Failure code [DFA9KB] BT lever 2: Short circuit ........................................................................................... 22
D155AX-6
SEN00720-02
40 Troubleshooting
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
D155AX-6
40 Troubleshooting
SEN00720-02
Failure code [DFA4KX] BL lever 1: Out of normal range

Action code
E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Failure code
DFA4KX
Trouble
BL lever 1: Out of normal range

In blade control lever lift potentiometer 1 and 2 systems, either of failure codes [DFA5KA] and
[DFA5KB] and either of failure codes [DFA6KA] and [DFA6KB] occurred simultaneously.
State of blade control lever lift potentiometer signal can be checked with monitoring function.
(Code: 73400 Blade Lift Lever A Potentio)
(Code: 73401 Blade Lift Lever B Potentio)
Method of reproducing failure code: Turn starting switch ON + Operate blade control lever
(in lifting direction).
Cause
Carry out troubleshooting for failure codes [DFA5KA], [DFA5KB], [DFA6KA], and [DFA6KB].
Failure code [DFA4KZ] BL lever: Disconnection or short circuit

Action code
Failure code
E03
DFA4KZ
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
D155AX-6
Trouble
BL lever: Disconnection or short circuit

In blade control lever lift potentiometer 1 and 2 systems, when starting switch is turned ON, only
either side is abnormal and then either of failure codes [DFA5KA] and [DFA5KB] and either of failure codes [DFA6KA] and [DFA6KB] occurred simultaneously.
Cause
SEN00720-02
40 Troubleshooting
Failure code [DFA4L8] BL lever: Signal mismatch

Action code
E03
DFA4L8
Trouble
BL lever: Signal mismatch

Contents of
trouble
In blade control lever lift potentiometer 1 and 2 systems, total of both signal voltages is below 4.41 V
or above 5.59 V.
Action of
controller
Continues control with signal of normal one of blade control lever lift potentiometer 1 and 2 systems.
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Failure code

Cause
D155AX-6
40 Troubleshooting
D155AX-6
SEN00720-02
SEN00720-02
40 Troubleshooting
Failure code [DFA5KA] BL lever 1: Disconnection

Action code
Failure code
E03
DFA5KA
Trouble
Contents of
trouble
Signal voltage of blade control lever lift potentiometer 1 system is below 0.5 V.
Action of
controller
Continues control with signal of blade control lever lift potentiometer 2 system.
Problem that
appears on
machine
Related
information

State of blade control lever lift potentiometer 1 signal can be checked with monitoring function.
Cause
1

supply system

If failure code [DB97KK] is also displayed, carry out troubleshooting for it first.
Defective blade control lever

2 lift potentiometer 1 (Internal
disconnection)
WLV1 (male)
Blade control lever
Between (4) (1)

Between (4) (3)
3.2 kz 40 %
Neutral
Between (3) (1)

Possible causes
and standard
value in normal
state
Resistance
1 5 kz
1 5 kz
Disconnection in wiring harness (Disconnection in wiring Wiring harness between WEC1 (female)
3
or defective contact in con- (22) WLV1 (female) (4)
nector)
WLV1 (female) (3)
Resistance
Max. 1 z
Resistance
Max. 1 z
4 ness (Contact with GND cirWiring harness between WEC1 (female) (2)
Resiscuit)
Min. 1 Mz
WLV1 (female) (3) and chassis ground
tance
5
controller

WEC1
Voltage
Between (2) (21)
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00720-02
Circuit diagram related to blade control lever potentiometer
D155AX-6
SEN00720-02
40 Troubleshooting
Failure code [DFA5KB] BL lever 1: Short circuit

Action code
Failure code
E03
DFA5KB
Trouble

Contents of
trouble
Signal voltage of blade control lever lift potentiometer 1 system is above 4.5 V.
Action of
controller
Problem that
appears on
machine
Related
information

Cause
1

supply system

Possible causes
and standard
value in normal
state

short circuit)
Blade control lever
Between (4) (1)

Between (4) (3)
Between (3) (1)
Resistance
3.2 kz 40 %
Neutral
1 5 kz
1 5 kz

3
24V circuit) in wiring harness Wiring harness between WEC1 (female) (2)
Voltage Max. 1 V
WLV1 (male)

controller

WEC1
Voltage
Between (2) (21)
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
SEN00720-02
40 Troubleshooting
Failure code [DFA6KA] BL lever 2: Disconnection

Action code
Failure code
E03
DFA6KA
Trouble
Contents of
trouble
Signal voltage of blade control lever lift potentiometer 2 system is below 0.5 V.
Action of
controller
Problem that
appears on
machine
Related
information

Cause
1

supply system


disconnection)
WLV1 (male)
Blade control lever
Between (4) (1)

Between (4) (2)
3.2 kz 40 %
Neutral
Between (2) (1)

Possible causes
and standard
value in normal
state
Resistance
1 5 kz
1 5 kz
3
nector)
(19) WLV1 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
Ground fault in wiring har4 ness (Contact with GND cir- Wiring harness between WEC1 (female)
Resiscuit)
(19) WLV1 (female) (2) and chassis
Min. 1 Mz
tance
ground
10

controller

WEC1
Voltage
Between (19) (21)
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
11
SEN00720-02
40 Troubleshooting
Failure code [DFA6KB] BL lever 2: Short circuit

Action code
Failure code
E03
DFA6KB
Trouble

Contents of
trouble
Signal voltage of blade control lever lift potentiometer 2 system is above 4.5 V.
Action of
controller
Problem that
appears on
machine
Related
information

Cause
1

supply system


short circuit)
Possible causes
and standard
value in normal
state
Blade control lever
Between (4) (1)

Between (4) (2)
Resistance
3.2 kz 40 %
Neutral
Between (2) (1)
1 5 kz
1 5 kz

12
WLV1 (male)

ground
controller
Voltage
Max. 1 V

WEC1
Voltage
Between (19) (21)
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
13
SEN00720-02
40 Troubleshooting
Failure code [DFA7KX] BT lever 1: Out of normal range

Action code
E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Failure code
DFA7KX
Trouble
BT lever 1: Out of normal range

In blade control lever tilt potentiometer 1 and 2 systems, either of failure codes [DFA8KA] and
[DFA8KB] and either of failure codes [DFA9KA] and [DFA9KB] occurred simultaneously.
State of blade control lever tilt potentiometer signal can be checked with monitoring function.
(Code: 73500 Blade Tilt Lever A Potentio)
(Code: 73501 Blade Tilt Lever B Potentio)
(in tilting direction).
Cause
Failure code [DFA7KZ] BT lever: Disconnection or short circuit

Action code
Failure code
E03
DFA7KZ
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
14
Trouble
BT lever: Disconnection or short circuit

In blade control lever tilt potentiometer 1 and 2 systems, when starting switch is turned ON, only
either side is abnormal and then either of failure codes [DFA8KA] and [DFA8KB] and either of failure codes [DFA9KA] and [DFA9KB] occurred simultaneously.
Cause
D155AX-6
40 Troubleshooting
SEN00720-02
Failure code [DFA7L8] BT lever: Signal mismatch

Action code
E03
Failure code
DFA7L8
Trouble
BT lever: Signal mismatch

Contents of
trouble
In blade control lever tilt potentiometer 1 and 2 systems, total of both signal voltages is below 4.41 V
or above 5.59 V.
Action of
controller
Continues control with signal of normal one of blade control lever tilt potentiometer 1 and 2 systems.
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
D155AX-6

Cause
15
SEN00720-02
40 Troubleshooting
Failure code [DFA8KA] BT lever 1: Disconnection

Action code
Failure code
E03
DFA8KA
Trouble
Contents of
trouble
Signal voltage of blade control lever tilt potentiometer 1 system is below 0.5 V.
Action of
controller
Continues control with signal of blade control lever tilt potentiometer 2 system.
Limits operation of engine and transmission
Problem that
appears on
machine
Related
information

State of blade control lever tilt potentiometer 1 signal can be checked with monitoring function.
Cause
1

supply system


2 tilt potentiometer 1 (Internal
disconnection)
WLV1 (male)
Blade control lever
Between (8) (5)

Between (8) (7)
3.2 kz 40 %
Neutral
Between (7) (5)

Possible causes
and standard
value in normal
state
Resistance
1 5 kz
1 5 kz
3
nector)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resiscuit)
Min. 1 Mz
tance
ground
16

controller

WEC1
Voltage
Between (13) (21)
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
17
SEN00720-02
40 Troubleshooting
Failure code [DFA8KB] BT lever 1: Short circuit

Action code
Failure code
E03
DFA8KB
Trouble

Contents of
trouble
Signal voltage of blade control lever tilt potentiometer 1 system is above 4.5 V.
Action of
controller
Problem that
appears on
machine
Related
information

Cause
1

supply system


short circuit)
Possible causes
and standard
value in normal
state
Blade control lever
Between (8) (5)

Between (8) (7)
Resistance
3.2 kz 40 %
Neutral
Between (7) (5)
1 5 kz
1 5 kz

18
WLV1 (male)

ground
controller
Voltage
Max. 1 V

WEC1
Voltage
Between (13) (21)
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
19
SEN00720-02
40 Troubleshooting
Failure code [DFA9KA] BT lever 2: Disconnection

Action code
Failure code
E03
DFA9KA
Trouble
Contents of
trouble
Signal voltage of blade control lever tilt potentiometer 2 system is below 0.5 V.
Action of
controller
Problem that
appears on
machine
Related
information

Cause
1

supply system


disconnection)
WLV1 (male)
Blade control lever
Between (8) (5)

Between (8) (6)
3.2 kz 40 %
Neutral
Between (6) (5)

Possible causes
and standard
value in normal
state
Resistance
1 5 kz
1 5 kz
3
nector)
WLV1 (female) (6)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resiscuit)
Min. 1 Mz
tance
5
controller
20

WEC1
Voltage
Between (7) (21)
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
21
SEN00720-02
40 Troubleshooting
Failure code [DFA9KB] BT lever 2: Short circuit

Action code
Failure code
E03
DFA9KB
Trouble

Contents of
trouble
Signal voltage of blade control lever tilt potentiometer 2 system is above 4.5 V.
Action of
controller
Problem that
appears on
machine
Related
information

Cause
1

supply system

Possible causes
and standard
value in normal
state

short circuit)
Blade control lever
Between (8) (5)

Between (8) (6)
Between (6) (5)
Resistance
3.2 kz 40 %
Neutral
1 5 kz
1 5 kz

3
Voltage Max. 1 V
22
WLV1 (male)

controller

WEC1
Voltage
Between (7) (21)
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
23
SEN00720-02
40 Troubleshooting
Failure code [DFAAKX] RL lever 1: Out of normal range

Action code
E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Failure code
DFAAKX
Trouble

In ripper control lever lift potentiometer 1 and 2 systems, either of failure codes [DFABKA] and
[DFABKB] and either of failure codes [DFACKA] and [DFACKB] occurred simultaneously.
State of ripper control lever lift potentiometer signal can be checked with monitoring function.
(Code: 73700 Ripper Lift Lever A Potentio)
(Code: 73701 Ripper Lift Lever B Potentio)
Method of reproducing failure code: Turn starting switch ON + Operate ripper control lever
Cause
Carry out troubleshooting for failure codes [DFABKA], [DFABKB], [DFACKA], and [DFACKB].
Failure code [DFAAKZ] RL lever: Disconnection or short circuit

Action code
Failure code
E03
DFAAKZ
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
24
Trouble

In ripper control lever lift potentiometer 1 and 2 systems, when starting switch is turned ON, only
either side is abnormal and then either of failure codes [DFABKA] and [DFABKB] and either of failure codes [DFACKA] and [DFACKB] occurred simultaneously.
Cause
D155AX-6
40 Troubleshooting
SEN00720-02
Failure code [DFAAL8] RL lever: Signal mismatch

Action code
E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
D155AX-6
Failure code
DFAAL8
Trouble

In ripper control lever lift potentiometer 1 and 2 systems, total of both signal voltages is below 4.41
V or above 5.59 V.
Continues control with signal of normal one of ripper control lever lift potentiometer 1 and 2 systems.
Cause
25
SEN00720-02
40 Troubleshooting
Failure code [DFABKA] RL lever 1: Disconnection

Action code
Failure code
E03
DFABKA
Trouble
Contents of
trouble
Signal voltage of ripper control lever lift potentiometer 1 system is below 0.5 V.
Action of
controller
Continues control with signal of ripper control lever lift potentiometer 2 system.
Problem that
appears on
machine
Related
information

State of ripper control lever lift potentiometer 1 signal can be checked with monitoring function.
Cause
1

supply system

Defective ripper control lever

disconnection)
WLV2 (male)
Between (8) (5)

Between (8) (7)
3.2 kz 40 %
Neutral
Between (7) (5)

Possible causes
and standard
value in normal
state
Resistance
1 5 kz
1 5 kz
3
nector)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resiscuit)
Min. 1 Mz
tance
ground
26

controller

WEC1
Voltage
Between (14) (21)
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00720-02
Circuit diagram related to ripper control lever potentiometer
D155AX-6
27
SEN00720-02
40 Troubleshooting
Failure code [DFABKB] RL lever 1: Short circuit

Action code
Failure code
E03
DFABKB
Trouble

Contents of
trouble
Signal voltage of ripper control lever lift potentiometer 1 system is above 4.5 V.
Action of
controller
Problem that
appears on
machine
Related
information

Cause
1

supply system


short circuit)
Possible causes
and standard
value in normal
state
Between (8) (5)

Between (8) (7)
Resistance
3.2 kz 40 %
Neutral
Between (7) (5)
1 5 kz
1 5 kz
28
WLV2 (male)

ground
controller
Resistance
Min. 1 Mz

WEC1
Voltage
Between (14) (21)
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
29
SEN00720-02
40 Troubleshooting
Failure code [DFACKA] RL lever 2: Disconnection

Action code
Failure code
E03
DFACKA
Trouble
Contents of
trouble
Signal voltage of ripper control lever lift potentiometer 2 system is below 0.5 V.
Action of
controller
Problem that
appears on
machine
Related
information

Cause
1

supply system


disconnection)
WLV2 (male)
Between (8) (5)

Between (8) (6)
3.2 kz 40 %
Neutral
Between (6) (5)

Possible causes
and standard
value in normal
state
Resistance
1 5 kz
1 5 kz
3
nector)
WLV2 (female) (6)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resiscuit)
Min. 1 Mz
tance
5
controller
30

WEC1
Voltage
Between (8) (21)
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
31
SEN00720-02
40 Troubleshooting
Failure code [DFACKB] RL lever 2: Short circuit

Action code
Failure code
E03
DFACKB
Trouble

Contents of
trouble
Signal voltage of ripper control lever lift potentiometer 2 system is above 4.5 V.
Action of
controller
Problem that
appears on
machine
Related
information

tate of ripper control lever lift potentiometer 2 signal can be checked with monitoring function.
Cause
1

supply system

Possible causes
and standard
value in normal
state

short circuit)
Between (8) (5)

Between (8) (6)
Between (6) (5)
Resistance
3.2 kz 40 %
Neutral
1 5 kz
1 5 kz

3
Voltage Max. 1 V
32
WLV2 (male)

controller

WEC1
Voltage
Between (8) (21)
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
33
SEN00720-02
40 Troubleshooting
Failure code [DFADKX] RL lever 1: Out of normal range

Action code
E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Failure code
DFADKX
Trouble

In ripper control lever tilt potentiometer 1 and 2 systems, either of failure codes [DFAEKA] and
[DFAEKB] and either of failure codes [DFAFKA] and [DFAFKB] occurred simultaneously.
State of ripper control lever tilt potentiometer signal can be checked with monitoring function.
(Code: 73600 Ripper Tilt Lever A Potentio)
(Code: 73601 Ripper Tilt Lever B Potentio)
Cause
Carry out troubleshooting for failure codes [DFAEKA], [DFAEKB], [DFAFKA], and [DFAFKB].
Failure code [DFADKZ] RL lever: Disconnection or short circuit

Action code
Failure code
E03
DFADKZ
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
34
Trouble

In ripper control lever tilt potentiometer 1 and 2 systems, when starting switch is turned ON, only
either side is abnormal and then either of failure codes [DFAEKA] and [DFAEKB] and either of failure codes [DFAFKA] and [DFAFKB] occurred simultaneously.
Cause
D155AX-6
40 Troubleshooting
SEN00720-02
Failure code [DFADL8] RL lever: Signal mismatch

Action code
E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
D155AX-6
Failure code
DFADL8
Trouble

In ripper control lever tilt potentiometer 1 and 2 systems, total of both signal voltages is
below 4.41 V or above 5.59 V.
Continues control with signal of normal one of ripper control lever tilt potentiometer 1 and 2 systems.
Cause
35
SEN00720-02
40 Troubleshooting
Failure code [DFAEKA] RL lever 1: Disconnection

Action code
Failure code
E03
DFAEKA
Trouble
Contents of
trouble
Signal voltage of ripper control lever tilt potentiometer 1 system is below 0.5 V.
Action of
controller
Continues control with signal of ripper control lever tilt potentiometer 2 system.
Problem that
appears on
machine
Related
information

State of ripper control lever tilt potentiometer 1 signal can be checked with monitoring function.
Cause
1

supply system


disconnection)
WLV2 (male)
Between (4) (1)

Between (4) (3)
3.2 kz 40 %
Neutral
Between (3) (1)

Possible causes
and standard
value in normal
state
Resistance
1 5 kz
1 5 kz
3
nector)
WLV2 (female) (3)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resiscuit)
Min. 1 Mz
tance
5
controller
36

WEC1
Voltage
Between (3) (21)
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
37
SEN00720-02
40 Troubleshooting
Failure code [DFAEKB] RL lever 1: Short circuit

Action code
Failure code
E03
DFAEKB
Trouble

Contents of
trouble
Signal voltage of ripper control lever tilt potentiometer 1 system is above 4.5 V.
Action of
controller
Problem that
appears on
machine
Related
information

Cause
1

supply system

Possible causes
and standard
value in normal
state

short circuit)
Between (4) (1)

Between (4) (3)
Between (3) (1)
Resistance
3.2 kz 40 %
Neutral
1 5 kz
1 5 kz

3
Voltage Max. 1 V
38
WLV2 (male)

controller

WEC1
Voltage
Between (3) (21)
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
39
SEN00720-02
40 Troubleshooting
Failure code [DFAFKA] RL lever 2: Disconnection

Action code
Failure code
E03
DFAFKA
Trouble
Contents of
trouble
Signal voltage of ripper control lever tilt potentiometer 2 system is below 0.5 V.
Action of
controller
Problem that
appears on
machine
Related
information

Cause
1

supply system


disconnection)
WLV2 (male)
Between (4) (1)

Between (4) (2)
3.2 kz 40 %
Neutral
Between (2) (1)

Possible causes
and standard
value in normal
state
Resistance
1 5 kz
1 5 kz
3
nector)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resiscuit)
Min. 1 Mz
tance
ground
40

controller

WEC1
Voltage
Between (20) (21)
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
41
SEN00720-02
40 Troubleshooting
Failure code [DFAFKB] RL lever 2: Short circuit

Action code
Failure code
E03
DFAFKB
Trouble

Contents of
trouble
Signal voltage of ripper control lever tilt potentiometer 2 system is above 4.5 V.
Action of
controller
Problem that
appears on
machine
Related
information

Cause
1

supply system


short circuit)
Possible causes
and standard
value in normal
state
Between (4) (1)

Between (4) (2)
Resistance
3.2 kz 40 %
Neutral
Between (2) (1)
1 5 kz
1 5 kz

42
WLV2 (male)

ground
controller
Voltage
Max. 1 V

WEC1
Voltage
Between (20) (21)
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00720-02
D155AX-6
43
SEN00720-02
40 Troubleshooting
Failure code [DGT1KA] T/C oil temp sensor: Abnormal

Action code
Failure code
E01
DGT1KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

Torque converter oil temperature sensor signal is out of normal range.

None in particular.
Power train oil temperature gauge may not indicate normally.
Torque converter oil temperature can be checked with monitoring function.
Method of reproducing failure code: Turn starting switch ON or start engine.
Cause
oil temperature sensor (Inter1
nal short circuit or disconnection)

TCT (male)
Resistance
Between (1) (2)
1 50 kz
Min. 1 Mz
Possible causes
and standard
value in normal
state
2
or defective contact in con- TCT (female) (1)
nector)
TCT (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resiscuit)
Min. 1 Mz
TCT (female) (1) and chassis ground
tance
4
Voltage Max. 1 V
5
44
STC1 (female)
Resistance
Between (9) (21)
1 50 kz
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00720-02
Circuit diagram related to torque converter oil temperature sensor
D155AX-6
45
SEN00720-02
40 Troubleshooting
Failure code [DGT1KX] T/C oil temp sensor: Abnormal

Action code
Failure code
E01
DGT1KX
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

Torque converter oil temperature sensor signal is out of normal range.

None in particular.
Power train oil temperature gauge may not indicate normally.
Torque converter oil temperature can be checked with monitoring function.
Method of reproducing failure code: Turn starting switch ON or start engine.
Cause
oil temperature sensor (Inter1
nal short circuit or disconnection)

TCT (male)
Resistance
Between (1) (2)
1 50 kz
Min. 1 Mz
Possible causes
and standard
value in normal
state
2
or defective contact in con- TCT (female) (1)
nector)
TCT (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resiscuit)
Min. 1 Mz
tance
4
Voltage Max. 1 V
5
46
STC1 (female)
Resistance
Between (9) (21)
1 50 kz
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00720-02
Circuit diagram related to torque converter oil temperature sensor
D155AX-6
47
SEN00720-02
40 Troubleshooting
Failure code [DH21KA] Weq pressure sensor: Disconnection

Action code
Failure code
DH21KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Weq pressure sensor: Disconnection

Signal voltage of work equipment pump oil pressure sensor is below 0.5 V.
None in particular.
Oil pressure of work equipment pump cannot be monitored.
State of work equipment pump oil pressure sensor can be checked with monitoring function.
(Code: 70701 Hydraulic Pressure Sensor 1)
Cause

1
supply system
or start engine and carry out troubleshooting in each case.
Defective work equipment oil

2 pressure sensor (Internal
trouble)
HHP
Voltage
Between (B) (A)
Power supply
4.5 5.5 V
Between (C) (A)
Signal
0.5 6.0 V

Possible causes
and standard
value in normal
state
3

(21) HHP (female) (A)
Resistance
Max. 1 z

(34) HHP (female) (B)
Resistance
Max. 1 z

HHP (female) (C)
Resistance
Max. 1 z
harness between WEC1 (female) (1)
Resiscuit)
Min. 1 Mz
HHP (female) (C) and chassis ground
tance
5
48

controller
If causes 1 4 are not detected, work equipment controller may be

carried out.)
D155AX-6
40 Troubleshooting
SEN00720-02
Circuit diagram related to work equipment oil pressure sensor
D155AX-6
49
SEN00720-02
40 Troubleshooting
Failure code [DH21KB] Weq pressure sensor: Short circuit

Action code
Failure code
DH21KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Weq pressure sensor: Short circuit

Signal voltage of work equipment pump oil pressure sensor is below 6.0 V.
None in particular.
Oil pressure of work equipment pump cannot be monitored.
State of work equipment pump oil pressure sensor can be checked with monitoring function.
(Code: 70701 Hydraulic Pressure Sensor 1)
Cause

1
supply system
Possible causes
and standard
value in normal
state
Defective work equipment oil

2 pressure sensor (Internal
trouble)
HHP
Voltage
Between (B) (A)
Power supply
4.5 5.5 V
Between (C) (A)
Signal
0.5 6.0 V

3
Voltage Max. 1 V
HHP (female) (C) and chassis ground
4
50

controller
If causes 1 3 are not detected, work equipment controller may be

carried out.)
D155AX-6
40 Troubleshooting
SEN00720-02
Circuit diagram related to work equipment oil pressure sensor
D155AX-6
51
SEN00720-02
40 Troubleshooting
Failure code [DHT5KA] T/C in-pressure sensor: Disconnection

Action code
Failure code
E02
DHT5KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
T/C in-pressure sensor: Disconnection

Signal voltage of torque converter inlet pressure sensor is below 0.5 V.

Torque converter inlet pressure cannot be monitored.
State of torque converter inlet pressure sensor can be checked with monitoring function.
(Code: 32602 T/C In Pressure Sensor)
Cause
Defective sensor 24 V power If failure code [DBE6KK] is also displayed, carry out troubleshoot1
supply system
ing for it first.
2 inlet pressure sensor (Internal trouble)
TIP
Voltage
Between (B) (A)
Power supply
20 30 V
Between (C) (A)
Signal
0.5 6.0 V

Possible causes
and standard
value in normal
state
3

TIP (female) (A)
Resistance
Max. 1 z

TIP (female) (B)
Resistance
Max. 1 z

TIP (female) (C)
Resistance
Max. 1 z
4 ness (Contact with GND cir- TIP (female) (B) or circuit branch end and
cuit)
chassis ground
Resistance
Min. 1 Mz

TIP (female) (C) and chassis ground
Resistance
Min. 1 Mz
52

carried out.)
D155AX-6
40 Troubleshooting
SEN00720-02
Circuit diagram related to torque converter inlet pressure sensor
D155AX-6
53
SEN00720-02
40 Troubleshooting
Failure code [DHT5KB] T/C in-pressure sensor: Short circuit

Action code
Failure code
E02
DHT5KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
T/C in-pressure sensor: Short circuit

Signal voltage of torque converter inlet pressure sensor is above 6.0 V.

Torque converter inlet pressure cannot be monitored.
State of torque converter inlet pressure sensor can be checked with monitoring function.
(Code: 32602 T/C In Pressure Sensor)
Cause
supply system
ing for it first.
2 inlet pressure sensor (Internal trouble)
Voltage
Between (B) (A)
Power supply
20 30 V
Between (C) (A)
Signal
0.5 6.0 V

Possible causes
and standard
value in normal
state

3
54
TIP

TIP (female) (A) or circuit branch end and
chassis ground
Voltage
Max. 1 V

TIP (female) (C) and chassis ground
Voltage
Max. 1 V

carried out.)
D155AX-6
40 Troubleshooting
SEN00720-02
Circuit diagram related to torque converter inlet pressure sensor
D155AX-6
55
SEN00720-02
40 Troubleshooting
Failure code [DHT7KA] T/C out-pressure sensor: Disconnection

Action code
Failure code
E02
DHT7KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
T/C out-pressure sensor: Disconnection

Signal voltage of torque converter outlet pressure sensor is below 0.5 V.

Torque converter outlet pressure cannot be monitored.
State of torque converter outlet pressure sensor can be checked with monitoring function.
(Code: 32604 T/C Out Pressure Sensor)
Cause
supply system
ing for it first.
2 outlet pressure sensor (Internal trouble)
TOP
Voltage
Between (B) (A)
Power supply
20 30 V
Between (C) (A)
Signal
0.5 6.0 V

Possible causes
and standard
value in normal
state
3

TOP (female) (A)
Resistance
Max. 1 z

TOP (female) (B)
Resistance
Max. 1 z

TOP (female) (C)
Resistance
Max. 1 z

4 ness (Contact with GND cir TOP (female) (B) or circuit branch end
cuit)
TOP (female) (C) and chassis ground
5
56
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

carried out.)
D155AX-6
40 Troubleshooting
SEN00720-02
Circuit diagram related to torque converter outlet pressure sensor
D155AX-6
57
SEN00720-02
40 Troubleshooting
Failure code [DHT7KB] T/C out-pressure sensor: Short circuit

Action code
Failure code
E02
DHT7KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
T/C out-pressure sensor: Short circuit

Signal voltage of torque converter outlet pressure sensor is above 6.0 V.

Torque converter outlet pressure cannot be monitored.
State of torque converter outlet pressure sensor can be checked with monitoring function.
(Code: 32604 T/C Out Pressure Sensor)
Cause
supply system
ing for it first.
Possible causes
and standard
value in normal
state

2 outlet pressure sensor (Internal trouble)
Voltage
Between (B) (A)
Power supply
20 30 V
Between (C) (A)
Signal
0.5 6.0 V

3
58
TOP
Hot short (Short circuit with Wiring harness between STC1 (female) (21)
24V circuit) in wiring harness TOP (female) (A) or circuit branch end
Voltage
Max. 1 V

TOP (female) (C) and chassis ground
Voltage
Max. 1 V

carried out.)
D155AX-6
40 Troubleshooting
SEN00720-02
Circuit diagram related to torque converter outlet pressure sensor
D155AX-6
59
SEN00720-02
40 Troubleshooting
Failure code [DK10KX] Fuel control Dial: Out of normal range

Action code
Failure code
E03
DK10KX
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Fuel control Dial: Out of normal range

Signal voltage of fuel control dial is out of normal range.

Continues control with signal of decelerator pedal potentiometer.
State of fuel control dial signal can be checked with monitoring function.
(Code: 03000 Fuel Dial Sensor)
Cause
1

supply system


short circuit)
DIAL (male)
Resistance
Between (1) (3)
4.0 6.0 kz
Between (1) (2)
0.25 7.0 kz
Between (2) (3)
0.25 7.0 kz
3
Possible causes
and standard
value in normal
state

DIAL (female) (1)
Resistance
Max. 1 z

DIAL (female) (2)
Resistance
Max. 1 z

DIAL (female) (3)
Resistance
Max. 1 z
4 ness (Contact with GND cir- DIAL (female) (1) or circuit branch end
cuit)
and chassis ground
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

DIAL (female) (1) or circuit branch end
and chassis ground

5

DIAL (female) (3) or circuit branch end
and chassis ground
Voltage
Max. 1 V
Voltage
Max. 1 V
Voltage
Max. 1 V

6
60
STC1
Voltage
Between (22) (21)
4.6 5.4 V
Between (1) (21)
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00720-02
Circuit diagram related to fuel control dial
D155AX-6
61
SEN00720-02
40 Troubleshooting
D155AX-6 Bulldozer
2008 KOMATSU
All Rights Reserved
62
D155AX-6
SEN00721-03
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
40 Troubleshooting

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
Failure code [DK56KB] FR lever 1: Short circuit........................................................................................... 22
D155AX-6
SEN00721-03
40 Troubleshooting
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
D155AX-6
40 Troubleshooting
D155AX-6
SEN00721-03
SEN00721-03
40 Troubleshooting
Failure code [DK30KA] ST lever 1: Disconnection

Action code
Failure code
E03
DK30KA
Trouble
ST lever1: Disconnection
Contents of
trouble
Signal voltage of PCCS lever steering potentiometer 1 system is below 0.5 V.
Action of
controller
Continues control with signal of PCCS lever steering potentiometer 2 system.

Problem that
appears on
machine
Related
information

State of PCCS lever steering potentiometer 1 signal can be checked with monitoring function.
(Code: 50300 S/T Lever 1 Potentio)
Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (in steering
direction).
Cause
1

supply system

1. Turn starting switch to OFF position.

2. Insert T-adapters into connector TLV1.
3. Turn starting switch to ON position.
4. Operate PCCS lever (steering) and perform troubleshooting.
Defective PCCS lever steer- a If power supply voltage is normal and sensor output voltage is
abnormal (0.5 V or lower), internal open circuit and ground fault
2 ing potentiometer 2 (internal
cannot be identified. In this case, go to cause 4.
open circuit) or ground fault
If check result of cause 4 is normal, PCCS lever steering potentiometer 2 is defective.
Possible causes
and standard
value in normal
state
Between TLV1 (female) (6) and

(8)
Sensor
output
0.96 to
4.04 V
Voltage
3
or defective contact in con- TLV1 (female) (5)
nector)
TLV1 (female) (7)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resiscuit)
Min. 1 Mz
TLV1 (female) (7) and chassis ground
tance

STC1
Voltage
Between (2) (21)
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00721-03
Circuit diagram related to PCCS lever potentiometer
D155AX-6
SEN00721-03
40 Troubleshooting
Failure code [DK30KB] ST lever 1: Short circuit

Action code
Failure code
E03
DK30KB
Trouble
ST lever1: Short circuit

Contents of
trouble
Signal voltage of PCCS lever steering potentiometer 1 system is above 4.5 V.
Action of
controller

Problem that
appears on
machine
Related
information

direction).
Cause
1
Possible causes
and standard
value in normal
state

supply system


(8)
Sensor
output
0.96 to
4.04 V
Voltage

3
Voltage Max. 1 V

STC1
Voltage
Between (2) (21)
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00721-03
D155AX-6
SEN00721-03
40 Troubleshooting
Failure code [DK30KX] ST lever 1: Out of normal range

Action code
E04
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Failure code
DK30KX
Trouble
ST lever 1: Out of normal range

In PCCS lever steering potentiometer 1 and 2 systems, either of failure codes [DK30KA] and
[DK30KB] and either of failure codes [DK31KA] and [DK31KB] occurred simultaneously.
State of PCCS lever steering potentiometer signal can be checked with monitoring function.
direction).
Cause
Carry out troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
Failure code [DK30KZ] RL lever: Disconnection or short circuit

Action code
Failure code
E04
DK30KZ
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Trouble
ST lever: Disconnection or short circuit

In PCCS lever steering potentiometer 1 and 2 systems, when starting switch is turned ON, only
either side is abnormal and then either of failure codes [DK30KA] and [DK30KB] and either of failure codes [DK31KA] and [DK31KB] occurred simultaneously.
direction).
Cause
D155AX-6
40 Troubleshooting
SEN00721-03
Failure code [DK30L8] ST lever: Signal mismatch

Action code
E03
Failure code
DK30L8
Trouble
ST lever: Signal mismatch

Contents of
trouble
In PCCS lever steering potentiometer 1 and 2 systems, total of both signal voltages is below 4.41 V
or above 5.59 V.
Action of
controller
Continues control with signal of normal one of PCCS lever steering potentiometer 1 and 2 systems.
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
D155AX-6

direction).
Cause
SEN00721-03
40 Troubleshooting
Failure code [DK31KA] ST lever 2: Disconnection

Action code
Failure code
E03
DK31KA
Trouble
Contents of
trouble
Signal voltage of PCCS lever steering potentiometer 2 system is below 0.5 V.
Action of
controller

Problem that
appears on
machine
Related
information

direction).
Cause
1

supply system


Possible causes
and standard
value in normal
state

(8)
Sensor
output
0.96 to
4.04 V
Voltage
3
nector)
TLV1 (female) (6)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resiscuit)
Min. 1 Mz
tance
10

STC1
Voltage
Between (19) (21)
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00721-03
D155AX-6
11
SEN00721-03
40 Troubleshooting
Failure code [DK31KB] ST lever 2: Short circuit

Action code
Failure code
E03
DK31KB
Trouble

Contents of
trouble
Signal voltage of PCCS lever steering potentiometer 2 system is above 4.5 V.
Action of
controller

Problem that
appears on
machine
Related
information

direction).
Cause
1
Possible causes
and standard
value in normal
state

supply system


(8)
Sensor
output
0.96 to
4.04 V
Voltage

3
Voltage Max. 1 V
12

STC1
Voltage
Between (19) (21)
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00721-03
D155AX-6
13
SEN00721-03
40 Troubleshooting
Failure code [DK40KA] Brake potentiometer: Disconnection

Action code
Failure code
E03
DK40KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Brake potentiometer: Disconnection

Signal voltage of brake pedal potentiometer is below 0.5 V.

Cannot recognize brake pedal position.
Auto shift-down function may not operate normally.

Cause

1
supply system
Defective brake pedal poten2 tiometer (Internal disconnection)
BRK (male)
Resistance
Between (A) (C)
4.0 6.0 kz
Between (A) (B)
0.25 7.0 kz
Between (B) (C)
0.25 7.0 kz
Possible causes
and standard
value in normal
state

3

BRK (female) (A)
Resistance
Max. 1 z

BRK (female) (B)
Resistance
Max. 1 z

BRK (female) (C)
Resistance
Max. 1 z
4 ness (Contact with GND cir- BRK (female) (B) and chassis ground
cuit)
BRK (female) (C) or circuit branch end
and chassis ground
troller
14
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

STC1
Voltage
Between (3) (21)
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00721-03
Circuit diagram related to brake pedal potentiometer
D155AX-6
15
SEN00721-03
40 Troubleshooting
Failure code [DK40KB] Brake potentiometer: Short circuit

Action code
Failure code
E03
DK40KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Brake potentiometer: Short circuit

Signal voltage of brake pedal potentiometer is above 4.5 V.

Cannot recognize brake pedal position.
Auto shift-down function may not operate normally.

Cause

1
supply system
Defective brake pedal poten2 tiometer (Internal short circuit)

Possible causes
and standard
value in normal
state
Resistance
Between (A) (C)
4.0 6.0 kz
Between (A) (B)
0.25 7.0 kz
Between (B) (C)
0.25 7.0 kz

3

BRK (female) (B) and chassis ground
BRK (female) (C) or circuit branch end
and chassis ground

troller
16
BRK (male)
Voltage
Max. 1 V
Voltage
Max. 1 V

STC1
Voltage
Between (3) (21)
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00721-03
Circuit diagram related to brake pedal potentiometer
D155AX-6
17
SEN00721-03
40 Troubleshooting
Failure code [DK55KX] FR lever: Out of normal range

Action code
E04
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Failure code
DK55KX
Trouble
FR lever 1: Out of normal range

In PCCS lever F-R potentiometer 1 and 2 systems, either of failure codes [DK56KA] and [DK56KB]
and either of failure codes [DK57KA] and [DK57KB] occurred simultaneously.
State of PCCS lever F-R potentiometer signal can be checked with monitoring function.
(Code: 50200 T/M Lever 1 Potentio)
Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (in F-R direction).
Cause
Failure code [DK55KZ] FR lever: Disconnection or short circuit

Action code
Failure code
E04
DK55KZ
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
18
Trouble
FR lever: Disconnection or short circuit

In PCCS lever F-R potentiometer 1 and 2 systems, when starting switch is turned ON, only either
side is abnormal and then either of failure codes [DK56KA] and [DK56KB] and either of failure
codes [DK57KA] and [DK57KB] occurred simultaneously.
Cause
D155AX-6
40 Troubleshooting
SEN00721-03
Failure code [DK55L8] FR lever: Signal mismatch

Action code
E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
D155AX-6
Failure code
DK55L8
Trouble
FR lever: Signal mismatch

In PCCS lever F-R potentiometer 1 and 2 systems, total of both signal voltages is below 4.41 V or
above 5.59 V.
Continues control with signal of normal one of PCCS lever F-R potentiometer 1 and 2 systems.
Cause
19
SEN00721-03
40 Troubleshooting
Failure code [DK56KA] FR lever 1: Disconnection

Action code
Failure code
E03
DK56KA
Trouble
Contents of
trouble
Signal voltage of PCCS lever F-R potentiometer 1 system is below 0.5 V.
Action of
controller
Continues control with signal of PCCS lever F-R potentiometer 2 system.

Problem that
appears on
machine
Related
information

State of PCCS lever F-R potentiometer 1 signal can be checked with monitoring function.
Cause
1

supply system

1.
2.
3.
4.
Defective PCCS lever Forward-reverse potentiometer

2
1 (internal open circuit) or
ground fault
Possible causes
and standard
value in normal
state
Turn starting switch to OFF position.

Insert T-adapters into connector TLV1.
Turn starting switch to ON position.
Operate PCCS lever (Forward-reverse) and perform troubleshooting.
a If power supply voltage is normal and sensor output voltage is
If check result of cause 4 is normal, PCCS lever Forwardreverse potentiometer 1 is defective.
(4)
Sensor
output
0.96 to
4.04 V
Voltage
Resis3
Max. 1 z
tance
nector)
ResisMax. 1 z
TLV1 (female) (3)
tance
Resiscuit)
Min. 1 Mz
tance
20

STC1
Voltage
Between (13) (21)
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00721-03
D155AX-6
21
SEN00721-03
40 Troubleshooting
Failure code [DK56KB] FR lever 1: Short circuit

Action code
Failure code
E03
DK56KB
Trouble

Contents of
trouble
Signal voltage of PCCS lever F-R potentiometer 1 system is above 4.5 V.
Action of
controller

Problem that
appears on
machine
Related
information

Cause
1

supply system

1.
2.
3.
4.
Possible causes
and standard
value in normal
state

2
ground fault

(4)
Sensor
output
0.96 to
4.04 V
Voltage

3
Voltage Max. 1 V
troller
22

STC1
Voltage
Between (13) (21)
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00721-03
D155AX-6
23
SEN00721-03
40 Troubleshooting
Failure code [DK57KA] FR lever 2: Disconnection

Action code
Failure code
E03
DK57KA
Trouble
Contents of
trouble
Signal voltage of PCCS lever F-R potentiometer 2 system is below 0.5 V.
Action of
controller

Problem that
appears on
machine
Related
information

Cause
1

supply system

1.
2.
3.
4.

2
ground fault
Possible causes
and standard
value in normal
state

(4)
Sensor
output
0.96 to
4.04 V
Voltage
Resis3
Max. 1 z
tance
nector)
ResisMax. 1 z
TLV1 (female) (2)
tance
Resiscuit)
Min. 1 Mz
tance
24

STC1
Voltage
Between (7) (21)
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00721-03
D155AX-6
25
SEN00721-03
40 Troubleshooting
Failure code [DK57KB] FR lever 2: Short circuit

Action code
Failure code
E03
DK57KB
Trouble

Contents of
trouble
Signal voltage of PCCS lever F-R potentiometer 2 system is above 4.5 V.
Action of
controller

Problem that
appears on
machine
Related
information

Cause
1

supply system

1.
2.
3.
4.
Possible causes
and standard
value in normal
state

2
ground fault

(4)
Sensor
output
0.96 to
4.04 V
Voltage

3
Voltage Max. 1 V
troller
26

STC1
Voltage
Between (7) (21)
0.5 4.5 V
D155AX-6
40 Troubleshooting
SEN00721-03
D155AX-6
27
SEN00721-03
40 Troubleshooting
Failure code [DKH1KA] Pitch angle sensor: Disconnection

Action code
Failure code
E03
DKH1KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Pitch angle sensor: Disconnection

Signal voltage of pitch angle sensor is below 0.5 V.

Cannot sense pitch angle of machine.
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.
(Code: 60100 Pitch Angle Sensor)
Cause
Defective sensor 24V power If failure code [DBE6KK] is also displayed, carry out troubleshoot1
supply system
ing for it first.
PT1
2
Defective pitch angle sensor

(Internal trouble)
Voltage
Between (C) (A)
Power supply
20 30 V
Between (B) (A)
Signal
0.15 4.85 V

Possible causes
and standard
value in normal
state
3

PT1 (female) (A)
Resistance
Max. 1 z

PT1 (female) (B)
Resistance
Max. 1 z

PT1 (female) (C)
Resistance
Max. 1 z
Resiscuit)
Min. 1 Mz
PT1 (female) (B) and chassis ground
tance
5
28

carried out.)
D155AX-6
40 Troubleshooting
SEN00721-03
Circuit diagram related to pitch angle sensor
D155AX-6
29
SEN00721-03
40 Troubleshooting
Failure code [DKH1KB] Pitch angle sensor: Short circuit

Action code
Failure code
E03
DKH1KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Pitch angle sensor: Short circuit

Signal voltage of pitch angle sensor is above 4.85 V.

Cannot sense pitch angle of machine.
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.
(Code: 60100 Pitch Angle Sensor)
Cause
Defective sensor 24V power If failure code [DBE6KK] is also displayed, carry out troubleshoot1
supply system
ing for it first.
PT1
Possible causes
and standard
value in normal
state
Defective pitch angle sensor

(Internal trouble)
Voltage
Between (C) (A)
Power supply
20 30 V
Between (B) (A)
Signal
0.15 4.85 V

3
Voltage Max. 1 V
PT1 (female) (B) and chassis ground
4
30

carried out.)
D155AX-6
40 Troubleshooting
SEN00721-03
Circuit diagram related to pitch angle sensor
D155AX-6
31
SEN00721-03
40 Troubleshooting
Failure code [DLT3KA] T/M out-speed sensor: Disconnection

Action code
Failure code
E01
DLT3KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
T/M out-speed sensor: Disconnection

No signal is input from transmission bevel speed sensor.

Recognizes that transmission bevel speed is 0 rpm.
Transmission bevel speed cannot be monitored.
Traction force cannot be calculated.
Transmission bevel speed can be checked with monitoring function.
(Code: 31400 T/M Out Speed)
Method of reproducing failure code: Turn starting switch ON + Drive machine (actually or with no
load).
Cause
Defective transmission bevel

1 speed sensor (Internal disconnection or short circuit)
Possible causes
and standard
value in normal
state

BVRV (male)
Resistance
Between (1) (2)
500 1,000 z
Min. 1 Mz
3
or defective contact in con- BVRV (female) (1)
nector)
BVRV (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resiscuit)
Min. 1 Mz
BVRV (female) (1) and chassis ground
tance
5

carried out.)
Circuit diagram related to transmission bevel speed sensor
32
D155AX-6
40 Troubleshooting
SEN00721-03
Failure code [DLT3KB] T/M out-speed sensor: Abnormal

Action code
Failure code
E01
DLT3KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
T/M out-speed sensor: Abnormal

No signal is input from transmission bevel speed sensor.

Recognizes that transmission bevel speed is 0 rpm.
Transmission bevel speed cannot be monitored.
Traction force cannot be calculated.
Transmission bevel speed can be checked with monitoring function.
(Code: 31400 T/M Out Speed)
Method of reproducing failure code: Turn starting switch ON + Drive machine (actually or with no
load).
Cause
Defective transmission bevel

1 speed sensor (Internal disconnection or short circuit)
Possible causes
and standard
value in normal
state

BVRV (male)
Resistance
Between (1) (2)
500 1,000 z
Min. 1 Mz
2
or defective contact in con- BVRV (female) (1)
nector)
BVRV (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resiscuit)
Min. 1 Mz
BVRV (female) (1) and chassis ground
tance
4

carried out.)
Circuit diagram related to transmission bevel speed sensor
D155AX-6
33
SEN00721-03
40 Troubleshooting
Failure code [DW7BKA] Fan rev EPC: Disconnection

Action code
Failure code
E01
DW7BKA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Fan rev EPC: Disconnection

When signal is output to fan reverse solenoid circuit, no current flows.

Turns signal to fan reverse solenoid circuit OFF.
Fan reverse function cannot be used.

Operating condition of fan reverse solenoid can be checked with monitoring function.
(Code: 40909 T/M Output 1)
Method of reproducing failure code: Turn starting switch ON + Select fan reverse mode.
Cause
Defective fan reverse solenoid (Internal disconnection)

FAR (male)
Resistance
Between (1) (2)
34 44 z
Possible causes
and standard
value in normal
state
2
or defective contact in con- FAR (female) (1)
nector)
FAR (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z

3
Voltage Max. 1 V
FAR (female) (1) and chassis ground
4

carried out.)
Circuit diagram related to fan reverse solenoid
34
D155AX-6
40 Troubleshooting
SEN00721-03
Failure code [DW7BKB] Fan rev EPC: Short circuit

Action code
Failure code
E01
DW7BKB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Fan rev EPC: Short circuit

When signal was output to fan reverse solenoid circuit, abnormal current flowed.
Turns signal to fan reverse solenoid circuit OFF.
Fan reverse function cannot be used.

Operating condition of fan reverse solenoid can be checked with monitoring function.
(Code: 40909 T/M Output 1)
Method of reproducing failure code: Turn starting switch ON + Select fan reverse mode.
Cause

Possible causes
and standard
value in normal
state
Defective fan reverse solenoid (Internal short circuit)
FAR (male)
Resistance
Between (1) (2)
34 44 z
Min. 1 Mz
Resiscuit)
Min. 1 Mz
FAR (female) (1) and chassis ground
tance
harness)
FAR (female) (1) and between STC3
(female) (13) FAR (female) (2)
Resistance
Min. 1 Mz

carried out.)
Circuit diagram related to fan reverse solenoid
D155AX-6
35
SEN00721-03
40 Troubleshooting
Failure code [DWN1KA] Hss EPC1: Disconnection

Action code
Failure code
E03
DWN1KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

When signal is output to HSS left EPC solenoid circuit, no current flows.
Turns signal to HSS left EPC solenoid circuit OFF.
Output to HSS left EPC solenoid can be checked with monitoring function.
(Code: 50600 HSS Solenoid LH (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (Left steering)
Cause
Defective HSS left EPC sole1
noid (Internal disconnection)
HSL (male)
Resistance
Between (1) (2)
4.5 14.5 z
Possible causes
and standard
value in normal
state
2
or defective contact in con- HSL (female) (1)
nector)
HSL (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z


HSL (female) (2) or circuit branch end and
chassis ground
Voltage
Max. 1 V

carried out.)
Circuit diagram related to HSS left EPC solenoid
36
D155AX-6
40 Troubleshooting
SEN00721-03
Failure code [DWN1KB] Hss EPC1: Short circuit

Action code
Failure code
E03
DWN1KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

When signal is output to HSS left EPC solenoid circuit, abnormal current flowed.
Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (Left steering).
Cause

Possible causes
and standard
value in normal
state
Defective HSS left EPC solenoid (Internal short circuit)
HSL (male)
Resistance
Between (1) (2)
4.5 14.5 z
Min. 1 Mz
Resiscuit)
Min. 1 Mz
HSL (female) (1) and chassis ground
tance
harness)
HSL (female) (1) and between STC3
(female) (3) HSL (female) (2)
Resistance
Min. 1 Mz

carried out.)
D155AX-6
37
SEN00721-03
40 Troubleshooting
Failure code [DWN1KY] Hss EPC1: Short circuit

Action code
Failure code
E03
DWN1KY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

When signal is output to HSS left EPC solenoid circuit, abnormal current flowed.
Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (Left steering).
Cause

Possible causes
and standard
value in normal
state
Defective HSS left EPC solenoid (Internal short circuit)
HSL (male)
Resistance
Between (1) (2)
4.5 14.5 z
Min. 1 Mz

2
Voltage Max. 1 V
HSL (female) (1) and chassis ground
harness)
HSL (female) (1) and between STC3
(female) (3) HSL (female) (2)
Resistance
Min. 1 Mz

carried out.)
38
D155AX-6
40 Troubleshooting
SEN00721-03
Failure code [DWN2KA] Hss EPC2: Disconnection

Action code
Failure code
E03
DWN2KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

When signal is output to HSS right EPC solenoid circuit, no current flows.
Turns signal to HSS right EPC solenoid circuit OFF.
Output to HSS right EPC solenoid can be checked with monitoring function.
(Code: 50601 HSS Solenoid RH (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (Right steering).
Cause
Defective HSS right EPC
1 solenoid (Internal disconnection)

HSR (male)
Resistance
Between (1) (2)
4.5 14.5 z
Possible causes
and standard
value in normal
state
2
or defective contact in con- HSR (female) (1)
nector)
HSR (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z


HSR (female) (2) or circuit branch end and
chassis ground
Voltage
Max. 1 V

carried out.)
Circuit diagram related to HSS right EPC solenoid
D155AX-6
39
SEN00721-03
40 Troubleshooting
Failure code [DWN2KB] Hss EPC2: Short circuit

Action code
Failure code
E03
DWN2KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

When signal is output to HSS right EPC solenoid circuit, abnormal current flowed.
Cause

1 solenoid (Internal short circuit)
Possible causes
and standard
value in normal
state

HSR (male)
Resistance
Between (1) (2)
4.5 14.5 z
Min. 1 Mz
2 ness (Contact with GND cirResisWiring harness between STC3 (female) (35)
cuit)
Min. 1 Mz
HSR (female) (1) and chassis ground
tance
harness)
HSR (female) (1) and between STC3
(female) (3) HSR (female) (2)
Resistance
Min. 1 Mz

carried out.)
40
D155AX-6
40 Troubleshooting
SEN00721-03
Failure code [DWN2KY] Hss EPC2: Short circuit

Action code
Failure code
E03
DWN2KY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

When signal is output to HSS right EPC solenoid circuit, abnormal current flowed.
Cause

Possible causes
and standard
value in normal
state

HSR (male)
Resistance
Between (1) (2)
4.5 14.5 z
Min. 1 Mz

2
Voltage Max. 1 V
HSR (female) (1) and chassis ground
harness)
HSR (female) (1) and between STC3
(female) (3) HSR (female) (2)
Resistance
Min. 1 Mz

carried out.)
D155AX-6
41
SEN00721-03
40 Troubleshooting
Failure code [DWN3KA] Ssp solenoid: Disconnection

Action code
Failure code
E04
DWN3KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Ssp solenoid: Disconnection

When signal is output to sudden stop prevent solenoid circuit, no current flows.
Brake is applied lightly during travel.
Output to sudden stop prevent solenoid can be checked with monitoring function.
(Code: 31628 SSP Solenoid)
Cause
Defective sudden stop pre1 vent solenoid (Internal disconnection)

SSP (male)
Resistance
Between (1) (2)
3.5 12.5 z
Possible causes
and standard
value in normal
state
2
or defective contact in con- SSP (female) (1)
nector)
SSP (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z

3
Voltage Max. 1 V
SSP (female) (1) and chassis ground
42
STC3 (female)
Resistance
Between (7) (23)
3.5 12.5 z
D155AX-6
40 Troubleshooting
SEN00721-03
Circuit diagram related to sudden stop prevent solenoid
D155AX-6
43
SEN00721-03
40 Troubleshooting
Failure code [DWN3KB] Ssp solenoid: Short circuit

Action code
Failure code
E04
DWN3KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

When signal was output to sudden stop prevent solenoid circuit, abnormal current flowed.
Cause
Defective sudden stop pre1 vent solenoid (Internal short

circuit)
Possible causes
and standard
value in normal
state

SSP (male)
Resistance
Between (1) (2)
3.5 12.5 z
Min. 1 Mz
Resiscuit)
Min. 1 Mz
tance
harness)
SSP (female) (1) and between STC3
(female) (23) SSP (female) (2)
Resistance
Min. 1 Mz
4
44
STC3 (female)
Resistance
Between (7) (23)
3.5 12.5 z
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00721-03
D155AX-6
45
SEN00721-03
40 Troubleshooting
Failure code [DWN3KY] Ssp solenoid: Short circuit

Action code
Failure code
E04
DWN3KY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

When signal was output to sudden stop prevent solenoid circuit, abnormal current flowed.
Cause
Defective sudden stop pre1 vent solenoid (Internal short

circuit)
Possible causes
and standard
value in normal
state

SSP (male)
Resistance
Between (1) (2)
3.5 12.5 z
Min. 1 Mz

2
Voltage Max. 1 V
harness)
SSP (female) (1) and between STC3
(female) (23) SSP (female) (2)
Resistance
Min. 1 Mz
4
46
STC3 (female)
Resistance
Between (7) (23)
3.5 12.5 z
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00721-03
D155AX-6
47
SEN00721-03
40 Troubleshooting
Failure code [DWN5KA] Fan pump solenoid: Disconnection

Action code
Failure code
E01
DWN5KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Fan pump solenoid: Disconnection

When signal is output to fan pump EPC solenoid circuit, no current flows.
Turns signal to fan pump EPC solenoid circuit OFF.

Output to fan pump EPC solenoid can be checked with monitoring function.
(Code: 31624 Fan pump Solenoid (F/B))
Cause
Defective fan pump EPC

FAC (male)
Resistance
Between (1) (2)
2 12 z
Possible causes
and standard
value in normal
state
2
or defective contact in con- FAC (female) (1)
nector)
FAC (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z


FAC (female) (2) or circuit branch end and
chassis ground
Voltage
Max. 1 V

carried out.)
Circuit diagram related to fan control solenoid
48
D155AX-6
40 Troubleshooting
SEN00721-03
Failure code [DWN5KB] Fan pump solenoid: Short circuit

Action code
Failure code
E01
DWN5KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Fan pump solenoid: Short circuit

When signal was output to fan pump EPC solenoid circuit, abnormal current flowed.
Turns signal to fan pump EPC solenoid circuit OFF.

Output to fan pump EPC solenoid can be checked with monitoring function.
(Code: 31624 Fan pump Solenoid (F/B))
Cause
Defective fan pump EPC

Possible causes
and standard
value in normal
state

FAC (male)
Resistance
Between (1) (2)
2 12 z
Min. 1 Mz
Resiscuit)
Min. 1 Mz
FAC (female) (1) and chassis ground
tance
harness)
FAC (female) (1) and between STC3
(female) (23) FAC (female) (2)
Resistance
Min. 1 Mz

carried out.)
Circuit diagram related to fan control solenoid
D155AX-6
49
SEN00721-03
40 Troubleshooting
Failure code [DXA0KA] TVC Sol.: Disconnection

Action code
Failure code
E01
DXA0KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
TVC Sol.: Disconnection

When signal is output to work equipment-HSS pump TVC solenoid circuit, no current flows.
Turns signal to work equipment-HSS pump TVC solenoid circuit OFF.
If engine is loaded while running at low speed, it stops.

Output to work equipment-HSS pump TVC solenoid can be checked with monitoring function.
(Code: 01300 TVC Solenoid (F/B))
Cause
Defective work equipment1 HSS pump TVC solenoid

TVC (male)
Resistance
Between (1) (2)
2 12 z
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between WEC3 (female) (7)
2
or defective contact in con- TVC (female) (1)
nector)
TVC (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z

3
Voltage Max. 1 V
TVC (female) (1) and chassis ground

controller
WEC3 (female)
Resistance
Between (7) (3)
2 12 z
Circuit diagram related to work equipment-HSS pump TVC solenoid
50
D155AX-6
40 Troubleshooting
SEN00721-03
Failure code [DXA0KB] TVC Sol.: Short circuit

Action code
Failure code
E01
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
DXA0KB
Trouble

When signal was output to work equipment-HSS pump TVC solenoid circuit, abnormal current
flowed.
If engine is loaded while running at low speed, it stops.

Cause

Possible causes
and standard
value in normal
state

TVC (male)
Resistance
Between (1) (2)
2 12 z
Min. 1 Mz
Resiscuit)
Min. 1 Mz
tance
harness)
TVC (female) (1) and between WEC3
(female) (3) TVC (female) (2)
Resistance
Min. 1 Mz
4

controller
WEC3 (female)
Resistance
Between (7) (3)
2 12 z
Min. 1 Mz
D155AX-6
51
SEN00721-03
40 Troubleshooting
Failure code [DXA0KY] TVC Sol.: Short circuit

Action code
Failure code
E01
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
DXA0KY
Trouble

When signal was output to work equipment-HSS pump TVC solenoid circuit, abnormal current
flowed.
Work equipment speed may be lowered.

Cause

Possible causes
and standard
value in normal
state

TVC (male)
Resistance
Between (1) (2)
2 12 z
Min. 1 Mz

2
Voltage Max. 1 V
harness)
TVC (female) (1) and between WEC3
(female) (3) TVC (female) (2)
Resistance
Min. 1 Mz
4

controller
WEC3 (female)
Resistance
Between (7) (3)
2 12 z
Min. 1 Mz
52
D155AX-6
40 Troubleshooting
D155AX-6
SEN00721-03
53
SEN00721-03
40 Troubleshooting
Failure code [DXH1KA] Lock-up ECMV: Disconnection

Action code
Failure code
E02
DXH1KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Lock-up ECMV: Disconnection

When signal is output to torque converter lockup clutch ECMV solenoid circuit, no current flows.
Turns signal to torque converter lockup clutch ECMV solenoid circuit OFF.
Torque converter lockup function does not operate.

Output to torque converter lockup clutch ECMV solenoid can be checked with monitoring function.
(Code: 31642 L/U ECMV (F/B))
Method of reproducing failure code: Start engine + Drive forward (in auto gearshift mode).
Cause
1 ECMV solenoid (Internal disconnection)

SLUC (male)
Resistance
Between (1) (2)
3.5 12.5 z
Possible causes
and standard
value in normal
state
2
or defective contact in con- SLUC (female) (1)
nector)
SLUC (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z

3
Voltage Max. 1 V
SLUC (female) (1) and chassis ground
54
STC3 (female)
Resistance
Between (17) (13)
3.5 12.5 z
D155AX-6
40 Troubleshooting
SEN00721-03
D155AX-6
55
SEN00721-03
40 Troubleshooting
Failure code [DXH1KB] Lock-up ECMV: Short circuit

Action code
Failure code
E02
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
DXH1KB
Trouble

When signal was output to torque converter lockup clutch ECMV solenoid circuit, abnormal current
flowed.
Torque converter lockup function does not operate.

Output to torque converter lockup clutch ECMV solenoid can be checked with monitoring function.
Method of reproducing failure code: Start engine + Drive forward (in auto gearshift mode).
Cause

1 ECMV solenoid (Internal
short circuit)
Possible causes
and standard
value in normal
state

SLUC (male)
Resistance
Between (1) (2)
3.5 12.5 z
Min. 1 Mz
Resiscuit)
Min. 1 Mz
tance
harness)
SLUC (female) (1) and between STC3
(female) (13) SLUC (female) (2)
Resistance
Min. 1 Mz
4
56
STC3 (female)
Resistance
Between (17) (13)
3.5 12.5 z
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00721-03
D155AX-6
57
SEN00721-03
40 Troubleshooting
Failure code [DXH1KY] Lock-up ECMV: Short circuit

Action code
Failure code
E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
DXH1KY
Trouble

When signal was output to torque converter lockup clutch ECMV solenoid circuit, abnormal current
flowed.
Torque converter lockup function operates constantly.
Output to lockup clutch ECMV solenoid can be checked with monitoring function.
Method of reproducing failure code: Start engine + Drive in auto gearshift mode (while lockup is in
operation).
Cause

1 ECMV solenoid (Internal
short circuit)
Possible causes
and standard
value in normal
state

SLUC (male)
Resistance
Between (1) (2)
3.5 12.5 z
Min. 1 Mz

2
Voltage Max. 1 V
harness)
SLUC (female) (1) and between STC3
(female) (13) SLUC (female) (2)
Resistance
Min. 1 Mz
4
58
STC3 (female)
Resistance
Between (17) (13)
3.5 12.5 z
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00721-03
D155AX-6
59
SEN00721-03
40 Troubleshooting
Failure code [DXH4KA] 1st clutch ECMV: Disconnection

Action code
Failure code
E03
DXH4KA
Contents of
trouble
Trouble
1st clutch ECMV: Disconnection

When signal is output to transmission 1st clutch ECMV solenoid circuit, no current flows.
Action of
controller
Turns signal to transmission 1st clutch ECMV solenoid circuit OFF.

Problem that
appears on
machine

Related
information
Output to 1st clutch ECMV solenoid can be checked with monitoring function.
(Code: 31602 T/M Clutch 1st ECMV (F/B))
Method of reproducing failure code: Start engine + Set gear to F1 or R1.
Cause

solenoid

S1T (male)
Resistance
Between (1) (2)
3.5 12.5 z
Possible causes
and standard
value in normal
state
2
or defective contact in con- S1T (female) (1)
nector)
S1T (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z


S1T (female) (2) or circuit branch end and
chassis ground
Voltage
Max. 1 V

carried out.)
60
D155AX-6
40 Troubleshooting
D155AX-6
SEN00721-03
61
SEN00721-03
40 Troubleshooting
D155AX-6 Bulldozer
2011 KOMATSU
All Rights Reserved
62
D155AX-6
SEN00722-01
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
40 Troubleshooting

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
SEN00722-01
40 Troubleshooting
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
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code [DXH4KB] 1st clutch ECMV: Short circuit
Action code
Failure code
E03
DXH4KB
Contents of
trouble
Trouble

When signal was output to transmission 1st clutch ECMV solenoid circuit, abnormal current flowed.
Action of
controller

Problem that
appears on
machine

Related
information
Cause
Possible causes
and standard
value in normal
state

S1T (male)
Resistance
Between (1) (2)
3.5 12.5 z
Min. 1 Mz
Resiscuit)
Min. 1 Mz
S1T (female) (1) and chassis ground
tance
harness)
S1T (female) (1) and between STC3
(female) (23) S1T (female) (2)
Resistance
Min. 1 Mz

carried out.)
D155AX-6
SEN00722-01
40 Troubleshooting
Failure code [DXH4KY] 1st clutch ECMV: Short circuit

Action code
Failure code
E03
DXH4KY
Contents of
trouble
Trouble

When signal was output to transmission 1st clutch ECMV solenoid circuit, abnormal current flowed.
Action of
controller

Problem that
appears on
machine

Related
information
Cause
Possible causes
and standard
value in normal
state

S1T (male)
Resistance
Between (1) (2)
3.5 12.5 z
Min. 1 Mz

2
Voltage Max. 1 V
harness)
Resistance
Min. 1 Mz

carried out.)
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection

Action code
Failure code
E03
DXH5KA
Contents of
trouble
Trouble
2nd clutch ECMV: Disconnection

When signal is output to transmission 2nd clutch ECMV solenoid circuit, no current flows.
Action of
controller
Turns signal to transmission 2nd clutch ECMV solenoid circuit OFF.

Problem that
appears on
machine

Related
information
Output to 2nd clutch ECMV solenoid can be checked with monitoring function.
(Code: 31603 T/M Clutch 2nd ECMV (F/B))
Cause

S2T (male)
Resistance
Between (1) (2)
3.5 12.5 z
Possible causes
and standard
value in normal
state
2
nector)
S2T (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z


chassis ground
Voltage
Max. 1 V

carried out.)
D155AX-6
SEN00722-01
40 Troubleshooting
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit

Action code
Failure code
E03
DXH5KB
Contents of
trouble
Trouble

When signal was output to transmission 2nd clutch ECMV solenoid circuit, abnormal current flowed.
Action of
controller

Problem that
appears on
machine

Related
information
Cause
Possible causes
and standard
value in normal
state

S2T (male)
Resistance
Between (1) (2)
3.5 12.5 z
Min. 1 Mz
Resiscuit)
Min. 1 Mz
tance
harness)
Resistance
Min. 1 Mz

carried out.)
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit

Action code
Failure code
E03
DXH5KY
Contents of
trouble
Trouble

When signal was output to transmission 2nd clutch ECMV solenoid circuit, abnormal current flowed.
Action of
controller

Problem that
appears on
machine

Related
information
Cause
Possible causes
and standard
value in normal
state

S2T (male)
Resistance
Between (1) (2)
3.5 12.5 z
Min. 1 Mz

2
Voltage Max. 1 V
harness)
Resistance
Min. 1 Mz

carried out.)
D155AX-6
SEN00722-01
40 Troubleshooting
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection

Action code
Failure code
E03
DXH6KA
Contents of
trouble
Trouble
3rd clutch ECMV: Disconnection

When signal is output to transmission 3rd clutch ECMV solenoid circuit, no current flows.
Action of
controller
Turns signal to transmission 3rd clutch ECMV solenoid circuit OFF.

Problem that
appears on
machine

Related
information
Output to 3rd clutch ECMV solenoid can be checked with monitoring function.
(Code: 31604 T/M Clutch 3rd ECMV (F/B))
Cause

S3T (male)
Resistance
Between (1) (2)
3.5 12.5 z
Min. 1 Mz
Possible causes
and standard
value in normal
state
2
nector)
S3T (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z


chassis ground
Voltage
Max. 1 V

carried out.)
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit

Action code
Failure code
E03
DXH6KB
Contents of
trouble
Trouble

When signal was output to transmission 3rd clutch ECMV solenoid circuit, abnormal current flowed.
Action of
controller

Problem that
appears on
machine

Related
information
Cause
Possible causes
and standard
value in normal
state

S3T (male)
Resistance
Between (1) (2)
3.5 12.5 z
Min. 1 Mz
cuit)
Min. 1 Mz
tance
harness)
Resistance
Min. 1 Mz

carried out.)
D155AX-6
SEN00722-01
40 Troubleshooting
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit

Action code
Failure code
E03
DXH6KY
Contents of
trouble
Trouble

When signal was output to transmission 3rd clutch ECMV solenoid circuit, abnormal current flowed.
Action of
controller

Problem that
appears on
machine

Related
information
Cause
Possible causes
and standard
value in normal
state

S3T (male)
Resistance
Between (1) (2)
3.5 12.5 z
Min. 1 Mz

2
Voltage Max. 1 V
harness)
Resistance
Min. 1 Mz

carried out.)
10
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code [DXH7KA] R clutch ECMV: Disconnection

Action code
Failure code
E03
DXH7KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
R clutch ECMV: Disconnection

When signal is output to transmission R clutch ECMV solenoid circuit, no current flows.
Turns signal to transmission R clutch ECMV solenoid circuit OFF.
Output to R clutch ECMV solenoid can be checked with monitoring function.
(Code: 31616 T/M Clutch R ECMV (F/B))
Method of reproducing failure code: Start engine + Set gear to R (Reverse).
Cause
Defective R clutch ECMV

SRT (male)
Resistance
Between (1) (2)
3.5 12.5 z
Possible causes
and standard
value in normal
state
2
or defective contact in con- SRT (female) (1)
nector)
SRT (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z


SRT (female) (2) or circuit branch end and
chassis ground
Voltage
Max. 1 V

carried out.)
D155AX-6
11
SEN00722-01
40 Troubleshooting
Failure code [DXH7KB] R clutch ECMV: Short circuit

Action code
Failure code
E03
DXH7KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

When signal was output to transmission R clutch ECMV solenoid circuit, abnormal current flowed.
Cause
Possible causes
and standard
value in normal
state

SRT (male)
Resistance
Between (1) (2)
3.5 12.5 z
Min. 1 Mz
cuit)
Min. 1 Mz
SRT (female) (1) and chassis ground
tance
harness)
SRT (female) (1) and between STC3
(female) (13) SRT (female) (2)
Resistance
Min. 1 Mz
If causes 1 - 3 are not detected, power train controller may be

carried out.)
12
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code [DXH7KY] R clutch ECMV: Short circuit

Action code
Failure code
E04
DXH7KY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

When signal was output to transmission R clutch ECMV solenoid circuit, abnormal current flowed.
Cause
Possible causes
and standard
value in normal
state

SRT (male)
Resistance
Between (1) (2)
3.5 12.5 z
Min. 1 Mz

2
Voltage Max. 1 V
SRT (female) (1) and chassis ground
harness)
SRT (female) (1) and between STC3
(female) (13) SRT (female) (2)
Resistance
Min. 1 Mz

carried out.)
D155AX-6
13
SEN00722-01
40 Troubleshooting
Failure code [DXH8KA] F clutch ECMV: Disconnection

Action code
Failure code
E03
DXH8KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
F clutch ECMV: Disconnection

When signal is output to transmission F clutch ECMV solenoid circuit, no current flows.
Turns signal to transmission F clutch ECMV solenoid circuit OFF.
Output to F clutch ECMV solenoid can be checked with monitoring function.
(Code: 31622 T/M Clutch F ECMV (F/B))
Method of reproducing failure code: Start engine + Set gear to F (Forward).
Cause
Defective F clutch ECMV

SFT (male)
Resistance
Between (1) (2)
3.5 12.5 z
Possible causes
and standard
value in normal
state
2
or defective contact in con- SFT (female) (1)
nector)
SFT (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z


SFT (female) (2) or circuit branch end and
chassis ground
Voltage
Max. 1 V

carried out.)
14
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code [DXH8KB] F clutch ECMV: Short circuit

Action code
Failure code
E03
DXH8KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

When signal was output to transmission F clutch ECMV solenoid circuit, abnormal current flowed.
Cause
Possible causes
and standard
value in normal
state

SFT (male)
Resistance
Between (1) (2)
3.5 12.5 z
Min. 1 Mz
cuit)
Min. 1 Mz
SFT (female) (1) and chassis ground
tance
harness)
SFT (female) (1) and between STC3
(female) (13) SFT (female) (2)
Resistance
Min. 1 Mz

carried out.)
D155AX-6
15
SEN00722-01
40 Troubleshooting
Failure code [DXH8KY] F clutch ECMV: Short circuit

Action code
Failure code
E04
DXH8KY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

When signal was output to transmission F clutch ECMV solenoid circuit, abnormal current flowed.
Cause
Possible causes
and standard
value in normal
state

SFT (male)
Resistance
Between (1) (2)
3.5 12.5 z
Min. 1 Mz

2
Voltage Max. 1 V
SFT (female) (1) and chassis ground
harness)
SFT (female) (1) and between STC3
(female) (13) SFT (female) (2)
Resistance
Min. 1 Mz

carried out.)
16
D155AX-6
SEN00722-01
40 Troubleshooting
Failure code [DXHBKA] Right brake ECMV: Disconnection

Action code
Failure code
E04
DXHBKA
Contents of
trouble
Trouble
Right brake ECMV: Disconnection

When signal is output to steering case right brake ECMV solenoid circuit, no current flows.
Action of
controller
Turns signal to steering case right brake ECMV solenoid circuit OFF.
Problem that
appears on
machine

Related
information
Output to right brake ECMV solenoid can be checked with monitoring function.
(Code: 31618 Brake RH ECMV (F/B))
Cause

SBRR (male)
Resistance
Between (1) (2)
3.5 12.5 z
Possible causes
and standard
value in normal
state
2
or defective contact in con- SBRR (female) (1)
nector)
SBRR (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z

3
Voltage Max. 1 V
SBRR (female) (1) and chassis ground
18
STC3 (female)
Resistance
Between (15) (3)
3.5 12.5 z
D155AX-6
40 Troubleshooting
SEN00722-01
D155AX-6
19
SEN00722-01
40 Troubleshooting
Failure code [DXHBKB] Right brake ECMV: Short circuit

Action code
Failure code
E04
Contents of
trouble
DXHBKB
Trouble

When signal was output to steering case right brake ECMV solenoid circuit, abnormal current
flowed.
Action of
controller
Problem that
appears on
machine

Related
information
Cause
Possible causes
and standard
value in normal
state

SBRR (male)
Resistance
Between (1) (2)
3.5 12.5 z
Min. 1 Mz
Resiscuit)
Min. 1 Mz
tance
harness)
SBRR (female) (1) and between STC3
(female) (3) SBRR (female) (2)
Resistance
Min. 1 Mz
4
20
STC3 (female)
Resistance
Between (15) (3)
3.5 12.5 z
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00722-01
D155AX-6
21
SEN00722-01
40 Troubleshooting
Failure code [DXHBKY] Right brake ECMV: Short circuit

Action code
Failure code
E04
Contents of
trouble
DXHBKY
Trouble

When signal was output to steering case right brake ECMV solenoid circuit, abnormal current
flowed.
Action of
controller
Problem that
appears on
machine

Related
information
Cause
Possible causes
and standard
value in normal
state

SBRR (male)
Resistance
Between (1) (2)
3.5 12.5 z
Min. 1 Mz

2
Voltage Max. 1 V
harness)
SBRR (female) (1) and between STC3
(female) (3) SBRR (female) (2)
Resistance
Min. 1 Mz
4
22
STC3 (female)
Resistance
Between (15) (3)
3.5 12.5 z
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00722-01
D155AX-6
23
SEN00722-01
40 Troubleshooting
Failure code [DXHCKA] Left brake ECMV: Disconnection

Action code
Failure code
E04
DXHCKA
Contents of
trouble
Trouble
Left brake ECMV: Disconnection

When signal is output to steering case left brake ECMV solenoid circuit, no current flows.
Action of
controller
Turns signal to steering case left brake ECMV solenoid circuit OFF.
Problem that
appears on
machine

Related
information
Output to left brake ECMV solenoid can be checked with monitoring function.
(Code: 31619 Brake LH ECMV (F/B))
Cause
Defective left brake ECMV

SBRL (male)
Resistance
Between (1) (2)
3.5 12.5 z
Possible causes
and standard
value in normal
state
2
or defective contact in con- SBRL (female) (1)
nector)
SBRL (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z

3
Voltage Max. 1 V
SBRL (female) (1) and chassis ground
24
STC3 (female)
Resistance
Between (5) (3)
3.5 12.5 z
D155AX-6
40 Troubleshooting
SEN00722-01
D155AX-6
25
SEN00722-01
40 Troubleshooting
Failure code [DXHCKB] Left brake ECMV: Short circuit

Action code
Failure code
E04
DXHCKB
Contents of
trouble
Trouble

When signal was output to steering case left brake ECMV solenoid circuit, abnormal current flowed.
Action of
controller
Problem that
appears on
machine

Related
information
Cause
Possible causes
and standard
value in normal
state

SBRL (male)
Resistance
Between (1) (2)
3.5 12.5 z
Min. 1 Mz
Resiscuit)
Min. 1 Mz
tance
harness)
SBRL (female) (1) and between STC3
(female) (3) SBRL (female) (2)
Resistance
Min. 1 Mz
4
26
STC3 (female)
Resistance
Between (5) (3)
3.5 12.5 z
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00722-01
D155AX-6
27
SEN00722-01
40 Troubleshooting
Failure code [DXHCKY] Left brake ECMV: Short circuit

Action code
Failure code
E04
DXHCKY
Contents of
trouble
Trouble

When signal was output to steering case left brake ECMV solenoid circuit, abnormal current flowed.
Action of
controller
Problem that
appears on
machine

Related
information
Cause
Possible causes
and standard
value in normal
state

SBRL (male)
Resistance
Between (1) (2)
3.5 12.5 z
Min. 1 Mz

2
Voltage Max. 1 V
harness)
SBRL (female) (1) and between STC3
(female) (3) SBRL (female) (2)
Resistance
Min. 1 Mz
4
28
STC3 (female)
Resistance
Between (5) (3)
3.5 12.5 z
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00722-01
D155AX-6
29
SEN00722-01
40 Troubleshooting
Failure code [DXHRKA] Blade up EPC: Disconnection

Action code
Failure code
E03
DXHRKA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Blade up EPC: Disconnection

When signal is output to blade lift-up EPC solenoid circuit, no current flows.
Turns signal to blade lift-up EPC solenoid circuit OFF.
Blade cannot be lifted up.
Output to blade lift-up EPC solenoid can be checked with monitoring function.
(Code: 71001 Blade Raise EPC (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate blade control lever (Raise).
Cause
Defective blade lift-up EPC
Possible causes
and standard
value in normal
state

WEP1 (male)
Resistance
Between (1) (2)
4.5 14.5 z
2
or defective contact in con- WEP1 (female) (1)
nector)
(13) WEP1 (female) (2)

controller
Resistance
Max. 1 z
Resistance
Max. 1 z
WEC3 (female)
Resistance
Between (6) (13)
4.5 14.5 z
Circuit diagram related to blade lift-up EPC solenoid
30
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code [DXHRKB] Blade up EPC: Short circuit

Action code
Failure code
E03
DXHRKB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

When signal was output to blade lift-up EPC solenoid circuit, abnormal current flowed.
Cause
Possible causes
and standard
value in normal
state

WEP1 (male)
Resistance
Between (1) (2)
4.5 14.5 z
Min. 1 Mz
Resiscuit)
Min. 1 Mz
WEP1 (female) (1) and chassis ground
tance
3

controller
WEC3 (female)
Resistance
Between (6) (13)
4.5 14.5 z
Min. 1 Mz
D155AX-6
31
SEN00722-01
40 Troubleshooting
Failure code [DXHRKY] Blade up EPC: Short circuit

Action code
Failure code
E03
DXHRKY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

When signal was output to blade lift-up EPC solenoid circuit, abnormal current flowed.
Cause
Possible causes
and standard
value in normal
state

WEP1 (male)
Resistance
Between (1) (2)
4.5 14.5 z
Min. 1 Mz

2
Voltage Max. 1 V
3

controller
WEC3 (female)
Resistance
Between (6) - (13)
4.5 14.5 z
Between (6) - chassis ground
Min. 1 Mz
32
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code [DXHSKA] Blade down EPC: Disconnection

Action code
Failure code
E03
DXHSKA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Blade down EPC: Disconnection

When signal is output to blade lift-down EPC solenoid circuit, no current flows.
Turns signal to blade lift-down EPC solenoid circuit OFF.
Blade cannot be lifted down.
Output to blade lift-down EPC solenoid can be checked with monitoring function.
(Code: 71003 Blade Down EPC (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate blade control lever (Lower).
Cause
Defective blade lift-down
1 EPC solenoid (Internal disconnection)
Possible causes
and standard
value in normal
state

WEP2 (male)
Resistance
Between (1) (2)
4.5 14.5 z
2
or defective contact in con- (16) WEP2 (female) (1)
nector)

controller
Resistance
Max. 1 z
Resistance
Max. 1 z
WEC3 (female)
Resistance
Between (16) (13)
4.5 14.5 z
Circuit diagram related to blade lift-down EPC solenoid
D155AX-6
33
SEN00722-01
40 Troubleshooting
Failure code [DXHSKB] Blade down EPC: Short circuit

Action code
Failure code
E03
DXHSKB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

When signal was output to blade lift-down EPC solenoid circuit, abnormal current flowed.
Cause
1 EPC solenoid (Internal short
circuit)
Possible causes
and standard
value in normal
state

WEP2 (male)
Resistance
Between (1) (2)
4.5 14.5 z
Min. 1 Mz
Resiscuit)
(16) WEP2 (female) (1) and chassis
Min. 1 Mz
tance
ground
3

controller
WEC3 (female)
Resistance
Between (16) (13)
4.5 14.5 z
Min. 1 Mz
34
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code [DXHSKY] Blade down EPC: Short circuit

Action code
Failure code
E03
DXHSKY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

When signal was output to blade lift-down EPC solenoid circuit, abnormal current flowed.
Cause
circuit)
Possible causes
and standard
value in normal
state

WEP2 (male)
Resistance
Between (1) (2)
4.5 14.5 z
Min. 1 Mz


ground
Voltage
Max. 1 V
3

controller
WEC3 (female)
Resistance
Between (16) (13)
4.5 14.5 z
Min. 1 Mz
D155AX-6
35
SEN00722-01
40 Troubleshooting
Failure code [DXHTKA] Blade left 1 EPC: Disconnection

Action code
Failure code
E03
DXHTKA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

When signal is output to blade tilt right head EPC solenoid circuit, no current flows.
Turns signal to blade tilt right head EPC solenoid circuit OFF.
Blade tilt cylinder or pitch right cylinder cannot be retracted.
Output to blade tilt right head EPC solenoid can be checked with monitoring function.
(Code: 90800 Blade Tilt RH-H EPC (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate blade control lever (Pitch
back).
Cause
Defective blade tilt right head
Possible causes
and standard
value in normal
state

WEP5 (male)
Resistance
Between (1) (2)
2 12 z
2
nector)
3
controller
Resistance
Max. 1 z
Resistance
Max. 1 z
WEC3 (female)
Resistance
Between (26) (23)
2 12 z
Circuit diagram related to blade tilt right head EPC solenoid
36
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code [DXHTKB] Blade left 1 EPC: Short circuit

Action code
Failure code
E03
DXHTKB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

When signal was output to blade tilt right head EPC solenoid circuit, abnormal current flowed.
back).
Cause
circuit)
Possible causes
and standard
value in normal
state

WEP5 (male)
Resistance
Between (1) (2)
2 12 z
Min. 1 Mz
Resiscuit)
Min. 1 Mz
tance
ground
3

controller
WEC3 (female)
Resistance
Between (26) (23)
2 12 z
Min. 1 Mz
D155AX-6
37
SEN00722-01
40 Troubleshooting
Failure code [DXHTKY] Blade left 1 EPC: Short circuit

Action code
Failure code
E03
DXHTKY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

When signal was output to blade tilt right head EPC solenoid circuit, abnormal current flowed.
back).
Cause
circuit)
Possible causes
and standard
value in normal
state

WEP5 (male)
Resistance
Between (1) (2)
2 12 z
Min. 1 Mz


ground
Voltage
Max. 1 V
3

controller
WEC3 (female)
Resistance
Between (26) (23)
2 12 z
Min. 1 Mz
38
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code [DXHUKA] Blade right 1 EPC: Disconnection

Action code
Failure code
E03
DXHUKA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

When signal is output to blade tilt right bottom EPC solenoid circuit, no current flows.
Turns signal to blade tilt right bottom EPC solenoid circuit OFF.
Output to blade tilt right bottom EPC solenoid can be checked with monitoring function.
(Code: 90801 Blade Tilt RH-B EPC (F/B))
forward).
Cause
Defective blade tilt right bot1 tom EPC solenoid (Internal
disconnection)
Possible causes
and standard
value in normal
state

WEP6 (male)
Resistance
Between (1) (2)
2 12 z
2
nector)
3
controller
Resistance
Max. 1 z
Resistance
Max. 1 z
WEC3 (female)
Resistance
Between (36) (23)
2 12 z
Circuit diagram related to blade tilt right bottom EPC solenoid
D155AX-6
39
SEN00722-01
40 Troubleshooting
Failure code [DXHUKB] Blade right 1 EPC: Short circuit

Action code
Failure code
E03
DXHUKB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

When signal was output to blade tilt right bottom EPC solenoid circuit, abnormal current flowed.
forward).
Cause
short circuit)
Possible causes
and standard
value in normal
state

WEP6 (male)
Resistance
Between (1) (2)
2 12 z
Min. 1 Mz
Resiscuit)
Min. 1 Mz
tance
ground
3

controller
WEC3 (female)
Resistance
Between (36) (23)
2 12 z
Min. 1 Mz
40
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code [DXHUKY] Blade right 1 EPC: Short circuit

Action code
Failure code
E03
DXHUKY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

When signal was output to blade tilt right bottom EPC solenoid circuit, abnormal current flowed.
forward).
Cause
short circuit)
Possible causes
and standard
value in normal
state

WEP6 (male)
Resistance
Between (1) (2)
2 12 z
Min. 1 Mz


ground
Voltage
Max. 1 V
3

controller
WEC3 (female)
Resistance
Between (36) (23)
2 12 z
Min. 1 Mz
D155AX-6
41
SEN00722-01
40 Troubleshooting
Failure code [DXHWKA] Ripper up EPC: Disconnection

Action code
Failure code
E03
DXHWKA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Ripper up EPC: Disconnection

When signal is output to ripper lift-up EPC solenoid circuit, no current flows.
Turns signal to ripper lift-up EPC solenoid circuit OFF.
Ripper cannot be lifted up.
Output to ripper lift-up EPC solenoid can be checked with monitoring function.
(Code: 71101 Ripper Raise EPC (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate ripper control lever (Raise).
Cause
Defective ripper lift-up EPC
Possible causes
and standard
value in normal
state

WEP7 (male)
Resistance
Between (1) (2)
2 12 z
2
or defective contact in con- WEP7 (female) (1)
nector)

controller
Resistance
Max. 1 z
Resistance
Max. 1 z
WEC3 (female)
Resistance
Between (5) (23)
2 12 z
Circuit diagram related to ripper lift-up EPC solenoid
42
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code [DXHWKB] Ripper up EPC: Short circuit

Action code
Failure code
E03
DXHWKB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

When signal was output to ripper lift-up EPC solenoid circuit, abnormal current flowed.
Cause
Possible causes
and standard
value in normal
state

WEP7 (male)
Resistance
Between (1) (2)
2 12 z
Min. 1 Mz
Resiscuit)
Min. 1 Mz
tance
3

controller
WEC3 (female)
Resistance
Between (5) (23)
2 12 z
Min. 1 Mz
D155AX-6
43
SEN00722-01
40 Troubleshooting
Failure code [DXHWKY] Ripper up EPC: Short circuit

Action code
Failure code
E03
DXHWKY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

When signal was output to ripper lift-up EPC solenoid circuit, abnormal current flowed.
Cause
Possible causes
and standard
value in normal
state

WEP7 (male)
Resistance
Between (1) (2)
2 12 z
Min. 1 Mz

2
Voltage Max. 1 V
3

controller
WEC3 (female)
Resistance
Between (5) (23)
2 12 z
Min. 1 Mz
44
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code [DXHXKA] Ripper down EPC: Disconnection

Action code
Failure code
E03
DXHXKA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Ripper down EPC: Disconnection

When signal is output to ripper lift-down EPC solenoid circuit, no current flows.
Turns signal to ripper lift-down EPC solenoid circuit OFF.
Ripper cannot be lifted down.
Output to ripper lift-down EPC solenoid can be checked with monitoring function.
(Code: 71103 Ripper Down EPC (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate ripper control lever (Lower).
Cause
Defective ripper lift-down
Possible causes
and standard
value in normal
state

WEP8 (male)
Resistance
Between (1) (2)
2 12 z
2
nector)

controller
Resistance
Max. 1 z
Resistance
Max. 1 z
WEC3 (female)
Resistance
Between (15) (23)
2 12 z
Circuit diagram related to ripper lift-down EPC solenoid
D155AX-6
45
SEN00722-01
40 Troubleshooting
Failure code [DXHXKB] Ripper down EPC: Short circuit

Action code
Failure code
E03
DXHXKB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

When signal was output to ripper lift-down EPC solenoid circuit, abnormal current flowed.
Cause
circuit)
Possible causes
and standard
value in normal
state

WEP8 (male)
Resistance
Between (1) (2)
2 12 z
Min. 1 Mz
Resiscuit)
Min. 1 Mz
tance
ground
3

controller
WEC3 (female)
Resistance
Between (15) (23)
2 12 z
Min. 1 Mz
46
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code [DXHXKY] Ripper down EPC: Short circuit

Action code
Failure code
E03
DXHXKY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

When signal was output to ripper lift-down EPC solenoid circuit, abnormal current flowed.
Cause
circuit)
Possible causes
and standard
value in normal
state

WEP8 (male)
Resistance
Between (1) (2)
2 12 z
Min. 1 Mz


ground
Voltage
Max. 1 V
3

controller
WEC3 (female)
Resistance
Between (15) (23)
2 12 z
Min. 1 Mz
D155AX-6
47
SEN00722-01
40 Troubleshooting
Failure code [DXHYKA] Ripper Tilt In EPC: Disconnection

Action code
Failure code
E03
DXHYKA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Ripper Tilt In EPC: Disconnection

When signal is output to ripper tilt-in EPC solenoid circuit, no current flows.
Turns signal to ripper tilt-in EPC solenoid circuit OFF.
Ripper cannot be tilted in.
Output to ripper tilt-in EPC solenoid can be checked with monitoring function.
(Code: 71105 Ripper Tilt In EPC (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate ripper control lever (Tilt in).
Cause
Defective ripper tilt-in EPC
Possible causes
and standard
value in normal
state

WEP9 (male)
Resistance
Between (1) (2)
2 12 z
2
nector)

controller
Resistance
Max. 1 z
Resistance
Max. 1 z
WEC3 (female)
Resistance
Between (25) (23)
2 12 z
Circuit diagram related to ripper tilt-in EPC solenoid
48
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code [DXHYKB] Ripper Tilt In EPC: Short circuit

Action code
Failure code
E03
DXHYKB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

When signal was output to ripper tilt-in EPC solenoid circuit, abnormal current flowed.
Cause
Possible causes
and standard
value in normal
state

WEP9 (male)
Resistance
Between (1) (2)
2 12 z
Min. 1 Mz
Resiscuit)
Min. 1 Mz
tance
ground
3

controller
WEC3 (female)
Resistance
Between (25) (23)
2 12 z
Min. 1 Mz
D155AX-6
49
SEN00722-01
40 Troubleshooting
Failure code [DXHYKY] Ripper Tilt In EPC: Short circuit

Action code
Failure code
E03
DXHYKY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

When signal was output to ripper tilt-in EPC solenoid circuit, abnormal current flowed.
Cause
Possible causes
and standard
value in normal
state

WEP9 (male)
Resistance
Between (1) (2)
2 12 z
Min. 1 Mz


ground
Voltage
Max. 1 V
3

controller
WEC3 (female)
Resistance
Between (25) (23)
2 12 z
Min. 1 Mz
50
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code [DXHZKA] Ripper Tilt Back EPC: Disconnection

Action code
Failure code
E03
DXHZKA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Ripper Tilt Back EPC: Disconnection

When signal is output to ripper tilt-back EPC solenoid circuit, no current flows.
Turns signal to ripper tilt-back EPC solenoid circuit OFF.
Ripper cannot be tilted back.
Output to ripper tilt-back EPC solenoid can be checked with monitoring function.
(Code: 71107 Ripper Tilt Back EPC (F/B))
Method of reproducing failure code: Turn starting switch ON + Operate ripper control lever (Tilt
back).
Cause
Defective ripper tilt-back
Possible causes
and standard
value in normal
state

WEPA (male)
Resistance
Between (1) (2)
2 12 z
2
or defective contact in con- (35) WEPA (female) (1)
nector)
(23) WEPA (female) (2)
3
controller
Resistance
Max. 1 z
Resistance
Max. 1 z
WEC3 (female)
Resistance
Between (35) (23)
2 12 z
Circuit diagram related to ripper tilt-back EPC solenoid
D155AX-6
51
SEN00722-01
40 Troubleshooting
Failure code [DXHZKB] Ripper Tilt Back EPC: Short circuit

Action code
Failure code
E03
DXHZKB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

When signal was output to ripper tilt-back EPC solenoid circuit, abnormal current flowed.
back).
Cause
circuit)
Possible causes
and standard
value in normal
state

WEPA (male)
Resistance
Between (1) (2)
2 12 z
Min. 1 Mz
Resiscuit)
(35) WEPA (female) (1) and chassis
Min. 1 Mz
tance
ground
3

controller
WEC3 (female)
Resistance
Between (35) (23)
2 12 z
Min. 1 Mz
52
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code [DXHZKY] Ripper Tilt Back EPC: Short circuit

Action code
Failure code
E03
DXHZKY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

When signal was output to ripper tilt-back EPC solenoid circuit, abnormal current flowed.
back).
Cause
circuit)
Possible causes
and standard
value in normal
state

WEPA (male)
Resistance
Between (1) (2)
2 12 z
Min. 1 Mz


(35) WEPA (female) (1) and chassis
ground
Voltage
Max. 1 V
3

controller
WEC3 (female)
Resistance
Between (35) (23)
2 12 z
Min. 1 Mz
D155AX-6
53
SEN00722-01
40 Troubleshooting
Failure code [DXJ4KA] Weq lock Sol.: Disconnection

Action code
Failure code
E03
DXJ4KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Weq lock Sol.: Disconnection

When signal is output to work equipment lock solenoid circuit, no current flows.
Turns signal to work equipment lock solenoid circuit OFF.
Blade and ripper cannot be operated.
Method of reproducing failure code: Turn starting switch ON + Operate work equipment lock lever
(Free).
Cause
1 lock solenoid (Internal disconnection)
Possible causes
and standard
value in normal
state

WLK (male)
Resistance
Between (1) (2)
20 60 z
Resis2
Max. 1 z
or defective contact in con- WLK (female) (1)
tance
nector)
ResisMax. 1 z
WLK (female) (2)
tance

controller
WEC3 (female)
Resistance
Between (8) (3)
20 60 z
Circuit diagram related to work equipment lock solenoid
54
D155AX-6
40 Troubleshooting
SEN00722-01
Failure code [DXJ4KB] Weq lock Sol.: Short circuit

Action code
Failure code
E03
DXJ4KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Weq lock Sol.: Short circuit

When signal was output to work equipment lock solenoid circuit, abnormal current flowed.
Turns signal to work equipment lock solenoid circuit OFF.
Blade and ripper cannot be operated.
Method of reproducing failure code: Turn starting switch ON + Operate work equipment lock lever
(Free).
Cause
1 lock solenoid (Internal short
circuit)
Possible causes
and standard
value in normal
state

WLK (male)
Resistance
Between (1) (2)
20 60 z
Min. 1 Mz
Ground fault in wiring har2 ness (Contact with GND cirWiring harness between WEC3 (female) (8)
cuit)
WLK (female) (1) and chassis ground
Resistance
Min. 1 Mz


WLK (female) (1) and chassis ground
Voltage
Max. 1 V
4

controller
WEC3 (female)
Resistance
Between (8) (3)
20 60 z
Min. 1 Mz
Circuit diagram related to work equipment lock solenoid
D155AX-6
55
SEN00722-01
40 Troubleshooting
D155AX-6 Bulldozer
2006 KOMATSU
All Rights Reserved
56
D155AX-6
SEN00723-01
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
40 Troubleshooting

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
SEN00723-01
40 Troubleshooting
Failure code [DXJ8KA] Blade left 2 EPC: Disconnection
Action code
Failure code
E03
DXJ8KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
When signal is output to blade tilt left bottom EPC solenoid circuit, no current flows.
Turns signal to blade tilt left bottom EPC solenoid circuit OFF.
Blade tilt cylinder or pitch left cylinder cannot be extended.
Output to blade tilt left bottom EPC solenoid can be checked with monitoring function.
(Code: 71007 Blade Tilt LH-B EPC (F/B))
forward).
Cause
Defective blade tilt left bot1 tom EPC solenoid (Internal
disconnection)
Possible causes
and standard
value in normal
state


WEP4 (male)
Resistance
Between (1) (2)
2 12 z
2
nector)
3
controller
Resistance
Max. 1 z
Resistance
Max. 1 z
WEC3 (female)
Resistance
Between (38) (13)
2 12 z
Circuit diagram related to blade tilt left bottom EPC solenoid
D155AX-6
40 Troubleshooting
SEN00723-01
Failure code [DXJ8KB] Blade left 2 EPC: Short circuit

Action code
Failure code
E03
DXJ8KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

When signal was output to blade tilt left bottom EPC solenoid circuit, abnormal current flowed.
forward).
Cause
short circuit)
Possible causes
and standard
value in normal
state

WEP4 (male)
Resistance
Between (1) (2)
2 12 z
Min. 1 Mz
Resiscuit)
Min. 1 Mz
tance
ground
3

controller
WEC3 (female)
Resistance
Between (38) (13)
2 12 z
Min. 1 Mz
D155AX-6
SEN00723-01
40 Troubleshooting
Failure code [DXJ8KY] Blade left 2 EPC: Short circuit

Action code
Failure code
E03
DXJ8KY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

When signal was output to blade tilt left bottom EPC solenoid circuit, abnormal current flowed.
forward).
Cause
short circuit)
Possible causes
and standard
value in normal
state

WEP4 (male)
Resistance
Between (1) (2)
2 12 z
Min. 1 Mz


ground
Voltage
Max. 1 V
3

controller
WEC3 (female)
Resistance
Between (38) (13)
2 12 z
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00723-01
Failure code [DXJ9KA] Blade right 2 EPC: Disconnection

Action code
Failure code
E03
DXJ9KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

When signal is output to blade tilt left head EPC solenoid circuit, no current flows.
Turns signal to blade tilt left head EPC solenoid circuit OFF.
Blade tilt cylinder or pitch left cylinder cannot be retracted.
Output to blade tilt left head EPC solenoid can be checked with monitoring function.
(Code: 71005 Blade Tilt LH-H EPC (F/B))
back).
Cause
Defective blade tilt left head
Possible causes
and standard
value in normal
state

WEP3 (male)
Resistance
Between (1) (2)
2 12 z
2
nector)
3
controller
Resistance
Max. 1 z
Resistance
Max. 1 z
WEC3 (female)
Resistance
Between (28) (13)
2 12 z
Circuit diagram related to blade tilt left head EPC solenoid
D155AX-6
SEN00723-01
40 Troubleshooting
Failure code [DXJ9KB] Blade right 2 EPC: Short circuit

Action code
Failure code
E03
DXJ9KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

When signal was output to blade tilt left head EPC solenoid circuit, abnormal current flowed.
back).
Cause
Possible causes
and standard
value in normal
state

WEP3 (male)
Resistance
Between (1) (2)
2 12 z
Min. 1 Mz
Resiscuit)
Min. 1 Mz
tance
ground
3

controller
WEC3 (female)
Resistance
Between (28) (13)
2 12 z
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00723-01
Failure code [DXJ9KY] Blade right 2 EPC: Short circuit

Action code
Failure code
E03
DXJ9KY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

When signal was output to blade tilt left head EPC solenoid circuit, abnormal current flowed.
back).
Cause
circuit)
Possible causes
and standard
value in normal
state
Hot short in wiring harness

(Contact with GND circuit)

WEP3 (male)
Resistance
Between (1) (2)
2 12 z
Min. 1 Mz

ground
Voltage
Max. 1 V
3

controller
WEC3 (female)
Resistance
Between (28) (13)
2 12 z
Min. 1 Mz
D155AX-6
SEN00723-01
40 Troubleshooting
Failure code [DXJAKA] Q-drop EPC: Disconnection

Action code
Failure code
E01
DXJAKA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Turns signal to blade quick drop EPC solenoid circuit OFF.

Blade quick drop function does not operate.
Output to blade quick drop EPC solenoid can be checked with monitoring function.
(Code: 90900 Quick Drop Solenoid (F/B))
Defective blade quick drop


QDP (male)
Resistance
Between (1) (2)
4.5 14.5 z
2
or defective contact in con- (37) QDP (female) (1)
nector)
QDP (female) (2)
Q-drop EPC: Disconnection

When signal is output to blade quick drop EPC solenoid circuit, no current flows.
Cause
Possible causes
and standard
value in normal
state

controller
Resistance
Max. 1 z
Resistance
Max. 1 z
WEC3 (female)
Resistance
Between (37) (3)
4.5 14.5 z
D155AX-6
40 Troubleshooting
SEN00723-01
Circuit diagram related to blade quick drop EPC solenoid
D155AX-6
SEN00723-01
40 Troubleshooting
Failure code [DXJAKB] Q-drop EPC: Short circuit

Action code
Failure code
E01
DXJAKB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

When signal was output to blade quick drop EPC solenoid circuit, abnormal current flowed.
Cause
circuit)
Possible causes
and standard
value in normal
state

QDP (male)
Resistance
Between (1) (2)
4.5 14.5 z
Min. 1 Mz
2 ness (Contact with GND cirResisWiring harness between WEC3 (female)
cuit)
Min. 1 Mz
(37) QDP (female) (1) and chassis ground
tance
3
10

controller
WEC3 (female)
Resistance
Between (37) (3)
4.5 14.5 z
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00723-01
D155AX-6
11
SEN00723-01
40 Troubleshooting
Failure code [DXJAKY] Q-drop EPC: Short circuit

Action code
Failure code
E01
DXJAKY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

When signal was output to blade quick drop EPC solenoid circuit, abnormal current flowed.
Cause
circuit)
Possible causes
and standard
value in normal
state

QDP (male)
Resistance
Between (1) (2)
4.5 14.5 z
Min. 1 Mz

2
Voltage Max. 1 V
(37) QDP (female) (1) and chassis ground
3
12

controller
WEC3 (female)
Resistance
Between (37) (3)
4.5 14.5 z
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00723-01
D155AX-6
13
SEN00723-01
40 Troubleshooting
Failure code [DXJBKA] S/C ECMV: Disconnection

Action code
Failure code
E02
DXJBKA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
S/C ECMV: Disconnection

When signal is output to torque converter stator clutch ECMV solenoid circuit, no current flows.
Turns signal to torque converter stator clutch ECMV solenoid circuit OFF.
Sufficient torque may not be obtained during travel.
Output to torque converter stator clutch ECMV solenoid can be checked with monitoring function.
(Code: 90700 S/C ECMV (F/B))
Cause
a Prepare with starting switch OFF, then carry out troubleshootDefective stator clutch ECMV
ing without turning starting switch ON.
1 solenoid (Internal disconnecSSTC (male)
Resistance
tion)
Between (1) (2)
5 25 z
Possible causes
and standard
value in normal
state
2
or defective contact in con- SSTC (female) (1)
nector)
SSTC (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z

3
Voltage Max. 1 V
SSTC (female) (1) and chassis ground
14
STC3 (female)
Resistance
Between (38) (13)
5 25 z
D155AX-6
40 Troubleshooting
SEN00723-01
D155AX-6
15
SEN00723-01
40 Troubleshooting
Failure code [DXJBKB] S/C ECMV: Short circuit

Action code
Failure code
E02
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
DXJBKB
Trouble

When signal was output to torque converter stator clutch ECMV solenoid circuit, abnormal current
flowed.
Cause
Defective stator clutch ECMV
Possible causes
and standard
value in normal
state

SSTC (male)
Resistance
Between (1) (2)
5 25 z
Min. 1 Mz
Resiscuit)
Min. 1 Mz
tance
harness)
SSTC (female) (1) and between STC3
(female) (13) SSTC (female) (2)
Resistance
Min. 1 Mz
4
16
STC3 (female)
Resistance
Between (38) (13)
5 25 z
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00723-01
D155AX-6
17
SEN00723-01
40 Troubleshooting
Failure code [DXJBKY] S/C ECMV: Short circuit

Action code
Failure code
E02
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
DXJBKY
Trouble

When signal was output to torque converter stator clutch ECMV solenoid circuit, abnormal current
flowed.
Cause
Defective stator clutch ECMV
Possible causes
and standard
value in normal
state

SSTC (male)
Resistance
Between (1) (2)
5 25 z
Min. 1 Mz

2
Voltage Max. 1 V
harness)
SSTC (female) (1) and between STC3
(female) (13) SSTC (female) (2)
Resistance
Min. 1 Mz
4
18
STC3 (female)
Resistance
Between (38) (13)
5 25 z
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00723-01
D155AX-6
19
SEN00723-01
40 Troubleshooting
D155AX-6 Bulldozer
2006 KOMATSU
All Rights Reserved
20
D155AX-6
SEN00807-02
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
40 Troubleshooting
Troubleshooting of electrical system

(E-mode)
Information in troubleshooting table................................................................................................................ 3
E-1 When starting switch turned ON, machine monitor displays nothing ....................................................... 4
E-2 When starting switch turned ON (before starting engine), basic check item lights up.............................. 6
E-3 Engine does not start (Engine does not turn) ........................................................................................... 8
E-4 Preheater does not operate.................................................................................................................... 10
E-5 Precaution item lights up while engine is running .................................................................................. 14
E-6 Emergency stop item lights up while engine is running.......................................................................... 16
E-7 Engine coolant temperature gauge does not indicate normally ............................................................. 18
E-8 Fuel level gauge does not indicate normally .......................................................................................... 19
E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally ........................................ 21
E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally .............................................. 22
E-11 Contents of display by machine monitor are different from applicable machine................................... 25
E-12 Machine monitor does not display some items .................................................................................... 25
E-13 Function switch does not work ............................................................................................................. 25
D155AX-6
SEN00807-02
40 Troubleshooting
E-14 Operation mode does not change ........................................................................................................ 26

E-15 Gearshift mode does not change ......................................................................................................... 26
E-16 Customize function does not operate normally .................................................................................... 27
E-17 Customize memory function does not normally.................................................................................... 27
E-18 Float mode does not change ................................................................................................................ 28
E-19 Alarm buzzer cannot be stopped.......................................................................................................... 28
E-20 Air conditioner does not operate normally (including air conditioner fault history) ............................... 29
E-21 When starting switch is turned OFF, service meter is not displayed .................................................... 42
E-22 Machine monitor cannot be set in service mode .................................................................................. 42
E-23 Ripper pin puller cylinder does not operate .......................................................................................... 44
E-24 Backup alarm does not sound or does not stop ................................................................................... 46
E-25 Headlamp, rear lamp, and ripper point lamp do not light up................................................................. 48
E-26 Windshield wiper and window washer do not operate.......................................................................... 52
E-27 KOMTRAX system does not operate normally..................................................................................... 68
D155AX-6
40 Troubleshooting
SEN00807-02
a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully.
Trouble
Related
information
Trouble which occurred in the machine

Cause

Standard value in normal state to judge possible causes
Remarks on judgment
<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
V) circuit is in contact with power source (24 V) circuit.
Short circuit
Independent wiring harnesses are in contact with each
other abnormally.
Possible causes
and standard
value in normal
state

(Given numbers are refer<Precautions for troubleshooting>
ence numbers, which do
(1) Method of indicating connector No. and handling of Tnot indicate priority)
adapter
Insert or connect T-adapter as explained below for troubleshooting, 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", disconnect 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.

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 (i
o): Roughly shows the location on the machine.
D155AX-6
SEN00807-02
40 Troubleshooting
E-1 When starting switch turned ON, machine monitor displays nothing 1
Trouble
Related
information
When starting switch turned ON, machine monitor displays nothing.

When starting switch is turned ON, machine monitor displays KOMATSU logo, screen to input password (if set), screen of check before starting, screen to check setting of preset, and ordinary screen
in order.
When the engine is started, the battery voltage may lower suddenly, depending on the ambient temperature and the condition of the battery. In this case, the machine monitor goes off for a moment.
This phenomenon is not a failure, however.
Cause

1 Low charge level of battery
Electrolyte specific gravity

(1 piece)
Min. 24 V
Min. 1.26

(CB30, CB6, or CB7)
Machine monitor connector may be connected wrongly. Check it

Wrong connection of connecdirectly (Connection between connectors CM01 and CM02 and
tor
between connectors CM03 and CM04).
4
Possible causes
and standard
value in normal
state
Battery voltage (2 pieces)
Defective starting switch

If circuit breaker is turned OFF, circuit probably has ground fault.

(See cause 6.)

Starting switch
Between 250 270
Resistance
ON
Wiring harness between battery () chassis ground
Resistance
Max. 1 z
Wiring harness between battery (+) terminal BRB CB30 (B30L)
Resistance
Max. 1 z
Wiring harness between CB30 (B30S)

CB7 (1)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z

CB6 (1)
Resistance
Max. 1 z
Wiring harness between CB6 (2) terminal

250
Resistance
Max. 1 z
Wiring harness between terminal 270

CM01 (female) (14)
Resistance
Max. 1 z
Disconnection in wiring harness (Disconnection in wiring Wiring harness between CB7 (2) CM01
5
or defective contact in con- (female) (1), (2)
nector)
Max. 1 z
D155AX-6
40 Troubleshooting
SEN00807-02
Cause

Possible causes
and standard
value in normal
state
Wiring harness between battery (+) terminal BRB CB30 (B30L) and chassis ground
Resistance
Min. 1 Mz

CB7 (1) or circuit branch end and chassis
ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Wiring harness between CB6 (2) terminal

250 or circuit branch end and chassis
ground
Resistance
Min. 1 Mz

CM01 (female) (14) or circuit branch end
and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CB7 (2) CM01

Ground fault in wiring har(female) (1), (2) or circuit branch end and
6 ness (Contact with GND circhassis ground
cuit)
CB6 (1) or circuit branch end and chassis
ground
a Prepare with starting switch OFF, then hold starting switch OFF
and ON and carry out troubleshooting in each case.
7 Defective machine monitor
CM01
Starting switch
Voltage
Between (1), (2)

(3) , (4)
OFF
20 30 V
Between (14)
(3), (4)
ON
20 30 V
Circuit diagram related to machine monitor power supply
D155AX-6
SEN00807-02
40 Troubleshooting
E-2 When starting switch turned ON (before starting engine), basic

check item lights up
Trouble
Related
information
When starting switch turned ON (before starting engine), basic check item lights up.
Basic check item is only lowering of radiator coolant level.
Cause
Lowering of radiator coolant
1 level (When system is normal)

Coolant level in radiator sub tank may be low. Check it and add
coolant if necessary.
Defective radiator coolant

2 level switch (Internal disconnection)
WLV (male)
Between (1) (2)

Possible causes
and standard
value in normal
state
Sub tank coolant

level
Resistance
Between FULL
LOW
Max. 1 z
Below LOW
Min. 1 Mz
3
or defective contact in con- WLV (female) (1)
nector)
CM02 (female) (7) WLV (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z

CM02
Between (3)
chassis ground
Sub tank coolant

level
Voltage
Between FULL
LOW
Max. 1 V
Below LOW
20 30 V
Circuit diagram related to radiator coolant level switch
D155AX-6
40 Troubleshooting
D155AX-6
SEN00807-02
SEN00807-02
40 Troubleshooting
E-3 Engine does not start (Engine does not turn)

Trouble
Related
information
Engine does not start (Engine does not turn).

Engine starting circuit has following 2 start lock mechanisms.
1) Start lock with password of machine monitor
2) Start lock with parking brake lever and work equipment lock lever
Cause

1 Low charge level of battery

Battery voltage (2 pieces)
Electrolyte specific gravity

(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.
Starting switch
Between 250 280
Resistance
OFF
Min. 1 Mz
START
Max. 1 z
a Prepare with starting switch OFF, then turn starting switch to

START and carry out troubleshooting.

Replace neutral safety relay (Right No.) with another
(Internal trouble)
relay. If engine starts at this time, neutral safety relay is
defective.
NSF
a Prepare with starting switch OFF, then turn starting switch to

START and carry out troubleshooting.
Starting motor
Defective starting motor
4
(Internal defect)
Possible causes
and standard
value in normal
state
Voltage
Between B
chassis ground
Battery power supply
20 30 V
Between ST (2)
chassis ground
Starting signal
20 30 V
Between ST (2)
chassis ground
Generation signal
Max. 1 V
If battery power supply, starting signal, and generation signal are

normal but starting motor does not turn, starting motor is defective.
Defective alternator (Internal

short circuit)

Alternator
Between R
chassis ground
Generation signal
Voltage
Max. 1 V
Disconnection in wiring harness (Disconnection in wiring Wiring harness between terminal 280 NSF
or defective contact in con- (female) (3)
nector)
PRE ST (female) (1)
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between terminal 280 NSF
Ground fault in wiring har7 ness (Contact with GND cir- (female) (3) or circuit branch end and chassis ground
cuit)
Resistance
Min. 1 Mz

PRE ST (female) (1) and chassis ground
Resistance
Min. 1 Mz


24V circuit) in wiring harness Wiring harness between terminal R ST
(female) (2) or circuit branch end and chassis ground
Voltage
Max. 1 V
D155AX-6
40 Troubleshooting
SEN00807-02
Circuit diagram related to preheating/starting of engine and charge of battery
D155AX-6
SEN00807-02
40 Troubleshooting
E-4 Preheater does not operate

Trouble
Related
information
(1) When starting switch is turned to HEAT position, preheating monitor does not light up.
Preheater monitor lights up when starting switch is turned to HEAT.
If engine coolant temperature is below -5 C, automatic warm-up system operates and preheating
monitor lights up for up to 40 seconds.
Cause


OFF and turn it to HEAT and carry out troubleshooting in each
case.
Starting switch
Between 250 255
Possible causes
and standard
value in normal
state
Resistance
OFF
Min. 1 Mz
HEAT
Max. 1 z
2
or defective contact in con- Wiring harness between CM01 (female)
ResisMax. 1 z
nector)
(16) terminal 255
tance
OFF and turn it to HEAT and carry out troubleshooting in each
case.
10
CM01
Starting switch
Voltage
Between (16)
chassis ground
OFF
Max. 1 V
HEAT
20 30 V
D155AX-6
40 Troubleshooting
SEN00807-02
Trouble
(2) When starting switch is turned to HEAT position, intake air heater mounting part does not become
warm.
Related
information
Check that engine can be turned with starting motor (If engine cannot be turned, carry out troubleshooting for E-3 Engine does not start (Engine does not turn)).
Cause
1

(CB105H)

(See cause 5).
a Prepare with starting switch OFF (with wiring harness connected), then turn starting switch to HEAT and carry out troubleshooting.
Defective heater relay (Internal disconnection)
Heater relay
Between HT
chassis ground
Between HT/B
chassis ground
Starting switch
Voltage
20 30 V
HEAT
20 30 V
a Prepare with starting switch OFF (with wiring harness connected), then turn starting switch to HEAT and carry out troubleshooting in each case.
3
Defective intake air heater

RH1
Starting switc
Voltage
Between terminal
chassis ground
HEAT
20 30 V
If voltage is normal but heater mounting part does not become

warm, intake air heater is defective.
Possible causes
and standard
value in normal
state
4
Wiring harness between terminal 255 terminal HT
Resistance
Max. 1 z
Wiring harness between terminal BRC

CB105H (B105HS)
Resistance
Max. 1 z
Wiring harness between CB105H (B105HL)

terminal HT/A
Resistance
Max. 1 z
Wiring harness between terminal HT/B

terminal RHT
Resistance
Max. 1 z
Wiring harness between terminal 255 terminal HT or CM01 (female) (16) or circuit
branch end and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Wiring harness between CB105H (B105HL)

terminal HT/A and chassis ground
Resistance
Min. 1 Mz
Wiring harness between terminal HT/B

terminal RHT and chassis ground
Resistance
Min. 1 Mz
Ground fault in wiring har5 ness (Contact with GND cir- Wiring harness between terminal BRC
cuit)
CB105H (B105HS) and chassis ground
D155AX-6
11
SEN00807-02
40 Troubleshooting
12
D155AX-6
40 Troubleshooting
D155AX-6
SEN00807-02
13
SEN00807-02
40 Troubleshooting
E-5 Precaution item lights up while engine is running

Trouble
Related
information
Precaution item lights up while engine is running.

Check item is only charge level monitor.
State of generation signal of alternator can be checked with monitoring function.
(Code: 04300 Battery Charge Volt)
Cause
Defective generation by
1 alternator (when system is
normal)
Possible causes
and standard
value in normal
state

Alternator
Engine speed
Voltage
Between R
chassis ground
Medium or higher
20 30 V
2
or defective contact in con- Wiring harness between CM01 (female) (11)
ResisMax. 1 z
nector)
terminal R
tance
Ground fault in wiring har3 ness (Contact with GND cir- Wiring harness between CM01 (female) (11)
cuit)
terminal R or circuit branch end and chassis ground
Resistance
Min. 1 Mz
14
CM01
Engine
Voltage
Between (11)
chassis ground
Medium or higher
20 30 V
D155AX-6
40 Troubleshooting
SEN00807-02
D155AX-6
15
SEN00807-02
40 Troubleshooting
E-6 Emergency stop item lights up while engine is running

Trouble
Related
information
(1) Engine coolant temperature monitor lights up.

Signals of engine coolant temperature sensor are input to engine controller and then transmitted to
Cause
Possible causes
and standard
value in normal
state
Trouble
Related
information

If cause 1 is not detected, engine coolant temperature sensor system may be defective. Carry out troubleshooting for failure codes
[CA144] and [CA145].
If causes 1 and 2 are not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried
out.)
(2) Engine oil pressure monitor lights up.

Signals of engine oil pressure sensor are input to engine controller and then transmitted to machine
monitor through communication system.
Engine oil pressure can be checked with monitoring function.
(Code: 37200 Engine Oil Pressure)
Lowering of engine oil pres1 sure (when system is normal)

2
Related
information
out.)
Signals of torque converter oil temperature sensor are input to power train controller and then transmitted to machine monitor through communication system.
Overheating of power train

oil (when system is normal)
If cause 1 is not detected, power train oil temperature sensor sysDefective power train oil temtem may be defective. Carry out troubleshooting for failure codes
perature sensor system
[DGT1KA] and [DGT1KX].
16
Engine oil pressure may be low. If it is low, remove cause.
(3) Power train oil temperature monitor lights up.
Cause
Possible causes
and standard
value in normal
state
If cause 1 is not detected, engine oil pressure sensor system may

be defective. Carry out troubleshooting for failure codes [CA135]
sensor system
and [CA141].
Trouble
Overheating of engine cool- Engine coolant may be overheated. If it is overheated, remove

1
ant (when system is normal) cause.
Cause
Possible causes
and standard
value in normal
state
Power train oil may be overheated. If it is overheated, remove

cause.
out.)
D155AX-6
40 Troubleshooting
Trouble
Related
information
SEN00807-02
(4) Hydraulic oil temperature monitor lights up.

Cause
Possible causes
and standard
value in normal
state
D155AX-6
Overheating of hydraulic oil

(when system is normal)
Hydraulic oil may be overheated. If it is overheated, remove

cause.
Defective hydraulic oil temperature gauge system
If cause 1 is not detected, hydraulic oil temperature gauge system

may be defective. Carry out troubleshooting for E-10 Hydraulic oil
temperature gauge (Multi-gauge) does not display normally.
17
SEN00807-02
40 Troubleshooting
E-7 Engine coolant temperature gauge does not indicate normally
Trouble
(1) While engine coolant temperature is rising normally, temperature gauge does not rise from white
range (C).
(2) While engine coolant temperature is stabilized normally, temperature gauge rises to red range (H).
Related
information
Possible causes
and standard
value in normal
state
Cause
1


Engine coolant temperature sensor system may be defective.
Carry out troubleshooting for failure codes [CA144] and [CA145].
If cause 1 is not detected, machine monitor may be defective.
(Since trouble is in system, troubleshooting cannot be carried out.)
Trouble
(3) Display of coolant temperature gauge is different from actual engine coolant temperature.
(4) Display of engine coolant temperature gauge is different from display of engine coolant temperature monitor.
Related
information
Cause

a Turn starting switch ON or start engine and carry out troubleshooting.
Possible causes
and standard
value in normal
state
Engine coolant tem- Coolant temperature Color of monitor light

perature
gauge level
(a)
105 C
102 C
100 C
85 C
60 C
30 C
Red
Blue
White
Engine coolant temperature gauge and coolant temperature monitor
18
D155AX-6
40 Troubleshooting
SEN00807-02
E-8 Fuel level gauge does not indicate normally

Trouble
Related
nformation
(1) While fuel is added, fuel level gauge does not rise from red range (E).
(2) While fuel level is low, fuel level gauge does not lower from green range top (F)
Signal voltage of fuel level sensor can be checked with monitoring function.
(Code: 04200 Fuel Level Sensor Volt)
Cause
Defective fuel level sensor
short circuit)

FLV (male)
Between (1) (2)
Fuel level
Resistance
FULL
Approx. 4 z
EMPTY
Approx. 85 z
Possible causes
and standard
value in normal
state
2
or defective contact in con- FLV (female) (1)
nector)
(12) FLV (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
harness between CM01 (female) (9)
Resiscuit)
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 defective. (Since trouble is in system, troubleshooting cannot be carried
out.)
Circuit diagram related to fuel level sensor
D155AX-6
19
SEN00807-02
Trouble
Related
information
40 Troubleshooting
(3) Display of fuel level gauge is different from actual fuel level.
(4) Display of fuel level gauge is different from display of fuel level monitor.
Signal voltage of fuel level sensor can be checked with monitoring function.
(Code: 04200 Fuel Level Sensor Volt)
Cause

Possible causes
and standard
value in normal
state
Quantity of fuel
Reading of fuel level Color of monitor light

gauge
(a)
565 l
425 l
310 l
220 l
150 l
75 l
Blue
Red
Fuel level gauge and fuel level monitor
20
D155AX-6
40 Troubleshooting
SEN00807-02
E-9 Power train oil temperature gauge (multi-gauge) does not indicate
normally
1
Trouble
(1) While power train oil temperature is rising normally, temperature gauge does not rise from white
range (C).
(2) While power train oil temperature is stabilized normally, temperature gauge rises to red range (H).
Related
information
Signals of power train oil temperature sensor are input to power train controller and then transmitted
to machine monitor through communication system.
Cause
Possible causes
and standard
value in normal
state
Power train oil temperature sensor system may be defective.

Defective power train oil tem1
Carry out troubleshooting for failure codes [DGT1KA] and
perature sensor system
[DGT1KX].

Trouble
(3) Display of power train temperature gauge is different from actual power train oil temperature.
(4) Display of power train oil temperature gauge is different from display of power train oil temperature
monitor.
Related
information
Signals of power train oil temperature sensor are input to power train controller and then transmitted
to machine monitor through communication system.
Cause

Possible causes
and standard
value in normal
state
Power train oil temperature

Power train oil tem- Color of monitor light

perature gauge level
(a)
130 C
120 C
118 C
80 C
50 C
0 C
Red
Blue
White
Power train oil temperature gauge and power train oil temperature monitor
D155AX-6
21
SEN00807-02
40 Troubleshooting
E-10 Hydraulic temperature gauge (multi-gauge) does not indicate

normally
Trouble
Related
information
(1) While hydraulic oil temperature is rising normally, temperature gauge does not rise from white
range (C).
(2) While hydraulic oil temperature is stabilized normally, temperature gauge rises to red range (H).
Hydraulic temperature can be checked with monitoring function.
Cause
Defective hydraulic oil temperature sensor system
1
(Internal disconnection or
short circuit)
Possible causes
and standard
value in normal
state

HDT (male)
Resistance
Between (1) (2)
3.5 90 kz
Min. 1 Mz
Resis2
Max. 1 z
or defective contact in con- HDT (female) (1)
tance
nector)
ResisMax. 1 z
(12) HDT (female) (2)
tance
3 ness (Contact with GND cirWiring harness between CM01 (female) (8)
Resiscuit)
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
22
out.)
D155AX-6
40 Troubleshooting
SEN00807-02
Circuit diagram related to hydraulic oil temperature sensor
D155AX-6
23
SEN00807-02
Trouble
Related
information
40 Troubleshooting
(3) Display of hydraulic oil temperature gauge is different from actual hydraulic oil temperature.
(4) Display of hydraulic oil temperature gauge is different from display of hydraulic oil temperature
monitor.
Cause

Possible causes
and standard
value in normal
state

Reading of hydraulic
Color of monitor light
oil temperature
(a)
gauge
110 C
100 C
98 C
70 C
20 C
0 C
Red
Blue
White
Hydraulic oil temperature gauge and hydraulic oil temperature monitor
24
D155AX-6
40 Troubleshooting
SEN00807-02
E-11 Contents of display by machine monitor are different from

applicable machine
Trouble
Contents of display by machine monitor are different from applicable machine.
Related
information
Possible causes
and standard
value in normal
state
Cause

Machine monitor may be defective. (Since trouble is in system,
troubleshooting cannot be carried out.)
E-12 Machine monitor does not display some items

Trouble
Related
information
Machine monitor does not display some items.

The LCD panel sometimes has black points (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.
Cause
Possible causes
and standard
value in normal
state

a Turn starting switch ON and carry out troubleshooting.

(LCD panel)
When following switches are operated, if all LCD panel is lighted

up (all surface becomes white), LCD panel is normal.
Operation of switches: [4] + [F2] (Press simultaneously)

(body)

E-13 Function switch does not work

Trouble
Function switch does not work.
Related
information
Possible causes
and standard
value in normal
state
D155AX-6
Cause

25
SEN00807-02
40 Troubleshooting
E-14 Operation mode does not change

Trouble
(1) When operation mode switch is operated, display of operation mode monitor does not change.
Related
information
Possible causes
and standard
value in normal
state
Trouble
Related
information
Possible causes
and standard
value in normal
state
Cause

(2) When operation mode is changed, engine output is not changed.

Engine output mode recognized by engine controller can be checked with monitoring function.
(Code: 17500 Engine Power Mode)
Cause

Engine controller may be defective. (Since trouble is in system,

E-15 Gearshift mode does not change

Trouble
(1) When gearshift mode switch is operated, display of speed mode section does not change.
Related
information
Possible causes
and standard
value in normal
state
Trouble
Cause

(2) When gearshift mode is changed, gearshift setting of power train is not changed.
Related
information
Possible causes
and standard
value in normal
state
26
Cause
2

Power train controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
D155AX-6
40 Troubleshooting
SEN00807-02
E-16 Customize function does not operate normally

Trouble
(1) When customize switch is operated, customize screen is not displayed.
Related
information
Possible causes
and standard
value in normal
state
Trouble
Cause

(2) When setting is changed on customize screen, setting of machine is not changed.
Related
information
Cause
Possible causes
and standard
value in normal
state

Defective engine controller,

Engine controller, power train controller, or pump controller may be
defective power train control2
ler, or defective pump concarried out.)
troller
E-17 Customize memory function does not normally

Trouble
(1) When customize memory switch is operated, customize memory screen is not displayed.
Related
information
Possible causes
and standard
value in normal
state
Trouble
Cause

(2) When selection is changed on customize memory screen, setting of machine is not changed.
Related
information
Cause
Possible causes
and standard
value in normal
state
D155AX-6

Defective engine controller,

Engine controller, power train controller, or pump controller may be
defective power train control2
ler, or defective pump concarried out.)
troller
27
SEN00807-02
40 Troubleshooting
E-18 Float mode does not change

Trouble
(1) When float mode switch is operated, float mode monitor does not light up or go off.
Related
information
Possible causes
and standard
value in normal
state
Trouble
Cause

(2) When float mode is changed, setting of machine is not changed.
Related
information
Possible causes
and standard
value in normal
state
Cause

2 Defective pump controller
Pump controller may be defective. (Since trouble is in system,

E-19 Alarm buzzer cannot be stopped

Trouble
Alarm buzzer cannot be stopped.
Related
information
Possible causes
and standard
value in normal
state
28
Cause

D155AX-6
40 Troubleshooting
SEN00807-02
E-20 Air conditioner does not operate normally

(including air conditioner fault history)
Trouble
(1) When air conditioner switch is operated, air conditioner control screen is not displayed.
Related
information
Possible causes
and standard
value in normal
state
Trouble
Cause

(2) When air conditioner switch is operated, air conditioner does not operate at all.
Related
information
Cause
1

(CB3)
2 Defective fuse in unit

(See cause 4).
If fuse in unit is broken, circuit in unit probably has ground fault
(See cause 4).
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between CB3 (2) fuse in
3
or defective contact in con- unit - ACW (wiring side) (6)
nector)
Wiring harness between ACW (wiring side)
Resistance
Max. 1 z
Resistance
Max. 1 z
Ground fault in wiring har4 ness (Contact with GND cir- Wiring harness between CB3 (2) fuse in
Resiscuit)
Min. 1 Mz
unit ACW (wiring side) (6) or circuit branch
tance
end and chassis ground
5
Defective air conditioner controller
ACW (wiring side)
Voltage
Between (6) (16)
20 30 V
If above voltage is normal, air conditioner controller may be defective.

D155AX-6
out.)
29
SEN00807-02
Trouble
40 Troubleshooting
(3) Air does not come out (Air flow is insufficient).
Related
information
Cause

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON (coil side).
Defective blower relay

Defective power transistor

(Internal defect)
AC03 (male)
Resistance
Between (1) (3)
140 340 z

and carry out troubleshooting (contact side).
AC03
Voltage
Between (4)
chassis ground
Air blow position
20 30 V

Fan switch
Operate between Low and
Medium and High.
If air flow changes according to

operation of fan switch, power
transistor (PTR) is normal.

Possible causes
and standard
value in normal
state
3 Defective blower motor

(Internal defect)
MB (wiring side)
Voltage
Between (1) (2)
Air blow position
20 30 V
If above voltage is normal and blower motor does not revolve,

blower motor (MB) is defective.
Wiring harness between CB3 (2) fuse in
unit - AC03 (female) (1)
Resistance
Max. 1 z
Wiring harness between AC03 (female) (3)

ACW (wiring side) (36)
Resistance
Max. 1 z
Wiring harness between CB3 (2) AC03

(female) (4)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between PTR (wiring side)

Resistance
Max. 1 z

(2) ACW (wiring side) (8)
Resistance
Max. 1 z

Resistance
Max. 1 z
Disconnection in wiring harness (Disconnection in wiring Wiring harness between AC03 (female) (5)
4
or defective contact in con- MB (wiring side) (1)
nector)
Wiring harness between MB (wiring side) (2)
PTR (wiring side) (3)
30
D155AX-6
40 Troubleshooting
SEN00807-02
Cause

Possible causes
and standard
value in normal
state
D155AX-6

ACW (wiring side) (36) and chassis ground
Resistance
Min. 1 Mz

Ground fault in wiring har5 ness (Contact with GND cir- MB (wiring side) (1) and chassis ground
cuit)
Wiring harness between MB (wiring side) (2)
PTR (wiring side) (3) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

(2) ACW (wiring side) (8) and chassis
ground
6
If causes 1 5 are not detected, air conditioner controller may be

Defective air conditioner condefective. (Since trouble is in system, troubleshooting cannot be
troller
carried out.)
If causes 1 5 are not detected, air conditioner system may be

Defective air conditioner sysdefective. See Machine Component Volume, Shop Manual, Troutem
bleshooting, Air conditioner, Troubleshooting.
31
SEN00807-02
Trouble
40 Troubleshooting
(4) Air is not cooled (Cooling performance is insufficient).
Related
information
Cause

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON (coil side).
Defective compressor relay

2 Defective internal air sensor
AC04 (male)
Resistance
Between (1) (3)
140 340 z

and carry out troubleshooting (contact side).
AC04
Voltage
Between (2)
chassis ground
Cooling position
20 30 V
Internal air sensor may be defective. Carry out troubleshooting for

"Abnormality in internal air sensor".
Defective high and low pres- High and low pressure switches may be defective. Carry out trousure switches
bleshooting for "Abnormality in refrigerant".
Defective compressor clutch

Compressor clutch may be defective. Check it directly.
(Internal defect)
Defective compressor (InterCompressor may be defective. Check it directly.

nal defect)
Possible causes
and standard
value in normal
state
Wiring harness between CB3 (2) fuse in
unit AC04 (female) (1)
6
or defective contact in con- ACW (wiring side) (35)
nector)
Wiring harness between CB3 (2) AC04
(female) (4)
A/C (female) (1)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Ground fault in wiring harWiring harness between AC04 (female) (3)

7 ness (Contact with GND cir ACW (wiring side) (35) and chassis ground
cuit)
A/C (female) (1) and chassis ground
32
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

troller
carried out.)
If causes 1 7 are not detected, air conditioner system may be

Defective air conditioner sysdefective. See Machine Component Volume, Shop Manual, Troutem
bleshooting, "Air conditioner", Troubleshooting.
D155AX-6
40 Troubleshooting
SEN00807-02
Trouble
(5) Air conditioner fault history: Communication condition "CAN disconnection", Communication condition "Abnormal"
Related
information
While abnormality in communication is being detected, "CAN disconnection" is displayed.

If abnormality in communication has been detected and reset, "Abnormality" is displayed.
If "CAN disconnection" is displayed as communication condition, communication cannot be carried
out normally. Accordingly, condition of other items is not displayed.
Method of reproducing fault history: Turn starting switch ON.
Cause
Resis1
Max. 1 z
or defective contact in con- CM02 (female) (8), (9)
tance
nector)
ResisMax. 1 z
CM02 (female) (10)
tance
Possible causes
and standard
value in normal
state

CM02 (female) (8), (9), EGC2 (female)
(46), STC2 (female) (32), WEC2 (female)
Ground fault in wiring har(32), CA1 (female) (A), or SRV (female) (3)
cuit)
CM02 (female) (10), EGC2 (female) (47),
STC2 (female) (22), WEC2 (female) (22),
CA1 (female) (B), or SRV (female) (10) and
chassis ground
Max. 1 z
Resistance
Max. 1 z

CM02 (female) (8), (9), EGC2 (female)
(46), STC2 (female) (32), WEC2 (female)
Hot short (Short circuit with (32), CA1 (female) (A), or SRV (female) (3)
3
24V circuit) in wiring harness and chassis ground
Resistance
Min. 1 Mz

CM02 (female) (10), EGC2 (female) (47),
STC2 (female) (22), WEC2 (female) (22),
CA1 (female) (B), or SRV (female) (10) and
chassis ground
Resistance
Min. 1 Mz

4 resistance (Internal short circuit or disconnection)
CA1 (male)
Resistance
Between (A) (B)
Approx. 120 z

troller
carried out.)
D155AX-6
Resistance
out.)
33
SEN00807-02
Trouble
Related
information
Possible causes
and standard
value in normal
state
Trouble
Related
information
40 Troubleshooting
(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.
out normally. Accordingly, this condition is not displayed.
Method of reproducing fault history: Turn starting switch ON.
Cause
1
Defective air conditioner con- Air conditioner controller may be defective. (Since trouble is in
troller
system, troubleshooting cannot be carried out.)

(7) Air conditioner fault history: Internal air sensor "Abnormality"

Method of reproducing fault history: Turn starting switch ON + Turn air conditioner (A/C) switch ON.
Cause
Defective internal air sensor
short circuit)

THI (device side)
Resistance
Between (1) (2)
300 z 430 kz
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ACW (wiring side)
2
or defective contact in con- (11) THI (wiring side) (2)
nector)
(27) THI (wiring side) (1)
Short circuit in wiring harness (with GND circuit)
Resistance
Max. 1 z
Resistance
Max. 1 z
(11) THI (wiring side) (2) and chassis
ground
Resistance
Min. 1 Mz

34

24V circuit) in wiring harness Wiring harness between ACW (wiring side)
(11) THI (wiring side) (2) and chassis
ground
Voltage
Max. 1 V

troller
carried out.)
D155AX-6
40 Troubleshooting
Trouble
Related
information
Possible causes
and standard
value in normal
state
Trouble
Related
information
SEN00807-02
(8) Air conditioner fault history: External air sensor "Unused"

External air sensor is not used in air conditioner system of this machine.
Cause
1 Normal display

Since external air sensor is not used in air conditioner system of
this machine, above display is normal.
(9) Air conditioner fault history: Air flow sensor "Abnormality"

Cause
Defective air flow sensor
short circuit)

THF (device side)
Resistance
Between (1) (2)
100 z 115 kz
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ACW (wiring side)
2
or defective contact in con- (12) THF (wiring side) (2)
nector)
(27) THF (wiring side) (1)
Short circuit in wiring harness (with GND circuit)
Resistance
Max. 1 z
Resistance
Max. 1 z
(12) THF (wiring side) (2) and chassis
ground
Resistance
Min. 1 Mz

D155AX-6

24V circuit) in wiring harness Wiring harness between ACW (wiring side)
(12) THF (wiring side) (2) and chassis
ground
Voltage
Max. 1 V

troller
carried out.)
35
SEN00807-02
Trouble
Related
information
40 Troubleshooting
(10) Air conditioner fault history: Daylight sensor "Abnormality"

Cause
1
Defective daylight sensor

(Internal defect)

Daylight sensor may be defective.
Disconnection in wiring harResisness (Disconnection in wiring Wiring harness between ACW (wiring side)
Max. 1 z
2
or defective contact in con- (3) SLS (female) (1)
tance
nector)
ResisMax. 1 z
(15) SLS (female) (2)
tance
Possible causes
and standard
value in normal
state
Ground fault in wiring harWiring harness between ACW (wiring side)

3 ness (Contact with GND cir- (3) SLS (female) (1) or circuit branch end
and chassis ground
cuit)
Resistance
Min. 1 Mz

(15) SLS (female) (2) and chassis ground
Resistance
Min. 1 Mz

4
36

(3) SLS (female) (1) or circuit branch end
and chassis ground
Voltage
Max. 1 V

(15) SLS (female) (2) and chassis ground
Voltage
Max. 1 V

troller
carried out.)
D155AX-6
40 Troubleshooting
Trouble
Related
information
SEN00807-02
(11) Air conditioner fault history: Air outlet damper "Abnormality"

Cause
1
Defective air outlet servomoAir outlet servomotor may be defective.

tor (Internal defect)

2
Wiring harness between MV1 (wiring side)

Resistance
Max. 1 z

Resistance
Max. 1 z

Resistance
Max. 1 z

Resistance
Max. 1 z

Resistance
Max. 1 z
(1) ACW (wiring side) (3) or circuit branch
Possible causes
and standard
value in normal
state

Ground fault in wiring har(5) ACW (wiring side) (9) and chassis
cuit)
(6) - ACW (wiring side) (24) and chassis
ground
ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

Voltage
Max. 1 V

Hot short (Short circuit with (5) ACW (wiring side) (9) and chassis
4
Voltage
Max. 1 V

ground
Voltage
Max. 1 V
Wiring harness between MV1(wiring side)

ground
Voltage
Max. 1 V
D155AX-6

troller
carried out.)
37
SEN00807-02
Trouble
Related
information
40 Troubleshooting
(12) Air conditioner fault history: A/M damper "Abnormality"

Cause
1
Defective air mix servomotor

Air mix servomotor may be defective.
(Internal defect)

2
Wiring harness between MAM (wiring side)

Resistance
Max. 1 z

Resistance
Max. 1 z
Wiring harness between MAM(wiring side)

(5) ACW(wiring side) (2)
Resistance
Max. 1 z

Resistance
Max. 1 z

Resistance
Max. 1 z
Possible causes
and standard
value in normal
state

Ground fault in wiring har(5) ACW (wiring side) (2) and chassis
cuit)
ground
ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

Voltage
Max. 1 V

Hot short (Short circuit with (5) ACW (wiring side) (2) and chassis
4
Voltage
Max. 1 V

ground
Voltage
Max. 1 V

ground
Voltage
Max. 1 V
38

troller
carried out.)
D155AX-6
40 Troubleshooting
Trouble
Related
information
SEN00807-02
(13) Air conditioner fault history: Refrigerant "Abnormality"

Cause
1
Possible causes
and standard
value in normal
state
Defective high and low pres2 sure switches (Internal disconnection)
Refrigerant (gas) may be insufficient. Check it directly.

AC05 (male)
Resistance
Between (1) (2)
Max. 1 z
Disconnection in wiring harResisness (Disconnection in wiring Wiring harness between ACW (wiring side)
Max. 1 z
3
tance
or defective contact in con- (4) AC05 (female) (1)
nector)
ResisMax. 1 z
tance
4
D155AX-6
Insufficient refrigerant (gas)

(when system is normal)

troller
carried out.)
39
SEN00807-02
40 Troubleshooting
Circuit diagram related to air conditioner
40
D155AX-6
40 Troubleshooting
D155AX-6
SEN00807-02
41
SEN00807-02
40 Troubleshooting
E-21 When starting switch is turned OFF, service meter is not

displayed
Trouble
Related
information
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 displayed at top center of screen.
Operation of switches: [4] + [1] (Press simultaneously)
Cause
Possible causes
and standard
value in normal
state
When starting switch is turned ON, if machine monitor displays

Defective backup power sup- nothing, backup power supply system may be defective. In this
1
ply system
case, carry out troubleshooting for "E-1 When starting switch
turned ON, machine monitor displays nothing".

E-22 Machine monitor cannot be set in service mode

Trouble
Related
information
Possible causes
and standard
value in normal
state
42
Machine monitor cannot be set in service mode.

If following switches are operated, machine monitor is set in service mode.
Operation of switches: [4] + [1] o [2] o [3] (While pressing [4], press other switches in order)
Cause

D155AX-6
40 Troubleshooting
D155AX-6
SEN00807-02
43
SEN00807-02
40 Troubleshooting
E-23 Ripper pin puller cylinder does not operate

Trouble
(1) When pin puller switch is pulled out, cylinder is not retracted.
(2) When pin puller switch is pushed in, cylinder is not extended.
Related
information
Cause
1 Defective fuse(FS2-3)

2 Defective pin puller switch
PLSW (male)
Between (1) (2)
Pin puller switch
Resistance
Pulled out
Max. 1 z
Pushed in
Min. 1 Mz
3 Defective pin puller solenoid
PPL (male)
Resistance
Between (1) (2)
10 80 z
Min. 1 Mz
Possible causes
and standard
value in normal
state

4
Wiring harness between FS22 (3) PLSW

(female) (1)
Resistance
Max. 1 z
Wiring harness between PLSW (female) (2)

PPL (female) (1)
Resistance
Max. 1 z

Resistance
Max. 1 z
Ground fault in wiring harWiring harness between FS22 (3) PLSW
5 ness (Contact with GND cir- (female) (1) or circuit branch end and chascuit)
sis ground
Resistance
Min. 1 Mz

PPL (female) (1) and chassis ground
Resistance
Min. 1 Mz

6
44
Wiring harness between FS22 (3) PLSW

(female) (1) or circuit branch end and chas24V circuit) in wiring harness
sis ground
Voltage
Max. 1 V

PPL (female) (1) and chassis ground
Voltage
Max. 1 V
D155AX-6
40 Troubleshooting
SEN00807-02
Circuit diagram related to ripper pin puller switch and solenoid
D155AX-6
45
SEN00807-02
40 Troubleshooting
E-24 Backup alarm does not sound or does not stop

Trouble
Backup alarm does not sound or does not stop.
Related
information
Cause

Defective backup alarm relay

Replace backup alarm relay (Right No.) with
another relay. If backup alarm operates norshort circuit)
mally at this time, backup alarm relay is
defective.
BKA
Possible causes
and standard
value in normal
state

2

branch point (F)
Resistance
Max. 1 z

BKAL (female) (1)
Resistance
Max. 1 z
Wiring harness between BKAL (female) (2)

Resistance
Max. 1 z
Ground fault in wiring har3 ness (Contact with GND cir- Wiring harness between BKA (female) (5)
cuit)
BKAL (female) (1) or circuit branch end and
chassis ground
Resistance
Min. 1 Mz

46

24V circuit) in wiring harness Wiring harness between BKA (female) (5)
BKAL (female) (1) or circuit branch end and
chassis ground
Defective backup alarm
(Internal trouble)
Voltage
Max. 1 V
If causes 1 4 are not detected, backup alarm may be defective.
D155AX-6
40 Troubleshooting
SEN00807-02
Circuit diagram related to backup alarm
D155AX-6
47
SEN00807-02
40 Troubleshooting
E-25 Headlamp, rear lamp, and ripper point lamp do not light up
Trouble
Related
information
(1) Headlamp does not light up.

Only when headlamp switch is set in "Moon" mark position, screen brightness of machine monitor is
changed for night.
Cause

(CB4)

(See cause 8).
Defective headlamp (Broken Headlamp bulb and ground wire may be defective. Check them
bulb, default grounding)
directly.
Defective headlamp switch

3
FLSW (male)
Headlamp switch
Resistance
Between (5) (4)
Moon mark
Max. 1 z
Between (5) (4)

Between (5) (6)
Neutral
Min. 1 Mz
Between (5) (6)
Sun mark
Max. 1 z

Defective left headlamp relay

Replace left headlamp relay (Right No.) with
another relay. If left headlamp becomes
short circuit)
normal at this time, left headlamp relay is
defective.
LMFL

Possible causes
and standard
value in normal
state
Defective right headlamp

5 relay (Internal disconnection Replace right headlamp relay (Right No.)
with another relay. If right headlamp
or short circuit)
becomes normal at this time, right headlamp relay is defective.
Defective assembled-type
6 diode LMD1 or LMD2 (Internal disconnection)
LMFR
LMD1 (male), LMD2 (male)
Continuity
Between (2) (1)
There is continuity

7
48

FLSW (female) (5)
Resistance
Max. 1 z
Wiring harness between FLSW (female) (4)

LMD1 (female) (2)
Resistance
Max. 1 z
Wiring harness between LMD1 (female) (1),

LMD2 (female) (1) LMFL (female) (1),
LMFR (female) (1)
Resistance
Max. 1 z
Wiring harness between LMFL (female) (2),

LMFR (female) (2) chassis ground
(GND03)
Resistance
Max. 1 z
Wiring harness between CB4 (2) LMFL

(female) (3), LMFR (female) (3)
Resistance
Max. 1 z
Wiring harness between LMFL (female) (5)

LHDL (female) (1)
Resistance
Max. 1 z
Wiring harness between LMFR (female) (5)

LHDR (female) (1)
Resistance
Max. 1 z
D155AX-6
40 Troubleshooting
SEN00807-02
Cause

Possible causes
and standard
value in normal
state
D155AX-6

FLSW (female) (5) or circuit branch end and
chassis ground
Resistance
Min. 1 Mz
Wiring harness between FLSW (female) (4),

(3) LMD1 (female) (2) or CM01 (female)
(13) and chassis ground
Resistance
Min. 1 Mz
Ground fault in wiring harWiring harness between LMD1 (female) (1),

8 ness (Contact with GND cirLMD2 (female) (1) LMFL (female) (1),
cuit)
LMFR (female) (1) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CB4 (2) LMFL

(female) (3), LMFR (female) (3) and chassis
ground
Resistance
Min. 1 Mz
Wiring harness between LMFL (female) (5)

LHDL (female) (1) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between LMFR (female) (5)

LHDR (female) (1) and chassis ground
Resistance
Min. 1 Mz
49
SEN00807-02
Trouble
40 Troubleshooting
(2) Rear lamp and ripper point lamp do not light up.
Related
information
Cause

(CB5)

(See cause 8).
Defective rear lamp (Broken Rear lamp bulb and ground wire may be defective. Check them
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.
4
Defective rear lamp switch

RLSW (male)
Between (5) (6)
Defective rear lamp relay

short circuit)
Possible causes
and standard
value in normal
state
Rear lamp switch
Resistance
OFF
Min. 1 Mz
ON
Max. 1 z

Replace rear lamp relay (Right No.) with
another relay. If rear lamp becomes normal
at this time, rear lamp relay is defective.
LMRE

Defective ripper point lamp

6 relay (Internal disconnection Replace ripper point lamp relay (Right No.)
with another relay. If ripper point lamp
or short circuit)
becomes normal at this time, ripper point
lamp relay is defective.
LMRP
RLSW (female) (5)
Resistance
Max. 1 z
Wiring harness between RLSW (female) (6)

LMRE (female) (1), LMRP (female) (1)
Resistance
Max. 1 z
Wiring harness between LMRE (female) (2),

LMRP (female) (2) chassis ground
(GND03)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between LREL (female) (2)

Resistance
Max. 1 z
Wiring harness between LRER (female) (2)

Resistance
Max. 1 z
Wiring harness between LMRP (female) (5)

LRP1 (female) (1)
Resistance
Max. 1 z

7
Wiring harness between CB5 (2) LMRE
or defective contact in con(female) (3), LMRP (female) (3)
nector)
Wiring harness between LMRE (female) (5)
LREL (female) (1), LRER (female) (1)
50
D155AX-6
40 Troubleshooting
SEN00807-02
Cause

Possible causes
and standard
value in normal
state

RLSW (female) (5) or circuit branch end and
chassis ground
Resistance
Min. 1 Mz
Wiring harness between RLSW (female) (6),

(1) LMRE (female) (1), LMRP (female) (1)
and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Wiring harness between LMRE (female) (5)

LREL (female) (1), LRER (female) (1) and
chassis ground
Resistance
Min. 1 Mz
Wiring harness between LMRP (female) (5)

LRP1 (female) (1) and chassis ground
Resistance
Min. 1 Mz
Ground fault in wiring har8 ness (Contact with GND cirWiring harness between CB5 (2) LMRE
cuit)
(female) (3), LMRP (female) (3) and chassis
ground
Circuit diagram related to headlamp, rear lamp, and ripper point lamp
D155AX-6
51
SEN00807-02
40 Troubleshooting
E-26 Windshield wiper and window washer do not operate

Trouble
(1) No windshield wipers and window washers do not operate.
Related
information
Cause
1
Defective fuse
(FS1 4 or
-4)
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between FS12 (4) fuse
2
or defective contact in con- (B3)
nector)
Wiring harness between fuse
(4) CN11
(female) (5)
Resistance
Max. 1 z
Resistance
Max. 1 z
Ground fault in wiring harWiring harness between FS12 (4) fuse
3 ness (Contact with GND cir(B3) and chassis ground
cuit)
(4) CN11
(female) (5) and chassis ground
52
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
D155AX-6
40 Troubleshooting
Trouble
Related
information
SEN00807-02
(2) Front windshield wiper does not operate (Continuous operation is defective).
If fuse ( -5) is broken, operations of both front windshield wiper and rear windshield wiper become
defective.
If fuse ( -4) is broken, intermittent operation of all windshield wipers becomes defective.
Carry out troubleshooting with front wiper switch ON and intermittent switch OFF.
Cause
1 Defective fuse (

-5)
Defective front wiper motor

(Internal trouble)
CN23
Front wiper switch
Voltage
Between (6) (1)
ON
20 30 V
If voltage is normal but wiper does not operate, motor is defective.

3
Defective front wiper switch

CN14 (male)
Between (2) (3)
Possible causes
and standard
value in normal
state
Defective front wiper inter4 mittent selector relay (Internal trouble)
Defective front wiper inter5 mittent relay (Internal trouble)
Front wiper switch
Resistance
OFF
Min. 1 Mz
ON
Max. 1 z

Replace front wiper intermittent selector
relay (Right No.) with another relay. If front
wiper becomes normal at this time, intermittent selector relay is defective.
CN29

Replace front wiper intermittent relay (Right
No.) with another relay. If front wiper
becomes normal at this time, intermittent
relay is defective.
CN28
(5) CN14
(female) (3), (5), CN28 (female) (3), or
CN23 (female) (3)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between CN28 (female) (5)

CN23 (female) (6)
Resistance
Max. 1 z

Resistance
Max. 1 z
Disconnection in wiring harWiring harness between CN14 (female) (2)

CN29 (female) (3)
6
or defective contact in conWiring harness between CN29 (female) (4)
nector)
CN28 (female) (4)
D155AX-6
53
SEN00807-02
40 Troubleshooting
Cause

Possible causes
and standard
value in normal
state
Trouble

(5) CN14
(female) (3), (5), CN28 (female) (3), CN23
(female) (3), or circuit branch end and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
Ground fault in wiring har7 ness (Contact with GND cirWiring harness between CN14 (female) (2)
cuit)
(3) Front windshield wiper does not operate intermittently.

Before carrying out troubleshooting, check that continuous operation is normal.
Related
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.
Cause

Defective intermittent switch

CN11 (male)
Between (5) (6)
Defective front wiper inter2 mittent selector relay (Internal trouble)
Possible causes
and standard
value in normal
state
Defective front wiper inter3 mittent relay (Internal trouble)
Intermittent switch
Resistance
OFF
Min. 1 Mz
ON
Max. 1 z

Replace front wiper intermittent selector
relay (Right No.) with another relay. If front
CN29

Replace front wiper intermittent relay (Right
No.) with another relay. If front wiper
relay is defective.
CN28
4

CN29 (female) (1)
Resistance
Max. 1 z

CN28 (female) (2)
Resistance
Max. 1 z

Resistance
Max. 1 z
54
Ground fault in wiring harWiring harness between CN11 (female) (6)

5 ness (Contact with GND cir- CN29 (female) (1) or circuit branch end
cuit)
and chassis ground
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
D155AX-6
40 Troubleshooting
Trouble
Related information
SEN00807-02
(4) Rear windshield wiper does not operate (Continuous operation is defective).
If fuse ( -5) is broken, operations of both front windshield wiper and rear windshield wiper become
defective.
Carry out troubleshooting with rear wiper switch ON and intermittent switch OFF.
Cause
1 Defective fuse (

-5)
Defective rear wiper motor

(Internal trouble)
CN37
Rear wiper switch
Voltage
Between (6) (1)
ON
20 30 V

3
Defective rear wiper switch

CN12 (male)
Between (2) (3)
Rear wiper switch
Resistance
OFF
Min. 1 Mz
ON
Max. 1 z

Possible causes
and standard
value in normal
state
Defective rear wiper intermitReplace rear wiper intermittent selector

4 tent selector relay (Internal
relay (Right No.) with another relay. If rear
trouble)
CN33

5
Defective rear wiper intermit- Replace rear wiper intermittent relay (Right
tent relay (Internal trouble)
No.) with another relay. If rear wiper
relay is defective.
CN32
(5) CN12
(female) (3), (5), CN32 (female) (3), or
CN37 (female) (6)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z

CN37 (female) (4)
Resistance
Max. 1 z

Resistance
Max. 1 z
Disconnection in wiring harWiring harness between CN12 (female) (2)

CN33 (female) (3)
6
nector)
CN32 (female) (4)
D155AX-6
55
SEN00807-02
40 Troubleshooting
Cause

Possible causes
and standard
value in normal
state
Trouble

(5) CN12
(female) (3), (5), CN32 (female) (3), CN37
(female) (6), or circuit branch end and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

- CN32 (female) (4) and chassis ground
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
Ground fault in wiring har7 ness (Contact with GND cirWiring harness between CN12 (female) (2)
cuit)
(5) Rear windshield wiper does not operate intermittently.

Related
information
Carry out troubleshooting with rear wiper switch and intermittent switch ON.
Cause


CN11 (male)
Between (5) (6)
Intermittent switch
Resistance
OFF
Min. 1 Mz
ON
Max. 1 z

Defective rear wiper intermitReplace rear wiper intermittent selector

2 tent selector relay (Internal
relay (Right No.) with another relay. If rear
trouble)
CN33

Possible causes
and standard
value in normal
state
Defective rear wiper intermit- Replace rear wiper intermittent relay (Right
tent relay (Internal trouble)
No.) with another relay. If rear wiper
relay is defective.
CN32
4

CN33 (female) (1)
Resistance
Max. 1 z

CN32 (female) (2)
Resistance
Max. 1 z

Resistance
Max. 1 z
56

cuit)
and chassis ground
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
D155AX-6
40 Troubleshooting
Trouble
Related
information
SEN00807-02
(6) Right door wiper does not operate (Continuous operation is defective).
If fuse (
-6) is broken, operations of both right door wiper and left door wiper become defective.
Carry out troubleshooting with right door wiper switch ON and intermittent switch OFF.
Cause
1 Defective fuse (

-6)
Defective right door wiper

motor (Internal trouble)
CN17
Right door wiper

switch
Voltage
Between (3) (1)
ON
20 30 V

CN13 (male)
Right door wiper

switch
Resistance
OFF
Min. 1 Mz
ON
Max. 1 z
Between (2) (3)

4 intermittent selector relay
(Internal trouble)
Possible causes
and standard
value in normal
state

5 intermittent relay (Internal
trouble)

Replace right door wiper intermittent selector relay (Right No.) with another relay. If
right door wiper becomes normal at this
time, intermittent selector relay is defective.
CN31

Replace right door wiper intermittent relay
(Right No.) with another relay. If right door
wiper becomes normal at this time, intermittent relay is defective.
CN30
D155AX-6

(6) CN13
(female) (3), (5) or CN17 (female) (4)
Resistance
Max. 1 z

(female) (3)
(6) CN30
Resistance
Max. 1 z
Disconnection in wiring har- Wiring harness between CN13 (female) (2)

ness (Disconnection in wiring CN31 (female) (3)
6
nector)
CN30 (female) (4)
Resistance
Max. 1 z
Resistance
Max. 1 z

CN17 (female) (3)
Resistance
Max. 1 z

Resistance
Max. 1 z

Resistance
Max. 1 z
57
SEN00807-02
40 Troubleshooting
Cause

Possible causes
and standard
value in normal
state
58

(6) CN13
(female) (3), (5), CN17 (female) (4), or circuit branch end and chassis ground
Resistance
Min. 1 Mz

(6) CN30
Ground fault in wiring har(female)
(3)
or
circuit
branch
end
and chas7 ness (Contact with GND cirsis
ground
cuit)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
D155AX-6
40 Troubleshooting
Trouble
SEN00807-02
(7) Right door wiper does not operate intermittently.

Related
information
Carry out troubleshooting with right door wiper switch and intermittent switch ON.
Cause


CN11 (male)
Between (5) (6)

(Internal trouble)
Possible causes
and standard
value in normal
state

trouble)
Intermittent switch
Resistance
OFF
Min. 1 Mz
ON
Max. 1 z

Replace right door wiper intermittent selector relay (Right No.) with another relay. If
right door wiper becomes normal at this
time, intermittent selector relay is defective.
CN31

Replace right door wiper intermittent relay
(Right No.) with another relay. If right door
CN30
4

CN31 (female) (1)
Resistance
Max. 1 z

CN30 (female) (2)
Resistance
Max. 1 z

Resistance
Max. 1 z
D155AX-6

cuit)
and chassis ground
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
59
SEN00807-02
Trouble
Related
information
40 Troubleshooting
(8) Left door wiper does not operate (Continuous operation is defective).
If fuse (
-6) is broken, operations of both right door wiper and left door wiper become defective.
Carry out troubleshooting with left door wiper switch ON and intermittent switch OFF.
Cause
1 Defective fuse (

-6)
Defective left door wiper

CN24
Left door wiper

switch
Voltage
Between (3) (1)
ON
20 30 V

CN15 (male)
Left door wiper

switch
Resistance
OFF
Min. 1 Mz
ON
Max. 1 z
Between (2) (3)

(Internal trouble)
Possible causes
and standard
value in normal
state

trouble)

Replace left door wiper intermittent selector
relay (Right No.) with another relay. If left
door wiper becomes normal at this time,
intermittent selector relay is defective.
CN27

Replace left door wiper intermittent relay
(Right No.) with another relay. If left door
CN26
(6) CN15
Resistance
Max. 1 z

(6) CN26
(female) (3) or CN24 (female) (4)
Resistance
Max. 1 z
Disconnection in wiring har- Wiring harness between CN15 (female) (2)

ness (Disconnection in wiring CN27 (female) (3)
6
nector)
CN26 (female) (4)
Resistance
Max. 1 z
Resistance
Max. 1 z

CN24 (female) (3)
Resistance
Max. 1 z

Resistance
Max. 1 z

Resistance
Max. 1 z

(female) (3), (5)
60
D155AX-6
40 Troubleshooting
SEN00807-02
Cause

Possible causes
and standard
value in normal
state
D155AX-6

(6) CN15
(female) (3), (5) or circuit branch end and
chassis ground
Resistance
Min. 1 Mz

(6) CN26
Ground fault in wiring har(female) (3), CN24 (female) (4) or circuit
7 ness (Contact with GND cirbranch end and chassis ground
cuit)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
61
SEN00807-02
Trouble
40 Troubleshooting
(9) Left door wiper does not operate intermittently.

Related
information
Carry out troubleshooting with left door wiper switch and intermittent switch ON.
Cause


CN11 (male)
Between (5) (6)

(Internal trouble)
Possible causes
and standard
value in normal
state

trouble)
Intermittent switch
Resistance
OFF
Min. 1 Mz
ON
Max. 1 z

Replace left door wiper intermittent selector
relay (Right No.) with another relay. If left
door wiper becomes normal at this time,
intermittent selector relay is defective.
CN27

Replace left door wiper intermittent relay
(Right No.) with another relay. If left door
CN26
4

CN27 (female) (1)
Resistance
Max. 1 z

CN26 (female) (2)
Resistance
Max. 1 z

Resistance
Max. 1 z
62

cuit)
and chassis ground
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
D155AX-6
40 Troubleshooting
Trouble
Related
information
SEN00807-02
(10) Water does not come out from front window washer.
Before carrying out troubleshooting, check that windshield wiper operates normally.
If fuse ( -5) is broken, operations of both front window washer and rear window washer become
defective.
Cause
1 Defective fuse (

-5)
Defective front window

2 washer motor (Internal trouble)
WSH1
Front wiper switch
Voltage
Between (3) (4)
ON
(Wash position)
20 30 V
If voltage is normal but washer does not operate, motor is defective.

3
Defective front wiper switch

Possible causes
and standard
value in normal
state
CN14 (male)
Between (5) (6)
Front wiper switch
Resistance
OFF
Min. 1 Mz
ON
(Wash position)
Max. 1 z
4
(5) CN14
Resistance
Max. 1 z

WSH1 (female) (3)
Resistance
Max. 1 z
Wiring harness between WSH1 (female) (4)

Resistance
Max. 1 z

(female) (3), (5)
D155AX-6
Ground fault in wiring harWiring harness between fuse

(5) CN14
5 ness (Contact with GND cir- (female) (3), (5) or circuit branch end and
cuit)
chassis ground
Resistance
Min. 1 Mz

WSH1 (female) (3) and chassis ground
Resistance
Min. 1 Mz
63
SEN00807-02
Trouble
Related
information
40 Troubleshooting
(11) Water does not come out from rear window washer.
If fuse ( -5) is broken, operations of both front window washer and rear window washer become
defective.
Cause
1 Defective fuse (

-5)
Defective rear window

2 washer motor (Internal trouble)
WSH2
Rear wiper switch
Voltage
Between (3) (4)
ON
(Wash position)
20 30 V

3
Defective rear wiper switch

Possible causes
and standard
value in normal
state
CN12 (male)
Between (5) (6)
Rear wiper switch
Resistance
OFF
Min. 1 Mz
ON
(Wash position)
Max. 1 z
4
(5) CN12
Resistance
Max. 1 z

WSH2 (female) (3)
Resistance
Max. 1 z

Resistance
Max. 1 z

(female) (3), (5)
64

(5) CN12
cuit)
chassis ground
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
D155AX-6
40 Troubleshooting
Trouble
Related
information
SEN00807-02
(12) Water does not come out from right door washer.
If fuse (
tive.
-6) is broken, operations of both right door washer and left door washer become defec-
Cause
1 Defective fuse (

-6)
and carry out troubleshooting
Defective right door washer

2
WSH2
Right door wiper

switch
Voltage
Between (1) (2)
ON
(Wash position)
20 30 V

Possible causes
and standard
value in normal
state

CN13 (male)
Between (5) (6)
Right door wiper

switch
Resistance
OFF
Min. 1 Mz
ON
(Wash position)
Max. 1 z
4
(6) CN13
Resistance
Max. 1 z

WSH2 (female) (1)
Resistance
Max. 1 z

Resistance
Max. 1 z

(female) (3), (5)
D155AX-6

(6) CN13
cuit)
chassis ground
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
65
SEN00807-02
Trouble
Related
information
40 Troubleshooting
(13) Water does not come out from left door washer.
If fuse ( -6) is broken, operations of both right door washer and left door washer become defective.
Cause
1 Defective fuse (

-6)
Defective left door washer

2
WSH1
Left door wiper

switch
Voltage
Between (1) (2)
ON
(Wash position)
20 30 V

Possible causes
and standard
value in normal
state

CN15 (male)
Between (5) (6)
Left door wiper

switch
Resistance
OFF
Min. 1 Mz
ON
(Wash position)
Max. 1 z
4
(6) CN15
Resistance
Max. 1 z

WSH1 (female) (1)
Resistance
Max. 1 z

Resistance
Max. 1 z

(female) (3), (5)
66

(6) CN15
cuit)
chassis ground
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
D155AX-6
40 Troubleshooting
SEN00807-02
Circuit diagram related to windshield wiper and window washer
D155AX-6
67
SEN00807-02
40 Troubleshooting
E-27 KOMTRAX system does not operate normally

Trouble
Related
information
KOMTRAX system does not operate normally.

If KOMTRAX system administrator makes request for checking system on machine side for trouble,
carry out following troubleshooting.
Even if KOMTRAX system has trouble, it does not particularly appear on machine.
Carry out all troubleshooting on service menu screen of machine monitor.
Cause
1 Defective transmission 1

a Turn starting switch ON and check "Setting condition of terminal" screen.
Check item
Normal display
Communication start check
Completion
a Turn starting switch ON and check "Condition of positioning

and communication" screen.
Normal display
Positioning
E ###,##,##(Longitude)
N ###,##,##(Latitude)
2 Defective GPS
Possible causes
and standard
value in normal
state
Check item
In positioning
If latitude and longitude are not displayed in 5 minutes on open
ground, notify KOMTRAX service hot line.
3
Defective communication
environment
Check item
Normal display
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

Check item
Normal display
Number of items not transmitted
0 9 (Normally 0)
a Select "Setting condition of terminal" from "12 Display

of KOMTRAX setting" in the service menu of the
machine monitor.
68
a Select "Condition of positioning and communication"

from "12 Display of KOMTRAX setting" in the service
menu of the machine monitor.
D155AX-6
40 Troubleshooting
D155AX-6
SEN00807-02
69
SEN00807-02
40 Troubleshooting
D155AX-6 Bulldozer
2008 KOMATSU
All Rights Reserved
70
D155AX-6
SEN00808-02
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up
40 Troubleshooting
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
SEN00808-02
H-13
H-14
H-15
H-16
H-17
H-18
H-19
H-20
H-21
H-22
H-23
40 Troubleshooting
Blade lift speed or power is low ................................................................................................ 15

Blade tilt speed or power is low ................................................................................................ 16
Ripper lift speed or power is low............................................................................................... 17
Ripper tilt speed or power is low............................................................................................... 18
Hydraulic drift of blade lift is large............................................................................................. 18
Hydraulic drift of blade tilt is large............................................................................................. 19
Hydraulic drift of ripper lift is large ............................................................................................ 19
Ripper pin puller cylinder does not operate .............................................................................. 20
Blade does not pitch ................................................................................................................ 20
Abnormal sound comes out from around work equipment pump ............................................. 21
Fan speed abnormal (Abnormally large sound or vibration of fan)........................................... 21
D155AX-6
40 Troubleshooting
SEN00808-02
Troubleshooting of hydraulic and mechanical system (H-mode)1

a The following information is summarized in the troubleshooting table. Before carrying out troubleshooting, understand that information fully.
Trouble
Related
information
Trouble which occurred in the machine

Cause
Possible causes
and standard
value in normal
state

(Given numbers are refer Standard value in normal state to judge possible causes
ence numbers, which do
Remarks on judgment
not indicate priority)
D155AX-6
SEN00808-02
40 Troubleshooting
H-1 Power is low (Drawbar pull is low)

Trouble
Related
information
Power is low (Drawbar pull is low).

Before carrying out troubleshooting, check that power train oil level is normal.
Cause

a Prepare with engine stopped, then run engine at high idle and
carry out troubleshooting.
1 Defective engine
2 Defective power train pump
PCCS lever
Engine speed
F3 stall
1,450 rpm
Power train pump may be defective. Check it directly.

Prepare with starting switch ON, then run engine at high idle and
3 Trouble in torque converter
PCCS lever
Torque converter
inlet pressure
Torque converter
outlet pressure
Neutral
Max. 1.0 MPa

{Max. 10.0 kg/cm2}
0.29 0.69 MPa

{3.0 7.0 kg/cm2}
PCCS lever
Neutral
Improper set pressure or
4 internal trouble of transmission main relief valve
Transmission main relief pressure

TM
Min. 2.84 MPa

{Min. 29.0 kg/cm2}
a Prepare with engine stopped, then keep engine stopped and

Check directly that free length of spring and number of shims are
normal and spool moves smoothly.
Free length of spring (large): 122 mm
Free length of spring (small): 108 mm
Number of shims: 6
Possible causes
and standard
value in normal
state
a Prepare with engine stopped, then run engine at low idle and
Malfunction of transmission
clutch valve (ECMV)
PCCS lever
Transmission clutch
Clutch pressure
F3 stall
Min. 2.26 MPa

{Min. 23.0 kg/cm2}
R3 stall
Min. 2.45 MPa

{Min. 25.0 kg/cm2}
F1 stall
1ST
Min. 2.62 MPa

{Min. 26.7 kg/cm2}
F2 stall
2ND
Min. 2.40 MPa

{Min. 24.5 kg/cm2}
F3 stall
3RD
Min. 2.62 MPa

{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
Free
RB
LB
2.16 MPa
{22.0 kg/cm2}
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.
D155AX-6
40 Troubleshooting
SEN00808-02
H-2 Machine does not travel (at 2nd or 3rd gear speed)
Trouble
Related
information
Machine does not travel (at 2nd or 3rd gear speed).

Before carrying out troubleshooting, check that transmission main relief pressure is normal (See H-1).
Cause

a Prepare with starting switch ON, then run engine at high idle
PCCS lever
Torque converter
inlet pressure
Torque converter
outlet pressure
Neutral
Max. 1.0 MPa

{Max. 10.0 kg/cm2}
0.29 0.69 MPa

{3.0 7.0 kg/cm2}
Possible causes
and standard
value in normal
state
clutch valve (ECMV)
PCCS lever
Transmission clutch
Clutch pressure
F2 stall
2ND
Min. 2.40 MPa

{Min. 24.5 kg/cm2}
F3 stall
3RD
Min. 2.62 MPa

{Min. 26.7 kg/cm2}
Trouble in transmission
clutch
Transmission clutch (2nd or 3rd gear speed) may have trouble in it.
Check it directly.
Malfunction of parking brake Parking brake may be malfunctioning (Dragging). Check linkage
(Dragging)
and valves.
a Move to level place, start engine, and check.
D155AX-6
Malfunction of brake (Drag5

ging)
Run engine at low idle and set transmission in F2. If machine does
not move at this time, brake is dragging. Carry out troubleshooting
for "H-8 Brake does not work".
6 Trouble in transmission
Transmission may have trouble in it. Check it directly.
SEN00808-02
40 Troubleshooting
H-3 Machine does not start at any gear speed

Trouble
Related
information
Machine does not start at any gear speed.

Cause

PCCS lever
Neutral


TM
Min. 2.84 MPa

{Min. 29.0 kg/cm2}

Number of shims: 6
carry out troubleshooting (after checking transmission main
relief pressure is normal).
Possible causes
and standard
value in normal
state
clutch valve (ECMV)
clutch
PCCS lever
Transmission clutch
Clutch pressure
F3 stall
Min. 2.26 MPa

{Min. 23.0 kg/cm2}
R3 stall
Min. 2.45 MPa

{Min. 25.0 kg/cm2}
F1 stall
1ST
Min. 2.62 MPa

{Min. 26.7 kg/cm2}
F2 stall
2ND
Min. 2.40 MPa

{Min. 24.5 kg/cm2}
F3 stall
3RD
Min. 2.62 MPa

{Min. 26.7 kg/cm2}
Transmission clutch (F or R) may have trouble in it. Check it

directly.
Brake pedal
5 Malfunction of brake
Released
Pressed
Steering brake
RB
LB
Brake pressure
2.16 MPa
{22.0 kg/cm2}
0 MPa
{0 kg/cm2}
If brake pressure is abnormal, carry out troubleshooting for "H-8

Brake does not work".
D155AX-6
40 Troubleshooting
SEN00808-02
H-4 Machine can travel only forward or in reverse

Trouble
Related
information
Machine can travel only forward or in reverse.

Cause

PCCS lever
Neutral

TM
Min. 2.84 MPa

{Min. 29.0 kg/cm2}

Number of shims: 6
Possible causes
and standard
value in normal
state
3
D155AX-6
clutch valve (ECMV)
PCCS lever
Transmission clutch
Clutch pressure
F3 stall
Min. 2.26 MPa

{Min. 23.0 kg/cm2}
R3 stall
Min. 2.45 MPa

{Min. 25.0 kg/cm2}
Defective transmission clutch If check result of cause 3 is abnormal, seal of transmission clutch
seal
(F or R) may be defective. Check it directly.
clutch
Transmission clutch (F or R) may have trouble in it. Check it

directly.
SEN00808-02
40 Troubleshooting
H-5 When gear speed or travel direction is changed, time lag is large 1
Trouble
Related
information
When gear speed or travel direction is changed, time lag is large.

Cause

PCCS lever
Neutral


TM
Min. 2.84 MPa

{Min. 29.0 kg/cm2}

Number of shims: 6
Possible causes
and standard
value in normal
state
3
clutch valve (ECMV)
PCCS lever
Transmission clutch
Clutch pressure
F3 stall
Min. 2.26 MPa

{Min. 23.0 kg/cm2}
R3 stall
Min. 2.45 MPa

{Min. 25.0 kg/cm2}
F1 stall
1ST
Min. 2.62 MPa

{Min. 26.7 kg/cm2}
F2 stall
2ND
Min. 2.40 MPa

{Min. 24.5 kg/cm2}
F3 stall
3RD
Min. 2.62 MPa

{Min. 26.7 kg/cm2}
Defective transmission clutch If check result of cause 3 is abnormal, seal of transmission clutch
seal
(F or R) may be defective. Check it directly.
clutch
Transmission clutch may have trouble in it. Check it directly.

a Move to level place, start engine, and check.
Malfunction of brake (Drag6

ging)
Run engine at low idle and set transmission in F2. If machine does
not move at this time, brake is dragging. Carry out troubleshooting
for "H-8 Brake does not work".
D155AX-6
40 Troubleshooting
SEN00808-02
H-6 Machine cannot be steered (Machine does not turn right or left)
Trouble
Related
information
Machine cannot be steered (Machine does not turn right or left)

Before carrying out troubleshooting, check that oil level in hydraulic tank is normal.
Cause

Possible causes
and standard
value in normal
state

1 malfunction of self-acting
pressure reducing valve
PCCS lever
Blade control lever
Control circuit basic pressure
Neutral
3.78 4.46 MPa

{38.5 45.5 kg/cm2}
If abnormal sound comes out from peripheral devices of HSS,

Abnormal sound from periphcarry 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

Trouble
Related
information
Steering speed or steering force is low.

Cause
1 malfunction of HSS main
relief valve
Possible causes
and standard
value in normal
state

PCCS lever
HSS relief pressure
Left steering relief

Right steering relief
38.2 41.7 MPa

{390 425 kg/cm2}
D155AX-6
PCCS lever
Blade control lever
Neutral
3.78 4.46 MPa

{38.5 45.5 kg/cm2}
If abnormal sound comes out from peripheral devices of HSS,

Abnormal sound from periphcarry out troubleshooting for "H-10 Abnormal sound comes out
eral devices of HSS
from around HSS pump or HSS motor".
SEN00808-02
40 Troubleshooting
H-8 Brake does not work

Trouble
Related
information
Brake does not work.

Cause

1 Malfunction of brake valve
Released
Possible causes
and standard
value in normal
state
Pressed
2
brake pedal limit switch
3 Defective brake seal

4
10
Brake pedal
Steering brake
RB
LB
Brake pressure
2.16 MPa
{22.0 kg/cm2}
0 MPa
{0 kg/cm2}
If check result of cause 1 is abnormal, brake pedal limit switch may

be adjusted defectively. Check it directly.
If check result of cause 1 is abnormal, brake seal may be defective. Check it directly.
Slip or wear of brake disc or

Brake disc or plate may be slipping or worn. Check them directly.
plate
D155AX-6
40 Troubleshooting
SEN00808-02
H-9 Power train oil is overheated

Trouble
Related
information
Power train oil is overheated.

Before carrying out troubleshooting, check that power train oil temperature gauge indicates actual
oil temperature (If it does not, carry out troubleshooting for "E-9 Power train oil temperature gauge
(Multi-gauge) does not indicate normally".
Cause
1 Defective engine
2
Defective power train pump

or air in suction circuit

Engine cooling system may be defective or engine output may be
increased. Carry out troubleshooting for engine unit (S mode).
Power train pump may be defective or air is in suction circuit.
Check them directly.

Possible causes
and standard
value in normal
state
clutch (Slip)
PCCS lever
Torque converter
inlet pressure
Torque converter
outlet pressure
Neutral
Max. 1.0 MPa

{Max. 10.0 kg/cm2}
0.29 0.69 MPa

{3.0 7.0 kg/cm2}
Transmission clutch may be malfunctioning (slipping). Check it

directly.
a Start engine and check.
Malfunction of brake (Dragging)
1. Float machine above ground with blade and ripper.

2. Run engine at low idle and set transmission gear in F3 or R3.
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)
D155AX-6
Stall machine at F3. If machine does not stop perfectly, brake is

slipping.
11
SEN00808-02
40 Troubleshooting
H-10 Abnormal sound comes out from around HSS pump or HSS
motor
Trouble
Related
information
Abnormal sound comes out from around HSS pump or HSS motor.
HSS pump is used for work equipment, too.
Cause
1 Use of improper oil
Possible causes
and standard
value in normal
state
Clogged hydraulic tank

strainer
3 Air in suction circuit

4

Oil used may be improper. Check it directly.
Hydraulic tank strainer may be clogged. Check it directly.
Suction circuit of work equipment and HSS pump may have
sucked in air. Check it directly.
Trouble in work equipment or

Work equipment or HSS pump may have trouble in it.
HSS pump
5 Trouble in HSS motor
12
HSS motor may have trouble in it. Check it directly.
D155AX-6
40 Troubleshooting
SEN00808-02
H-11 Speed of all work equipment is low

Trouble
Related
information
Speed of all work equipment is low.

Cause
Defective PTO (work equip1 ment and HSS pump drive
section)
2

Work equipment and HSS pump drive section of PTO may be
defective. Check them directly.
Defective work equipment or Work equipment or HSS pump may be defective. Check them
HSS pump
directly.
Defective line filters (2

3 places) in EPC valve control Since line filters may be clogging, check filters directly.
circuit
4 Malfunction of unload valve
Possible causes
and standard
value in normal
state
5 malfunction of main relief
valve
PCCS lever
Blade control lever
Unload pressure
Neutral
2.45 (+1.37/0) MPa

{25 (+14/0) kg/cm2}
Blade control lever
Main relief pressure
Raise relief
27.5 1.5 MPa

{280 15 kg/cm2}
7 Trouble in fan pump
D155AX-6
PCCS lever
Blade control lever
Neutral
3.78 4.46 MPa

{38.5 45.5 kg/cm2}
If check result of cause 5 is abnormal, fan pump may have trouble

in it. Check it directly.
13
SEN00808-02
40 Troubleshooting
H-12 No work equipment moves

Trouble
Related
information
No work equipment moves.

Cause
Defective PTO (work equip1 ment and HSS pump drive
section)
2

Work equipment and HSS pump drive section of PTO may be
defective. Check them directly.
Defective work equipment or Work equipment or HSS pump may be defective. Check them
HSS pump
directly.
Defective line filters (2

3 places) in EPC valve control Since line filters may be clogging, check filters directly.
circuit
4 Malfunction of unload valve
Possible causes
and standard
value in normal
state

valve
PCCS lever
Blade control lever
Unload pressure
Neutral
2.45 (+1.37/0) MPa

{25 (+14/0) kg/cm2}
Blade control lever
Raise relief
27.5 1.5 MPa

{280 15 kg/cm2}
PCCS lever
Blade control lever
Neutral
3.78 4.46 MPa

{38.5 45.5 kg/cm2}
7
14
Malfunction of work equipment lock solenoid valve
Solenoid valve output pressure
Lock
0 MPa
{0 kg/cm2}
Free
3.78 4.46 MPa

{38.5 45.5 kg/cm2}
D155AX-6
40 Troubleshooting
SEN00808-02
H-13 Blade lift speed or power is low

Trouble
Related
information
Blade lift speed or power is low.

Check that blade has not been modified.
If hydraulic drift of blade lift is large, carry out troubleshooting for "H-17 Hydraulic drift of blade lift is
large" first.
Cause
valve

Blade control lever
Raise relief

27.5 1.5 MPa
{280 15 kg/cm2}
Possible causes
and standard
value in normal
state

PCCS lever
Blade control lever
Neutral
3.78 4.46 MPa

{38.5 45.5 kg/cm2}
Malfunction of blade lift con- Spool of blade lift control valve may be malfunctioning. Check it
trol valve (spool)
directly.
Suction valve of blade lift control valve may be malfunctioning.

Check it directly.
Malfunction of blade lift con4
* This suction valve can be checked by replacing it with suction
trol valve (suction valve)
valve of ripper lift or ripper tilt control valve and observing
change of phenomenon.
5 Air in blade lift cylinder
D155AX-6
Air may be in blade lift cylinder. Bleed air and then judge from
15
SEN00808-02
40 Troubleshooting
H-14 Blade tilt speed or power is low

Trouble
Related
information
Blade tilt speed or power is low.

If hydraulic drift of blade tilt is large, carry out troubleshooting for "H-18 Hydraulic drift of blade tilt is
large" first.
Cause
valve

Blade control lever
Left tilt relief
Possible causes
and standard
value in normal
state
PCCS lever
Blade control lever
Neutral
3.78 4.46 MPa

{38.5 45.5 kg/cm2}
Malfunction of blade tilt con- Spool of blade tilt control valve may be malfunctioning. Check it
trol valve (spool)
directly.
4 Air in blade tilt cylinder
16

27.5 1.5 MPa
{280 15 kg/cm2}
Air may be in blade tilt cylinder. Bleed air and then judge from
D155AX-6
40 Troubleshooting
SEN00808-02
H-15 Ripper lift speed or power is low

Trouble
Related
information
Ripper lift speed or power is low.

Check that ripper has not been modified.
If hydraulic drift of ripper lift is large, carry out troubleshooting for "H-19 Hydraulic drift of ripper lift is
large" first.
Cause
valve

Raise relief

27.5 1.5 MPa
{280 15 kg/cm2}
Possible causes
and standard
value in normal
state

PCCS lever
Blade control lever
Neutral
3.78 4.46 MPa

{38.5 45.5 kg/cm2}
Malfunction of ripper lift con- Spool of ripper lift control valve may be malfunctioning. Check it
trol valve (spool)
directly.
Suction valve of ripper lift control valve may be malfunctioning.

Check it directly.
Malfunction of ripper lift con4
* This suction valve can be checked by replacing suction valves
on head side and bottom side with each other and observing
5 Air in ripper lift cylinder
D155AX-6
Air may be in ripper lift cylinder. Bleed air and then judge from
17
SEN00808-02
40 Troubleshooting
H-16 Ripper tilt speed or power is low

Trouble
Related
information
Ripper tilt speed or power is low.

Cause
valve

Tilt-in relief

27.5 1.5 MPa
{280 15 kg/cm2}
Possible causes
and standard
value in normal
state

PCCS lever
Blade control lever
Neutral
3.78 4.46 MPa

{38.5 45.5 kg/cm2}
Malfunction of ripper tilt con- Spool of ripper tilt control valve may be malfunctioning. Check it
trol valve (spool)
directly.
Suction valve of ripper tilt control valve may be malfunctioning.

Check it directly.
Malfunction of ripper tilt con4
* This suction valve can be checked by replacing suction valves
on head side and bottom side with each other and observing
5 Air in ripper tilt cylinder
Air may be in ripper tilt cylinder. Bleed air and then judge from
H-17 Hydraulic drift of blade lift is large

Trouble
Related
information
Hydraulic drift of blade lift is large.

Before carrying out troubleshooting, check that oil is not leaking from work equipment circuit.
Cause

a Start engine and prepare, then stop engine and carry out troubleshooting.
Possible causes
and standard
value in normal
state
Defective seal of blade lift

1
control valve (spool)
18
Defective seal of blade lift

cylinder
Perform following procedure. If hydraulic drift is increased at this

time, seal of blade lift control valve spool is defective.
1. Brace blade against ground by lifting operation to push up front
part of machine.
2. Stop engine and then turn starting switch ON.
3. Set blade control lever in "Lower" position and check phenomenon.
Seal of blade lift cylinder may be defective. Check it directly.
D155AX-6
40 Troubleshooting
SEN00808-02
H-18 Hydraulic drift of blade tilt is large

Trouble
Related
information
Hydraulic drift of blade tilt is large.

Cause

Possible causes
and standard
value in normal
state
Defective seal of blade tilt

Defective seal of blade tilt

2
cylinder

time, seal of blade tilt control valve spool is defective.
1. Brace blade against ground by tilting operation to push up front
part of machine.
3. Set blade control lever in "Tilt left" position and check phenomenon.
Blade tilt cylinder
Left tilt relief
12 cc/min
H-19 Hydraulic drift of ripper lift is large

Trouble
Related
information
Hydraulic drift of ripper lift is large.

Cause

Possible causes
and standard
value in normal
state
D155AX-6
Defective seal of ripper lift

Defective seal of ripper lift

cylinder

time, seal of ripper lift control valve spool is defective.
1. Brace ripper against ground by lifting operation to push up rear
part of machine.
3. Set ripper control lever in "Lower" position and check phenomenon.
Lower relief
11 cc/min
19
SEN00808-02
40 Troubleshooting
H-20 Ripper pin puller cylinder does not operate
Giant ripper specification

Trouble
Related
information
Ripper pin puller cylinder does not operate.

Cause
Possible causes
and standard
value in normal
state

Malfunction of pin puller solenoid
Pin puller switch
Check point
Pushed in
Cylinder bottom side
Pulled out
Cylinder head side
Solenoid output
pressure
Min. 2.84 MPa
{Min. 29.0 kg/cm2}
2 Trouble in pin puller cylinder Pin puller cylinder has trouble in it. Check it directly.
H-21 Blade does not pitch
Dual tilt specification

Trouble
Blade does not pitch.
Related
information
Possible causes
and standard
value in normal
state
20
Cause
Malfunction of blade pitch

Spool of blade pitch control valve may be malfunctioning. Check it

directly.
Malfunction of blade pitch

cylinder
Blade pitch cylinder may be malfunctioning. Check it directly.
D155AX-6
40 Troubleshooting
SEN00808-02
H-22 Abnormal sound comes out from around work equipment pump 1
Trouble
Related
information
Abnormal sound comes out from around work equipment pump.

Work equipment pump is used for HSS, too.
Cause
1 Use of improper oil
Possible causes
and standard
value in normal
state
Clogged hydraulic tank

strainer
3 Air in suction circuit

4

Oil used may be improper. Check it directly.
Hydraulic tank strainer may be clogged. Check it directly.
Suction circuit of work equipment and HSS pump may have
sucked in air. Check it directly.
Trouble in work equipment or

Work equipment or HSS pump may have trouble in it.
HSS pump
H-23 Fan speed abnormal (Abnormally large sound or vibration of fan)1

Trouble
Related
information
Fan speed is abnormal (Sound or vibration of fan is abnormally large)

Before performing troubleshooting, check that the oil level in the hydraulic tank is normal.
Cause

a Start engine and perform check
1 Defective engine rotation

Possible causes
and standard
value in normal
state
Engine at low idle
740 rpm
Engine at high idle
2100 rpm
If engine speed is low, perform troubleshooting in [S-5 Engine does

not run smoothly].
2
Defective PTO (fan pump

drive portion)
Internal defect of fan pump

or fan motor
4 Defective fan
D155AX-6
Engine speed
PTO fan pump drive portion may be defective. Check it directly.

a Prepare with starting switch in OFF position, then troubleshoot
with engine at high idle.
Fan speed
Fan 100% mode
1250 (+50/0) rpm
Fan may be broken or installed defectively. Check it directly.
21
SEN00808-02
40 Troubleshooting
D155AX-6 Bulldozer
2010 KOMATSU
All Rights Reserved
22
D155AX-6
SEN00852-02
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
D155AX-6
Serial number
80001 and up
40 Troubleshooting

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
D155AX-6
SEN00852-02
40 Troubleshooting
S-15 Abnormal noise is made ....................................................................................................................... 27

S-16 Vibration is excessive ........................................................................................................................... 28
D155AX-6
40 Troubleshooting
SEN00852-02
Method of using troubleshooting chart

Causes
Questions
1
2
3
4
5
6
Check items
Troubleshooting
The troubleshooting chart consists of the "questions", "check items", "causes", and "troubleshooting" blocks.
The questions and check items are used to pinpoint
high probability causes by simple inspection or
from phenomena without using troubleshooting
tools.
Next, troubleshooting tools or direct inspection are
applied to check the narrowed causes in order from
the most probable one to make final confirmation
according to the troubleshooting procedure.
[Questions]
Items to be drawn from the user or operator.
They correspond to A and B in the chart on the
right. The items in A are basic ones. The
items in B can be drawn from the user or operator, depending on their level.
[Check items]
Simple check items used by the serviceman to
narrow the causes. They correspond to C in
the chart on the right.
[Causes]
Items to be narrowed from the questions and
check items. The serviceman narrows down
the probable causes from A, B, and C.
[Troubleshooting]
Items used to find out the true cause by verifying the narrowed causes finally in order from
the most probable one by applying troubleshooting tools or direct inspection.
8
9
10
11
a
b
c
d
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, and w.
E: Causes to be referred to for questions and check items
Q : Causes related to questions and check items
w : Causes highly probable among ones marked with Q
a When narrowing the "causes", apply the items marked with w before those marked with Q.
When narrowing the "causes", do not apply the items marked with E. (If no items have other marks and
the causes cannot be narrowed, however, you may apply them.)
D155AX-6
SEN00852-02
40 Troubleshooting
<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)
Clogged fuel spill piping (on cylinder head side)
Improper fuel injection timing
Improper fuel injection pressure
Defective coolant temperature sensor or wiring harness
Correct
Adjust
Adjust
Replace
Clogged or seized injector
Abnormally worn injector

Replace
Stuck or seized supply pump plunger

Replace
Replace
Crushed or clogged muffler
Worn piston ring or cylinder liner

Replace
Leakage of air between turbocharger and cylinder head

Correct
Replace
Defective contact of valve and valve seat
Improper valve clearance

Adjust
Replace
Replace
Stuck EGR valve
Clogged EGR gas pressure piping
Replace
Clogged air cleaner element
Seized turbocharger or interference of turbocharger

Replace
General causes why exhaust gas is black

Insufficient intake of air
Excessive injection of fuel
Defective condition of fuel injection
Improper selection of fuel
Overheating
See "S-14 Coolant temperature becomes too high
(Overheating)"
Control by controller in derate mode (limiting injection
rate (output) because of an error in electrical system)
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)
Clean
Cause
Confirm recent repair history

Degree of use of machine
Operated for long period
Questions
Suddenly became black

Exhaust gas color
Gradually became blackB

Blue under light load
Non-specified fuel is used

Oil must be added more frequently
Power was lost
Suddenly
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
Check items
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
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
Troubleshooting
Turbocharger is heavy to rotate with hand

Carry out troubleshooting according to "EGR Valve Servo Error 1 (*1)"
in E mode
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
Remedy
D155AX-6
40 Troubleshooting
SEN00852-02
There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 6 items in
the [Causes] section.
The method of pinpointing the [Causes] from the causal relationship and approaching the [troubleshooting]
is explained according to Step 1 - Step 3 shown below.
[Causes]: 6 items
Step 1
Clarify the relationship between the 3 items in the
[Questions] and [Check items] sections and the 6 items
in the [Causes] section.
[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
SEN00852-02
40 Troubleshooting
S-1 Starting performance of engine is poor

General causes why starting performance is poor
q
Defective electrical system
q
Insufficient supply of fuel
q
q
q
Coolant in exhaust pipe
a The common rail fuel injection system (CRI) recognizes the fuel injection timing electrically. Accordingly, even if the starting operation is carried out, the
engine may not start until the crankshaft revolves 2
turns at maximum. This phenomenon does not indicate a trouble, however
Defective or deteriorated battery
Defective alternator (generator section)
Defective alternator (regulator section)
Defective intake air heater system
Defective injector
Clogged feed pump gauze filter
Clogged fuel filter
Leaking or clogged fuel piping or entry of air
Clogged air breather hole of fuel tank cap
Worn piston ring, cylinder
Defective contact of valve and vale seat
Cracked EGR cooler (Coolant in exhaust pipe)
Causes
Questions
Starting performance
E E
E E
Became worse gradually
Q Q w w
Q Q
E
w
Engine starts easily when warm
Filters have not been replaced according to Operation and Maintenance Manual
w w Q Q
w
Engine oil must be added more frequently

When engine is preheated or when temperature is low, preheating monitor does not
indicate normally (if monitor is installed)
During operation, charge level monitor indicates abnormal charge

(if monitor is installed)
w w
w
Air breather hole of fuel tank cap is clogged

Fuel is leaking from fuel piping
Priming pump is too light or too heavy to operate
w Q Q
Check items
When air bleeding plug of fuel filter is removed, fuel does not
flow out
w w
w
When spill hose from injector is disconnected, little fuel spills
Immediately after engine is started, temperature of exhaust manifold of a cylinder is

low
w
Q Q
w
Q w Q Q
Engine hunts (rotation is irregular)

When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows
out (*1)
q
q q
When air is bled from fuel system, air comes out

Troubleshooting
Starting motor cranks engine slowly

While engine is
rotated with starting
motor
Inspect fuel filter directly
Inspect feed pump gauze filter directly

Carry out troubleshooting according to "Rail Press (Very) Low Error (*2)" indicated by
code
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
not change
When starting switch is turned to HEAT, intake air heater mount does not become
warm
Is voltage of 20 30 V generated between alternator terminals B and E
while engine is running at low idle?
Q Q Q Q
q
q
Yes
No
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Correct
Clean
Replace
Correct
Replace
Remedy
Clean
Specific gravity of electrolyte and battery voltage are low
Replace
Degree of use of
machine
D155AX-6
40 Troubleshooting
SEN00852-02
*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
SEN00852-02
40 Troubleshooting
S-2 Engine does not start
a) Engine does not rotate

General causes why engine does not rotate
q
Seized internal parts of engine
o See "S-4 Engine stops during operation"
q
Water hammer caused by coolant which entered cylinder
q
Defective electrical system
q
Trouble in drive devices on applicable machine side
o Carry out troubleshooting for devices on applicable machine
Defective starting circuit wiring
Defective starting motor (motor section)
Defective starting motor (safety relay section)
Defective battery relay
Defective connection of battery terminal
Broken flywheel ring gear
Cracked EGR cooler (Coolant in exhaust pipe)
Causes
E E E
When starting switch is Horn does not sound

turned ON
Horn volume is low
Battery electrolyte level is low
w
Q
When starting switch is turned to START, starting pinion does not move out
Q
Q
Speed of rotation is low
When starting switch is

turned to START, start- Makes grating noise
ing pinion moves out,
Soon disengages again
but
Makes rattling noise and does not turn
w
w
w
w
Q w
q
q
Inspect flywheel ring gear directly

There is not voltage (20 30 V) between battery relay terminals B
and E
When terminals B and C of starting switch are connected, engine

starts
When terminals B and C at safety relay outlet are connected, engine

starts
Even if terminals B and C at safety relay outlet are connected,

engine does not start
Replace
Replace
Replace
Correct
Replace
Replace
Replace
Remedy
Carry out troubleshooting on

applicable machine side
Check items
When starting switch is turned ON, no operating sound comes out from battery relay
When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows out (*1).
Troubleshooting
Battery terminal is loose
Turn starting switch

OFF, connect cables,
turn starting switch ON,
and carry out troubleshooting
Degree of use of
machine
Replace
Questions
D155AX-6
40 Troubleshooting
SEN00852-02

D155AX-6
SEN00852-02
40 Troubleshooting
b) Engine rotates but no exhaust gas comes out

General causes why engine rotates but no exhaust gas
comes out
q
Fuel is not supplied
q
Supply of fuel is extremely small
q
Improper selection of fuel (particularly in winter)
Defective fuel injector
Malfunction flow damper
Malfunction of overflow valve (Does not close)
Wrong connection of supply pump PCV
Defective supply pump PCV
Broken supply pump shaft or key

Seized or abnormally worn feed pump
Clogged fuel filter
Insufficient fuel in tank
Use of improper fuel
Causes
E E E
w Q w w w
Exhaust gas suddenly stopped coming out (when starting again)

Fuel tank is empty
Q w
There are rust and water in fuel drained from fuel tank
w
Check items
There is not fuel in removed fuel filter
Q Q Q
Q Q
w Q Q
When air bleeding plug of fuel filter is removed, fuel does

not flow out
While engine is
rotated with starting
When spill hose from injector is disconnected, little fuel
motor
spills
E E
Q
w Q
w w w w
q q

Troubleshooting
w w
Inspect feed pump directly

Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by code
Carry out troubleshooting according to "PCV1 Short/Open Error (*2) or PCV2
Short/Open Error (*3)" indicated by code
q
q
q
Inspect overflow valve directly
q q
Replace
Correct
Replace
Replace
Replace
Clean
Replace
Replace
Correct
Correct
Add
Remedy
Replace
Engine can be started in reduced cylinder mode
Replace
Degree of use of
machine
Replace
Questions
*1: Displayed failure codes [CA559] and [CA2249]

10
D155AX-6
40 Troubleshooting
SEN00852-02
c) Exhaust gas comes but engine does not start

(fuel is injected)
General causes why exhaust smoke comes out but engine
does not start
q
Lack of rotating force due to defective electrical system
q
q
q
Defective intake air heater system
Clogged injector or defective spray
Clogged fuel filter
Leaking or clogged fuel system or entry of air
Worn dynamic valve system (Valve, rocker lever, etc.)
Causes
E E
Suddenly failed to start
E
w
Q Q

w w
w

When engine is preheated or when temperature is low, preheating monitor does not indicate normally (if monitor is installed)
w
w
w w
There is not fuel in removed fuel filter

w Q Q
w
Check items
Starting motor rotates engine slowly
When engine is rotated, abnormal sound comes out from around cylinder head
While engine is rotated
with starting motor,
When air bleeding plug of fuel filter is removed, fuel does not
flow out
When spill hose from injector is disconnected, little fuel spills
Immediately after engine is started, temperature of exhaust manifold of a cylinder is low
Inspect dynamic valve system directly

Troubleshooting
w w

code
q
q
When injector unit is tested, spray condition is bad
Coolant temperature gauge does not indicate normally (if it is installed)
q
Replace
Replace
Clean
Replace
Clean
Clean
Correct
Clean
Replace
Replace
Replace
Remedy
Clean
When starting switch is turned to HEAT, intake air heater mount does not become warm
Replace
Questions
Degree of use of machine Operated for long period
D155AX-6
11
SEN00852-02
40 Troubleshooting
S-3 Engine does not pick up smoothly
General causes why engine does not pick up smoothly

q
q
q
Defective condition of fuel spray
q
q
Control by controller in derate mode
(limiting injection rate (output) because of an error in
electrical system)
q
EGR valve stuck open
(There is much EGR gas and intake of air is insufficient)
Clogged injector or defective spray
Malfunction of flow damper (Large leakage from injector)
Clogged fuel filter
Stuck EGR valve
Causes
E E E
Engine pick-up suddenly became worse
E E
Q Q
Q
w w w

w
w
Dust indicator is red (if indicator is installed)
w w
w Q Q
Q
Check items
Exhaust gas color
Black
When engine is rotated, interference sound comes out from around turbocharger
High idle speed under no load is normal, but speed suddenly drops when load is applied
w w
Q w
Carry out troubleshooting according to "EGR Valve Servo Error (*1)" indicated by code

Troubleshooting
w w
q
q

code
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
change
Replace
Clean
Clean
Correct
Clean
Replace
Replace
Adjust
Replace
Replace
Clean
Remedy
q q
Correct
Degree of use of
machine
Replace
Questions

12
D155AX-6
40 Troubleshooting
SEN00852-02
S-4 Engine stops during operation
General causes why engine stops during operation

q
Seized parts inside engine
q
q
Overheating
q
Trouble in drive devices on applicable machine
side
o Carry out troubleshooting for devices on applicable machine
Broken auxiliary equipment (pump, compressor, etc.)
Trouble in drive devices on applicable machine side
Broken supply pump shaft or key
Q w Q w
Broken or seized feed pump
Clogged fuel filter
Leaking or clogged fuel piping
Broken or seized gear train
Broken or seized crankshaft bearing
Broken or seized piston or connecting rod
Broken dynamic valve system (valve, rocker arm, etc.)
Causes

E E

w w w w
Questions
Made abnormal noise stopped suddenly

Engine
w Q
Overheated and stopped
Stopped slowly
Q Q
Hunted and stopped
w Q
Q Q 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)
Fuel tank is empty
w
w

w Q Q
w w
Check items
w w
There are metal particles in oil drained from oil pan
Q Q
w w
Engine does not rotate at all

When engine is
rotated with hand
Engine rotates in opposite direction
Engine moves by gear backlash
w
w
Supply pump shaft does not turn
Engine rotates, but stops when load is applied to machine
Inspect piston and connecting rod directly
Inspect crankshaft bearing directly
Inspect gear train directly
Inspect feed pump directly

Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)"
indicated by code
q q
Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is

removed
Replace
Replace
Replace
Clean
Clean
Correct
Clean
Add
Replace
Replace
Replace
Replace
Remedy
q
Replace
Troubleshooting
Carry out troubleshooting

on applicable machine
Degree of use of
machine
D155AX-6
13
SEN00852-02
40 Troubleshooting
S-5 Engine does not rotate smoothly
General causes why engine does not rotate smoothly

q
Air in fuel system
q
Defective speed sensor
(Error at degree that it is not indicated)
q
Defective EGR valve
q
Defective bypass valve
Defective Bkup speed sensor or wiring harness
Defective Ne speed sensor or wiring harness
Clogged injector or defective spray (dirt in injector)
Malfunction of flow damper (Large leakage from injector)
Clogged fuel filter
Malfunction of bypass valve
Malfunction of EGR valve
Low setting of low idle speed
Causes
E E
At a certain speed range
Q Q Q
At low idle
Engine hunts
E E
Q Q
Q Q Q Q Q Q Q
Q Q
Even when speed is raised
Q Q
On slopes
Q Q
w w
w
Check items
Fuel tank is empty
Q Q
w Q Q
q
Carry out troubleshooting according to "EGR Valve Servo Error (*1)" indicated by code
Troubleshooting
Carry out troubleshooting according to "Bypass Valve Servo Error (*2)" indicated by
code
q
q

When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
change
q q
Carry out troubleshooting according to "Eng Ne Speed Sensor Error (*3)" indicated by
code
Carry out troubleshooting according to "Eng Bkup Speed Sensor Error (*4)" indicated
by code
Correct
Correct
Replace
Replace
Replace
Correct
Clean
Add
Replace
Replace
Correct
Remedy
q
Correct
Questions

*2: Displayed failure code [CA1628] and [CA1629]
*3: Displayed failure code [CA689]
*4: Displayed failure code [CA778]
14
D155AX-6
40 Troubleshooting
SEN00852-02
S-6 Engine lack output (or lacks power)
D155AX-6
E E
Q Q
Q Q
Q Q Q
Q
Defective fuel temperature sensor or wiring harness
Defective charge pressure sensor or wiring harness
Defective installation of charge pressure sensor (air leakage)
Defective drive of injector (signal or solenoid)
Clogged injector or defective spray (dirt in injector)
Q
w
Q Q Q
w
w
w
w
w w
w
w
w
w
Q
w w Q
w
Q Q
Q Q Q Q
q
q
q
q q
q
q
Replace
Replace
Correct
Replace
Replace
Replace
Clean
Correct
q
Clean
Replace
Adjust
Replace
Replace
Correct
Remedy
E
Q

q
Inspect air intake piping directly
q
Boost pressure is low
q q q
q
q
q
indicated by code
When a cylinder is cut out for reduced cylinder mode operation, engine speed
does not change
Inspect boost pressure sensor mount directly
Carry out troubleshooting according to "Chg Air Press Sensor High (Low)
Error (*2)" indicated by code
Carry out troubleshooting according to "Fuel Temp Sensor High (Low) Error
(*3)" indicated by code

Clogged fuel filter
Leaking or clogged fuel piping
Replace

Suddenly
Power was lost
Gradually
Filters have not been replaced according to Operation and Maintenance
Manual
Output becomes insufficient after short stop of operation
Black
Exhaust gas is
Immediately after engine is started, temperature of exhaust manifold of a
cylinder is low
turbocharger
High idle speed is too high
High idle speed under no load is normal, but speed suddenly drops when load
is applied
Air leakage from air intake piping
Causes
Clean
Troubleshooting
Check items
Questions
General causes why engine lacks output

q
q
q
Defective spray condition of fuel
q
q
Overheating
o See "S-14 Coolant temperature becomes too
high (Overheating)"
q
(limiting injection rate (output) because of an
error in electrical system)
15
SEN00852-02
40 Troubleshooting
S-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black
q
q
q
Defective condition of fuel injection
q
q
Overheating
o See "S-14 Coolant temperature becomes too
high (Overheating)"
q
(limiting injection rate (output) because of an
error in electrical system)
q
EGR valve stuck open
(There is much EGR gas and intake of air is
insufficient)
q
(Exhaust gas is mixed in intake air during acceleration and deceleration)
1
Improper fuel injection pressure
Clogged fuel spill piping (on cylinder head side)
Abnormally worn injector
Crushed or clogged muffler
Stuck EGR valve
Causes
E
E
w Q Q
w
w
Questions
Suddenly became black

Exhaust gas color
Gradually became black
E
Q
w
Q Q

Power was lost
E
Q Q
Q Q
Suddenly
Q
w
Gradually
Q Q
Q
Muffler is crushed
Air leaks between turbocharger and cylinder head or clamp is loosened
Q Q Q
Engine is operated in low-temperature mode at normal temperature
Check items

cylinder is low
Q w

turbocharger
When engine is rotated, abnormal sound comes out from around cylinder
head
Torque converter stall speed or pump relief speed is high (Fuel is injected
excessively)
Q Q
Q
Q Q
Exhaust noise is abnormal

w
Q Q Q
Q
Q w
w
When spill hose from injector is disconnected, abnormally much fuel spills

Carry out troubleshooting according to "EGR Valve Servo Error (*1)" indicated
by code
q
q
Troubleshooting
Inspect EGR gas pressure piping directly (*2)
q
q
When muffler is removed, exhaust gas color improves

indicated by code
does not change
q
q
q
Inspect fuel spill piping (on cylinder head side) directly

Carry out troubleshooting according to "Coolant Temp Sens High (Low) Error
(*4)" indicated by code
16
Adjust
Adjust
Correct
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Replace
Replace
Replace
Replace
Clean
Remedy
q
Replace
D155AX-6
40 Troubleshooting
SEN00852-02

*2: EGR gas pressure piping
Remove 2 EGR gas pressure pipes (2) and check their inside for clogging.

D155AX-6
17
SEN00852-02
40 Troubleshooting
S-8 Oil consumption is excessive (or exhaust gas is blue)

General causes why oil consumption is excessive
q
Abnormal consumption of oil
q
Long-time operation of engine at low idle or high
idle (Do not run engine at idle for more than 20
minutes continuously)
q
External leakage of oil
q
Wear of parts in lubrication system
1
Oil leakage from oil pan, cylinder head, etc.
Oil leakage from oil drain plug
Oil leakage from oil piping
Oil leakage from oil filter
Oil leakage from oil cooler
Broken oil cooler
Worn or damaged rear oil seal
Broken piston ring
Clogged breather or breather hose
Oil leakage from EGR valve stem
Turbocharger
Worn seal at blower end
Worn seal at turbocharger end
Worn or damaged valve (stem, guide, or seal)
Dust sucked in from intake system
Causes
E E E E
E
w
Oil consumption suddenly increased

Q
Q
w
Q Q w
Oil becomes dirty quickly
w w w w w
Outside of engine is dirty with oil

w
There are loose piping clamps in intake system
w
Q w
Inside of turbocharger exhaust outlet pipe is dirty with oil
There is oil in coolant

w
Oil level in damper chamber is high

Q
Exhaust gas is blue under light load

Q
Excessive
w w
w
There is dust in intake manifold
Inside of intake manifold is abnormally dirty
q q
Play of turbocharger shaft is excessive
Exhaust port of EGR valve is dirty with oil
Check breather and breather hose directly
q q
Inspect rear oil seal directly
q q
Leakage from oil cooler is detected by pressure test
q q q q
18
Replace
Replace
Correct
Replace
Replace
Clean
Replace
Replace
Replace
Correct
Remedy
Correct
Oil leaks out of engine
Correct
Troubleshooting
None
Correct
Amount of blow-by gas
w w
Correct
Check items
Inside of turbocharger intake outlet pipe is dirty with oil
Correct
Questions
D155AX-6
40 Troubleshooting
SEN00852-02
S-9 Oil becomes dirty quickly
Exhaust gas color is bad
Clogged turbocharger lubrication drain tube
E E E E

Q
w
w Q
Q Q
Inside of exhaust pipe is dirty with oil
w
w
Engine oil temperature rises quickly
Blow-by gas
Black
Q
Comes out excessively
Q w
Q
w
Does not come out at all

q
Play of turbocharger shaft is excessive
Exhaust port of EGR valve is dirty with oil
q q
See S-7
Exhaust gas is
Check breather and breather hose directly
Inspect oil cooler directly
Inspect oil filter directly
Spring of oil filter safety valve is hitched or broken
D155AX-6
Replace
Replace
Clean
Clean
Replace
Replace
Replace
Remedy
Replace
Inspect turbocharger lubrication drain tube directly
Check items
Defective oil filter safety valve
Even when engine oil temperature rises, oil filter clogging monitor indicates clogging
(if monitor is installed)
Troubleshooting
Clogged oil filter
Clogged oil cooler
Clogged breather or breather hose
Worn valve or valve guide
Worn EGR valve guide
Defective seal at turbocharger turbine end
Causes
Clean
Questions
General causes why oil becomes dirty quickly

q
Entry of exhaust gas into oil due to internal wear
q
Clogging of lubrication passage
q
q
Use of improper oil
q
Overload operation
19
SEN00852-02
40 Troubleshooting
S-10 Fuel consumption is excessive
General causes why fuel consumption is excessive

q
Leakage of fuel
q
Defective condition of fuel injection (fuel pressure or injection timing)
q
Malfunction of injector
Defective spray by injector
Defective common rail pressure
Defective supply pump plunger
Defective feed pump oil seal
Fuel leakage from fuel filter, piping, etc.
Fuel leakage inside head cover
Causes
E E
Gradually increased
Q Q
Suddenly increased
There is external leakage of fuel from engine
Combustion is irregular
w
w
w
Low idle speed is high
Torque converter stall speed or pump relief speed is high

Exhaust gas is
Q Q
Black
Q Q
White
Remove head cover and inspect inside directly
Inspect feed pump oil seal directly
Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by code
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change
When spill hose from injector is disconnected, much fuel spills

Carry out troubleshooting according to "Coolant Temp Sens High (Low) Error (*2)" indicated by
code
Correct
Replace
Replace
Correct
Correct
Remedy
q
Replace
Confirm with monitoring function on applicable machine side
Correct
Check items
Engine oil level rises and oil smells of diesel fuel
Troubleshooting
Q Q Q
Q
Correct
Fuel consumption
E
Q
Is large compared to other machines of same model
Replace
Questions

20
D155AX-6
40 Troubleshooting
SEN00852-02
S-11 Oil is in coolant

(or coolant spurts back or coolant level goes down)
General causes why oil is in coolant

q
Leakage in lubrication system
q
Leakage in cooling system
Broken hydraulic oil cooler or power train oil cooler on

Broken oil cooler core or O-ring
Insufficient protrusion of cylinder liner
Damaged cylinder liner O-ring or holes caused by pitting
Crack in cylinder block
Broken cylinder head or head gasket
Causes

Oil level
Q
Q
Q Q
Oil level has risen and oil is milky

w
There are excessive air bubbles in radiator and coolant spurts back
w
w
w
When hydraulic oil or power train oil is drained, water flows out
Leakage from cylinder head is detected by pressure test
q q
Inspect cylinder block and liner directly
Inspect cylinder liner directly
D155AX-6
Replace
Replace
Replace
Remedy
Replace
Carry out troubleshooting on

Hydraulic oil or power train oil on applicable machine side is milky
Check items
Q Q
Gradually increased
Hard water is used as coolant
Troubleshooting
Suddenly increased
Replace
Questions
21
SEN00852-02
40 Troubleshooting
S-12 Oil pressure drops
General causes why oil pressure drops

q
Leakage from, clogging, or wear of lubrication system
q
Defective oil pressure control
q
Selection of oil by the temperature etc. specified in the
Operation and Maintenance Manual is not observed.
q
Deterioration of oil due to overheating
Defective oil pressure sensor or wiring harness
Leaking EGR hydraulic piping
Defective EGR oil pump
Leaking, crushed, or clogged hydraulic piping
Clogged oil filter
Defective oil pump relief valve
Defective oil pump
Clogged or broken pipe in oil pan
Clogged strainer in oil pan
Coolant or fuel in oil
Lack of oil in oil pan
Worn journal of bearing
Causes
E
Q w
Oil pressure monitor indicates low oil pressure (if monitor is installed)
Q
Non-specified oil is used
Q
w
w
Indicates pressure drop at low idle

Oil pressure monitor
(if installed)
Indicates pressure drop at low, high idle
Indicates pressure drop on slopes
Check items
w w w Q
Q Q
Sometimes indicates pressure drop

Oil level monitor indicates oil lever drop (if monitor is installed)
Oil level in oil pan is low
External hydraulic piping is leaking or crushed
Oil is milky or smells of diesel oil

There are metal particles in oil drained from oil filter
There are metal particles in oil filter
q q
Inspect oil pan strainer and pipe directly
Oil pump is heavy to rotate or it has play

See S-13
Troubleshooting
Valve spring of oil pump relief valve is fatigued or damaged

Inspect oil filter directly
Relief valve of EGR oil pump is damaged or oil leaks through it
q
q
q
q
Inspect EGR hydraulic piping directly

Carry out troubleshooting according to "Eng Oil Press Sensor High (Low) Error (*1)"
indicated by code
Replace
Replace
Correct
Replace
Adjust
Replace
Clean
Clean
Add
Replace
Remedy
q
Replace
Questions
*1: Displayed codes [CA135] and [CA141]
22
D155AX-6
40 Troubleshooting
D155AX-6
SEN00852-02
23
SEN00852-02
40 Troubleshooting
S-13 Oil level rises (Entry of coolant or fuel)
General causes why oil level rises

q
Coolant in oil (milky)
q
Fuel in oil (smells diluted diesel fuel)
a If oil is in coolant, carry out troubleshooting for "S-11 Oil is in
coolant"
Fuel consumption has increased
Q Q
Coolant must be added more frequently
Q Q
Oil smells of diesel fuel

Oil is milky
Q Q
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
come out or coolant spurts back
w
w
Q
Q
Exhaust gas is white
Q
w
Water pump drain hole (breather hole) is clogged
When water pump drain hole (breather hole) is cleaned, coolant flows out
w
Oil level in damper chamber on applicable machine side is low
Oil level in hydraulic tank on applicable machine is low

When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows out
(*1).
q
q
Troubleshooting
Remove and inspect head cover directly
q q
Inspect cylinder block and liner directly
Inspect rear oil seal directly
Remove and inspect water pump directly
Remove and inspect thermostat cover directly
Remove and inspect supply pump directly
q
Replace
Correct
Replace
Replace
Correct
Replace
Replace
Correct
Replace
Remedy
Replace
Inspect seal of auxiliary equipment directly
24
Defective seal of auxiliary equipment (pump and compressor)
Defects in supply pump
Defective thermostat seat
Clogged water pump drain hole (breather hole) or defective seal
Broken oil cooler core or O-ring
Worn or damaged rear oil seal
Cracks inside cylinder block
E E
There is oil in coolant
Check items
Fuel leakage inside cylinder block
Replace
Questions
Cracked EGR cooler (Entry of coolant)
Causes
D155AX-6
40 Troubleshooting
SEN00852-02

D155AX-6
25
SEN00852-02
40 Troubleshooting
S-14 Coolant temperature becomes too high (Overheating)

General causes why coolant temperature becomes too
high
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
side
1
Rise of power train oil temperature on applicable machine side
Defective coolant temperature gauge
Malfunction of fan
Defective radiator cap (pressure valve)
Clogged radiator core
Clogged or crushed radiator fins
Malfunction of thermostat
Broken water pump
Low coolant level
Clogged or broken oil cooler
External leakage of coolant from EGR cooler
Causes
E E E

Overheating
Coolant temperature
gauge (if installed)
Q w
Q
Q w w
Has continued at low level

Q
Rises quickly
w
w
Does not go down from red range

Q
Radiator coolant level monitor indicates low (if monitor is installed)
w
w Q
Engine oil level has risen and oil is milky
Milky oil is floating on coolant

w
There are many bubbles in radiator and coolant spurts back

Check items
E E
Occurred suddenly
When light applied to radiator core, no light passes through
Dirt and mud are accumulated in radiator shroud and undercover on applicable
machine side
Coolant is leaking because of cracks in hose or loose clamps
Coolant flows out from radiator overflow hose

Power train oil temperature enters red range faster than engine coolant
temperature (if oil temperature gauge and coolant temperature gauge are
installed)
Inspect EGR cooler for coolant leakage
Inspect cylinder liner directly
Inspect oil cooler directly
Temperature difference between upper and lower tanks of radiator is large
Thermostat does not open at cracking temperature
Temperature difference between upper and lower tanks of radiator is slight
Inspect radiator core directly
Cracking pressure of radiator cap is low
Inspect fan directly
26
Correct
Replace
Correct
Correct
Replace
Replace
Add
Replace
Replace
Replace
Remedy
Replace
Coolant temperature is normal
Replace
Troubleshooting
Carry out troubleshooting

on applicable machine side
Questions
D155AX-6
40 Troubleshooting
SEN00852-02
S-15 Abnormal noise is made
General causes why abnormal noise is made

q
Abnormality due to defective parts
q
Abnormal combustion
q
Air sucked in from intake system
a Judge if the noise is an internal noise or an external
noise before starting troubleshooting.
a The engine is operated in the low-temperature mode
while it is not warmed up sufficiently. Accordingly, the
engine sound becomes a little larger. This does not
indicate abnormality, however
a When the engine is accelerated, it is operated in the
acceleration mode and its sound becomes a little
larger for up to about 5 seconds. This does not indicate abnormality, however

(Defective coolant temperature sensor)
Dirt caught in injector
Deformed cooling fan
Removed or seized gear train bushing
Improper gear train backlash
Excessive wear of piston ring or cylinder liner
Defective inside of muffler (Removal of bulkhead)
Broken dynamic valve system (valve, rocker lever, etc.)
Cracked or leaking EGR gas piping
Interference of turbocharger or seized turbocharger
Causes

Abnormal noise
Gradually increased
Q
Q

w
Air leaks between turbocharger and cylinder head
When engine is rotated, interference sound comes out from around turbocharger
When engine is rotated, abnormal sound comes out from around EGR gas
piping
w
w
Check items
Q Q Q
Suddenly increased
w
w
When engine is rotated, beat noise comes out from around muffler
cylinder is low
Exhaust gas is
w Q
w

Q w
Black
Q
w

Q
Abnormal noise is loud when engine is accelerated
Q Q
Inspect EGR gas piping directly

Troubleshooting
Q
w
When muffler is removed, abnormal noise disappears
q q
Inspect fan directly

does not change
q q
q
Abnormal noise comes out only at start of engine
D155AX-6
Correct
Replace
Correct
Replace
Replace
Replace
Adjust
Replace
Correct
Replace
Replace
Remedy
Replace
Correct
Questions
27
SEN00852-02
40 Troubleshooting
S-16 Vibration is excessive
General causes why vibration is excessive

q
Defective parts (abnormal wear, breakage, etc.)
q
Misalignment between engine and applicable machine
q
Abnormal combustion
a If abnormal noise is made and vibration is excessive, carry out troubleshooting for "S-15 Abnormal noise is made", too
Broken parts in damper on applicable machine side
Worn front support spigot joint
Misalignment between engine and devices on applicable machine side
Loose engine mounting bolts or broken cushions
Improper injection timing
Worn camshaft bushing
Improper gear train backlash
Worn main bearing or connecting rod bearing
Stuck dynamic valve system (valve, rocker lever, etc.)
Causes
Oil pressure is low at low idle

Vibration
Suddenly increased
Gradually increased
Vibration occurs at medium speed

Q
Vibration follows engine speed

Exhaust gas is black
Q Q Q Q
Inspect main bearing and connecting rod bearing directly

Troubleshooting
Inspect camshaft bushing directly
Inspect engine mounting bolts and cushions directly
Radial runout or facial runout is detected
Inspect front support spigot joint directly
28
Replace
Adjust
Replace
Adjust
Replace
Replace
Replace
Remedy
Replace
Inspect inside of damper directly
Replace
Check items
Questions
D155AX-6
40 Troubleshooting
D155AX-6
SEN00852-02
29
SEN00852-02
40 Troubleshooting
D155AX-6 Bulldozer
2008 KOMATSU
All Rights Reserved
30
D155AX-6
SEN01204-04
BULLDOZER
1SHOP MANUAL
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 .............................................................................................................................. 15
D155AX-6
SEN01204-04
How to read this manual

1.
(Rev. 2009.01)
1
Removal and installation of assemblies

Special tools
q
Special tools which are necessary for
r e mo v a l or i n s ta l l at i o n o f pa r ts a r e
described as A1,X1 etc. and their parts
numbers, part names and quantities are
described in the special tool list.
q
Also the following information is described
in the special tool list.
1) Necessity
t : Special tools that cannot be substituted and should always be used
q : Special tools that will be useful if available and are substitutable with tools
available on the market
2) Distinction of new and existing special tools
N:
Tools newly developed for this
model. They have a new part number respectively.
R:
Tools made available by redesigning the existing tools which were
developed for other models. Each
of them has a new part number
assigned by setting forward the
part number of the existing tool.
Blank: Tools already available for other
models. They can be used without
any modification.
3) Circle mark Q in sketch column:
q
The sketch of the special tool is presented in the section of "Sketches of
special tools".
q
Part No. of special tools starting with
79*T-***-****:
means that they are not available
from Komatsu Ltd. (i.e. tools to be
made locally).
Removal
q
In "Removal" section, the work procedures,
precautions and know-how to do the work, and
the amount of oil and coolant to be drained are
described.
q
Common tools that are necessary for removal
are described as [1], [2] etc. and their part
numbers, part names and quantities are not
described.
q
Various symbols used in "Removal" section
are explained and listed below.
k
: Precautions related to work safety
a: Guidance or precautions for the work

[*1] : This mark shows that instructions or precautions for parts installation work are given in
"Installation" section.
6
: Amount of oil or coolant to be drained
: Weight of part or component
Installation
q
Unless otherwise instructed, installation of parts
is to be done in the reverse order to removal.
q
Instructions and precautions for parts installation is shown with the mark ([*1], [*2]...) which
corresponds to the mark in "Removal" section.
q
Common tools that are necessary for installation are described as [1], [2] etc. and their
part numbers, part names and quantities are not
described.
q
Marks shown in the "Installation" section stand
for the following.
k

2
: Type of coating material
: Tightening torque
: Amount of oil or coolant to be replenished
Sketches of special tools

q
Various special tools are illustrated for the local
manufacture.
D155AX-6
2.
SEN01204-04
Disassembly and assembly of assemblies

Special tools
q
Special tools which are necessary for disassembly and assembly of parts are
described as A1,X1 etc. and their part
numbers, part names and quantities are
described in the special tool list.
q
Also the following information is described
in the special tool list.
1) Necessity
t : Special tools that cannot be substituted
and should always be used.
q : Special tools that will be useful if available and are substitutable with tools
available on the market.
2) Distinction of new and existing special tools
N
: Tools newly developed for this
model. They have a new part
number respectively.
R
: Tools made available by redesigning the existing tools which were
developed for other models. Each
of them has a new part number
assigned by setting forward the
part number of the existing tool.
Blank : Tools already available for other
models. They can be used without
any modification.
3) Circle mark Q in sketch column:
q
The sketch of the special tool is presented in the section of "Sketches of
special tools".
q
Part No. of special tools starting with
79*T-***-****:
means that they are not available
from Komatsu Ltd. (i.e. tools to be
made locally).
Disassembly
q
In "Disassembly" section, the work procedures,
the amount of oil and coolant to be drained are
described.
q
Common tools that are necessary for disassembly are described as [1], [2] etc. and
their part numbers, part names and quantities
are not described.
q
The meanings of the symbols used in "Disassembly" section are as follows.
k

6:
Amount of oil or coolant drained
Assembly
q
In "Assembly" section, the work procedures,
the amount of oil and coolant to be replenished
are described.
q
Common tools that are necessary for assembly are described as [1], [2] etc. and their
part numbers, part names and quantities are
not described.
q
The meanings of the symbols used in "Assembly" section are as follows.
k

2
: Type of coating material
: Tightening torque
: Amount of oil or coolant to be replenished

q
Various special tools are illustrated for the local
manufacture.
D155AX-6
SEN01204-04
Coating materials list
(Rev. 2009.02)
1
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disassembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Category
Komatsu
code
Part number
Q'ty
Container
Main features and applications
LT-1A
790-129-9030
150 g
Tube
Used to prevent rubber gaskets, rubber cushions, and cork plugs from coming out.
LT-1B
790-129-9050
20 g
(2 pcs.)
Used for plastic (except polyethylene,

polypropylene, tetrafluoroethylene and vinyl
Polyethylene
chloride), rubber, metal, and non-metal parts
container
which require immediate and strong adhesion.
LT-2
09940-00030
50 g
Polyethylene Features: Resistance to heat and chemicals.

container Used to fix and seal bolts and plugs.
Adhesive
LT-3
LT-4
790-129-9040
250 g
Holtz MH 705
790-129-9120
75 g
ThreeBond
1735
Gasket sealant
790-129-9140
Can
Used to stick and seal metal, glass, and plastics.
Polyethylene
Used to seal plugs.
container
Tube
Heat-resistant seal used to repair engines.
50 g
Quick-setting adhesive.
Polyethylene Setting time: Within 5 sec. to 3 min.
container Used mainly to stick metals, rubbers, plastics,
and woods.
Quick-setting adhesive.
Quick-setting type.
Polyethylene
(max. strength is obtained after 30 minutes)
container
Used mainly to stick rubbers, plastics, and
metals.
Aron-alpha
201
790-129-9130
2g
Loctite
648-50
79A-129-9110
50 cc
Features: Resistance to heat and chemicals.

Polyethylene
Used for fitted portions used at high temperacontainer
tures.
1 kg
Used to seal various threaded portions, pipe

Polyethylene
joints, and flanges.
container Used to seal tapered plugs, elbows, and nipples of hydraulic piping.
LG-5
790-129-9080
LG-6
790-129-9160
200 g
Tube
Features: Silicon-based heat and cold-resistant sealant.

Used to seal flange surfaces and threaded
portions.
Used to seal oil pan, final drive case, etc.
LG-7
790-129-9170
1 kg
Tube
Features: Silicon-based quick-setting sealant.

Used to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc.
Tube
Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant.

Used to seal transfer case, etc.
Tube
Used for rough surfaces such as the circle

gear top seal which does not need to be
clamped, water resistance of the clearance at
the welded area, etc.
Can be coated with paint.
LG-8
ThreeBond
1207B
LG-9
ThreeBond
1206D
790-129-9060
Adhesive: 1 kg
(Set of adhesive
Hardener: 500 g
and hardener)
419-15-18131
790-129-9310
100 g
200 g
D155AX-6
Gasket sealant
CateKomatsu code
gory
Part number
Q'ty
Container
LG-10
ThreeBond
1206E
790-129-9320
200 g
Tube
Used as lubricant/sealant when the radiator

hoses are inserted.
Can be coated with paint.
LG-11
ThreeBond
1121
790-129-9330
200 g
Tube
Feature: Can be used together with gaskets.

Used for covers of the transmission case and
steering case etc.
ThreeBond
1211
790-129-9090
100 g
Tube
Gasket sealant used to repair engine.
Tube
Used to prevent scuffing and seizure of press-fitted portions, shrink-fitted portions, and threaded
portions.
Used to lubricate linkages, bearings, etc.
Can
Spray type
Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuffing each other.
Applicable for the propeller shaft splines, needle
bearings, pins and bolts of various links, etc.
Can
Feature: Seizure and scuffing prevention compound with metallic super-fine-grain, etc.
Used for the mounting bolt in the high temperature area of the exhaust manifold and the turbocharger, etc.
Various
Various
Feature: Lithium grease with extreme pressure

lubrication performance.
General purpose type.
Seizure
prevention
compound
Molybdenum
disulfide
lubricant
LM-P
LC-G
NEVER-SEEZ
09940-00040
09995-00250
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI
SYG2-160LI
G0-LI
SYGA-160CNLI
*: For cold district
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
Molybdenum
SYG2-400M
disulfide grease SYG2-400M-A
LM-G (G2-M)
SYGA-16CNM
Grease
SEN01204-04
SYG2-400T-A
SYG2-16CNT
SYG0-400T-A (*)
*: For cold district SYG0-16CNT (*)
Hyper White
Grease G2-T,
G0-T (*)
SYG2-400B
Biogrease
G2-B, G2-BT (*) SYGA-16CNB
*: For use at high SYG2-400BT (*)
temperature and SYGA-16CNBT
under high load
(*)
G2-S
ThreeBond
1855
G2-U-S
ENS grease
D155AX-6
427-12-11871
200 g
190 g
Used for parts under heavy load.

Caution:
400 g x 10 Bellows-type Do not apply grease to rolling bearings like
swing circle bearings, etc. and spline.
400 g x 20 container
The grease should be applied to work equipment
16 kg
Can
pins at their assembly only, not applied for
greasing afterwards.
400 g
16 kg
400 g
16 kg
200 g
2 kg
Bellows-type
container
Can
Seizure resistance, heat resistance and water

resistance higher than molybdenum disulfide
grease.
Not conspicuous on machine since color is
white.
Bellows-type Since this grease is decomposed by natural baccontainer

teria in short period, it has less effects on microorganisms, animals, and plants.
Can
Tube
Feature: Silicone grease with wide using temperature range, high resistance to thermal-oxidative degradation and performance to prevent
deterioration of rubber and plastic parts.
Used for oil seals of the transmission, etc.
Can
Feature: Urea (organic system) grease with heat

resistance and long life. Enclosed type.
Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
SEN01204-04
Part number
SUNSTAR
PAINT PRIMER
580 SUPER
SUNSTAR
PAINT PRIMER
435-95
Container
20 ml
Glass
container
Used as primer for cab side.

(Using limit: 4 months after date of manufacture)
20 ml
Glass
container
Used as primer for glass side.

20 ml
Glass
container
417-926-3910
22M-54-27230
Used as primer for painted surface on cab

side.
Used as primer for black ceramic-coated
surface on glass side and for hard polycarbonate-coated surface.
SUNSTAR
GLASS
PRIMER
435-41
22M-54-27240
150 ml
Can
SUNSTAR
SASH PRIMER
GP-402
22M-54-27250
20 ml
Glass
container
Used as primer for sash (Almite).

SUNSTAR
PENGUINE
SEAL 580
SUPER S or
W
417-926-3910
320 ml
Polyethylene
container
S is used for high-temperature season

and W for low-temperature season as
adhesive for glass.
Sika Japan,
Sikaflex 256HV
20Y-54-39850
310 ml
Polyethylene
container
Used as adhesive for glass.

SUNSTAR
PENGUINE
SUPER 560
22M-54-27210
320 ml
Ecocart
(Special
container)
SUNSTAR
PENGUINE
SEAL No. 2505
417-926-3920
320 ml
Polyethylene
container
SEKISUI
SILICONE
SEALANT
20Y-54-55130
333 ml
Polyethylene
container
Used to seal front window.

Cartridge
Used to seal joint of glasses.

Translucent white seal.
GE TOSHIBA
SILICONES
TOSSEAL 381
22M-54-27220
333 ml
Adhesive for cab glass
Caulking material
Adhesive
Primer
SUNSTAR
GLASS
PRIMER 580
SUPER
Q'ty
Adhesive for cab glass
CateKomatsu code
gory
Used as adhesive for glass.

Used to seal joints of glass parts.
D155AX-6
SEN01204-04
Special tool list
a Tools with part number 79*T-***-**** cannot be supplied (they must be locally manufactured).
a Necessity
: t . . . . . . Cannot be substituted, should always be installed (used)
: q . . . . . . Extremely useful if available, can be substituted with commercially available part
a New/Remodel: N. . . . . . Tools newly developed for this model and given new part Nos.
Work item
Symbol

of fuel supply pump
assembly

of cylinder head assembly, engine rear seal
Part No.
Part name
Standard puller
01010-81090
Bolt
01643-31032
Washer
790-331-1110
Wrench
795T-521-1111 Push tool

01050-31635
Bolt
t 3
795-931-1100
Seal puller
t 1
795T-421-1270 Push tool

4

of engine front seal, rear
seal
Bolt
t 4
01643-31645
Washer
t 8
Disassembly and assembly of damper assembly
Bolt
t 4
01643-31645
Washer
t 4
795T-521-1150 Push tool

01050-31635
Bolt
791-612-1100
Installer
t 1
790-101-4200
Puller (294 kN {30 ton})
t 1
790-101-1102
Hydraulic pump
t 1
791T-615-1300 Puller assembly
t 1
Bolt
D155AX-6
t 8
Oil leak tester kit (A)
1
1
Q Operation check of clutch

piston
t 1
t 1 N Q
791T-615-1320 Plate
t 1 N Q
Bolt
791T-615-1330 Plate
01282-61230
Bolt
791T-615-1340 Plate
Installation of Engine rear

seal
Press fitting of bearing
791T-615-1350 Push tool

01017-31620
Installation of Engine rear

seal (Press fit of sleeve)
Wrench
01010-82040
t 1
01643-31645
799-301-1600
Q Installation of Engine rear

seal
Q Installation of Engine front

seal (Press fit of sleeve)
t 4
Installation of Engine front

seal
t 4
Bolt
791T-615-1310 Plate
t 1
01050-31645
Disassembly and assem3

bly of transmission
G
assembly
4
t 1
01050-31640
795T-421-1250 Push tool

9
t 1
01050-31645
795T-421-1240 Push tool

5
Tightening of cylinder head

bolt
t 1 R Q
t 3
Separation of drive gear
q 1
Bolt
01050-31655
Nature of work and remarks
t 1
795-630-5500
Necessity
Q'ty
New/Remodel
Sketch
: R. . . . . . Tools remodeled from tools already available for other models and given
upgraded part Nos.
: Blank . . Tools already available for other models, usable without any modification
a Tools marked with Q in the sketch column are tools introduced in the sketches of the special tools (See
Sketches of special tools).
t 4
t 2 N Q
Installation of snap ring
t 4
t 1 N Q
Work item
Symbol
Part No.
Part name
Necessity
Q'ty
New/Remodel
Sketch
SEN01204-04
791-662-1110
Bracket
t 1
01010-31685
Bolt
t 1
Disassembly and assemH

bly of HSS case assembly
2
01017-31620
Bolt
t 1
790-302-1500
Spanner kit
t 1
09003-09200
Spanner
790-302-1500
Spanner kit
t 1
09003-08290
Spanner
790-337-1032
Lifting tool
t 1
791-627-1320
Shackle
t 2

of final drive assembly
791T-627-1910 Plate
Disassembly and assemK

bly of final drive assembly
t 1
01010-82080
Bolt
t 2
790-431-1031
Block
t 1
791-520-4140
Screw
t 2
790-101-2360
Plate
t 2
791-112-1180
Nut
t 2
790-101-2480
Adapter
t 2
791T-627-1920 Plate
t 1
790-101-2102
Puller
t 1
790-101-1102
Hydraulic pump
t 1
790-431-1031
Block
t 1
791-520-4140
Screw
t 1
791-112-1180
Nut
t 2
01643-32460
Washer
t 2
791T-627-1930 Plate
t 1
791T-627-1940 Push tool
t 1
790-101-2102
Puller
t 1
790-101-1102
Hydraulic pump
t 1
791-627-1280
Installer
t 1
790-101-5401
Push tool kit
t 1
790-101-5441
Plate
790-101-5421
Grip
01010-51240
Bolt
790-101-5401
Push tool kit
790-101-5451
Plate
790-101-5421
Grip
01010-51240
Bolt
Removal and installation of

brake and carrier assembly
nut (bevel pinion side)
nut (bevel gear side)
Q final drive assembly
Pulling out of pinion shaft

Q
Pulling out and press fitting

of sprocket and hub assemQ bly
Q
Installation of floating seal
Press fitting of oil seal
1
t 1
791T-627-1950 Plate
t 1
791T-627-1960 Plate
t 1
790-201-1500
Push tool kit
t 1
790-201-1680
Plate
790-101-5021
Grip
01010-50816
Bolt
D155AX-6
Work item
Symbol
Disassembly and assemK 7

bly of final drive assembly

of track frame assembly
and track roller assembly
SEN01204-04
Part No.
Part name
791-520-4140
Screw
t 1
790-101-2420
Adapter
t 1
791-112-1180
Nut
t 1
01643-22460
Washer
t 1
792-785-1120
Plate
t 1
791-830-1410
Push tool
t 1
790-101-2102
Puller
t 1
790-101-1102
Hydraulic pump
t 1
791T-130-1010 Bracket
KK
Bolt
12
01643-33080
Washer
12
t 1
791-630-1220
Rod
t 2
790-101-2510
Block
t 1
790-101-2570
Washer
t 2
01580-01411
Nut
t 2
01643-31445
Washer
t 2
790-101-2102
t 1
790-101-1102
Hydraulic pump
t 1
796-670-1020
Installer
t 1
791-601-1000
Oil pump
t 1
Refilling with oil
14
22
L
23
15
16
D155AX-6
t 6 N Q
01010-63060
791T-130-1010 Bracket

of No. 1 boggy assembly
791T-630-1230 Plate
Disassembly and assembly of idler assembly
Necessity
Q'ty
New/Remodel
Sketch
01010-63060
Bolt
Press fitting of idler bushing
t 2 N Q
t 4
01643-33080
Washer
t 4
790-401-1700
Lifting tool
t 1
790-401-1761
Adapter
t 1
791-630-1860
Bracket
t 1
791-630-1870
Bracket
t 1
790-101-2310
Block
t 1
790-101-2360
Plate
t 2
790-445-4130
Screw
t 2
791-112-1180
Nut
t 2
790-101-4000
t 1
790-101-1102
Pump
t 1
790-201-2760
Spacer
t 1
791-630-1370
Adapter
t 1
790-434-1060
Screw
t 2
01580-13024
Nut
t 2
01643-33080
Washer
t 1
790-101-4000
t 1
790-101-1102
Pump
t 1
Fixing of boggy
Work item
Symbol

of No. 1 boggy assembly
Part No.
Part name
17
796-430-1110
Push tool
18
790-701-3000
Seal checker
19 791T-630-1390 Guide
791T-130-1010 Bracket
14
15
L
of No. 2, No. 3 and No. 4
boggy assemblies
16
t 1
t 1
Bolt
t 4
01643-33080
Washer
t 4
791-630-1360
Spacer
t 1
790-101-2310
Block
t 1
790-101-2360
Plate
t 2
790-445-4130
Screw
t 2
791-112-1180
Nut
t 2
790-101-4000
t 1
790-101-1102
Pump
t 1
790-201-2760
Spacer
t 1
791-630-1370
Adapter
t 1
790-434-1060
Screw
t 2
01580-13024
Nut
t 2
01643-33080
Washer
t 2
t 1
790-101-1102
Pump
t 1
17
796-430-1110
Push tool
t 1
18
790-701-3000
Seal checker
21
Disassembly and assembly of recoil spring assem- M 2

bly
1
Disassembly and assembly of track roller assem- N 2
bly
3
4
t 2 N Q
790-101-4000
20
t 1
01010-63060
19 791T-630-1390 Guide
10
Necessity
Q'ty
New/Remodel
Sketch
SEN01204-04
Fixing of boggy
t 1
t 1
790-101-2310
Block
t 1
790-445-4130
Screw
t 2
796T-470-1130 Plate
t 1
790-101-2360
Plate
t 2
790-112-1180
Nut
t 2
790-101-4000
t 1
790-101-1102
Pump
t 1
791-601-1000
Oil pump
t 1
791-685-8006
Compressor
t 1
791-635-3160
Extension
t 1
791T-630-2610 Spacer
t 1
790-101-1300
Cylinder
t 1
790-101-1102
Hydraulic pump
t 1
Compression of recoil
spring
791T-630-1290 Plate
t 1
Pulling out of shaft and pullQ ing out and press fitting of
seal guide
791T-630-1330 Push tool
t 1
Q Press fitting of bushing
791-651-1510
Installer
t 2
791-601-1000
Oil pump
t 1
Refilling with oil
D155AX-6
Work item
Symbol
SEN01204-04
Part No.
Part name
Necessity
Q'ty
New/Remodel
Sketch
790-101-2310
Block
t 1
790-445-4130
Screw
t 2
796T-470-1130 Plate
t 1
790-101-2360
Plate
t 2
791-112-1180
Nut
t 2
790-101-4000
t 1
790-101-1102
Pump
t 1
21
791-601-1000
Oil pump
t 1
790-102-1891
Nut wrench
t 1
Disassembly and assembly of carrier roller assem- R 2

bly
3

nut
791-651-1510
Installer
t 1
791T-630-1350 Spacer
t 1
Press fitting of ring
791-601-1000
Oil pump
t 1
Refilling with oil
791-675-9701
Remover and installer
t 1
791-101-4300
Cylinder (196 kN {20 ton}) t 1
791-101-4200
t 1
791-101-1102
Hydraulic pump
t 1
20
Disassembly and assemQ
bly of boggy assembly
Q
Pulling out and press fitting
of pin assembly and shaft
Disassembly and assembly

of track shoe assembly
2
General disassembly and
general assembly of track S 3
shoe assembly
4
791-932-1110
Plug push tool
t 1
Driving of plug (small)
791-660-7460
Pin brush
t 1
Cleaning of pin
791-432-1110
Plug push tool
t 1
Driving of plug (large)
791-632-1052
Installer
t 1
Insertion of link seal
790-701-3000
Seal checker
t 1
Check of oil supply and airtightness
791-601-1000
Oil pump
t 1
Refilling with oil
791-675-9581
Adapter
t 1
791-675-9590
Guide
t 1
01010-52460
Bolt
t 2
01010-51440
Bolt
t 2
790-101-1102
Pump
t 1
790-101-4300
Cylinder
(1,470 kN {150 ton})
t 1
791-685-9510
Frame
t 1
791-685-9520
Frame
t 1
791-685-9530
Rod
t 1
791-685-9550
Nut
t 1
791-685-9560
Bolt
t 1
791-675-9570
Adapter
t 1
Field disassembly and

assembly of 1 link
D155AX-6
04530-12030
Eyebolt
t 1
790-101-1102
Pump
t 1
790-101-4300
Cylinder
(1,470 kN {150 ton})
t 1
791-685-9540
Rod
t 1
791-685-9550
Nut
t 3

Disassembly of 1 link
11
Work item
Symbol
Part No.
Guide
t 1
791-675-5530
Pusher
t 1
01010-51030
Bolt
t 1
791-685-9620
Extension
t 1
790-101-1102
Pump
t 1
790-101-4200
t 1
791-675-5542
Adapter
t 1
791-675-5571
Adapter
t 1
790-101-1102
Pump
t 1
790-101-4300
Cylinder
(1,470 kN {150 ton})
t 1
791-675-5580
Guide
t 1
791-685-9510
Frame
t 1
791-685-9520
Frame
t 1
791-685-9530
Rod
t 1
791-685-9540
Rod
t 1
791-685-9550
Nut
t 3
791-685-9560
Bolt
t 4
791-126-0150
Adapter
t 1
01010-51030
Bolt
t 1
791-685-9620
Extension
t 1
791-675-5542
Adapter
t 1
791-675-5560
Guide
t 1
790-101-1102
Pump
t 1
790-101-4300
Cylinder
(1,470 kN {150 ton})
t 1
791-675-5560
Guide
t 1
791-675-5542
Adapter
t 1
790-101-1102
Pump
t 1
790-101-4200
t 1
791-670-3270
Guide
t 1
791-126-0150
Adapter
t 1
791-675-5560
Guide
t 1
791-675-9570
Adapter
t 1
01010-51030
Bolt
t 1
790-101-1102
Pump
t 1
790-101-4200
t 1
791-675-9701
Remover and installer
t 1
790-101-1102
Pump
t 1
790-101-4200
t 1
790-101-4300
Cylinder
(1,470 kN {150 ton})
t 1
791-675-5520
5
Field disassembly and

assembly of 1 link
T
9
10
11
12
13
1
Disassembly and assemU
bly of master link
12
Part name
Necessity
Q'ty
New/Remodel
Sketch
SEN01204-04
Assembly of 1 link
Assembly of 1 link
Assembly of 1 link
Assembly of 1 link
Assembly of 1 link
Assembly of 1 link
Assembly of 1 link
Assembly of 1 link
Expansion of link

D155AX-6
SEN01204-04
Necessity
Q'ty
New/Remodel
Sketch
791-432-1110
Plug push tool
t 1
Driving of plug (large)
Disassembly and assemU 4

bly of master link
790-701-3000
Seal checker
t 1
Check of oil supply and airtightness
791-932-1110
Plug push tool
t 1
Driving of plug (small)
Work item
Symbol

of pivot shaft assembly

of equalizer bar assembly

of operator's cab
(stuck glass)
X 1
1
2
3
Disassembly and assembly of hydraulic cylinder
Y
assembly
D155AX-6
Part No.
Part name
791T-650-2110 Sleeve
t 1
790-201-2770
t 1
Spacer
791T-650-2120 Plate
t 1
792-104-3940
Bolt
t 2
790-101-2510
Block
t 1
790-101-2570
Washer
t 2
01580-01613
Nut
t 1
790-105-2300
Jack assembly
(196 kN {20 ton})
t 1
790-101-1102
Hydraulic pump
t 1
Q
Q
Press fitting of ring
791T-650-2130 Sleeve
t 1
790-101-2420
Adapter
t 1
791-502-4140
Screw
t 1
790-101-2540
Washer
t 2
790-112-1180
Nut
t 2
790-101-4000
t 1
790-101-1102
Hydraulic pump
t 1
793-498-1210
Lifter (Suction cup)
t 2
Installation of window glass
790-502-1003
Cylinder repair stand
t 1
790-101-1102
Hydraulic pump
t 1

of hydraulic cylinder
790-102-3802
Multi-wrench
t 1
Installation of round head

(Blade lift)
790-201-1702
Push tool kit
t 1
Press fitting of bushing
790-201-1721
Push tool
790-201-1821
Push tool
Blade lift
790-201-1841
Push tool
Blade tilt
790-201-1851
Push tool
Ripper lift
790-201-1861
Push tool
Ripper tilt
790-101-5021
Grip
01010-50816
Bolt
790-201-1500
Push tool kit
790-201-1630
Plate
Blade lift
790-201-1650
Plate
Blade tilt
790-201-1660
Plate
Ripper lift
790-201-1670
Plate
Ripper tilt
790-101-5021
Grip
01010-50816
Bolt
t 1
Pulling out of center pin
Press fitting of dust seal
Press fitting of dust seal
13
Work item
Symbol
Disassembly and assem5

bly of hydraulic cylinder
Y
assembly
14
Necessity
Q'ty
New/Remodel
Sketch
SEN01204-04
790-720-1000
Expander
t 1
Installation of piston ring
796-720-1670
Ring
t 1
07281-01279
Clamp
t 1
796-720-1690
Ring
t 1
07281-01919
Clamp
t 1
796-720-1720
Ring
t 1
07281-02429
Clamp
t 1
790-102-4300
Wrench
t 1
790-102-4310
Pin
t 2
Part No.
Part name
Blade lift
Blade tilt
Ripper lift
Ripper tilt
screw-type piston
D155AX-6
SEN01204-04
1
Note) We will not be liable for any result of use of special tools
manufactured according to the following drawings.
A2: Push tool
A4: Push tool
D155AX-6
15
SEN01204-04
A5: Push tool
A8: Push tool
16
D155AX-6
SEN01204-04
A9: Push tool
G1: Plate
D155AX-6
17
SEN01204-04
G3: Push tool
G4: Plate
18
D155AX-6
SEN01204-04
G5: Plate
G6: Plate
D155AX-6
19
SEN01204-04
J: Plate
K1: Plate
20
D155AX-6
SEN01204-04
K2: Plate
K2: Push tool
D155AX-6
21
SEN01204-04
K5: Plate
K5: Plate
22
D155AX-6
SEN01204-04
KK, L14: Bracket
L1: Plate
D155AX-6
23
SEN01204-04
L19: Guide
L20, Q20: Plate
24
D155AX-6
SEN01204-04
M2: Spacer
N1: Plate
D155AX-6
25
SEN01204-04
N2: Push tool
V: Sleeve
26
D155AX-6
SEN01204-04
V: Plate
W: Sleeve
D155AX-6
27
SEN01204-04
D155AX-6 Bulldozer
2009 KOMATSU
All Rights Reserved
28
D155AX-6
SEN01205-05
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine Model
Serial Number
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 ............................................................................................... 28
Removal and installation of engine hood assembly ...................................................................................... 33
Removal and installation of engine front seal ............................................................................................... 35
Removal and installation of engine rear seal ................................................................................................ 39
Removal and installation of fuel tank assembly ............................................................................................ 44
Removal and installation of fan drive assembly ............................................................................................ 45
Removal and installation of fan motor assembly .......................................................................................... 46
D155AX-6
SEN01205-05
Removal and installation of fuel

supply pump assembly
1
3.
Remove two fuel tube joint bolts, and remove

fuel main filter head assembly (5). [*1]
Disconnect the negative terminal () of the

battery.
4.
Remove tubes (6) and (7) between fuel supply

pump and fuel main filter.
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).
795-630-5500
A 1
Standard puller
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
t 1
01010-81090
Bolt
01643-31032
Washer
Removal
k
1.
2.
Open undercover (4).

k
Open carefully using floor jack, wire

rope, etc.
D155AX-6
10. Remove stay (20), two covers (21), and two

covers (22), and remove high pressure pipes
(23) and (24). [*4]
a If the common rail side sleeve nut for high
pressure pipe is hard to loose, loosen the
mounting bolts for gate type frame (25).
SEN01205-05
13. Check that the mounting bolt hole (c) at the top
of cover align to the forcing tap of drive gear.
a If they are not aligned, rotate crankshaft
one more turn.
14. Remove nut (29). [*5]
a Take care not to drop into the case.
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
SEN01205-05
15. Remove bracket (30), and loosen four mounting bolts (31).
16. Set tool A1 on drive gear (32), and tighten the
center bolt of tool A1 to remove drive gear (32)
from the shaft.
17. Remove mounting bolts (31) and remove fuel
supply pump assembly (33).
a Keep tool A1 set on drive gear (32) until
fuel supply pump assembly is installed, for
the drive gear falls off without the tools.
Installation
1.
Set fuel supply pump assembly (33).

a Before setting, check that key (d) of shaft
aligns to the key slot (e) of drive gear.
2.
Temporarily tighten four mounting bolts (31)

and bracket (30) with fingers.
2 Mounting bolt: Liquid adhesive (LT-2)
D155AX-6
3.
Temporarily tighten high pressure pipes (23)

and (24) with fingers and tighten permanently
with the following torque.
3 Common rail side sleeve nut:
39.2 58.8 Nm {4 6 kgm}
Supply pump side sleeve nut:
39.2 49 Nm {4 5 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) permanently.

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.
SEN01205-05
[*4]
a Install covers (21) and (22) with the notch in
the following direction.
q
Cover (21): Cylinder block side
q
Cover (22): Underside
[*5]
Nut (29): 176 196 Nm {18 20 kgm}
[*1]
Fuel tube joint bolt:

24.5 34.3 Nm {2.5 3.5 kgm}
[*2]
Fuel tube sleeve nut:

43 47 Nm {4.4 4.8 kgm}
[*3]
3
3
Fuel tube (16) common rail side joint bolt:

17.7 22.6 Nm {1.8 2.3 kgm}
Fuel tube (16) supply pump side joint bolt:
14.8 19.6 Nm {1.5 2.0 kgm}
D155AX-6
SEN01205-05

injector assembly
1
5.
Remove tube (5) and block (6).
6.
Remove clamp (7) and stay (8), and remove

gate type frame (9). [*2]
7.
Remove clamp (10), and remove cover (11).
8.
Loosen sleeve nut (12).
9.
Remove stays (13) through (16).
Removal
a
This section explains the procedure for removing No.1 fuel injector assembly.
1.
Remove the engine hood referring to the section "Removal and installation of engine hood
assembly".
2.
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]
4.
Remove stay (4).
D155AX-6
SEN01205-05
13. Loosen sleeve nut (26), and remove high pressure pipe (27) from injector.
14. Remove wiring harness clamping bolt (28) and
clip (29). [*6]
15. Remove two wiring harness capture nuts (30)
from fuel injector assembly. [*7]
a Tighten capture nuts alternately.
16. Remove holder mounting bolt (31).
10. Remove cylinder head cover (17). [*3]
11. Remove cover (18). [*4]

12. Remove mounting bolts (19) through (21), and
remove rocker arm and rocker shaft assembly
(22). [*5]
a Loosen lock nut (24), and loosen adjustment screw (25) two or three turns to prevent excessive force applied to push rod
(23), when installing rocker arm and
rocker shaft assembly.
D155AX-6
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
the top of injector by pinching with pliers,
etc.
SEN01205-05
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)
7)
3)
4)
5)
Tighten bolts (31) to the specified torque.

3 Bolt (31):
58.8 73.5 Nm {6 7.5 kgm}
Tighten sleeve nuts (26) and (12).
3 Sleeve nuts (26) and (12):
39.2 49 Nm {4 5 kgm}
Set fuel injector assembly (32) with holder

(33) to cylinder head.
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" )
Tighten temporarily high pressure pipe
sleeve nuts (26) and (12).
k Install high pressure pipe after
checking the followings. 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 finger nail (no fatigue).
D155AX-6
2.
Install high pressure pipe clamp and stay.

1) Temporarily tighten high pressure pipe
clamp, stay (16), clamping bolts (38)
through (42), and stay mounting bolt, with
fingers.
2) Tighten permanently high pressure pipe
clamping bolt.
3 Clamping bolt:
9.8 1 Nm {1 0.1 kgm}
3) Tighten permanently stay mounting bolt.
4) Temporarily tighten high pressure pipe
clamp, stay (15), clamping bolts (44)
through (48), and stay mounting bolt, with
fingers.
5) Install cover (11).
a Install with the notch toward cylinder
block side.
6) Install high pressure pipe clamp (10) and
gate type frame (9) temporarily.
7) Tighten clamping bolt for high pressure
pipe clamp (10) permanently.
3 Clamping bolt:
9.8 1 Nm {1 0.1 kgm}
8) Tighten gate type frame (9) permanently.
9) Tighten high pressure pipe clamp, stay
(15) and clamping bolts (44) through (48),
permanently.
3 Clamping bolt:
9.8 1 Nm {1 0.1 kgm}
10) Tighten permanently stay mounting bolt.
D155AX-6
SEN01205-05
3.
Install the subsequent procedure in the reverse

order of removal.
[*1]
Joint bolt: 24.5 34.3 Nm {2.5 3.5 kgm}
[*2]
Clamping bolt (7): 9.8 1 Nm {1 0.1 kgm}
[*3]
Cylinder head cover mounting bolt:

29.4 34.3 Nm {3.0 3.5 kgm}
[*4]
a Install with the notch downward.
[*5]
a When installing rocker arm and rocker shaft
assembly (22), check the ball portion of adjustment screw (25) to be inserted securely into
socket of push rod (23), and tighten mounting
bolts.
a As 3 mounting bolts are different each other,
install them referring to the followings.
q
Mounting bolt (19): Stem length 120mm
q
Mounting bolt (20): Stem length 90 mm
q
Mounting bolt (21): Stem length 75.2 mm
3 Mounting bolts (19), (20) and (21):
93 103 Nm {9.5 10.5 kgm}
a Adjust valve clearance referring to the section
of Testing and adjusting, "Adjusting valve
clearance".
SEN01205-05
[*6] [*7]
a Install wiring harness according to the following procedure.
1) Install clip (29).
2) Tighten two capture nuts (30).
3 Capture nut:
2 0.2 Nm {0.2 0.02 kgm}
3) Tighten wiring harness clamping bolt (28).
10
D155AX-6
SEN01205-05

cylinder head assembly
790-331-1110
Wrench
Sketch
A 6
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
q 1
Removal
1.
2.
assembly".
8.
Remove two joint bolts (8), and remove fuel

main filter head assembly (9). [*1]
Drain the coolant.
9.
Remove two joint bolts (10), and remove corrosion resistor head assembly (11). [*2]
3.
Coolant: 82l
Remove stay (1).
10. Remove fuel tube (12), and remove priming

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).
5.
Disconnect fuel hose (4).
6.
Remove fuel tube (5), and remove fuel pre filter head assembly (6).
7.
Remove bracket (7).
D155AX-6
12. Disconnect connecters, BP, SBP, EGR and

SEGR.
11
SEN01205-05
13. Disconnect connector PEVA (19).
19. Remove air intake housing.

1) Remove tube (25) and block (26).
14. Disconnect terminal RHT (20).

2)
15. Remove breather tube (21).
16. Remove wiring harness bracket (22).
17. Remove air intake connector (23). [*4]
3)
To secure the room for operation, loosen

the tension of belt and move air conditioner compressor (27a) downward, referring the section of Testing and adjusting,
"Testing and adjusting air conditioner compressor belt tension". [*5]
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).

23. Remove mounting bolts of bracket (32), and
move bracket (32) with hose (33).
24. Disconnect connectors, TFUEL (34), TIM (35)

and PIM (36).
SEN01205-05
26. Remove two, upper and lower side, wiring harness clamps (38) at the rear side of intake
manifold.
27. Remove charge pressure sensor (39) with

plate (40) and bracket (41).
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
SEN01205-05
29. Remove stays (43), (44), (45) and (45a) for

high pressure pipe clamp. [*8]
32. Remove heat insulation covers, (48), (49) and

(50).
30. Remove water tube (46) in front of intake manifold.
33. Remove muffler (51).
31. Remove intake manifold (47). [*9]

4
14
Muffler: 55 kg
34. Remove tube (52). [*10]
Intake manifold: 50 kg
D155AX-6
35. Remove heat insulation covers (53) and (54),

and bracket (56).
SEN01205-05
40. Remove heat insulation cover (62).

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
D155AX-6
Turbocharger and exhaust manifold

assembly: 80 kg
15
SEN01205-05
44. Disconnect connectors CN1 (69), CN2 (70),

CN3 (71), CN4 (72), CN5 (73) and CN6 (74),
and move wiring harnesses (75) and (76).
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).
48. Remove water tube (82). [*19]

49. Remove cylinder head cover (83). [*20]
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

(86), and remove rocker arm and rocker shaft
assembly (87).
a Loosen lock nut (89), and loosen adjustment screw (90) two or three turns to prevent excessive force applied to push rod
(88), when installing rocker arm and
rocker shaft assembly. [*21]
52. Remove fuel injector assembly.

1) Remove wiring harness clamping bolt (92)
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
SEN01205-05
5)
6)
Remove mounting bolt (100) of holder.

[*25]
Set L type bar [2] under fuel injector
assembly inlet connector (e), and remove
slowly fuel injector assembly (101) with
holder using leverage action. [*26]
a Do not grip the solenoid valve at the
top of the injector to pull off the injector.
53. Remove two push rods (102).
17
SEN01205-05
54. Remove crosshead (103).
Installation
55. Remove 3 mounting bolts (104), 3 bolts (105)

and bolt (106), and remove cylinder head
assembly (107).
1.
18
Install cylinder head assembly.

1) Install cylinder head gasket (115).
a Check that the mounting surface of
cylinder head and the inside of cylinders 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)
4)
Install cylinder head assembly.

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 disulfide (LM-P)
D155AX-6

3
5)
Mounting bolt
1st time:
137 157 Nm {14 16 kgm}
2nd time:
284 294 Nm {29.0 30.0 kgm}
3rd time: Retighten 90 (+30/0) with
tool A6.
a When tool A6 is not available, put
marks (a) and (b) to bolt and cylinder
head, and retighten bolt 90 (+30/0).
Tighten mounting bolt (106) (tightening
order: 7th) with the following torque.
3 Mounting bolt:
66.6 7.4 Nm {6.8 0.8 kgm}
D155AX-6
SEN01205-05
2.
After installing cross head (103), make adjustment as follows.

1) Loosen lock nut (111), and loosen adjustment screw (112).
2) Lightly push cross head (103) contact surface (h) with rocker arm, and hold cross
head to contact with push rod (102) side
valve stem (113).
3) Screw slowly adjustment screw (112), and
check the position where adjustment
screw touches valve stem (114).
4) From the above condition, screw adjustment screw (112) 20.
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 follower.
19
SEN01205-05
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
(BD) to Min. 5 mm.
3) Tighten bolt (BC).
a Do not use an impact wrench.
2 Threaded part of bolt: Lubricating
oil (THREEBOND, PANDO 18B)
q
When reusing the hose, install it to the
clamp mark on it.
3 Bolt (BC):
25 5 Nm {2.55 0.5 kgm}
q
When using a new hose, tighten until
dimension (BDG) is as follows.
a Dimension (BDG): 8 10 mm
[*7] [*8] [*15] [*18]

a Install high pressure pipe, clamp, stay and gate
type frame referring to the section, "Removal
and installation of fuel injector assembly".
[*9]
a Tighten intake manifold mounting bolts in the
numerical order shown below.
3 Mounting bolt: 58.8 73.5 Nm {6 7.5 kgm}
[*11]
[*5]
a Adjust the tension of air compressor belt, referring Testing and adjusting section "Testing and
adjusting of air conditioner compressor belt
tension".
[*6]
3
3
20
Joint bolt (37a):

9.8 12.7 Nm {1.0 1.3 kgm}
Joint bolt (37b):
19.6 29.4 Nm {2.0 3.0 kgm}
EGR tube mounting bolt threaded portion:

Lubricant with molybdenum disulfide
(LM-P)
EGR tube mounting bolt, EGR tube and
bracket mounting bolt:
44.1 53.9 Nm {4.5 5.5 kgm}
[*12]
Threads and seat surface of bypass tube

mounting bolt: Lubricant with molybdenum disulfide (LM-P)
Bypass tube mounting bolt:
44.1 53.9 Nm {4.5 5.5 kgm}
[*13]
Oil tube cylinder block side joint bolt:

24.5 34.3 Nm {2.5 3.5 kgm}
D155AX-6
SEN01205-05
[*14]
a Tighten exhaust manifold mounting bolts in the
numerical order shown below.
2 Threads of mounting bolt:
Lubricant with molybdenum disulfide
(LM-P)
3 Mounting bolt: 58.8 73.5 Nm {6 7.5 kgm}
[*16]
Spill tube joint bolt:

9.8 12.7 Nm {1.0 1.3 kgm}
[*17]
a Install cover with the notch downward.
[*19]
Water tube joint bolt:

9.8 12.7 Nm {1.0 1.3 kgm}
[*22] [*23] [*24]

a Install injector wiring harness according to the
a Eliminate the slack of the injector wiring harness and press it against the injector body so
that it will not interfere with the rocker arm.
1) Install O-ring to injector wiring harness (98).
2) Install injector wiring harness (98) in rocker
housing, install holder (96) and tighten bolt
(95).
3) Install clip (93).
4) Tighten two capture nuts (94).
3 Capture nut: 2 0.2 Nm {0.2 0.02 kgm}
5) Install wiring harness clamping bolt (92).
[*20]
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 adjustment screw (90) to be inserted securely into
socket of push rod (88), and tighten mounting
bolts.
a As three mounting bolts are different each
other, install them referring the followings.
q
q
q
Mounting bolt (86): Stem length 75.2 mm
3 Mounting bolt:
93 103 Nm {9.5 10.5 kgm}
a Adjust valve clearance referring to the section
of Testing and adjusting, "Adjusting valve
clearance".
[*25] [*26]
a Install the fuel injector assembly referring to
the section, "Removal and installation of fuel
injector assembly".
q
Refilling with coolant

Add coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.
5
D155AX-6
Coolant: 82 l
(For details, see "Table of fuel, coolant
and lubricants")
21
SEN01205-05

radiator assembly
Removal
k
1.

battery.
Drain the coolant.
6
2.
Coolant: 82l
Remove cover at the top of radiator, and disconnect connector LHD (1).
6.
Sling radiator assembly (12) and remove it.

[*3]
4
3.
Remove cover (2).

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
Radiator assembly: 25 kg
D155AX-6
SEN01205-05
Installation
q
Carry out installation in the reverse order of

removal.
[*1]
a Install hoses (5) and (7) with the red circle
paint upward.
2 Tube flange: gasket sealant
3 Hose clamp: 8.8 0.5 Nm {90 5 kgcm}
a Tighten two parallel clamps for hose (6) with its
bolt location rotated 180 each other.
2 Tube flange: gasket sealant
3 Hose clamp: 8.8 0.5 Nm {90 5 kgcm}
[*2]
a Install radiator mounting brackets (9) (11)
and cushion (19) according to the following
procedure.
1) Set plate (18), cushion (19) and brackets
(9) (11) on the mounting boss of radiator
(12). At this time, fit brackets (9) (11) to
the mounting seat of upper tank (17).
(You may tighten bracket mounting bolts
(22) temporarily.)
2) Install collar (20) upside down (with the
small diameter side up) and tighten
mounting bolt (21).
Compress cushion (19). (L1 o L2)
3) With mounting bolt (21) tightened, tighten
mounting bolts (22) of brackets (9) (11).
4) Once remove mounting bolt (21).
5) Install collar (20) again in the normal (with
the small diameter side down).
6) Tighten mounting bolt (21).
7) Check clearance (L3) (approx. 7 mm).
D155AX-6
23
SEN01205-05
[*3]
a Set radiator assembly according to the following procedure.
1) Set rubber (13) with its stepped portion (a)
downward.
a Apply appropriate amount of grease
to prevent drop down when lifted up.
2) Install O-ring (14).
2 O-ring periphery: Grease (G2-LI)
3)
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 condition from the machine front.

5
24
Coolant: 82 l
and lubricants")
D155AX-6

aftercooler assembly
SEN01205-05
3.
Open undercover.
4.
Disconnect the tube (3) from the lower part of

the after cooler. [*1]
5.
Remove four mounting bolts for tube (4). [*2]
6.
Remove brackets, (5), (6) and (7).
7.
Sling aftercooler assembly (8) and remove it.
Removal
k
1.
2.

battery.
Remove cover at the top of radiator, and disconnect connector LHD (1).
Remove cover (2).

4
Cover: 50 kg
D155AX-6
Aftercooler assembly: 35 kg
25
SEN01205-05

a
Installation
q

removal.
Check the charged air cooler mounting face for

air leakage. If air leaks, replace the gasket,
hose clamp and tube mounting bolts. (Apply
LG-6 to the gasket mating face.)
1.
Remove the small hood sub-assembly (on

the radiator) and the undercover at the
front of the machine.
2.
Check the mounting faces (1) of the charged

air cooler, duct and tube for air leakage.
a Check for abnormal sound and spray soap
water to check for air leakage.
a Check for air leakage for 3 minutes while
running the engine at full throttle.
3.
If air leaks, remove the engine upper hood,

side cover, air cleaner and right and left mudguards.
4.
Remove lower duct and tube (2) and replace

the gasket.
2 Charged air cooler flange and duct and
tube flange: Gasket sealant (LG-6)
a Spread gasket sealant (LG-6) on the narrow places of the flange with a spatula.
Spread it thinly on the inside to prevent it
from projecting into the duct or tube.
26
Assemble the duct and tube in 30 minutes after applying the gasket sealant.
5.
Assemble the charged air cooler, duct and

tube so that the faces coated with LG-6 will be
stuck to both sides of the new gasket.
a When installing the duct and tube, take
care not to misalign them. After assembling them, be sure to dry them for at least
2 hours.
a Use new gasket, mounting bolts and
washers.
3 Mounting bolt:
98 123 Nm {10 12.5 kgm}
6.
Remove upper duct and tube (3) and replace

the gasket.
2 Charged air cooler flange and duct and
tube flange: Gasket sealant (LG-6)
a Spread gasket sealant (LG-6) on the narrow places of the flange with a spatula.
Spread it thinly on the inside to prevent it
from projecting into the duct or tube.
a Assemble the duct and tube in 30 minutes
after applying the gasket sealant.
D155AX-6
7.
SEN01205-05
Assemble the charged air cooler, duct and

tube so that the faces coated with LG-6 will be
stuck to both sides of the new gasket.
a When installing the duct and tube, take
care not to misalign them. After assembling them, be sure to dry them for at least
2 hours.
a Use new gasket, mounting bolts and
washers.
3 Mounting bolt:
98 123 Nm {10 12.5 kgm}
[*1] [*2]
clamp with new one.
(BD) to Min. 5 mm.
q
clamp mark on it.
3 Bolt (BC):
25 5 Nm {2.55 0.5 kgm}
q
D155AX-6
27
SEN01205-05

engine assembly
7.
Remove heat insulation cover (3) and drain

tube (4).
8.
Remove muffler (5).
Removal
1.
2.
Collect the air conditioner refrigerant (R134a)

from air conditioner circuit in advance. [*1]
a Ask professional traders for collecting and
filling operation of refrigerant.
a Never release the refrigerant to the atmosphere.
k If refrigerant gets in your eyes, you
may lose your sight. Accordingly, put
on protective goggles, gloves and
working suits with long sleeves while
you are collecting the refrigerant or filling the air conditioner circuit with the
refrigerant. Collecting and filling work
must be conducted by a qualified person.
Muffler: 50 kg
Drain the coolant.

6
Coolant: 82l
3.
assembly".
4.
Open undercovers (front and center)

k
Open carefully using floor jack, wire

rope, etc.
5.
Disconnect hose from air intake connector (1).

[*2]
6.
Remove stay (2).
9.
Remove radiator assembly referring to the section, "Removal and installation of radiator
assembly".
10. Remove aftercooler assembly referring to the

section, "Removal and installation of aftercooler assembly".
11. Remove reservoir tank (6) with bracket (7).
28
D155AX-6
SEN01205-05
12. Disconnect ground (8) at engine left side.
15. Remove after cooler tube (11). [*3]
13. Disconnect fuel hose (9) from fuel supply

pump.
16. Sling water tube (12) and remove it. [*4]
14. Disconnect fuel hose (10) from fuel pre filter.
17. Disconnect starting motor B terminal ST/B (13)

and heater hose (14).
18. Disconnect two hoses each from air conditioner condenser (15) and oil cooler (16), and
remove frame (17).
D155AX-6
29
SEN01205-05
19. Remove flame (18).
22. Disconnect connector AC05 (22).

23. Remove receiver tank (23) and move.
24. Disconnect connectors EG1 (24) and EG2 (25).
20. Disconnect fuel spill hose (19).

21. Remove clamp (20), and remove bracket (21).
25. Disconnect hose (26) from radiator lower tank.
[*5]
26. Separate universal joint (27) at the engine

side. [*6]
30
D155AX-6
27. Temporarily sling engine assembly.

28. Remove mounting bolts (28) and (29), four
pcs.each. [*7]
29. Sling engine assembly (30) and remove it.

a Check all wires and pipes are removed.
a Remove carefully to avoid any interference with the machine body.
SEN01205-05
Installation
q
Carry out installation in the reverse order to

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):
12 15 Nm {1.2 1.5 kgm}
20 25 Nm {2.0 2.5 kgm}
30 35 Nm {3.0 3.5 kgm}
Filling air conditioner circuit with refrigerant (R134a)

Fill the air conditioner circuit with refrigerant
(R134a).
a Quantity of refrigerant: 1,200 50 g
[*2] [*3]
clamp with new one.
(BD) to Min. 5 mm.
D155AX-6
31
SEN01205-05

clamp mark on it.
3 Bolt (BC):
25 5 Nm {2.55 0.5 kgm}
[*4]
2
3
Engine side tube flange:

Gasket sealant (LG-1)
Hose clamp: 8.8 0.5 Nm {90 5 kgcm}
[*5]
[*6]
Universal joint mounting bolt:

98 123 Nm {10 12.5 kgm}
[*7]
Engine mount fixing bolt:

823.8 1029.7 Nm {84 105 kgm}

5
32
Coolant: Approx. 82 l
and lubricants")
D155AX-6

engine hood assembly
SEN01205-05
Removal
k
1.

battery.
Remove pre cleaner duct (1) and exhaust tube
(2). [*1]
2.
Remove cover (3).
3.
Open cover (4), and remove covers (5) through

(7).
a Carry out the same operation to the opposite side.
4.
5.
Remove hose (10). [*2]
6.
Disconnect connector AF1 (11).
Remove two mounting bolts (9) for tube (8).
D155AX-6
33
SEN01205-05
7.
Sling engine hood (12) and remove it.

4
Engine hood: 170 kg
Installation
q

removal
[*1]
Pre cleaner duct and exhaust pipe mounting

bolt: 98 123 Nm {10.0 12.5 kgm}
[*2]
34
D155AX-6
SEN01205-05

engine front seal
a
a
Sketch
Push tool
t 1 R Q
2 01050-31655
Bolt
t 3
01050-31635
Bolt
t 3
Seal puller
t 1
795T-521-1150
Push tool
t 1
01050-31635
Bolt
t 4
795T-521-1111
Part name
New/Remodel
Part No.
Q'ty
Sym
bol
Necessity
Special tools
3 795-931-1100
8
Removal
1.
2.
a
a
Remove the radiator and oil cooler guard

assembly.
Remove damper (1) and flange (2).
3.
Remove all the chips.

Take care in the removal not to damage
front seal (3) installation position on front
cover (4) and the seal contact face on
crankshaft (5).
Before removing, slightly drive the front
seal in once to free it from fixation.
When front seal (3) is fixed too hard to the
front cover (4), carry out the following procedure.
1) Drill through a hole of approx. 3 mm
dia. on front seal (3).
2) Replace the tip of tool A3 with the drill
type one.
3) Insert the top end of tool A3 into the
drilled hole, and remove the front seal
by the impact of slide hammer (SH).
(Apply the slide hammer evenly not to
tilt the front seal.)
Remove the metal powders completely.
When the sleeve is attached, cut sleeve
(6) using a gad and hammer to remove it.
Take care not to damage crankshaft (5).
Tool A3
Remove front seal (3).
D155AX-6
35
SEN01205-05
Installation
a Check the seal by checking the wear of the
shaft and replace it with the "standard seal" or
"sleeved seal".
If the shaft is worn to the degree of luster (If
wear which you feel with your finger is less than
10 mmm) and does not have any flaw, install
"standard seal A". In other cases, install
"sleeved seal B".
a (7): Plastic inside cylinder which is also used as
installation guide.
a (6): Sleeve.
a Do not remove installation guide (7) from front
seal (3) before installing the front seal.
a Handle front seal (3) and sleeve (6) as an
assembly and never separate them from each
other.
Standard spare seal
Sleeved seal
1. Procedure for installing standard seal

a Before installing the seal, check that the
end corners and lip sliding surfaces of the
crankshaft are free from flaw, burr, and rust
of the front cover.
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 installation guide (7) of the
replacement seal before installing the seal.
1) Set large inside diameter side (b) of installation guide (7) to the end of crankshaft (5).
a Take care not to mistake the direction of
the plastic inside cylinder.
36
2) Push in the metal ring of seal (3) evenly as

if you are passing over the large diameter
side of plastic inside cylinder (7).
3) After pushing in the seal to a depth where it
does not come off the front cover, remove
plastic inside cylinder (7).
a When removing the inside cylinder, take
care not to damage the seal lip.
4) Tighten tool A2 until the bolts (55 mm) reach
the end.
D155AX-6
5) Tighten tool A2 with the bolts (35 mm) again

to press fit seal (3) until the end of tool A2
reaches the end of crankshaft (5).
a Seal driving distance (a) from crankshaft: 9.1 10.1 mm
a When press fitting the seal, take care
not to damage the lip of the seal with
the tool set etc.
a After press fitting the seal, remove the
red sealant layer from its periphery.
2. Procedure for installing sleeved seal

a When installing the front seal, do not apply
oil or grease to the shaft, inside cylinder
surface of sleeve (6) and seal lip.
1) Set sleeve and front seal assembly (8) to
tool A8 (for fitting the sleeved seal).
2
Sleeve inside cylinder surface (6):

D155AX-6
SEN01205-05
2) Set the sleeve of the front seal assembly

(8) to the end of crankshaft (5) and tighten
the 3 bolts evenly to press fit sleeve and
rear seal assembly (8) until the end of tool
A8 (for press fitting the sleeved seal)
3) Remove tool A8 (for press fitting the

sleeved seal) and install tool A2 (for press
fitting the seal).
4) Tighten the 3 bolts (35 mm) evenly to press
fit sleeve and front seal assembly (8) until
the end of tool A2 reaches the end of crankshaft (5)
a Seal driving distance (a) from crankshaft: 9.1 10.1 mm
not to damage the lip of the seal with
the tool set etc.
37
SEN01205-05
3.
4.
38
Install flange (2).

3
Flange mounting bolt:

245 309 Nm {25.0 31.5 kgm}
Install damper (1).
D155AX-6
SEN01205-05

engine rear seal
t 1
Push tool
t 1
Bolt
t 4
01643-31645
Washer
t 8
795T-421-1240
Push tool
t 1
Bolt
t 4
01643-31645
Washer
t 4
795T-421-1250
Push tool
t 1
Bolt
t 4
Wrench
t 8
795T-421-1270
4 01050-31645
5 01050-31645
9 01050-31645
01643-31645
While moving flywheel (2) toward this side, lift

it off.
k Since the socket part of the flywheel is
shallow, it may fall suddenly. Take care
not to catch your fingers in the flywheel.
4
Flywheel: 60 kg
Removal
1.
Remove the engine assembly. For details, see

"Removal and installation of engine assembly".
2.
Remove damper assembly (1). For details,

see "Removal and installation of damper
assembly".
D155AX-6
4.
Sketch
New/Remodel
Q'ty
Seal puller
3 795-931-1100
Part name
Necessity
Part No.
Install eyebolt [1] to flywheel (2), sling flywheel

(2), and remove bolts (3).
Special tools
Sym
bol
3.
5.
Remove rear seal (4) according to the following procedure.

a Measure the distance from the end of the
housing. (5)
1) Before pulling out rear seal (4), drive it in a
little to separate it from housing (5).
39
SEN01205-05
2)
If the seal is sleeved, cut and remove

sleeve (6) with a chisel and a hammer.
a When cutting, take care extremely not
to damage crankshaft (7).
3) Hitch the end of tool A3 to the metal ring
of rear seal (4) and pull out the seal with
impacts of slide hammer (SH).
a Do not use a drill etc. since chips may
enter the engine.
a If chips were made, remove all of
them.
Tool A3
Installation
a
a
a
a
a
Check the wear of the shaft and select the

"standard" or "sleeved" Teflon seal (Laydown
lip seal) to replace the used seal.
If the shaft is worn to the degree of luster (If the
wear depth which you feel with your finger is
less than 10 mm) and does not have any flaw,
install "standard seal (A)". In other cases,
install "sleeved seal (B)".
(8): Plastic inside cylinder which is also used
as installation guide.
(6): Sleeve.
Do not remove installation guide (8) from rear
seal (4) before installing the rear seal.
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
Seal type: Single seal

(Inside of flywheel housing is dry)
Left side: Standard seal, Right side: Sleeved
seal
a
a
a
40
Clean, degrease, and dry the contact surface

of the seal to the flywheel housing side.
Clean, degrease, and dry the seal lip surface
(periphery of the crankshaft).
Check that the end corners and lip sliding surface of the crankshaft and the housing are free
from flaw, burr and rust.
D155AX-6
1.
SEN01205-05
Procedure for installing standard seal

a When installing rear seal (4), do not apply
oil or grease to the shaft and seal lip.
1) Set large inside diameter side (b) of plastic inside cylinder (8) of rear seal (4) to the
end of crankshaft (7).
a Take care not to mistake the direction
of the plastic inside cylinder.
2)
3)
Push in the metal ring of rear seal (4)

evenly as if you are passing over the large
diameter side of plastic inside cylinder (8).
After pushing in rear seal (4) to a depth
where it does not come off the housing,
remove plastic inside cylinder (8).
a When removing the inside cylinder,
take care not to damage the seal lip.
D155AX-6
4)
2.
Tighten the 3 bolts evenly to press fit rear

seal (4) until the end of tool A4 (for press
fitting the seal) reaches the end of crankshaft (7).
a Tighten tool A4 (for press fitting the
seal) first with o u t i n s er t i n g a n y
washer until the bolts reach the end
and then tighten with 2 washers
inserted (in each bolt).
not to damage the lip on the PTO side
with the tool set etc.
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 A5 (for press fitting the sleeved seal).
2 Sleeve inside cylinder surface (C):
41
SEN01205-05
2)
Set sleeve of the rear seal to the end of

crankshaft (7) and tighten the 4 bolts of
tool A5 evenly to press fit sleeve and rear
seal assembly (9).
a Tighten tool A5 (for press fitting the
sleeved seal) with 1 washer inserted
in each bolt until the bolts reach the
end.
3.
Flywheel
Using eyebolt [1] (12 mm, P = 1.75), sling flywheel (1), install it to the crankshaft, and
tighten the bolts.
a If there are 5 punch marks on a bolt, do
not use that bolt but replace it.
2 Threads and seat of bolt: Engine oil
and lubricants" )
4
3)
4)
Remove tool A5 (for press fitting the

sleeved seal) and install tool A9 (for press
fitting the seal).
Tighten the 3 bolts evenly to press fit
sleeve and rear seal assembly (9) until the
end of tool A9 (for press fitting the seal)
a Tighten the bolt of tool A9 (for press
fitting the seal) without washer until it
reaches, and then tighten the bolt
using 2 washers (for each bolt).
a Rear seal driving depth: 13.2 0.2
mm from end of crankshaft
42
Flywheel: 65 kg
When installing, set the dowel pin of

the crankshaft to the dowel hole of
the flywheel.
D155AX-6

a
Tighten the mounting bolts according to the following procedure.

3 Flywheel mounting bolts
1st time: 118 4.9 Nm {12 0.5 kgm}
2nd time: 1) When using tool A6 (See the
tools list)
Retighten each bolt by 90 +30
in
+0
the following order.
2) When not using tool A6
Make marks (f) on each bolt and
flywheel with paint, then retighten
each bolt by 90 +30
in the follow+0
ing order.
After tightening, make 1 punch mark (g) on
each bolt head to indicate the number of tightening time.
D155AX-6
SEN01205-05
a
After installing the flywheel, measure the facial

runout and radial runout with tool [1].
a Radial runout: Max. 0.30 mm
a Facial runout: Max. 0.30 mm
Carry out the following installation in the

reverse order to removal.
43
SEN01205-05

tank assembly
1
6.
Remove 6 fuel tank mounting bolts (6) on the

right and left sides.
7.
Sling the fuel tank assembly, move it back

about 100 mm, and disconnect hoses (7) and
(8).
Removal
k
1.
Disconnect the cable from the negative ()

terminal of the battery.
Remove cover (1) from the fuel tank bottom.
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
44

removal.
D155AX-6
SEN01205-05
Removal and installation of fan

drive assembly
1
4.
Disconnect wiring harness connector FAR (5)

and remove wiring harness clamp.
Removal
5.
Disconnect fan motor hoses (6), (7) and (8).

a Plug the hoses so that foreign matter will
not enter them.
6.
Using eyebolts [1], sling fan drive assembly (9)

and remove mounting bolts (10).
7.
Lift off fan drive assembly (9).
1.

Drain the hydraulic oil.
6
2.
Hydraulic tank: Approx. 91.5 l
Remove 4 mounting bolts (1) and open mask

(2).
3.
Fan drive assembly: 125 kg
Remove 4 mounting bolts (3) and remove

guard (4).
Installation
q

removal.
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
D155AX-6
Hydraulic oil (For details, see "Table of

fuel, coolant and lubricants"):
Approx. 91.5 l
45
SEN01205-05
Removal and installation of fan

motor assembly
1
Installation
q
Removal

removal.
1.
Remove the fan motor assembly. For details,

see "Removal and installation of fan drive
assembly".
[*1]
Be sure to align the hole of lock plate (1) by turning
nut (2) in the tightening direction.
2.
Remove the mounting bolt and lock plate (1).

[*1]
[*2]
3.
Mounting nut (2):

441 539 Nm {45 55 kgm}
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
46
Fan motor assembly: 40 kg
D155AX-6
D155AX-6
SEN01205-05
47
SEN01205-05
D155AX-6 Bulldozer
2012 KOMATSU
All Rights Reserved
48
D155AX-6
SEN01206-03
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine Model
Serial Number
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
SEN01206-03

damper assembly
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
pump assembly".
4.
Remove the cooling fan pump assembly referring to the section, "Removal and installation of
cooling fan pump assembly".
5.
Disconnect breather hose (1).
6.
Remove oil level gauge (2).
7.
Sling universal joint assembly (3) and remove

it. [*1]
4
8.
9.
Remove mounting bolts for damper cover

assembly (5), and install two guide bolts [1]
diagonally. [*2]
10. Using forcing bolt [2], pull out damper cover

assembly (5) so that the lifting tool can be
applied, and then remove it. [*3]
4
Damper cover assembly: 60 kg
Universal joint assembly: 20 kg
Pull out torque converter side coupling (4).
D155AX-6
11. Remove damper assembly.

1) Remove two mounting bolts for damper
assembly (6), and set guide bolts [3]. [*4]
2) Remove the rest of mounting bolts, and
pull out damper assembly using forcing
bolt [4]. [*5]
3) Use eyebolt [5] to remove damper assembly (6).
4
SEN01206-03
Installation
q

removal.
[*1]
2
3
Damper assembly: 60 kg

Liquid adhesive (LT-2)
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 minutes.
2) Fill (b) portion of inner body (8) with about 80 g
of lithium base extreme pressure grease with
molybdenum disulphide (B).
A
Dry lubricant with

molybdenum disulphide
Sumiko lubricant Rocol

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 equivmolybdenum disulphide
alent
Nippon Oil Corporation
Molytex or an equivalent
D155AX-6
SEN01206-03
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}
q
Refilling with oil

5
Damper case: 1.5 l

(For details, see "Table of fuel, coolant and
lubricants")
Drain plug: 58.5 78.5 Nm {6 8 kgm}
D155AX-6
SEN01206-03
Disassembly and assembly of damper assembly
t 1
791-612-1100
Installer
790-101-4200
Puller
t 1
(294 kN {30 ton})
790-101-1102
Hydraulic pump
D155AX-6
Sketch
Part name
New/Remodel
Part number
Q'ty
Symbol
Necessity
Special tools
t 1
SEN01206-03
Disassembly
2)
Disassembly of damper cover assembly (1)

1.
Coupling
Remove bolt (3) from cover (2), then remove
holder (4) and coupling (5).
3.
2.
Bearing and oil seal

1) Remove oil seal (9) from cover (2), and
pull out inner race (7-3) of bearing (7).
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 collar (7-2) and O-ring of bearing

(7) from shaft (6), and pull out inner race
(7-1).
Remove outer races (7-4) and (7-5) of

bearing (7) from cover (2).
D155AX-6
SEN01206-03
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 replacing plug.
D155AX-6
SEN01206-03
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)
D155AX-6
2.
SEN01206-03
Install cushion (15).

a Apply grease (G2-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.
4.
Press fit inner race (7-1) of bearing (7) to shaft

(6) with tool F.
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 equivalent
D155AX-6
SEN01206-03
3.
Install collar (7-2) and O-ring to shaft (6).
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
6.
Install coupling (5) and holder (4), and tighten

bolt (3).
3 Mounting bolt:
245.2 308.9 Nm {25.0 31.5 kgm}
D155AX-6
Removal and installation of power

train unit assembly
1
SEN01206-03
5.
Disconnect hoses (4) through (7).
6.
Disconnect hoses (8) through (11), and

remove hose clamps (12) and (13).
7.
Disconnect hoses (14) and (15) at the rear of

hydraulic tank.
8.
Remove oil level gauge (16) and oil filler tube

(17).
9.
Remove clamps (18) through (20), and remove

hose.
Removal
k
k
1.
Park the machine at the level place, lower

the work equipment fully to the ground.
Drain the oil from hydraulic tank and power
train case.
6
Hydraulic tank: 91.5l

Power train case: 90 l
2.
Remove floor frame assembly referring to the

section, "Removal and installation of floor
frame assembly".
3.
Disconnect connectors PUMP (1) and HSS (2)

at power train unit right side.
4.
Disconnect 13 hoses (3) of split flange from

control valve.
D155AX-6
11
SEN01206-03
10. Remove the clamps for wirings (21) through

(23), and move wires.
15. Remove final drive shaft cover (29).
11. Disconnect tube (24).
12. Remove covers (25) at both sides of steering

case. [*1]
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).
a If the shaft is hard to be pulled out, set
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) outward slightly. [*2]
12
17. Disconnect hoses (31) and (32) at the right

front of power train unit.
D155AX-6
18. Disconnect hose (33) under the left front of the

power train unit.
SEN01206-03
21. Disconnect universal joint (37) from the torque

converter. [*3]
a After disconnecting, push the yoke into the
torque converter to disconnect completely.
19. Lift off power train filter (34).

4
Power train filter: 20 kg
22. Remove 4 each of mounting bolts (38) on the

front right and left sides of the power train unit.
[*4]
20. Disconnect additional filter hoses (35) and

(36).
23. Lift off power train unit assembly (39). [*5]
a Check that all the wirings and pipings are
disconnected.
a When lifting off the unit, take that it will not
interfere with the machine.
4
D155AX-6
Power train unit assembly: 2,400 kg
13
SEN01206-03
Installation
removal.
[*1]
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]
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).
Refilling with oil
Fill the oil through oil filler port to the specified
level. Start the engine to circulate the oil
through the piping, and recheck the oil level.
14
Hydraulic tank: Approx. 91.5l

lubricants")
Power train case: Approx. 90l
lubricants")
D155AX-6
Disconnection and connection of

power train unit assembly
1
SEN01206-03
5.
Remove tube (5).
6.
Remove work equipment and HSS pump assembly (6).
Disconnection
1.
Set power train unit assembly (1) on block [1].

4
Power train unit assembly: 2,400 kg

7.
Remove cooling fan pump assembly (7).

4
2.
Disconnect all the connectors from power train

unit to remove wiring harness referring to Diagrams and drawings section, "Electrical circuit
diagram, Connector table and arrangement
drawing".
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
Work equipment and HSS pump assembly: 110 kg
8.
Cooling fan pump assembly: 25 kg
Remove tubes (8) and (9), and remove

scavenging pump assembly (10).
4
Scavenging pump assembly: 20 kg
15
SEN01206-03
9.
Remove tubes (11) and (12), and remove

power train and lubrication pump assembly
(13).
4
Power train and

assembly: 30 kg
lubrication
pump
12. Temporarily sling PTO, torque converter and

transmission assembly (16), and remove 18
mounting bolts to separate from HSS unit
assembly (17). [*2]
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
SEN01206-03
15. Remove cover (19), and remove spring (20)

and magnet assembly (21).
17. Remove cover (24).
16. Remove pressure sensor block (22) and

remove two sleeves (23).
D155AX-6
17
SEN01206-03
18. Remove torque converter valve assembly (25),

and remove two sleeves (26).
20. Sling torque converter assembly (28) and

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
18
PTOAss'y: 200 kg
D155AX-6
SEN01206-03
Connection
[*2]
Carry out connection in the reverse order of

disconnection.
[*1]
a Connect the pressure pick up hose to power
train unit referring to the table which indicates
the band color at the mouthpiece of pressure
pick up hose.
Symbol
Pressure pick up point
Band color
Torque converter lockup clutch pressure
Yellow red
Torque converter stator clutch pressure
Yellow blue
Transmission 1st clutch pressure
Red
Transmission 3rd clutch pressure
Yellow
black
Transmission R clutch pressure
Red blue
Transmission 2nd clutch pressure
White yellow
Transmission F clutch pressure
White blue
Left brake pressure
White
Right brake pressure
Yellow
D155AX-6
Transmission case mounting bolt:

98 123 Nm {10.0 12.5 kgm}
[*3]
PTO assembly mounting bolts:

98 123 Nm {10.0 12.5 kgm}
[*4]
2
3
Torque converter assembly mounting bolts:

Liquid adhesive (LT-2)
Torque converter assembly mounting bolts:
98 123 Nm {10.0 12.5 kgm}
No color
19
SEN01206-03
D155AX-6 Bulldozer
2012 KOMATSU
All Rights Reserved
20
D155AX-6
SEN01207-03
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine Model
Serial Number
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
SEN01207-03
Disassembly and assembly of

PTO assembly
3)
Remove cover (5) from gear and bearing

assembly (6).
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).
5)
Remove bearing (40) from case (17).
Disassembly
1.
Lubrication tube
1) Remove shaft lubrication tube (1).
2)
2.
Remove pump drive gear lubrication tube

(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).
D155AX-6
3.
SEN01207-03
Cooling fan pump drive gear and cover

assembly
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).
3)
Remove snap ring (14) and remove bearing (15) from cover (12).
6)
Remove case (17) from bearing (16).
While supporting cover (12) with block [1],

push in gear (13) to separate it from the
cover.
4.
4)
5)
Scavenging pump drive gear assembly

1) Remove snap ring (18).
2) Remove gear (19) by pushing it into the
case.
Remove inner race (41) from gear (13).
D155AX-6
SEN01207-03
3)
Remove snap ring (20) and remove bearing (21) from the case.
1]
2]
5.
Idler gear assembly

1) Remove the mounting bolt and plate (22).
6.
2)
3)
Remove bearing (25) and spacer (26)

from gear (24).
a When reusing the bearing and
spacer, keep them so that they
will be combined with the original
outer race.
Remove outer race (27) and snap
ring (28) from gear (24).
Input shaft outer race

Remove snap ring (29) and input shaft outer
race (30).
Remove the mounting bolts and set guide

bolt [2].
Using forcing screws [3], remove shaft
(23).
a Keep holding the gear in the case.
D155AX-6
Assembly
a
a
a
1.
2.
SEN01207-03
1)
Install snap ring (28) to gear (24) and

press fit outer race (27).
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)
3)
4)
Install bearing (25) to shaft (23).

Install spacer (26).
Clean all the parts thoroughly and check them

for dirt or damage before installing.
After press fitting each bearing, drop 6 cc of
TO30 or TO10 onto it and rotate it about 10
turns.
Check that each snap ring is fitted to the
groove.
Input shaft outer race
Press fit input shaft outer race (30) and install
snap ring (29).
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.
D155AX-6
SEN01207-03
5)
6)
7)
Install gear (24).

Install bearing (25) and tighten plate (22)
with the bolt to press fit the bearing to the
shaft.
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
245.0 308.7 Nm {25.0 31.5 kgm}
While holding the inner race side of the

bearing with push tool [5], install drive
gear (19).
3)
Install snap ring (18).
Fix shaft (23) with the mounting bolts.
4.
3.
2)
Cooling fan pump drive gear and cover

assembly
1) Press fit bearing (16) to case (17).
Scavenging pump drive gear

1) Press fit bearing (21) to the case and
install snap ring (20).
D155AX-6
2)
Press fit bearing (15) to cover (12) and

3)
Press fit inner race (41) to gear (13).
SEN01207-03
5)
5.
4)
Install gear and cover assembly (11),

meshing it with the idler gear.
2 Mounting bolt; Adhesive (LT-2)
3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
Work equipment and HST pump drive gear

and cover assembly
1) Press fit bearing (40) to case (17).
Using the push tool, press fit gear (13) to

cover (12).
2)
D155AX-6
Press fit bearing (7) and inner race (8) to

gear (9).
SEN01207-03
6.
3)
Install gear and bearing assembly (6) to

cover (5).
4)
nstall gear and cover assembly (4) to the

case.
3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
2)
Install lubrication tube (1).

3 Joint bolt:
34.3 44.2 Nm {3.5 4.5 kgm}
Lubrication tube
1) Install lubrication tube (2).
3 Joint bolt:
34.3 44.2 Nm {3.5 4.5 kgm}
D155AX-6

torque converter assembly
SEN01207-03
3.
Disassembly of drive case and housing

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)
2.
2)
Using 2 forcing screws [5] from the turbine

side, remove bearing (8).
3)
Remove the 30 mounting bolts. Using

eyebolts [2], remove housing assembly
(6).
Remove snap ring (2) and bearing (3).
Drive case and housing assembly

1) Remove 30 mounting bolts (57) between
the drive case and pump. Using eyebolts
[3], remove drive case and housing
assembly (56).
D155AX-6
SEN01207-03
4)
4.
5.
10
Remove 2 seal rings (7) from housing (9).
6.
Turbine gear
Remove turbine gear (15).
Piston
1) Remove piston (10).
2) Remove 2 seal rings (11) from piston (10).
7.
Stator and race assembly

1) Remove snap ring (16) and stator and
race assembly (17).
Discs and plate

Remove 2 discs (12) and plate (13).
2)
Remove 2 snap rings (18) and remove

race (19) from stator (20).
D155AX-6
3)
8.
Remove snap ring (21).
Pump
2) Remove pump assembly (25) from stator
shaft and clutch assembly (24).
SEN01207-03
9.
Stator clutch assembly

1) Loosen 3 mounting bolts (31) gradually to
disconnect housing and shaft assembly
(32).
2)
3)
4)
3)
4)
Remove stator clutch piston (33).

Remove seal ring (34) from stator clutch
piston (33).
Remove 5 pins (35) and 10 springs (36)
and remove 2 stator clutch discs (37) and
stator clutch plate (38) from housing (39).
Remove 12 mounting bolts (26) and

remove pump (28) from retainer (27).
Remove snap ring (29) and remove bearing (30) from retainer (27).
D155AX-6
11
SEN01207-03
5)
Disassemble housing and shaft assembly

1] Remove 6 mounting bolts (40).
2] Using forcing screws, remove shaft
assembly (41).
3]
4]
Remove seal ring (42), bushing (43)

and sleeve (44) from shaft (45).
5]
Press the shaft with a press to

remove shaft and bearing assembly
(48) from housing (49).
6]
Remove snap ring (50) and remove

spacer (51) and bearing (52) from
shaft (53).
Remove seal ring (54) from shaft
(53).
7]
Remove snap ring (46) and gear (47).

8]
12
Remove seal ring (55) from housing

(49).
D155AX-6
Assembly
a
a
a
1.
SEN01207-03
4)
Using the push tool and press, press fit

shaft and bearing assembly (48) to housing (49).
5)
Install bushing (43) and sleeve (44) to

shaft (45).
a Install the bushing and sleeve by
expansion fit.
Install seal ring (42) to shaft (45).
a Fix the seal ring securely with grease.
2 Seal ring: Grease (G2-LI)
Clean all the parts and check them for dirt or

damage. Coat their sliding surfaces with
engine oil before installing.
After press fitting each bearing, drop 10 cc of
TO30 or TO10 onto it and rotate it about 10
turns.
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.
Stator clutch assembly
1) Using push tool [3] and the press, press fit
bearing (52) to shaft (53).
6)
2)
3)
Install spacer (51) and snap ring (50) to

shaft (53).
Install seal ring (54) to shaft (53).
a Fix the seal ring securely with grease.
2 Seal ring: Grease (G2-LI)
7)
D155AX-6
Install shaft assembly (41) to housing (49)

with 6 bolts (40).
3 Mounting bolt:
58.8 73.6 Nm {6.0 7.5 kgm}
13
SEN01207-03
8)
9)
Reverse the housing assembly and install

gear (47) and snap ring (46).
Install seal ring (55) to housing (49).

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)
12) Install 5 pins (35).

13) Install 2 stator clutch discs (37) and stator
clutch plate (38).
14) Install 10 springs (36).
14
D155AX-6
15) Place housing (39) and tighten 3 mounting

bolts (a) from under side.
a Tighten 3 mounting bolts (a) gradually
and evenly.
3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
16) Before installing the pump, insert 10
mounting bolts (b) of the transmission
assembly and torque converter assembly.
SEN01207-03
2.
Pump
1) Press fit bearing (30) to retainer (27) and
2) Install retainer (27) to pump (28).
2 Mounting bolt (26): Adhesive (LT-2)
3 Mounting bolt (26):
58.8 73.6 Nm {6.0 7.5 kgm}
3)
4)
3.
D155AX-6
Install pump assembly (25) to stator shaft

and clutch assembly (24).
Install spacer (23) and snap ring (22).
Snap ring
Install snap ring (21) to the shaft.
15
SEN01207-03
4.
Stator and race assembly

1) Install race (19) to stator (20) and install 2
snap rings (18).
2)
5.
16
2)
Place drive case (14) on turbine gear (15).
3)
Install 2 discs (12) and plate (13).
4)
Install 2 seal rings (11) to piston (10).

a The seal rings must be installed in the
Grease (G2-LI)
Install stator and race assembly (17) and

snap ring (16).
Drive case and housing

1) Set turbine gear (15) on block [4].
D155AX-6
5)
Install piston (10).
6)
Install 2 seal rings (7) to housing (9).

a The seal rings must be installed in the
Grease (G2-LI)
7)
Sling housing assembly (6) and install it to

the drive case.
a While aligning the 3 holes on the piston top with the pins on the inside of
the housing, lower the housing gradually.
3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
D155AX-6
SEN01207-03
8)
Using push tool [6], push the inner race of

bearing (8) to press fit.
9)
Install spacer (5) and snap ring (4).
10) Install drive case and housing assembly

(56).
a Align plug (57) of the pump with the
oil groove of the drive case.
3 Mounting bolt:
49.0 58.8 Nm {5.0 6.0 kgm}
3 Plug:
14.7 19.6 Nm {1.5 2.0 kgm}
17
SEN01207-03
6.
Input shaft
1) Install bearing (3) and snap ring (2).
2)
18
Install input shaft (1).

3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
D155AX-6
SEN01207-03

transmission assembly
2)
Remove the nut of wiring harness connector (2A) and push in the connector.
3)
Remove sleeve (3) and flanges (4) and

(5).
4)
Remove control valve assembly (6).
791T-615-1300 Puller assembly

1 791T-615-1310 Plate
01010-82040
Bolt
799-301-1600
Oil leak tester kit

(A)
G 3 791T-615-1350 Push tool

791T-615-1320 Plate
4
01017-31620 Bolt
5
791T-615-1330 Plate
01282-61230
Bolt
6 791T-615-1340 Plate
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
t 1
1
1
t 1
t 1 N Q
t 1 N Q
t 4
t 2 N Q
t 4
t 1 N Q
Disassembly
a
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).
2.
Control valve assembly

1) Remove cover assembly (2).
D155AX-6
19
SEN01207-03
3.
4.
Snap ring
Remove snap ring (123) from output shaft
(124).
a Remove the snap ring at this time.
Transmission case
1) Set the block with the torque converter
side up.
2) Remove sleeve (7).
5.
Tie bolts
Remove 4 remaining tie bolts (9).
6.
Input shaft-front cover-No. 1 carrier assembly

1) Using sling bar [3], remove input shaftfront cover-No. 1 carrier assembly (11).
2)
3)
20
Using eyebolts [2], sling transmission case

(8), remove 13 tie bolts (9) (used to clamp
the transmission case, too), and remove
case (8).
Disassemble the input shaft-front coverNo. 1 carrier assembly according to the

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).
D155AX-6
3]
4]
Using tool G3, remove snap rings

(18) and (126).
Using tool G3, drive out carrier toward
the torque converter and remove front
cover (19).
5]
Remove snap ring (20) and drive out

input shaft (21) toward the torque
converter.
6]
7]
Remove collar (128).

Remove snap ring (22) and No. 1 ring
gear (23).
Pull out shaft (24) and remove thrust
washer (25), gear (26), bearing (27)
and ball (28).
a Take care not to lose the ball.
8]
D155AX-6
SEN01207-03
7.
No. 1 disc, plate and spring

1) Remove spring (29).
2) Remove springs (30), discs (31) and
plates (32).
8.
No. 1 housing assembly

1) Using eyebolts [4], remove No. 1 housing
assembly (33).
2) Remove No. 1 piston (34) from the housing.
9.
Guide pin
Remove guide pins (35).
10. No. 2 disc, plate and spring

plates (39).
21
SEN01207-03
11. Remove through bolt guide (40), lubricating oil

relief valve (41) and spring (130).
12. Snap ring

Remove snap ring (125).
1]
Remove snap ring [44] and pull out

No. 2 carrier assembly (45) from No.
2 housing (46).
2]
Remove spacer (47) from No. 2 carrier assembly (49).

Pull out shaft (50) and remove thrust
and ball (54).
3]
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]
3)
22
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.
Disassemble No. 2 housing and No. 2 carrier assembly according to the following
procedure.
D155AX-6
5]
Remove seal ring (57) and snap ring

(58) from No. 2 housing (46) and
remove bearing (59).

1) Remove springs (60).
plates (63).
15. No. 3 carrier assembly

1) Remove No. 3 carrier assembly (64).
2)
SEN01207-03
4]

Remove snap ring (71) and bearing
(72).
16. Output shaft and No. 4 sun gear

1) Pull out output shaft (73).
2) Remove snap ring (74) from the output
shaft.
3) Remove No. 4 sun gear (75).
17. No. 4 carrier and No. 3 ring gear assembly

1) Remove No. 4 carrier and No. 3 ring gear
assembly (76).
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).
D155AX-6
23
SEN01207-03
2)
Disassemble the No. 4 carrier and No. 3

ring gear assembly according to the following procedure.
1] Remove snap ring (77) and ring gear
(127).
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).
19. No. 4 disc, plate, spring and guide pin

2) Remove springs (90), No. 4 discs (91) and
plates (92).
3) Remove guide pin (93).

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)
24
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).
D155AX-6
2]
Remove snap ring (101) and remove

No. 4 ring gear (102) from carrier
(103).
21. No. 5 sun gear

Remove No. 5 sun gear (104).
SEN01207-03

1) Remove springs (107).
2) Remove discs (108), plates (109) and
springs (110).
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
SEN01207-03
2)
3)
Remove seal rings (116) and (117) from

cover (118).
Remove bearing (119) from cover (118).
Assembly
q
a
a
a
a
Precautions for assembly

Coat the sliding surfaces of each part with
engine oil (For details, see "Table of fuel, coolant and lubricants") before installing.
When installing piston seal ring (a), direct the
pressure receiving side (b) toward housing (c).
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 output housing (123).
2) Remove bearing (121) from spacer (122).
1.
26
Output housing
1) Using the push tool, press fit bearing (121)
to spacer (122).
D155AX-6
2)
3)
2.
Using the push tool, press fit spacer (122)

and bearing assembly (121) to output
housing (123).
Cover assembly
to cover (118).
2) Install seal rings (117) and (116) to cover
(118).
3)
4)
SEN01207-03
3.
No. 5 piston
Install No. 5 piston (112) to the output housing.
4.
No. 5 ring gear

Install No. 5 ring gear (111).
5.
Guide pin
Install guide pin (93).
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
Using the push tool, install cover assembly (114) to output housing assembly
(115).
a Press fit the inner race side of the
bearing to install.
D155AX-6
27
SEN01207-03
7.
No. 4 housing assembly

1) Fit the seal ring and install No. 4 piston
(106).
2) Install No. 4 housing assembly (105).
a Check that the springs are fitted to
the grooves.
8.
No. 5 carrier and No. 4 ring gear assembly

1) Assemble the No. 5 carrier and No. 4 ring
procedure.
1] Set No. 4 ring gear (102) to carrier
(103) and install snap ring (101).
2]
3]
28
Install bearing (99) to gear (98).

While fitting thrust washers (97) to
both sides of them, set them to the
carrier.
Fit ball (100) and install shaft (96).
2)
9.
Using guide bolts, set No. 5 carrier and

No. 4 ring gear assembly (95) and tighten
mounting bolts (94).
2 Threaded part of mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
66.2 7.4 Nm {6.75 0.75 kgm}
No. 5 sun gear

Install No. 5 sun gear (104).
10. No. 4 discs, plates and springs

1) Install No. 4 discs (91), plates (92) and
springs (90).
2) Install springs (89).
D155AX-6
SEN01207-03

(88).
2) Install No. 3 housing (87).
the grooves.
8]
2)
Set the No. 3 ring gear to No. 4 carrier and install snap ring (77).
a Check that the snap ring is fitted
to the groove.
Install No. 4 carrier and No. 3 ring gear

assembly (76).

1) Assemble No. 4 carrier and No. 3 ring
procedure.
1] Using the push tool, press fit bearing
(85) to spacer (86).
13. No. 4 sun gear

Install No. 4 sun gear (75).
2]
3]
4]
5]
6]
7]
D155AX-6
Using the push tool, press fit spacer

(86) and bearing assembly (85) to the
No. 4 carrier.
Install bearing (83) to planetary gear
(82). While fitting thrust washers (81)
to both sides of them, set them to the
carrier.
While setting the shaft pin hole to the
carrier pin hole, install shaft (80A).
Check that the pin holes are aligned
and drive roll pin (80).
Install seal rings (79) and (78).
14. Output shaft

1) Install snap ring (74) to the output shaft.
2) While setting output shaft (73) to the
spline of the sun gear, push it in.
29
SEN01207-03
15. No. 3 carrier assembly

1) Assemble the No. 3 carrier assembly
(72) to the carrier and install snap ring
(71).
2] Install bearing (69) to planetary gear
(68). While fitting thrust washers (67)
to both sides of them, set them to the
carrier.
3] Fit ball (70) and install shaft (66).
4] Install seal ring (65).
2)
Install No. 3 carrier assembly (64).

1) Install discs (62), plates (63) and springs
(61).
17. No. 2 housing and No. 2 carrier assembly

1) Assemble the No. 2 housing and No. 2
carrier assembly according to the following procedure.
1] Press fit bearing (59) to No. 2 housing
(46) and install snap ring (58).
2] Install seal ring (57).
3]
30
Set No. 1 ring gear (56) and No. 2

carrier (45) and install snap ring (55).
D155AX-6
4]
5]
Install bearing (53) to gear (52).

carrier.
Fit ball (54) and install shaft (50).
6]
7]
Install No. 2 ring gear (48).

a Direct the side of the cut inside
toward the carrier.
8]
Install No. 2 housing (46) to No. 2 carrier assembly (45).

a Press fit the inner race side of
the housing bearing.
9]
D155AX-6
SEN01207-03
2)
3)
4)
Using eyebolts [5], install No. 2 housing

and No. 2 carrier assembly (42).
the grooves.
Fit the seal ring and install No. 2 piston
(43).
Install tool G1 to the inside groove of the

No. 3 carrier, pull it up, and install snap
ring (125).
18. Install through bolt guide (40), spring (130) and

lubricating oil relief valve (41).
31
SEN01207-03
19. Guide pin

Install guide pins (35).
3]
Set No. 1 ring gear (23) to No. 1 carrier and install snap ring (22).
4]
Press fit bearing (117) to input shaft

(21).
Install No. 1 carrier assembly (118) to
input shaft (21) and install snap ring
(18).

springs (37).
a Free length of spring: 81.7 mm
5]

(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]
7]
8]
Install collar (17).

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 procedure.
1] Install bearing (27) to gear (26).
carrier.
32
D155AX-6
9]
2)
Install No. 2 sun gear (13) and snap

ring (12).
Sling input shaft and No. 1 carrier assembly (119) and install it, while meshing the
No. 2 sun gear with No. 2 planetary gear.

1) Install collar (128).
spring (30).
a Install 6 discs and 5 plates.
a Free length of spring: 81.7 mm
D155AX-6
SEN01207-03
24. Front cover

1) Install seal ring (121) to front cover (122).
2)
Using eyebolts [6], install front cover

(122), while aligning it with the guide pins
and springs.
25. Tie bolts

Install tie bolts (9) (4 pieces). (The 4 bolts
marked with * in the attached drawing).
3 166.7 9.8 Nm {17 1 kgm}
33
SEN01207-03
26. Snap ring

a While tighten bolt (b) and bracing the inner
side of bearing (123) with tool G6, raise
the input shaft (A) and carrier (B) (hatched
part) and set the groove of snap ring (124)
in position.
a When it becomes hard to tighten bolt (b),
the groove of snap ring (124) is set in
position.
a Check that the springs are fitted to the
cover.
28. Transmission case

Fit the O-ring. Using eyebolts [2], install transmission case (8) and remaining 13 tie bolts (9).
3 Tie bolt: 166.7 9.8 Nm {17 1 kgm}
29. Sleeve
Install sleeve (7).
27. Operation check of piston

Using tool G2, check the operating condition
and stroke of each piston.
34
Piston
Standard stroke (mm)
No. 1
7.2
No. 2
No. 3
No. 4
No. 5
30. Snap ring

Raise the case assembly and install snap ring
(123) to output shaft (124).
D155AX-6
31. Control valve assembly

1) Install control valve assembly (6).
3 Mounting bolt:
49.1 4.9 Nm {5.0 0.5 kgm}
2)
Install flanges (4) and (5) and sleeve (3).
3)
Install cover assembly (2).

2 Threaded part of mounting bolt:
Gasket sealant (LG-11 or LG-5)
D155AX-6
SEN01207-03
32. Main relief valve assembly

Install main relief valve assembly (1).
3 Mounting bolt:
49.1 4.9 Nm {5.0 0.5 kgm}
35
SEN01207-03

HSS case assembly
Disassembly of brake and carrier assembly

1) Remove flange (2) and plate (3).
1
H
2
3
791-662-1110
Bracket
t 1
01010-31685
Bolt
t 1
01017-31620
Bolt
t 1
790-302-1500
Spanner kit
t 1
09003-09200
Spanner
790-302-1500
Spanner kit
t 1
09003-08290
Spanner
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
2)
Loosen the hexagon socket head bolts

evenly. Using eyebolts [1], remove brake
case (5).
a Since the brake case is pressed by
the brake spring, loosen the bolts
evenly.
a The outside bearing comes off
together with the cover.
3)
Remove spacer (6), brake springs (7), piston (8) and cylinder (9).
Disassembly
1.
36
Brake and carrier assembly

1) Slant HSS case assembly about 15 so
that tool H1 will be installed vertically.
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 assembly on the opposite side similarly.
D155AX-6
4)
Remove brake drum (12), discs and plates

together.
SEN01207-03
8)
9)
5)
Remove ring (21) and remove ring gear

(22) from gear (108).
Remove snap ring (23) and pull out shaft
(24).
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)
7)
Remove the mounting bolts and remove

carrier assembly (19) from hub (18).
Remove gear assembly (20) form hub
assembly (18).
D155AX-6
11) Remove snap ring (31) and remove stopper (32) from hub (18).
37
SEN01207-03
2.
Bevel pinion assembly

1) Using guide bolt [3] and forcing screws,
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).
2]
3]
6]
3.
Sun gear
Remove sun gear (45).
a Remove the sun gear on the opposite side
similarly.
4.
Gear
Hold the pinion securely with a press.

Using tool H2, remove locknut (39).
Using push tool [5], remove bevel pinion (40) from cage (41).
2)
4]
5]
38
Remove bearing (109) from bevel

pinion (40).
Using gear puller [6], remove gear (49).
Remove bearing (42).

Remove outer races (43) and (107)
from cage (41).
D155AX-6

a
a
SEN01207-03
Only inner race (50) of bearing (55) is

left.
Remove the gear on the opposite
side similarly.
2)
3)
7.
5.
Valve seat
1) Pull out and remove 2 brake circuit tubes
(51) and 2 lubrication tubes (52).
2) Remove valve seat (53).
Motor output gear

1) Remove flange (61) from case (62).
2) Remove flange and gear assembly (63).
3)
6.
Remove lubrication tubes (57) and (58).

Remove oil level gauge pipe (59) and suction tube (60).
Remove gear assembly (65) from flange

(64).
Lubrication tubes, oil level gauge pipe and

suction tube
1) Remove lubrication tubes (52) and (56).
D155AX-6
39
SEN01207-03
4)
5)
Remove inner race (67) and bearing (68)

from gear (66).
Remove bearing (69) from flange (61).
3)
4)
9.
8.
Right-hand carrier drive gear

1) Remove bolt (70), plate (71) and gear
(72).
2)
40
Remove inner race (75) from bearing (74).

Remove bearing (74).
Intermediate gear
1) Remove shaft mounting bolts.
2) Using shock hammer [8], pull out shaft
(76) and remove gear (77) and bearing
(78).
Drive out shaft (73) with a plastic hammer

etc.
D155AX-6
10. Bevel gear shaft and bevel gear assembly

1) Remove mounting bolts (85) of the lefthand retainer.
2) Remove mounting bolts (86) of the righthand 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.
4)
SEN01207-03
2]
Remove right-hand retainer (89) from

shaft (92).
3]
Remove hexagon socket head bolts

(95), plate (93) and shim (94).
4]
Using tool H3, remove nut (96).
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.
D155AX-6
41
SEN01207-03
5]
6]
Using puller [12], pull out left-hand

retainer (97) from shaft (92).
Remove bearing (98) from retainer
(97).
Assembly
q
a
a
a
a
a
a
7]
Remove nut (99) and remove bevel

gear (100) from shaft (92).
1.
8]
42
Remove bearing (101) from righthand retainer (89).
Precautions for assembly

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.
When installing the piston seal ring, apply
grease (G2-LI) to it, direct the pressure receiving side toward the housing, and fit it evenly.
Fix the rotary seal ring with grease (G2-LI) and
install it carefully so that it will not be caught.
groove.
Bevel gear shaft and bevel gear assembly

1) Assembly of bevel gear shaft and bevel
gear assembly
1] Using the push tool, press fit bearings
(101) and (74) to right-hand retainer
(89).
D155AX-6
2]
Install inner race (108) to shaft (92) by

shrink fit.
a Shrink fit temperature: 100 C for
about 30 minutes
3]
Set bevel gear (100) to shaft (92) and

tighten nut (99).
3 Nut:
215.8 274.6 Nm {22.0 28.0 kgm}
Install the seal ring.
4]
5]
6]
D155AX-6
SEN01207-03
7]
Support the bevel gear with block

[13]. Using push tool [14], press fit
retainer assembly (102) to the shaft.
8]
Fix the shaft. Using tool H3, tighten

nut (96).
2 Nut: Adhesive (LT-2)
3 Nut:
735.5 902.2 Nm {75.0 92.0 kgm}
a Remove the bolts which the tool
will interfere with.
Install outer race (103), bearing (104),

spacer (105), bearing (104) and outer
race (103) to left-hand retainer (97) in
order.
Install plate (93) and fix it with several
hexagon socket head bolts.
43
SEN01207-03
9]
Adjustment of shim
Tighten the 4 bolts lightly and measure dimensions [a] and [c] to obtain
dimension [b] and then select a shim
of dimension [b].
Shim thickness [b] =
([a] [c]) (0.1 0.2 mm)
10] Set selected shim (94) and tighten
bolts (95).
2)
3)
4)
11] Install right-hand retainer (89) to shaft

(92).
Install left-hand retainer (88) and guide

bolts [9].
Using eyebolts [10], sling the right-hand
retainer. While aligning the guide bolts to
the bolt holes, install bevel gear shaft and
bevel gear assembly (90) to the case.
Install the shim to the left-hand retainer

and tighten right-hand and left-hand
retainer mounting bolts (85) and (86).
a Shims of 0.1, 0.2 and 0.5 mm thickness are prepared.
a The left-hand retainer mounting bolts
need to be loosened later to adjust
the backlash 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)
SEN01207-03
Push the tooth tip of bevel gear (100) with

push-pull scale [7] to measure the "starting torque" of the bevel gear shaft.
a Starting torque:
Max. 3.0 Nm {0.3 kgm}
(At bevel gear tooth tip: Max. 19.6 N
{2.0 kg})
3)
3.
2.
Intermediate gear
1) Install snap ring (83) and spacer (84) to
gear (77). Using the push tool, press fit
outer race (82).
2) Install lower bearing (78), spacer (81) and
upper bearing (78).
Right-hand carrier drive gear

to the case.
2) Using the push tool, press fit inner race
(75) to shaft (73).
a Press fit to about 27 mm from the
shaft face.
a Install to only 1 side.
3)
D155AX-6
Install gear assembly (79) to case (80).

While aligning the bolt holes, install shaft
(76).
a When installing the shaft, align the
bolt holes.
Install shaft (73), while setting it to the

bearing.
45
SEN01207-03
4.
46
4)
Using the push tool, install inner race (75)

between the shaft and bearing.
a Hold the shaft from the opposite side.
5)
Install gear (72) and plate (71) and tighten

bolt (70).
3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
Lubrication tubes, oil level gauge pipe and

suction tube
1) nstall suction tube (60) and oil level gauge
pipe (59).
2) Install lubrication tubes (57) and (58).
3 Joint bolt:
7.8 9.8 Nm {0.8 1.0 kgm}
3)
5.
Install lubrication tube (56).

3 Joint bolt:
7.8 9.8 Nm {0.8 1.0 kgm}
Bevel pinion assembly

1) Assembly of bevel pinion
(109) to bevel pinion (40).
2]
3]
Using the push tool, press fit outer

races (43) and (107) to cage (41).
Place bevel pinion (40) on the press
stand and set cage (41).
D155AX-6
4]
5]
Press fit bearing (42) to cage (41).

Hold the pinion with the press. Using
tool H2, tighten locknut (39).
2 Locknut: Adhesive (LT-2)
3 Locknut:
696.3 863.0 Nm {71 88 kgm}
a While rotating the cage, tighten
the locknut.
a After tightening the nut, check
that the bevel pinion rotates
smoothly.
6.
Adjustment of backlash and tooth contact

1) Adjustment of backlash
Apply the probe of dial gauge [6] to the
tooth tip at the end of the bevel gear perpendicularly. While fixing the bevel pinion,
move the bevel gear forward and backward and read the dial gauge.
a Standard backlash: 0.25 0.33 mm
a Measure the backlash diagonally at 3
or more places.
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]
2)
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}
Using guide bolts [3], set shim (34) and
install bevel pinion assembly (33).
a Shims of 0.1, 0.2 and 0.5 mm thickness are prepared.
SEN01207-03
D155AX-6
When backlash is too large

Decrease the thickness of the shim
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).)
47
SEN01207-03
2)
Adjustment of tooth contact

Testing
1] Apply red lead thinly to the tooth surfaces of the bevel gear and turn the
bevel gear in the forward and reverse
directions, and then check the tooth
contact pattern on the bevel gear.
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
Check that there is not a strong
contact at tips (A), roots (B),
small end (C) or large end (D).
a If the bevel gear and bevel pinion
are adjusted in this way, their
teeth come in contact with each
other correctly when they are
loaded.
Adjustment
If the tooth contact pattern is not proper,
adjust the tooth contact according to the
1) If the bevel pinion is too far from the
center line of the bevel gear, the contact is at the small end of the bevel
gear tooth faces curved outward and
at the large end of the bevel gear
tooth faces curved inward.
q
In this case, adjust the tooth contact
Adjust the thickness of the shims on
the bevel pinion side to move the
bevel pinion in direction (A). Move
the bevel gear in direction (B) and
then check the tooth contact pattern
and backlash again.
2)
48
If the bevel pinion is too close to the

center line of the bevel gear, the contact is at the large end of the bevel
gear tooth faces curved outward and
the small end of the bevel gear tooth
faces curved inward.
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), then
check the tooth contact pattern and
backlash again.
Do not change the total thickness of
the shims on the right and left sides.
D155AX-6
3)
SEN01207-03
When adjustment is finished, tighten

the mounting bolts of the cage and
bevel pinion assembly to the specified torque.
3 Mounting bolts of cage and
bevel pinion assembly:
98 123 Nm {10.0 12.5 kgm}
4)
5)
8.
7.
Install flange and gear assembly (63) to

case (62).
Install flange (61).
Valve seat
1) Install lubrication tube (52).
Motor output gear

to flange (61).
(67) and bearing (68) to gear (66).
2)
3)
3)
Install valve seat (53), while setting it to

lubrication tube (52) installed in 8-1).
Install brake circuit tube (51) and lubrication tube (52).
Install gear assembly (65) to flange (64).
D155AX-6
49
SEN01207-03
9.
Gear
1) Install inside bearing (55), snap ring (54)
and outside bearing (55) to gear (49).
2) Install gear (49), while setting it to the
bevel gear shaft bearing.
3)
4)
11. Brake and carrier assemblies

a Assemble both assemblies according to
the same procedure.
q
Assembly of brake and carrier assembly
1) Install stopper (32) to hub (18) and install
snap ring (31).
2) Install bushing (38).
(37).
Using the push tool, press fit inner race

(50).
Fit spacer (48) and install snap ring (47).
4)
Carrier assembly
1] Install bearing (26) to gear (25).
carrier.
3] Install snap ring (23).
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]
6]
7]
8]
5)
6)
Install bushings (29) and (30) to gear

(108).
Set gear (108) to ring gear (22),
install ring (21), and install the ring
gear to the gear.
Install gear assembly (20) to hub (18).

Install carrier assembly (19) to hub
(18).
3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
Set brake drum (12) to hub assembly (18).

Install discs (15), plates (14) and (13) and
springs (16).
a Install the 5 discs, 4 plates (14) and 1
plate (13).
D155AX-6
SEN01207-03
7)
8)
9)
Hub
(17) to hub (9).
2] Fit the seal ring and install hub (9).

Install spacer (6).
Install piston (8) and spring (7).
a Install the spring so that its outside
will open.
10) Brake cover assembly

(11) to brake cover (10).
2] Install guide bolt [2] to hub (9).
51
SEN01207-03
3]
Using eyebolts [1], install brake cover

assembly (5), while aligning the bolt
holes of the hub and brake drum.
a Tighten the mounting bolts temporarily.
a Tighten the hexagon socket head
bolts evenly since the springs are
working.
1)
2)
a
a
4]
5]
6]
52
Installation of brake and carrier assembly

Slant the steering case assembly about 15
degrees so that tool H1 will be installed vertically.
Using tool H1, install brake and carrier assembly (1).
3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
Install the brake and carrier assembly on the
opposite side similarly.
If rear cover (109) of HSS case (107) was
removed, install new gasket (108).
2 Gasket (Apply to both sides):
Using the push tool, press fit inner

race (4).
Install plate (3) and flange (2).
3 Flange:
58.8 73.6 Nm {6.0 7.5 kgm}
Periodically tighten the bolts tightened temporarily in 3].
3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
D155AX-6
Removal and installation of HSS

motor assembly
1
SEN01207-03
Installation
q

removal.
Refilling with oil (Hydraulic tank)

again.
Removal
k
1.

Drain the oil.
6
2.
Remove the fuel tank assembly. For details,

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 mounting bolts, and lift off the motor assembly.
4
D155AX-6

Approx. 91.5 l
Motor assembly: 75 kg
53
SEN01207-03
D155AX-6 Bulldozer
2012 KOMATSU
All Rights Reserved
54
D155AX-6
SEN02707-01
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine Model
Serial Number
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
SEN02707-01
Removal and installation of final

drive assembly
1
3.
Raising of machine
k 1)
Using a jack (686 kN {70 ton}) and
the ripper of the work equipment,
raise the machine and set right and
left support stands [1] under the
steering case.
2) Set right and left support stands [2]
under the main frame on the front
side of the machine.
a After setting support stands [1] and [2], set
the hydraulic jack and ripper as auxiliary
supports.
4.
Remove guards (3) and (4).
790-337-1032
Lifting tool
t 1
791-627-1320
Shackle
t 2
791T-627-1910 Plate
01010-82080
Bolt
t 1
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
t 2
Removal
1.
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]
D155AX-6
5.
Remove drive shaft cover (5).
SEN02707-01
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
6.
Final drive assembly: 1,400 kg
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
q

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
SEN02707-01

final drive assembly
Disassembly
1.
790-431-1031
Block
t 1
791-520-4140
Screw
t 2
790-101-2360
Plate
t 2
791-112-1180
Nut
t 2
790-101-2480
Adapter
t 2
791T-627-1920 Plate
t 1
790-101-2102
Puller
t 1
790-101-1102
Hydraulic pump
t 1
790-431-1031
Block
t 1
791-520-4140
Screw
t 1
791-112-1180
Nut
t 2
01643-32460
Washer
t 2
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
Draining oil
Remove the drain plug to drain the oil in the
final drive case.
Final drive case: Approx. 31 l
2.
Drive shaft
Remove drive shaft (1).
3.
Shaft
1) Set the final drive assembly to the block.
791T-627-1930 Plate
t 1
791T-627-1940 Push tool
t 1
790-101-2102
Puller
t 1
790-101-1102
Hydraulic pump
t 1
791-627-1280
Installer
t 1
790-101-5401
Push tool kit
t 1
790-101-5441
Plate
790-101-5421
Grip
01010-51240
Bolt
1
t 1
790-101-5401
Push tool kit
790-101-5451
Plate
790-101-5421
Grip
01010-51240
Bolt
791T-627-1950 Plate
t 1
791T-627-1960 Plate
t 1
790-201-1500
Push tool kit
t 1
790-201-1680
Plate
790-101-5021
Grip
01010-50816
Bolt
791-520-4140
Screw
t 1
790-101-2420
Adapter
t 1
791-112-1180
Nut
t 1
01643-22460
Washer
t 1
792-785-1120
Plate
t 1
791-830-1410
Push tool
t 1
790-101-2102
Puller
t 1
790-101-1102
Hydraulic pump
t 1
D155AX-6
3)
4.
SEN02707-01
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.
5)
Reverse the sprocket hub assembly and

remove 9 sprockets (11).
Sprocket hub assembly

1) Remove mounting bolts (4) and plate (5).
2)
3)
Using tool K1, pull out sprocket hub

assembly (6).
a Bearing (7) comes off, too.
Using eyebolts [2], remove sprocket hub
assembly (6).
D155AX-6
5.
Wear guard
Remove wear guard (12).
SEN02707-01
6.
Cover assembly
1) Remove spacer (13).
2) Remove floating seal (14).
a Keep the floating seal in a safe place
so that it will not be damaged.
6)
7)
7.
4)
Carrier assembly
1) Using 3 eyebolts [5], remove carrier
assembly (21).
Using eyebolts [3], sling cover assembly

(16). Using 3 forcing screws [4], remove
the cover assembly.
2)
5)
Reverse the cover assembly and remove

6 lock plates (19).
Remove ring gear (20).
Remove bearing (17) and spacer (18).
Disassemble the carrier assembly according to the following procedure.

1] Remove bolts (22) and holders (23).
2] Pull out planetary gear shaft (24).
D155AX-6
8.
3]
Remove planetary gear (25), bearings (26) and (27) and spacer (28)
from the carrier.
4]
Remove bearing outer races (29) and

(30) from the planetary gear.
SEN02707-01
9.
Holder
Remove mounting bolt (33) and holder (34).
10. Gear
1) Remove the gear according to the following procedure.
1] Sling case-hub-case assembly (35) a
little.
2] Push the shaft of case (36) to make a
clearance between bearing (37) and
case shaft.
a Take care not to damage the
bearing holding area on the pinion side.
Sun gear
Remove thrust washer (31) and sun gear (32).
3]
4]
D155AX-6
Remove mounting bolts (38).

Using eyebolts [6], sling gear (39),
and slant the hub to remove the gear.
SEN02707-01
11. Hub and case assembly

1) Using tool K2, remove hub assembly (40)
and bearing (37).
2)
3)
4)
Remove collar (43) and remove bearing

(44) from case (36).
5)
Remove sump plate (45) from case (36).
Using eyebolts [7], remove hub assembly

(40).
Remove 2 bearing outer races (42) from

hub (41).
12. Cage assembly

1) Remove the mounting bolts of cage
assembly (46). Using forcing screws [8],
remove the cage assembly from case
(36).
D155AX-6
2)
Remove outer race (48) and oil seal (49)

from cage (47).
3)
Remove shims (50).
SEN02707-01
14. Outer race and oil seal

Remove outer race (55) and oil seal (56) from
case (36).
13. Gear assembly

1) Remove gear assembly (51).
2) Using puller [9], remove bearings (52) and
(53) from gear (54).
D155AX-6
SEN02707-01
Assembly
a
a
1.
2.
Gear assembly
1) Using the push tool [11], press fit bearings
(52) and (53) to gear (54).
q
Bearing press fitting force:
6 17 kN {0.6 1.7 ton}
2) Install the drive shaft cover.
3) Install gear assembly (51).
3.
Cage assembly
1) Using tool K4, press fit oil seal (49) to
cage (47).
a When press fitting the oil seal, take
care of its direction.
a Apply gasket sealant thinly to the
inside wall of the housing and wipe off
projected part.
2 Oil seal lip: Grease (G2-LI)
2 Oil seal press fitting area:

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:
2)
10
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}
D155AX-6
2)
Using tool K5, press fit bearing outer race

(48) to cage (47).
q
1 13 kN {0.1 1.4 ton}
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 quantity (c) of the shim from the total of
clearances (a) and (b).
D155AX-6
SEN02707-01
4]
Install determined shim (50) to the

cage and tighten the 6 mounting bolts
of cage (47) evenly.
3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
11
SEN02707-01
Table 1
4.
Number of shims
to be used
a + b (mm)
Above
Below
t = 0.15
3.05
3.15
3.15
3.25
3.25
3.35
3.35
3.45
3.45
3.55
3.55
3.65
3.65
3.75
3.75
3.85
3.85
3.95
3.95
4.05
4.05
4.15
4.15
4.25
4.25
4.35
4.35
4.45
4.45
4.55
4.55
4.65
4.65
4.75
4.75
4.85
4.85
4.95
4.95
5.05
5.05
5.15
5.15
5.25
5.25
5.35
5.35
5.45
5.45
5.55
5.55
5.65
5.65
5.75
5.75
5.85
5.85
5.95
5.95
6.05
6.05
6.15
3.25
6.15
6.25
3.30
6.25
6.35
3.35
6.35
6.45
3.40
6.45
6.55
3.45
6.55
6.65
3.50
6.65
6.75
6.75
6.85
6.85
6.95
6.95
7.05
7.05
7.15
7.15
7.25
7.25
7.35
12
t = 0.5
t = 1.0
Total
shim
thickness
(mm)
1.75
1.80
1.85
1.90
1.95
2.00
2.05
2.10
2.15
2.20
2.25
2.30
2.35
1
1
1
2.40
2.45
2.50
2.55
2.60
2.65
2.70
2.75
2.80
2.85
2.90
2.95
3.00
3.05
3.10
3.15
3.20
1
1
1
Hub and case assembly

1) Install oil sump plate (45) to case (36).
a When installing the plate, press its
surface against case faces (a) and
(b).
3.55
3.60
3.65
3.70
3.75
3.80
3.85
2)
3)
Using tool K5, press fit bearing (44) to

case (36).
q
21 54 kN {2.1 5.5 ton}
Install collar (43).
D155AX-6
5.
SEN02707-01
4)
Using tool K5, press fit 2 bearing outer

races (42) to hub (41).
q
3 18 kN {0.3 1.8 ton}
2)
Tighten gear mounting bolts (38).

3 Mounting bolt:
230 289 Nm {23.5 29.5 kgm}
5)
Using eyebolts [7], set hub assembly (40)

to the shaft.
3)
Using tool K7, press fit bearing (37) to

case (36).
q
21 54 kN {2.1 5.5 ton}
Gear
1) Using eyebolts [6], sling gear (39). While
slanting the hub, set the gear to the hub.
D155AX-6
6.
Holder
Install holder (34) and tighten mounting bolt
(33).
3 Mounting bolt:
230 289 Nm {23.5 29.5 kgm}
13
SEN02707-01
7.
Sun gear
Install sun gear (32) and thrust washer (31).
8.
Carrier assembly
a Since each planetary gear bearing is an
assembly, assemble it from the inner race,
outer race and spacer of the same identification mark.
1) Using tool K6, press fit bearing outer
races (29) and (30) to the planetary gear.
q
10 35 kN {1.0 3.6 ton}
2)
14
3)
Set the planetary gear assembly to the

carrier and press fit shaft (24).
a While aligning the holes of the bearing spacer, press fit the shaft gradually.
4)
Install holders (23) and tighten bolts (22).

3 Mounting bolt:
230 289 Nm {23.5 29.5 kgm}
5)
Using 3 eyebolts [4], install carrier assembly (21).
Install bearings (26) and (27) and spacer

(28) to planetary gear (25).
D155AX-6
9.
Cover assembly
1) Install ring gear (20) and 6 lock plates (19)
and tighten the mounting bolts.
2)
3)
4)
SEN02707-01
5)
Using eyebolts [3], fit the O-ring to cover

assembly (16) and install them to the case
assembly.
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.
6)
Tighten mounting bolts (15).

3 Mounting bolt:
455 565 Nm {46.5 58 kgm}

Using tool K3, press fit bearing (17).
q
15 43 kN {1.5 4.4 ton}
Using tool K4, press fit floating seal (14).

a Degrease and dry the O-ring and Oring 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
SEN02707-01
10. Wear guard

Install wear guard (12).
3 Mounting bolt:
824 1,030 Nm {84 105 kgm}
11. Sprocket hub assembly

1) Using tool K5, press fit bearing outer
races (9) and (10).
q
14 59 kN {1.5 4.4 ton}
2)
16
3)
Using tool K3, press fit floating seal (8).

a Degrease and dry the O-ring and Oring contact surface before installing
the floating seal.
a After installing the floating seal, check
that its tilt is 1 mm or less.
4)
Using eyebolts [2], install sprocket hub

assembly (6) to the cover assembly.
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.
Install 9 sprockets (11) to the sprocket

hub.
3 Mounting bolt:
1,176 98 Nm {120 10 kgm}
D155AX-6
5)
SEN02707-01
Using tool [10], press fit bearing (7).

a While rotating the sprocket hub
assembly, press fit the bearing.
q
15 43 kN {1.5 4.4 ton}
2)
Tighten mounting bolts (2).

3 Mounting bolt:
1,225 1,470 Nm {125 150 kgm}
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}
a
12. Shaft
1) Fit the O-ring to the sprocket hub assembly. Using eyebolts [1], install shaft (3).
Refilling with oil

Tighten the drain plug and add oil through the
oil filler.
After installing the final drive assembly to the
machine, check the oil level again.
5
3
3
D155AX-6
Final drive case: Approx. 31 l (TO30)

Oil filler/Drain plug:
127 176 Nm {13 18 kgm}
Oil level gauge plug:
58.8 76.4 Nm {6 8 kgm}
17
SEN02707-01
D155AX-6 Bulldozer
2007 KOMATSU
All Rights Reserved
18
D155AX-6
SEN01208-02
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine Model
Serial Number
D155AX-6
80001 and up

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
SEN01208-02
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
D155AX-6
SEN01208-02
Removal and installation of track

frame assembly
1
2)
791T-130-1010 Bracket
KK
3)
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
t 6 N Q
01010-63060
Bolt
t 12
01643-33080
Washer
t 12
Set hydraulic jack [2] under the center of

the equalizer bar and float the front part of
the machine and then set right and left
support stands [3] under the main frame
on the front side of the machine.
Set blocks under the front part of the
floated track frame to secure safety during
work.
a After setting support stands [1] and
[3], set the hydraulic jack and ripper
as auxiliary supports.
Removal
1.
Remove the blade assembly. For details, see

"Removal and installation of blade assembly".
2.

3.
Using tool KK, fix the bogie assembly.
4.
Raise the machine according to the following

procedure.
1) Raise the machine with a jack or the ripper
and set right and left support stands [1]
under the frame to float the rear part of the
machine.
D155AX-6
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
frame.
k If the track frame on the opposite side
is floated before the pin is removed,
support it with blocks etc.
SEN01208-02
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) connected 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.
D155AX-6
Installation
q

removal.
[*1]
Threaded part of mounting bolt (1):

Adhesive (LT-2)
3 Mounting bolt (1): 7
84 981 Nm {80 100 kgm}
q
Add grease (G2-LI) through the grease fitting.
[*2]
a Install seal (13) according to the following procedure.
1) Reverse seal (13) so that the molded letter (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.
SEN01208-02
[*4]
1) Reverse seal (17) so that the molded letter (c) face will be on the inside.
2) With the seal reversed, insert seal (17) in
pivot shaft (18).
3) Apply engine oil (For details, see "Table of
fuel, coolant and lubricants") to face (d) of
track frame assembly (16).
4) Install track frame assembly (16) to the
pivot shaft (18).
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
SEN01208-02
Removal and installation of idler

assembly
1
7.
Removal
1.

k Never stand in front of the idler assembly 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 outside support.
Remove spring seats (6) and tension springs

(7).
a The above parts are installed between the
support and track frame.
Installation
q

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
D155AX-6
SEN01208-02

idler assembly
791T-630-1230 Plate
t 1
791-630-1220
Rod
t 2
790-101-2510
Block
t 1
790-101-2570
Washer
t 2
01580-01411
Nut
t 2
01643-31445
Washer
t 2
790-101-2102
Puller
t 1
(294 kN {30 ton})
790-101-1102
Hydraulic pump
t 1
796-670-1020
Installer
t 1
791-601-1000
Oil pump
t 1
1
L
7.
Remove plate (7).
8.
Reverse the idler assembly.
9.
Remove nut (8), bolt (9) and support (10).
Sketch
New/Remodel
Q'ty
Part name
Necessity
Part No.
Remove the mounting bolts. Using forcing

screws [2], remove retainer (6).
Special tools
Symbol
6.
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 (2) 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
SEN01208-02
14. Remove floating seal (15) from rings (5) and

(11).
15. Remove floating seal (16) from retainers (6)
and (12).
Assembly
a

for dirt or damage.
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}
2.
Using tool L2, install floating seal (12) to retainers (5) and (9).
a Dimension (b) of projection of the seal
shown in the figure (A) must be 7 11
mm.
a After inserting the seal, check that its tilt is
1 mm or less.
a Before inserting the seal, thoroughly
clean, degrease and dry the parts indicated with the thick lines in figure (B) (the
O-ring and the O-ring contact surface).
3.
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 indicated with the thick lines in figure (B) (the
O-ring and the O-ring contact surface).
16. Remove bushing (17) from idler (1).
D155AX-6
4.
Set idler (1) to blocks [1].
5.
Install plate (13) and retainer (12).
SEN01208-02
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
10. Reverse idler (1) and set it to block [1].
D155AX-6
SEN01208-02
11. Using the push tool, press fit ring (6) to dimension (d).
a Ring press fitting dimension (d):
80 0.2 mm
a Before installing the ring, apply engine oil
and lubricants") thinly to the mating face of
the floating seal.

a
If oil was added with tool L3, be sure to

slant the idler about 10 and check that
the oil level is at the bottom of the oil filler
as shown below.
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
3
10
Idler: 670 730 cc (GO140B)

Plug: 160 255 Nm {16.0 26.0 kgm}
D155AX-6
Removal and installation of recoil

spring assembly
1
SEN01208-02
Installation
q

removal.
While checking the recoil spring assembly

through the lubricator adjustment window,
install in the track frame.
Removal
1.
Remove the idler assembly. For details, see

"Removal and installation of idler assembly".
2.
Pull out the recoil spring assembly (1) forward

to remove.
4
D155AX-6
Recoil spring assembly: 510 kg
11
SEN01208-02

recoil spring assembly
3)
Using push tool [1], pull out piston (9) from

yoke (8) with a press.
791-685-8006
Compressor
791-635-3160
Extension
M 2 791T-630-2610 Spacer
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
t 1
t 1
t 1
790-101-1300
Cylinder
t 1
790-101-1102
Hydraulic pump
t 1
Disassembly
1.
Remove yoke and piston assembly (2) from

recoil spring assembly (1).
2.
Disassembly of yoke and piston assembly

1) Remove snap ring (3), packing (4) and
ring (5).
2) Remove bolt (6) and plate (7).
12
3.
If cylinder (10) has not been broken

and shaft end nut (11) has not come
off, disassemble according to the following procedure.
Remove holder (13) from recoil spring case

(12).
k Never stand in front of or at the rear of
the recoil spring assembly to avoid
danger.
D155AX-6
4.
5.
Disassembly of holder
1) Remove cover (15) from holder (14).
2) Remove seal (16) and bushing (17) from
holder (14).
SEN01208-02
7.
Apply hydraulic pressure gradually to tool M2

to compress the spring and tighten nut (11)
until spacer (19) comes off and then remove
the spacer.
8.
Remove nut (11) and release the hydraulic oil

gradually to release the spring tension.
9.
Remove recoil spring (20) and cylinder (10)

from recoil spring case (12).
Remove the lock plate from cylinder (10) and

remove lubricator (18).
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
SEN01208-02
1)
2)
3)
4)
14
If cylinder (10) has been broken or shaft

end nut (11) has come off and the mounting bolt of holder (13) is removed, recoil
spring (20) will jump out forward. In this
case, disassemble according to the following procedure.
Never stand in front of or at the rear of
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.
Set recoil spring assembly (1) to tool M2.

k Set the spring securely since its
installed load is heavy and dangerous.
314 kN {32,000 kg}
Apply hydraulic oil gradually and fix recoil
spring assembly (1).
Assembly
1.
Using the push tool, press fit bushing (23) to

recoil spring case (12) and install seal (22).
2 Bushing: Grease (G2-LI)
2.
Using the push tool, press fit bushing (21) to

cylinder (10).
2 Bushing: Grease (G2-LI)
3.
Temporarily install recoil spring (20) and cylinder (10) to recoil spring case (12) and set them
to tool M2.
2 Inside of case and parts in case:
Grease (Apply G2-LI to minimum
thickness of 3 mm)
k Set the spring securely since its installed
load is heavy and dangerous.
314 kN {32,000 kg}
a When compressing the spring, align it by
using lever block [2] etc. so that the
threaded part will not be damaged.
a Installed length of spring: 656 mm
Remove the mounting bolts of holder (13).

Release the hydraulic oil gradually to
release the spring tension.
D155AX-6
4.
5.
Install nut (11) and spacer (19).

a Eliminate the clearance between the nut
and spacer.
(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.
SEN01208-02
6.
Install lubricator (18) to cylinder (10) and install

the lock plate.
a Install the grease fitting at 45 5 out.
7.
Assembly of holder
1) Using the push tool, press fit bushing (17)
to holder (14) and install seal (16).
2 Bushing and oil seal:
Grease (G2-LI)
2) Install cover (15) to holder (14).
8.
Install holder (13) to recoil spring case (12).

2 Mating faces of holder and case:
Grease (G2-LI)
Release the hydraulic pressure gradually to

release the spring tension completely and then
remove recoil spring assembly (1) from tool
M2.
D155AX-6
15
SEN01208-02
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)
3)
Install plate (7) and tighten bolt (6).

a Check that the plate is not on the
yoke.
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
SEN01208-02
Removal and installation of track

roller
1
Note 1: Sling No. 1 bogie (1) with lever block

[1] etc. and fix it. The fixing tool cannot be used to fix the No. 1 bogie.
791T-130-1010 Bracket
KK
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
t 6 N Q
01010-63060
Bolt
t 12
01643-33080
Washer
t 12
Removal
1.
2.
Lower the track assembly tension. For details,

see "Spreading and installation of track assembly".
3.
Operate the blade and ripper to raise the

machine until track roller assembly (2) floats
above the track shoe.
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.
5.
Operate the blade and ripper to lower the

machine.
a Operate the blade and ripper slowly while
running the engine at low idle.
6.
Remove the mounting bolts and roller cap (3).

[*2]
a Take care not to damage the dowel pin
installed.
Install tool KK to fix bogie assembly (1).
When removing track roller assembly (2),

fix the related bogie assembly with the tool
according to the following table.
Track roller
assembly to be
removed
Bogie assembly to be fixed

with tool
Bogie of track
roller to be
removed
Related bogie
No. 1 roller
Note 1
No. 2 bogie
No. 2 roller
No. 2 bogie
No. 1 bogie
No. 3 roller
No. 2 bogie
No. 3 bogie
No. 4 roller
No. 3 bogie
No. 2 bogie
No. 5 roller
No. 3 bogie
No. 4 bogie
No. 6 roller
No. 4 bogie
No. 3 bogie
No. 7 roller
No. 4 bogie
D155AX-6
17
SEN01208-02
7.

machine until track roller assembly (2) floats
above the bogie. [*3]
Installation
q

removal.
[*1], [*2]
Install the track roller assembly according to the following procedure.
1. Set the track roller assembly on the track shoe.
a Direct the oil filler of the track roller
assembly out of the machine.
8.
Pull track roller assembly (2) out of the machine.

4
4
Track roller assembly (single flange):

95 kg
Track roller assembly (double flange):
110 kg
2.
Lower the machine until the roller cap bolts can

be installed and then install roller cap (3) temporarily.
3.
Align dowel pin (4) with the dowel pin hole of

the track roller and tighten the roller cap bolts.
a Take care not to break the dowel pin.
2 Roller cap mounting bolt:
Adhesive (LT-2)
662 829 Nm {67.5 84.5 kgm}
[*3]
Installation composition of track roller assembly
S: Track roller assembly (single flange)
D: Track roller assembly (double flange)
a Install the track roller assembly with the oil filler
plug directed out.
18
D155AX-6
SEN01208-02

track roller assembly
7.
Remove rings (2) and (6) from retainers (3)

and (7).
8.
Remove floating seal (9) from rings (2) and (6).

a Keep the floating seal so that it will not be
damaged.
9.
Remove floating seal (10) from retainers (3)

and (7).
a Keep the floating seal so that it will not be
damaged.
Sketch
New/Remodel
Q'ty
Part name
Necessity
Part No.
Using the press, remove ring (6), retainer (7)

and plates (4) and (8) from the shaft.
Special tools
Symbol
6.
1 791T-630-1290 Plate
t 1
2 791T-630-1330 Push tool
t 1
791-651-1510
Installer
t 2
791-601-1000
Oil pump
t 1
Disassembly
1.
Remove the oil filler plug to drain the oil.

6
Track roller: 820 880 cc
2.
Set track roller (1) on block [1].
3.
Remove the mounting bolts. Using forcing

screws [2], remove ring (2), retainer (3) and
plate (4) together.
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
SEN01208-02
Assembly
a

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:
19 120 kN {2 12 ton}
2.
Set shaft (5) to the roller.
3.
Using tool N3, install floating seal (10) to

retainers (3) and (7).
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 projection (a) of
the seal is 7 11 mm.
4.
20
5.
Using tool N3, install floating seal (9) to seal

guides (2) and (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
6.
Using tool N2, press fit ring (2) to the shaft.

q
Ring press fitting force:
39 69 kN {4 7 ton}
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.
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
Reverse the track roller assembly and
press fit ring (6) on the opposite side similarly.
7.
Using tool N4, apply the standard pressure to

the roller oil filler to check the seal for air leakage.
a Standard pressure: 0.1 MPa {1 kg/cm2}
a Check method: Keep the standard pressure for 10 seconds and confirm that the
gauge pointer does not lower.
8.
Using tool N4, add oil to the track roller assembly.

5
9.
SEN01208-02
Track roller oil: 820 880 cc (GO140)
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
SEN01208-02
Removal and installation of No. 1

bogie assembly
1
791T-130-1010 Bracket
14
22
23
t 2 N Q
01010-63060
Bolt
t 4
01643-33080
Washer
t 4
790-401-1700
Lifting tool
t 1
790-401-1761
Adapter
t 1
791-630-1860
Bracket
t 1
791-630-1870
Bracket
t 1
790-101-2310
Block
t 1
790-101-2360
Plate
t 2
Screw
t 2
Nut
t 2
790-445-4130
15 791-112-1180
790-101-4000
Puller
t 1
(490 kN {50 ton})
790-101-1102
Pump
t 1
790-201-2760
Spacer
t 1
791-630-1370
Adapter
t 1
790-434-1060
Screw
t 2
01580-13024
Nut
t 2
01643-33080
Washer
t 1
790-101-4000
Puller
t 1
(490 kN {50 ton})
790-101-1102
Pump
t 1
17 796-430-1110
Push tool
t 1
18 790-701-3000
Seal checker
t 1
16
19 791T-630-1390 Guide
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
t 1
4.
Sling No. 1 bogie assembly (2) with wires so

that it will not lower.
5.
Loosen the mounting bolts of roller cap (3)

about 20 mm.
a Loosen both inside and outside bolts.
6.
Hit the end of shaft (4) with a plastic hammer,

etc. to separate the track roller from the bogie.
a Take care not to damage the installed
dowel pin.
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.

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 lowering.
22
D155AX-6
7.
Set tool L22 and remove roller cap (3).
8.
Using tool L22, remove track roller assembly

(5).
a While balancing the track roller assembly,
remove it.
4
SEN01208-02
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}
Track roller assembly: 95 kg
3)
9.
Remove cover (6).
D155AX-6
Remove floating seals (9) from the ends of

rings (8) and (10).
a Keep the floating seals so that they
will not be damaged.
23
SEN01208-02
4)
5)
6)
7)
Set pulling tool L16 to pull out rings (10)

and (11).
q
Pulling force (Reference):
216 402 kN {22 41 ton}
Remove spacer (12).

Remove spacer (13) and floating seal (14)
between rings (10) and (11).
a Keep the floating seal so that it will
not be damaged.
Installation
1.
Assembly of cartridge pin assembly

1) Press fit shaft (7) to ring (8).
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)
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).
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
24
Bogie assembly: 60 kg
D155AX-6

a
SEN01208-02
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.
After inserting the floating seal, check
that its tilt is 1 mm or less and projection (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
3)
4)
5)
Cartridge pin assembly (81 95%

of full level): 50 60 CC (GO140)
Install spacer (12) and ring (10) to shaft

(7) and ring (8).
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 position.
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.
Using tool L18, check the airtightness of

the floating seal.
D155AX-6
25
SEN01208-02
4.
5.
Insert cartridge pin assembly (15) in the pin

hole.
a Set arrow (b) at the end face of the cartridge pin assembly up (in the installed
state on the machine).
6.
Press fit the cartridge pin on the opposite side

according to steps 4 6.
7.
Install covers (6).

a Install the covers to 2 places of inside and
outside.
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.
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 assembly: 216 402 kN {22 41 ton}
26
Track roller assembly: 95 kg
D155AX-6
9.
SEN01208-02
Install roller cap (3) and tighten the bolts temporarily.

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 Testing and adjusting, "Testing and adjusting track
tension".
D155AX-6
27
SEN01208-02
Removal and installation of No. 2,

No, 3 and No. 4 bogie assemblies1
2.
791T-130-1010 Bracket
Bolt
t 4
01643-33080
Washer
t 4
791-630-1360
Spacer
t 1
790-101-2310
Block
t 1
790-101-2360
Plate
t 2
790-445-4130
Screw
t 2
791-112-1180
Nut
t 2
790-101-4000
Puller
t 1
(490 kN {50 ton})
790-101-1102
Pump
t 1
790-201-2760
Spacer
t 1
791-630-1370
Adapter
t 1
790-434-1060
Screw
t 2
01580-13024
Nut
t 2
01643-33080
Washer
t 1
790-101-4000
Puller
t 1
(490 kN {50 ton})
790-101-1102
Pump
t 1
17 796-430-1110
Push tool
t 1
18 790-701-3000
Seal checker
t 1
15
t 2 N Q
01010-63060
14
16
19 791T-630-1390 Guide
20
t 1
790-101-2310
Block
t 1
790-445-4130
Screw
t 2
796T-470-1130 Plate
t 1
790-101-2360
Plate
t 2
790-112-1180
Nut
t 2
790-101-4000
Puller
t 1
(490 kN {50 ton})
790-101-1102
Pump
t 1
Oil pump
t 1
21 791-601-1000
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
Remove the undercovers.

a Remove the undercovers which will be
obstacles to removal of the bogie assembly.
4
Engine undercover: 220 kg
Power train undercover: 270 kg
3.
Using tool L14, fix bogie assembly (1).
4.
Remove cover (2).

a Remove the cover on the opposite side,
too.
5.

machine until the track roller floats above the
track link.
k Set a block between the track roller and
track link so that the machine will not
lower.
6.
Set steel plate [2] on the track shoe and block

[1].
a Set block [1] so that it will fit to the height
of the track link.
7.
Operate the blade and ripper to lower the

machine until the track roller of bogie assembly
(1) touches steel plate [2].
a Operate the blade and ripper slowly.
Removal
1.
28
Spread the track shoe assembly. For details,

assembly".
D155AX-6
8.
SEN01208-02
Pulling out shaft and ring

1) Set tool L15
2) Push shaft (3) with tool L15 to push out
ring (4) toward the opposite side.
q
Pushing out force (Reference):
216 402 kN {22 41 ton}
3)
4)
Set pulling tool L16 to pull out rings (6)

and (7).
q
Pulling force (Reference):
216 402 kN {22 41 ton}
5)
6)
Remove spacer (8).

Remove spacer (9) and floating seal (10)
between rings (6) and (7).
a Keep the floating seal so that it will
not be damaged.
7)
Pull out the shaft and ring of the bogie on

the opposite side according to steps 1)
6).
Remove floating seals (5) from the ends of

rings (4) and (6).
a Keep the floating seals so that they
will not be damaged.
9.
D155AX-6

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.
29
SEN01208-02
10. Sling bogie assembly (1) and slide it out on

steel plate [2] to remove.
4
Bogie assembly: 525 kg
Installation
1.

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)
30
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).
D155AX-6

a
3)
4)
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.
After inserting the floating seal, check
that its tilt is 1 mm or less and projection (a) of the seal is 3 5 mm.
Install spacer (8) and ring (6) to shaft (3)

and ring (4).
Install spacer (9) to ring (6) and press fit
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
SEN01208-02
5)
Using tool L18, check the airtightness of

the floating seal.
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.
4.
Slide bogie assembly (1) on the steel plate with

lever block [4] and set it to the mounting position.
31
SEN01208-02
5.

machine.
6.
Adjustment procedure for cartridge pin hole

1) Set block [5] and hydraulic jack [6] to the
rear side of the machine.
4)
5)
2)
3)
32
Adjust front and rear jacks [6] and [7] to

align the pin holes of the track frame and
bogie assembly.
k When aligning the pin holes, never
insert your fingers in them.
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.
Insert guide tool L19 in the pin hole.
Set support stands [7] and hydraulic jacks

[8].
Lower the machine with front and rear

jacks [6] and [7] and install fixing tool L14
to bogie assembly (1).
7.
Insert cartridge pin assembly (11) in the pin

hole.
a Set arrow (b) at the end face of the cartridge 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).
machined surface (c) of the track frame.
2 Outside of pin:
a Press fitting force of cartridge pin assembly: 216 402 kN {22 41 ton}
D155AX-6
SEN01208-02
12. Install the track shoe assembly. For details,

assembly".
13. Adjust the track tension. For details, see Testing 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).
outside.
D155AX-6
33
SEN01208-02

bogie assembly
20
790-101-2310
Block
790-445-4130
Screw
790-101-2360
Plate
t 2
791-112-1180
Nut
t 2
790-101-4000
Puller
t 1
(490 kN {50 ton})
790-101-1102
Pump
t 1
Oil pump
t 1
34
4.
Bogies
Disconnect inner bogie (5) and outer bogie (6).
Sketch
Q
Track roller assembly

1) Reverse bogie assembly (1).
2) Remove the roller cap and lift off 2 track
roller assemblies (2).
dowel pin.
4
Cartridge pin assembly

Remove cartridge pin assembly (4) according
to the procedure in "Removal and installation
of bogie assembly".
t 2
t 1
Disassembly
1.
3.
t 1
796T-470-1130 Plate
21 791-601-1000
New/Remodel
Q'ty
Part name
Necessity
Part No.
Cover
Remove cover (3).
Special tools
Symbol
2.

(single flange): 95 kg
(double flange): 105 kg
D155AX-6
Assembly
1.
SEN01208-02
4.

Assemble cartridge pin assembly (4) according
to the procedure in "Removal and installation
of bogie assembly".
2.
Bogies
Set outer bogie (6) and inner bogie (5).
3.
Cartridge pin assembly

1) Set tool Q20.
2)
Press fit cartridge pin assembly (4).

a Push in the cartridge pin assembly
with cover (3).
a Set arrow (a) at the end face of the
cartridge pin assembly up (in the
installed state on the machine).
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
Refilling with oil

Using tool Q21, 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)
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 assembly, adjust the inner bogie so that it will
slide lightly.
6.
Cover
Install covers (3).
outside.
35
SEN01208-02
7.

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 assembly is installed.
4
2)
36

(single flange): 95 kg
4 Track roller assembly
(double flange): 105 kg
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}
D155AX-6

carrier roller assembly
SEN01208-02
4.
Removal
1.
Pass rope [2] through the link hole and wind it

onto carrier roller (3) and stretch it. Loosen the
rope gradually to pull out carrier roller (3) from
support (4). [*1]
4
Remove the track frame top cover and loosen

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 sufficiently after the lubricator is loosened,
move the machine forward an d in
reverse.
Carrier roller: 45 kg
Installation
q
2.
Using hydraulic jacks [1], raise the track shoe.
3.
Remove mounting bolts (2).
[*1]
When installing the carrier roller to the support,
make clearance (a) shown in the figure.
q
Clearance (a): 1.2 mm
2 Support mounting bolt: Adhesive (LT-2)
q
D155AX-6

removal.
Adjust the track shoe assembly tension. For

details, see Testing and adjusting, "Testing and
adjusting track shoe assembly tension".
37
SEN01208-02

carrier roller assembly
5.
Using tool R1, remove nut (4).
6.
Using puller [2], remove the ring press fitting

part. Using eyebolts, remove bearing (5) and
roller (6) together.
7.
Remove outer race (7) from the roller.
8.
Using puller [3], remove ring (8) and the inner

race of bearing (9) together.
9.
Remove floating seal (10) from ring (8).
790-102-1891
Nut wrench
791-651-1510
Installer
t 1
t 1
3 791T-630-1350 Spacer
t 1
t 1
791-601-1000
Oil pump
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
Disassembly
1.
Remove the plug to drain the oil.

a While rotating the shaft, drain the oil.
6
Carrier roller: 570 680 cc
2.
Set carrier roller assembly (1) to block [1].
3.
Remove the mounting bolts and cover (2).
4.
Remove ring (3).
38
D155AX-6
10. Using push tool [4], remove ring (11).

11. Remove floating seal (12) from ring (11).
D155AX-6
SEN01208-02
Assembly
a

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 bearing until the roller becomes a little heavy to
rotate.
39
SEN01208-02
5.
6.
Using tool R1, tighten nut (4) to "58.8 Nm {6

kgm}".
a After tightening the nut, if the nut hole is
not aligned with the shaft hole, align it by
loosening it.
9.
Using tool R2, install floating seal (10) to ring

(8).
10. Fit the O-ring and install ring (8) while setting it
to the dowel pin.
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.
a
8.
Reverse roller (6) and add oil between the

shaft and roller.
5
Refill capacity: 570 680 cc (GO140)

a
40
Before installing the floating seal, thoroughly clean, degrease and dry the O-ring
and O-ring contact surface (hatched
areas).
After inserting the floating seal, check that
Coat the sliding surfaces of the floating
seal and take care that dirt will not stick to
them.
D155AX-6
12. Using tool R3, press fit ring (11).

a Press fit the ring so that dimension (a)
from the shaft end to the ring top will be
131.95 0.2 mm.
SEN01208-02
14. After checking for air leakage, check again that

the oil supplied in step 8 is still at a proper
level.
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 leakage.
a Standard pressure: 0.1 MPa {1 kg/cm2}
a Check method
Keep the standard pressure for 10 seconds and confirm that the gauge pointer
does not lower.
D155AX-6
41
SEN01208-02
Removal and installation of pivot

shaft assembly
1
791T-650-2110 Sleeve
Spacer
t 1
Pivot shaft assembly: 135 kg
Sketch
New/Remodel
Q'ty
Part name
Necessity
Part No.
790-201-2770
Sling pivot shaft assembly (3) and remove the

mounting bolts. Using eyebolts [1], lift off pivot
shaft assembly (3). [*2]
4
Special tools
Symbol
3.
t 1
791T-650-2120 Plate
t 1
792-104-3940
Bolt
t 2
790-101-2510
Block
t 1
790-101-2570
Washer
t 2
01580-01613
Nut
t 1
790-105-2300
Jack assembly
t 1
(196 kN {20 ton})
790-101-1102
Hydraulic pump
t 1
Removal
1.
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
SEN01208-02
Installation
q

removal.
[*1]
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).
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]
Pivot shaft mounting bolt: Adhesive (LT-2)

Pivot shaft mounting bolt:
784 981 Nm {80 100 kgm}
D155AX-6
43
SEN01208-02
Spreading and installation of

track shoe assembly
Check before spreading track shoe

assembly
k
1.
Since it may be very dangerous to spread

the track shoe assembly, check the following items in advance.
Do not loosen the lubricator more than 1
turn. If the grease does not come out sufficiently, move the machine forward and in
reverse.
If no abnormality is detected by "Check before

spreading track shoe assembly", perform the
1.
Set the master link in position.

a Set master link (3) above the idler (a little
after the center of the idler).
a Set blocks [1] and [2] at the front of the
idler and between the carrier rollers so
that the mating part of the master link will
not open until the master bolt is pulled out.
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.
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.
After the shoe is loosened, perform "Spreading

of track shoe assembly (Ordinary)".
3.
If the track shoe is not loosened by the above

work, perform "Spreading of track shoe assembly (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
Spreading of track shoe assembly

(Ordinary)
D155AX-6
3.
4.
Remove track shoe (4). [*2]

a Loosen the 4 bolts by 1 2 turns each and
check that they rotate lightly, and then pull
them out. Do not pull them out one by one
without checking their looseness.
a If the bolts are loosened forcibly while they
are still tight, their threads and master link
(3) may be damaged.
Sling the front end of the master link and move

the machine slowly in reverse to spread track
shoe assembly (5).
a Length of track shoe: Approx. 10.5 m
k Never stand in front of the idler to
avoid danger.
D155AX-6
SEN01208-02
Spreading of track shoe assembly

(When track frame has internal trouble)
a
k
If any abnormality is detected by "Check

before spreading track shoe assembly", perform the following procedure.
If the track shoe is removed while the track
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 discharge the grease.
a Check that all the grease has been discharged.
3.
Move the machine slowly forward against large

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.
45
SEN01208-02
Installation
q

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
SEN01208-02
a
General disassembly and

assembly of track shoe
Remover and
installer
791-101-4300
Cylinder
t 1
(196 kN {20 ton})
791-101-4200
Puller
t 1
(294 kN {30 ton})
791-101-1102
Hydraulic pump
t 1
791-932-1110
Plug push tool
t 1
791-660-7460
Pin brush
t 1
Sketch
New/Remodel
Part name
791-675-9701
Part No.
Q'ty
Symbol
Necessity
Special tools
t 1
791-432-1110
Plug push tool
t 1
791-632-1052
Installer
t 1
790-701-3000
Seal checker
t 1
791-601-1000
Oil pump
t 1
For the general disassembly of the track shoe,

see "Parts judgment guide, Undercarriage, Oil
lubricated track" and "Parts judgment guide,
Undercarriage, Reversing procedure for oil
lubricated track".
General disassembly
1.
Removal of shoe
Sling the shoe assembly and set it with the
shoe up on the floor and remove the shoe by
using a shoe bolt impact wrench.
a If a shoe bolt is not loosened after it is
unscrewed by 1 turn (If its torque is not
reduced to 0), loosen the other bolts first,
and it will be removed smoothly.
a If a shoe bolt is turned forcibly while its
torque is not 0, it and link will adhere to
each other and they will need to be
repaired.
a When moving the shoe assembly, take
care not to damage the master link.
D155AX-6
If it is obliged to cut a shoe nut with gas,

keep the seal temperature below 80 C to
prevent thermal deterioration of the seal
and take measures to prevent the spatters
from entering through the clearances
among the links.
2.
Disassembly of link
1) Set the link assembly on a link press and
hit it with a hammer so that the bushing
will be fitted to the jaw.
a If the link tread, outside of the bushing, etc. are worn, adjust the height of
jaw [1] or guide plate and align disassembly jigs [2] and [3] with the pin
and bushing so that the link hole will
not be damaged during disassembly
work.
a If the disassembly jigs are not aligned
well, the link hole may be damaged
and the pin and bushing may be broken during disassembly work.
47
SEN01208-02
a
2)
3)
48
Using tool S2, drive the small plug of

the pin inward after the disassembly
work so that the workplace will not
become dirty.
Operate the left cylinder to pull out the pin

and bushing from the left link simultaneously.
a Check the pulling out force of the pin
and bushing to see if press fitting
force for them necessary for reversed
reassembly is obtained.
4)
3.
Return the right cylinder and take out the

links, pins, bushings, and spacers on the
right and left sides and feed the next 1 set
of the link assembly to the jaw.
a If the bushing ends and sealing surfaces are damaged, oil will leak.
Accordingly, handle them carefully.
Inspection
Check the parts for the following items to see if
they can be used for an oil lubricated track or a
grease lubricated track, then examine them
generally and determine to use them for an oil
lubricated track or a grease lubricated track.
a For judgment of reuse of the parts, see
"Parts judgment guide, Undercarriage, Oil
lubricated track".
1) Check the parts visually for damage. If a
part seems to be damaged, check it by
dye penetrant test or magnaflux inspection. If it has any crack, it cannot be used
again. Discard it.
Return the left cylinder and operate the

right cylinder to pull out the pin and bushing from the right link simultaneously.
D155AX-6
2)
Measure the outside diameters of the

press fitting parts of the pin and bushing
and the inside diameters of the pin and
bushing fitting parts of the link with a
micrometer and a cylinder gauge to see if
the interference is larger than the limit.
When using the pin, bushing, and link for
an oil lubricated track, however, secure
the standard interference between the pin
and link.
a If the interference is less than the
limit, replace the parts with new ones.
a For the dimensional criteria, see
"Maintenance Standard".
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) Apply rust-preventive oil to the pin and
bushing fitting parts, shoe mating surface
and master link mating surface of the link.
3) When storing, apply rust-preventive oil to
all the surfaces of the pin, bushing and
spacer. Take care not to damage the ends
of the bushing in particular.
D155AX-6
SEN01208-02
General assembly
a
For the whole assembly of the track shoe, see

"Parts judgment guide, Undercarriage, Reversing procedure for oil lubricated track".
When recycling for oil lubricated track

1. Preparation work
1) Cleaning of seal assembly
Remove the seal assembly from the link
and divide it into the seal ring (1) and load
ring (2), and then clean them.
a Since the seal ring (1) and load ring
(2) are deteriorated easily by the
cleaning liquid (trichloroethylene etc),
clean them quickly. After cleaning
them, wipe off the cleaning liquid from
them.
2)
When reusing the pin, chamfer its end corners smoothly with a grinder. Remove the
nodules sticking to the press fitting parts
with the grinder, too.
a If the ends are worn and sharpened,
they may scuff the press fitting parts
and cause oil leakage.
49
SEN01208-02
3)
4)
If the link, pin, bushing and spacer are

dirty, clean them. Remove the nodules
sticking to the link and bushing with the
grinder.
a Since these parts rust easily, clean
them just before assembling.
a Do not polish the bushing ends. If
they are polished, oil may leak.
If the large plug was pulled out, drive it in
by using tool S4.
a Clean the pin hole in advance by
using tool S3.
1]
2]
3]
50
Insert plug (3) through the plug insertion window into the guide hole.
Push the bar with the hand and insert
the plug until it stops.
Push the plug with the bar to press
the guide against pin (4).
a Driving distance (a) from pin end:
10 1 mm
a If the chamfered part of the pin
hole has been worn, chamfer it
with a small-sized grinder (grindstone tip angle: 45 60) so that
the plug will not be damaged.
a Coat the plug with oil (GO90) and
drive it with the small diameter
end ahead.
5)
Installation of seal assembly

Clean the counterbore portion of the link
carefully and push in the seal to the bottom by using tool S5.
a If oil sticks to the counterbore portion
of the link or seal assembly, the seal
will turn and its sealing performance
will lower. Accordingly, do not apply
any oil. When inserting the seal in the
counterbore portion, take care that oil
not stick to the seal.
6)
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 dimensions so that the projections of the
pins and bushings on the right and
left sides will be even.
D155AX-6
7)
2.
SEN01208-02
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 bushing: 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.)
Assembly of link
1) Apply oil (GO90) to the mating surfaces of
the pin and bushing with a clean brush
and assemble them, and then set them
before the jaw of the link press.
a When reusing (reversing) the bushing, set the worn outside surface of
the bushing on the shoe fitting side of
the link (set the bushing with the worn
outside surface up on the link press).
3)
4)
5)
2)
Set shoe mounting faces of the right and

left master links on bushing side up and
press fit the bushing.
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
Using the shoe bolt hole pitch gauge,

press fit the master links until the distance
between the shoe bolt holes of both links
is the standard value.
a Blow off all the steel chips caused by
press fitting of the bushing with compressed air.
Reverse the master links and check that
they are press fitted in parallel.
Measure the projections of the bushing on

the right and left sides with a depth gauge.
a Adjust the press fitting jig of the link
press so that the projections on the
right and left sides will be even.
51
SEN01208-02
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 lowered. Accordingly, indicate the direction of side hole (e) on the end face to
prevent a mistake.
9)
7)
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.
Set the right link and install the spacer to

the pin.
a Check that the seal surface and bushing 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)
52
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}
D155AX-6
11) Set the left jig on the receiving side and

the right one on the pushing side and
press fit the left link.
a When press fitting, take care that both
seals and spacers will not come off.
a Link press fitting force:
343 490 kN {35 50 ton}
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. Accordingly, 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
Preparation work.
a Check that adjacent 2 links can turn
around each other.
D155AX-6
SEN01208-02
13) Using a shoe bolt hole pitch gauge, measure the distance between the shoe bolt
holes and check that the result is within
the standard range.
a If the distance between the shoe bolt
holes is longer than the standard
range, disassemble and check for
abnormality, then press fit again.
a If the distance between the shoe bolt
holes is shorter than the standard
range and the shoe cannot be
installed, the spacer or bushing end
may be worn more than repair limit.
In this case, disassemble and replace
the parts.
14) After each link is assembled, bleed air

from the pin by using tool S6 and check
the sealing performance.
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, disassemble and check the seal. If the seal is
free from abnormality, assemble
again.
53
SEN01208-02
15) Using tool S7, supply oil (G090) until the

oil supply pressure rises to 196 294 kPa
{2 3 kg/cm2}.
a In a cold or very cold district, supply
K O MAT SU genu ine oil ( 150- 0919270 for cold district or 195-3261990 for very cold district) having
better low-temperature characteristics
instead of G090.
a If the oil pressure is heightened too
much, it has bad effects on the seal.
Take care.
54
16) After supplying oil, drive in the small plug

into the specified position, using tool S2.
a Apply oil (G090) around the small
plug.
a Drive in the small plug to the following
depth.
Driving depth from end: 7.5 1 mm
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.
Determine oil level (a) as follows;
supply oil (d) so that depth (L) of the
hollow of pin hole (c) will be in the following range when the link is left with
small plug side (b) up (with the link
assembly on its side) for 30 minutes.
Dimension (L): 35 65 mm
3.
Installation of shoe
1) Set the link assembly on the bed and
install the shoe with a shoe bolt impact
wrench and a torque wrench.
a When reusing (reversing) the bushing, set the worn outside face of the
bushing to the shoe mounting side of
2 Shoe bolt:
(LM-P)
3 Shoe bolt (Regular link)
Initial torque:
590 60 Nm {60 6 kgm}
Retightening angle: 120 10
D155AX-6
2)
3)
4)
5)
When installing a 2-piece shoe, place the

assembled 2-piece shoes on a level place
in 1 line with the shoe side up.
Pull pin-side master link (1) and bushingside master link (2) together and set them
to each other by the mating faces.
Place shoe (3) and fit the mating surfaces
of the links.
Check that master bolts (4) can be tightened 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}
SEN01208-02
When recycling for grease lubricated track

1. Preparation work
1) Cleaning of seal assembly
Remove the seal assembly from the link
and divide it into the seal ring (1) and load
ring (2), and then clean them.
a Since the seal ring (1) and load ring
(2) are deteriorated easily by the
cleaning liquid, clean them quickly.
After cleaning them, wipe off the
cleaning liquid from them.
2)
D155AX-6
When reusing the pin, chamfer its end corners carefully with a grinder so that it will
be press fitted smoothly.
Tighten the bolts in the following

order.
55
SEN01208-02
3)
4)
5)
56
Using tools S2 and S4, drive the large and

small plugs into the pin.
1] Insert each plug through the plug
insertion window into the guide hole.
a Apply oil to the plug.
2] Push the bar with the hand until the
plug stops.
3] Push the plug with the bar to press
the guide against the pin.
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 disassembled, reuse them as they
are.
6)
Installation of seal assembly

Clean the counterbore portion of the link
carefully. Using tool S5, push in the seal
to the bottom.
a If grease sticks to the counterbore
portion of the link or seal assembly,
the seal will turn and its sealing performance will lower. Accordingly, do
not apply any grease.
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 dimensions so that the projections of the
pins and bushings on the right and
left sides will be even.
If the outside of the pin, surfaces of the

spacer, and ends and inside of the bushing are dirty, clean them.
Apply grease to the outside of the pin and
surfaces of the spacer.
D155AX-6
2.
Assembly of link
1) Apply lithium grease (G2-LI) to the mating
surfaces of the pin and bushing and
assemble them, then set them before the
jaw of the link press.
SEN01208-02
3)
4)
5)
2)
Press fit the master links on both bushing

sides to the bushing with the shoe fitting
faces up.
a At this time, use the master links on
the pin side as supports.
a Press fitting force for bushing:
88 304 kN {9 31 ton}
D155AX-6
Using the shoe bolt hole pitch gauge,

press fit the master links until the distance
between the shoe bolt holes of both links
is the standard value.
a Blow off all the steel chips caused by
press fitting of the bushing with compressed air.
Reverse the master links and check that
they are press fitted in parallel.
Measure the projections of the bushing on

the right and left sides with a depth gauge.
a Adjust the press fitting jig of the link
press so that the projections on the
right and left sides will be even.
57
SEN01208-02
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 lowered. Accordingly, indicate the direction of the side hole on the end face
to prevent a mistake.
a If the outside of the pin is worn, install
it so that the un-worn surface will be
on the traction side. In this case,
install the pin so that its side hole will
be on the link tread side.
3.
7)
58
Set the right and left links and operate

both pushing jigs to 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, then start
press fitting again.
a Final pressing force for pin and bushing: 343 490 Nm {35 50 ton}
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.)
8)
Using a shoe bolt hole pitch gauge, measure the distance between the shoe bolt
holes. When the distance is in the standard range, stop press fitting.
9)
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.
Installation of shoe
1) Set the link assembly on the bed and
install the shoe with a impact wrench and
a torque wrench.
2 Shoe bolt:
(LM-P)
3 Shoe bolt (Regular link):
Initial torque:
590 60 Nm {60 6 kgm}
D155AX-6
2)
3)
4)
5)
SEN01208-02
When installing the assembled 2-piece

track shoes, place them on a level place in
1 line with the shoe side up.
Pull pin-side master link (1) and bushingside master link (2) together and set them
to each other by the mating faces.
Place shoe (3) and fit the mating surfaces
of the links.
Check that master bolts (4) can be tightened 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}
D155AX-6
Tighten the bolts in the following

order.
59
SEN01208-02
Dimensions table of fitting jig of link press
Adjustment
Adjust the dimensions of the press fitting jig of the
link press to keep the projection of the pin and
bushing constant and keep the installed dimensions of the seal within the standard range.
a If the pin end (part P) or the sides of the link
(parts Q and R) are worn, add the dimensions
of the worn parts when adjusting the standard
dimensions so that the projections of the pins
and bushings on the right and left sides will be
even.
Unit: mm
Precaution
1. The link receiving faces of jaw (5) must be vertical.
2. Wear plate (6) should be replaceable.
Dimensions of jig
60
4.5
3.25
50.6
D155AX-6
SEN01208-02
Disassembly and assembly of 1

link in field
791-675-5580
Guide
t 1
t 1
791-685-9510
Frame
t 1
t 2
791-685-9520
Frame
t 1
Bolt
t 2
791-685-9530
Rod
t 1
790-101-1102
Pump
t 1
791-685-9540
Rod
t 1
790-101-4300
Cylinder
t 1
(1,470 kN {150 ton})
791-685-9550
Nut
t 3
Bolt
t 4
791-685-9510
Frame
t 1
791-685-9560
Adapter
t 1
Frame
t 1
791-126-0150
791-685-9520
Bolt
t 1
Rod
t 1
01010-51030
791-685-9530
Extension
t 1
Nut
t 1
791-685-9620
791-685-9550
Adapter
t 1
791-685-9560
Bolt
t 1
791-675-5542
Guide
t 1
Adapter
t 1
791-675-5560
791-675-9570
Pump
t 1
Eyebolt
t 1
790-101-1102
04530-12030
790-101-1102
Pump
t 1
790-101-4300
Cylinder
t 1
(1,470 kN {150 ton})
790-101-4300
Cylinder
t 1
(1,470 kN {150 ton})
791-675-5560
Guide
t 1
791-675-5542
Adapter
Rod
t 1
t 1
791-685-9540
790-101-1102
Pump
Nut
t 3
t 1
791-685-9550
791-675-5520
Guide
t 1
790-101-4200
Puller
(294 kN {30 ton})
t 1
791-675-5530
Pusher
t 1
12 791-670-3270
Guide
t 1
791-675-9581
Adapter
t 1
791-675-9590
Guide
01010-52460
Bolt
01010-51440
10
11
01010-51030
Bolt
t 1
791-126-0150
Adapter
t 1
791-685-9620
Extension
t 1
791-675-5560
Guide
t 1
790-101-1102
Pump
t 1
791-675-9570
Adapter
t 1
790-101-4200
Puller
(294 kN {30 ton})
t 1
01010-51030
Bolt
t 1
791-675-5542
Adapter
t 1
791-675-5571
Adapter
t 1
790-101-1102
Pump
t 1
790-101-4300
Cylinder
t 1
(1,470 kN {150 ton})
D155AX-6
13
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
61
SEN01208-02
Disassembly of 1 link in field

k Only how to use the tools is explained below.
For details of disassembly and assembly,
see "General disassembly (or assembly) of
track shoe".
1.
2.
62
3.
Insert the rod of tool T4 from the cylinder side

and install it with the nuts (2 pieces).
Pass the rod through the hole of link (1) and
install it.
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.
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.
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).
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.
D155AX-6
Assembly of 1 link in field

1. Assemble the link sub-assembly.
1) Set tool T7 the link end face and press fit
bushing (1).
a Busing press fitting force:
88 304 kN {9 31 ton}
2)
2.
SEN01208-02
3.
Set link (4) on the opposite side and support it

with tool T8 (guide).
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,
guide, adapter and bolt) for (c) on the pin side,
press fit (d) and (c) alternately.
a Pin press fitting force:
284 686 kN {29 70 ton}
a Bushing press fitting force:
88 304 kN {9 31 ton}
5.
Using tool T11 (294 kN {30 ton} puller) as in

the disassembly procedure, push open link (5)
on the bushing side.
Set tool T7 to the end face of the link (on

the pin side) and press fit pin (2).
a Set the pin with its side hole (a)
directed toward link tread (b).
a Pin pressing force:
284 686 kN {29 70 ton}
Set the link to be connected to link sub-assembly (3).
D155AX-6
63
SEN01208-02
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
SEN01208-02

master link
2.
790-101-1102
Pump
t 1
790-101-4200
Puller
(294 kN {30 ton})
t 1
791-675-9701
Remover and
installer
t 1
790-101-1102
Pump
t 1
790-101-4200
Puller
(294 kN {30 ton})
t 1
790-101-4300
Cylinder
t 1
(1,470 kN {150 ton})
791-432-1110
Plug push tool
t 1
790-701-3000
Seal checker
t 1
791-932-1110
Plug push tool
t 1
U 2
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
Disassembly
a
1.
For the using method of tool U2, see "Disassembly in field".

Removal of track shoe assembly
Remove the track shoe assembly from the
track frame. For details, see "Spreading and
installation of track shoe assembly".
D155AX-6
Removal of master link

1) Cutting and removal of master link on
bushing side with gas
Cut at (a) with gas and remove the
hatched part. Pull out master links (5) and
(6) by moving them up and down. Then,
remove pins (8) and (9) from regular link
(7) by pressing them up and down with the
press.
Special tool : 1. Gas cutting machine
: 2. Tool U2
2)
Removal of master link on pin side

Cut at (b) with gas and remove the
hatched parts. Remove pin (10) from link
(11) by pressing it down with the press,
and then remove pin (10) and link (12)
from bushing (13) simultaneously.
Special tool : 1. Gas cutting machine
: 2. Tool U2
65
SEN01208-02
Assembly
a
1.
2.
66
2)
Set spacer (3) and seal assembly (4) to

the counterbore of the link at the connecting section.
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

master link (1) on the bushing side.
2 Apply gasket sealant (198-32-19890)
to the pin hole of the link.
a Direct the side hole of the pin toward
the link tread.
For the using method of U2, see "Assembly of

1 link in field".
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 bushing.
Unit: mm
L1
169 0.7
L2
219.8 0.7
D1
27 drill hole
D2
24 x 2.0
Installation of link on bushing side

1) Push open the central part of the link tread
with tool U1 as shown in the figure (Open
the link tip by 10 mm).
Dimension (a): 5 mm
D155AX-6
5)
6)
SEN01208-02
Install the shoe to the link at the connecting section.

Drive in large plug (6) with tool U3, add oil
with tool U4, and drive in small plug (7)
with U5.
a When press fitting the right and left
master links, take care extremely that
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 bushing.
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.
2)
3)
4.
3.
Assembly of link on pin side

1) Set spacer (3) and seal assembly (4) to
the counterbore of the master link.
D155AX-6
Insert pin (9) in bushing (8), set master

links (10) on the pin side from the right
and left sides, and press fit them with tool
U2.
Drive in large plug (11) with tool U3, add
oil with tool U4, and drive in small plug
(12) with U5.
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 bushingside 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.
4) Check that the master bolts can be tightened easily with the fingers, and then connect the links with the master bolts.
2 Shoe bolt:
(LM-P)
3 Shoe bolt (Master link)
Initial torque:
590 60 Nm {60 6 kgm}
67
SEN01208-02

a

equalizer bar assembly
791T-650-2130 Sleeve
t 1
790-101-2420
Adapter
t 1
791-502-4140
Screw
t 1
790-101-2540
Washer
t 2
790-112-1180
Nut
t 2
790-101-4000
Puller
t 1
(294 kN {50 ton})
790-101-1102
Hydraulic pump
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
t 1
5.
Operate hydraulic jacks [2] slowly to lower the

machine until the equalizer bar reaches the
right and left track frames.
Disconnect grease hose (5).
7.
Remove lock plate (6).
Removal
1.
2.
Remove the engine undercover and power

train undercover.
4
Engine undercover: 220 kg
Power train undercover: 270 kg
Set a hydraulic jack under the center of the

equalizer bar to raise the machine and set support stands [1] and hydraulic jacks [2] under
the radiator guard.
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
Repeat steps 3 and 4 to remove the pin on

the opposite side.
If the track frame assembly on the
opposite side is floated before the pin
is pulled out, support it on a block, etc.
D155AX-6
8.
Sling equalizer bar assembly (7) with a crane

and a chain block.
SEN01208-02
Installation
q

removal.
[*1]
2
3
Threaded part of cover mounting bolt:

Adhesive (LT-2)
Cover mounting bolt:
784 981 Nm {80 100 kgm}
[*2]
9.
Using tool W, pull out center pin (8). [*3]

k Do not operate the hydraulic device in
front of or under the puller, but operate
as far from the puller as possible.
When 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
frame hole.
2 Seal lip: Grease (G2-LI)
[*3]
When aligning the pin holes, never insert

your fingers in them.
a Before installing the center pin, sling the equalizer 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
k
Equalizer bar assembly: 240 kg
Do not lower the machine after removing the equalizer bar assembly.
D155AX-6
69
SEN01208-02

equalizer bar assembly
Assembly
1.
Center bushing
Using the press, press fit center bushing (5) to
equalizer bar (4).
a Press fitting force for center bushing:
47.1 131.4 kN {4.8 13.4 ton}
2 Periphery of spherical bushing:
2.
Side bushing
1) Install ring (2) to one side of equalizer bar
(4).
2) Using the press, press fit spherical bushing (3) to equalizer bar (4).
a Press fitting force for spherical bushing: 27.4 64.7 kN {2.8 6.6 ton}
2 Periphery of spherical bushing:
(LM-P)
Disassembly
1.
Remove the equalizer bar. For details, see

"Removal and installation of equalizer bar
assembly".
2.
Side bushing
1) Remove seal (1).
2) Remove ring (2).
3)
3.
70
Using tool [1], remove spherical bushing

(3) from equalizer bar (4).
Center bushing
Remove center bushing (5) from equalizer bar
(4).
D155AX-6
3)
4)
SEN01208-02
Install ring (2) on the opposite side.

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
SEN01208-02

segment teeth
Installation
Removal
1.
Stop the machine in a position where the segment teeth can be removed easily (between
the shoe and track frame).
2.
Remove the mounting bolts and segment teeth

(1). [*1]
72

removal.
[*1]
a When installing, press segment teeth (1)
toward the center of sprocket hub (2) and
tighten the nuts in the order of [1] o [2] o [3].
2 Threaded part of segment teeth mounting
nut: Adhesive (LT-2)
3 Segment teeth mounting nut:
1,176 98 Nm {120 10 kgm}
D155AX-6
D155AX-6
SEN01208-02
73
SEN01208-02
D155AX-6 Bulldozer
2009 KOMATSU
All Rights Reserved
74
D155AX-6
SEN01209-02
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine Model
Serial Number
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
SEN01209-02

hydraulic tank assembly
Removal
k
1.
3.
4.
Disconnect return hose (3).
6.
Disconnect hoses (4) and (5).
7.
Disconnect suction tube (6).
8.
Disconnect hoses (7) and (8).
9.
Remove the 4 mounting bolts at the hydraulic

tank bottom and lift off hydraulic tank assembly
(9).
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 pressure of the hydraulic tank.
Drain the oil from the hydraulic tank.
6
2.
5.

assembly".
Remove control valve cover (1).
Disconnect hose (2) between the control

valves from the hydraulic tank.
Hydraulic tank assembly: 100 kg
D155AX-6
SEN01209-02
Installation
q

removal.

again.
5
Hydraulic oil (For details of specification, see "Table of fuel, coolant and
lubricants"): Approx. 91.5 l
Bleeding air
Bleed air from each part. For details, see Testing and adjusting, "Bleeding air from each
part".
D155AX-6
SEN01209-02

hydraulic pump assembly
3)
4)
Disconnect hoses (3), (4), (5) and (6).

Disconnect accumulator (7) and hose
together.
5)
6)
Disconnect hoses (8), (9) and (10).

Remove block (11).
7)
Disconnect wiring harness connectors

TVC (12), FAC (13) and HDT (14).
Remove wiring harness bracket (15).
Removal
k
1.
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 pressure of the hydraulic tank.
Drain the oil from the hydraulic tank and power
train case.
6
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.
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).
8)
D155AX-6
9)

a Remove the suction tube mounting
bolts on the fuel pump side, too.
SEN01209-02
Removal of power train and steering lubricating oil pump assembly

1) Disconnect tubes (1), (2) and (3).
2) Sling power train and steering lubricating
oil pump assembly (4), remove 2 mounting 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
D155AX-6
Removal of cooling fan pump assembly

1) Remove the floor mat and cover.
2) Disconnect wiring harness connector FAC
(1).
SEN01209-02
3)
4)
5)
Disconnect hoses (2), (3) and (4).

Sling cooling fan pump assembly (6),
remove 4 mounting bolts (7), and lift off
cooling fan pump assembly (6).
4
Installation
q

removal.
Refilling with oil (Hydraulic tank and power

train case)
again.
Cooling fan pump assembly: 25 kg
q
q
Removal of scavenging pump assembly

1) Remove suction tube (1).
2) Disconnect outlet tube (2).
3) Remove the 2 mounting bolts and scavenging pump assembly (3).
4

Approx. 91.5 l
Power train oil (For details, see "Table
of fuel, coolant and lubricants"):
Approx. 90 l
Bleeding air
Bleed air from each part. For details, see Testing and adjusting, "Bleeding air from each
part".
Scavenging pump assembly: 20 kg
D155AX-6
SEN01209-02

hydraulic cylinder assembly
Disassembly
1.
Remove the tubes.

a Blade lift cylinder and ripper cylinder
2.
Piston rod assembly

q
Blade lift cylinder
1) Set cylinder assembly (1) to tool Y1.
2) Using the hydraulic pump or the
power wrench and tool Y2, remove
head assembly (2).
3) Pull piston rod assembly (3).
a Put an oil pan under the cylinder
to receive the oil.
1
2
Y
4
790-502-1003
Cylinder repair
stand
t 1
790-101-1102
Hydraulic pump
t 1
790-102-3802
Multi-wrench
t 1
790-201-1702
Push tool kit
t 1
790-201-1721
Push tool
790-201-1821
Push tool
790-201-1841
Push tool
790-201-1851
Push tool
790-201-1861
Push tool
790-101-5021
Grip
01010-50816
Bolt
790-201-1500
Push tool kit
790-201-1630
Plate
790-201-1650
Plate
790-201-1660
Plate
790-201-1670
Plate
790-101-5021
Grip
01010-50816
Bolt
790-720-1000
Expander
t 1
796-720-1670
Ring
t 1
t 1
07281-01279
Clamp
t 1
796-720-1690
Ring
t 1
07281-01919
Clamp
t 1
796-720-1720
Ring
t 1
07281-02429
Clamp
t 1
790-102-4300
Wrench
t 1
790-102-4310
Pin
t 2
D155AX-6
Sketch
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
Blade tilt cylinder, ripper lift cylinder, and

ripper tilt cylinder
1) Remove the mounting bolt assembly
and disconnect head assembly (4).
q
Width across flats of blade tilt cylinder: 16 mm
q
Width across flats of ripper lift
and tilt cylinders: 18 mm
2) Pull piston rod assembly (5).
a Put an oil pan under the cylinder
to receive the oil.
SEN01209-02
3.
Piston assembly
q
Blade lift cylinder
1) Remove the mounting bolts and
spacer (6) and pull out valve (7).
2) Pull out piston assembly (8).
3) Remove backup rings (9) and O-ring
(10).
4) Remove retainer (11).
Ripper tilt cylinders

1) Remove the mounting bolts and
spacer (16).
2) Pull out piston assembly (17).
3) Remove backup rings (18) and O-ring
(19).
4)
5)
Disassembly of piston assembly

1] Remove wear rings (12).
2] Remove piston ring (13).
a Do not remove seat (14) and
valve (15) from the piston.

1] Remove wear rings (20).
Ripper lift cylinder and ripper tilt cylinder

1) Set piston rod assembly (5) to tool
Y1.
D155AX-6
2)
SEN01209-02
Remove lock screw (22) of piston

assembly (17).
q
Screw size: M12 x Pitch 1.75
4.
a
Head assembly
1) Remove head assembly (2) or (4).
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)
3)
Using tool Y6, remove piston assembly (17) from piston rod (23).
4)

1] Remove backup ring and O-ring
(24).
2] Remove wear ring (25).
D155AX-6
Disassembly of head assembly

1] Remove O-ring (27). (Blade lift cylinder only)
2] Remove O-ring (28) and backup ring
(29).
3] Remove packing (30).
4] Remove ring (31).
5] Remove snap ring (32) and dust seal
(33).
6] Remove snap ring (34) and bushing
(35).
SEN01209-02
Assembly
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 Oring.
1.
Head assembly
1) Assembly of head assembly
1]
3]
Using tool Y4, install dust seal (33).
4]
5]
6]
7]
Install ring (31).

Install packing (30).
Install O-ring (28) and backup ring
(29).
Install O-ring (27). (Blade lift cylinder
only)
Using tool Y3, press fit bushing (35).
8]
2]
10
Install snap ring (34)
D155AX-6
2)
2.
SEN01209-02
Install head assembly (2) or (4) to the piston rod.
2)
Install piston assembly (17) to piston

rod (23) and set piston rod assembly
(5) to tool Y1.
3)
When reusing piston rod (23) and pist o n a s s e m b l y ( 1 7 ) , i n s ta l l t h 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.
Piston assembly
q
Ripper lift cylinder and ripper tilt cylinder
1) Assembly of piston assembly
1] Using tool Y5, expand piston ring
(26).
a Set the piston ring to tool Y5
and turn the handle of the
tool by 8 10 turns to
expand the piston ring.
2] Remove piston ring (26) from
tool Y5 and install it to the piston.
3] Using tool Y5, compress piston
ring (26).
4]
5]
D155AX-6
Install wear ring (25).

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.
11
SEN01209-02
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]
4)
12
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
cut threads horizontally.
q
Thread cutting dimensions
(mm):
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.
Install screw (22).

a Before installing the screw,
degrease and dry it thoroughly.
2 Threaded part:
Adhesive (LOCTITE No. 262)
3 Screw:
58.9 73.6 Nm {6.0 7.5 kgm}
Blade tilt cylinder

1) Using tool Y5, install piston ring (21)
and wear ring (20), similarly to steps
2-1)-1] 4] above.
D155AX-6
2)
3)
SEN01209-02
Install O-ring (19) and backup ring

(18) to the piston rod and then install
piston assembly (17).
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.
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}
5)
3.
Blade lift cylinder

1) Using tool Y5, install piston ring (13)
and wear ring (12), similarly to steps
2-1)-1] 4] above.
2)
3)
4)
D155AX-6
Install valve (7) to spacer (6) and

install them with the mounting bolts.
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
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.
3) Using tool Y2, tighten head assembly
(2).
3 Head assembly:
932 93.0 Nm {95 9.5 kgm}
Install retainer (11).

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.
Install piston assembly (8).
13
SEN01209-02
14
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})
D155AX-6
D155AX-6
SEN01209-02
15
SEN01209-02
D155AX-6 Bulldozer
2012 KOMATSU
All Rights Reserved
16
D155AX-6
SEN01210-01
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine Model
Serial Number
D155AX-6
80001 and up

Work equipment
Removal and installation of blade assembly ................................................................................................... 2
Disassembly and assembly of multi-shank ripper ........................................................................................... 4
D155AX-6
SEN01210-01
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.
1.
Remove cap (1) of the lift cylinder assembly.

[*1]
a Check the quantity and thickness of the
shims.
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 adjusting, "Releasing residual pressure in
hydraulic circuit". Then, loosen the
hydraulic tank cap gradually to release
the internal pressure of the hydraulic
tank.
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).
6.
Remove blade assembly (6). [*2]

a Run the engine and move the machine
slowly in reverse to disconnect the blade
assembly from the trunnion.
D155AX-6
SEN01210-01
Installation
q

removal.
[*1]
a Adjust clearance (a) at the cap mating surfaces to the following range with the shim and
check that the cylinder turns smoothly.
q
Standard clearance (a): 0.2 0.5 mm
q
Standard shim thickness: 4 mm
a After installing the blade, adjust the blade tilting
distance. For details, see Testing and adjusting, "Adjusting blade".
q

again.
5

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
SEN01210-01

multi-shank ripper
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 maximum 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
3.
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 adjusting, "Releasing residual pressure in
hydraulic circuit". Then, loosen the
hydraulic tank cap gradually to release
the internal pressure of the hydraulic
tank.
6.
Disconnect lift cylinder hose (7) and tilt cylinder

hose (8) and move them toward the fuel tank.
Set support stands [1] under the beam, set

block [2] under the arm, and lower the ripper
assembly.
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.
D155AX-6
7.
Sling lift cylinder assembly (3), remove the lock

plate, pull out pin (9), and lift off lift cylinder
assembly (3).
4
8.
SEN01210-01
Assembly
1.
Lift cylinder assembly: 190 kg
Sling tilt cylinder assembly (5), pull out pin (9),

and lift off tilt cylinder assembly (5).
4
Sling beam (10), remove the lock plates, pull

out right and left pins (11), and lift off beam
(10).
4
Arm: 650 kg
Set block [2] under the arm.
Tilt cylinder assembly: 260 kg
2.
9.
Sling arm (12), install right and left pins (13),

and fix them with the lock plates.
Sling beam (10), install right and left pins (11),

and fix them with the lock plates.
4
Beam: 1,250 kg
Set support stands [1] under the beam.
Beam: 1,250 kg
10. Sling arm (12), remove the lock plates, pull out
right and left pins (13), and lift off arm (12).
4
D155AX-6
Arm: 650 kg
SEN01210-01
3.
Sling tilt cylinder assembly (5) and install pin

(9).
7.
Sling lift cylinder assembly (3), run the engine,

extend the piston rod, align the pin holes,
install pin (4), and fix it with the lock plate.
8.
Run the engine and set the ripper in the maximum 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.
a
4.
Tilt cylinder assembly: 260 kg

After installing, lower the rod side to the
arm.
Sling lift cylinder assembly (3), push in pin (9),

and fix it with the lock plate.
4
Lift cylinder assembly: 190 kg

After installing, lower the rod side to the
arm.
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.
Shank: 270 kg
D155AX-6
SEN01210-01
10. Greasing
After assembling, supply sufficient amount of
grease to each pin.
2 Pin: Grease (G2-LI)
q

again.
5
D155AX-6

Only necessary quantity
SEN01210-01
D155AX-6 Bulldozer
2007 KOMATSU
All Rights Reserved
D155AX-6
SEN01211-02
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine Model
Serial Number
D155AX-6
80001 and up

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
SEN01211-02

operator's cab assembly
6.
Disconnect wiring harness connector DSH (9).

[*2]
7.
Remove mounting bolts (10) at the bottom of

the operator's cab.
a Remove the bolts on the right and left
side. [*3]
8.
Remove mounting bolts (11) in the operator's

cab.
a Remove the bolts on the right, left and
rear side. [*4]
Removal
k

1.
Remove cigarette lighter cover (1) and disconnect wiring harness connector ACC.
2.
Remove garnishes (2) and (3).
3.
Disconnect 4 window washer hoses (5). [*1]
4.
Disconnect wiring harness connectors CBPW

(6) and WST (7).
5.
Remove cover (8).
D155AX-6
9.
Lift off operator's cab assembly (12).

4
Operator's cab assembly: 410 kg
SEN01211-02
Installation
q

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)
D155AX-6
Retighten bolts (1) (21) (M20, M24) by 60

10 .
SEN01211-02
Removal and installation of operator's cab glass (Stuck glass)
Among the panes of window glass of the operator's cab, the 3 panes of (1) and (3) on both
sides are stuck. In this section, the procedure
for replacing the stuck glass is explained.
(1): Front window glass

(2): Both-sided adhesive tape
(3): Door window glass (Left and right)
(4): Both-sided adhesive tape (Left and right)
(5): Trim seal (Left and right)
(6): Door handle (Left and right)
D155AX-6
SEN01211-02
793-498-1210
Lifter
(Suction cup)
(The following figure shows the operator's cab of a

wheel loader.)
Sketch
X 1
Part name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
t 2
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
a
If the window glass is broken finely, it may

be removed with knife [4] and a screwdriver.
Widening the cut with a screwdriver, cut
the adhesive and both-sided adhesive
tape with knife [4].

wheel loader.)
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 something) and move the wire to the right and
left to cut the adhesive and both-sided
adhesive tape. Since the wire may be
broken by the frictional heat, apply lubricant to it.
D155AX-6
2.
Remove the window glass.
SEN01211-02
Installation
1.
Using a knife and scraper [5], remove the

remaining adhesive and both-sided adhesive
tape from the metal sheets (glass sticking surfaces) of the operator's cab.
a Remove the adhesive and both-sided
adhesive tape to a degree that they will
not affect adhesion of the new adhesive.
Take care not to scratch the painted surfaces.
(If the painted surfaces are scratched,
adhesion will be lowered.)

wheel loader.)
2.
3.
Stick both-sided adhesive tape (3) along the

inside edges of the front window glass sticking
section and both door window glass sticking
sections.
a Do not remove the release tape of the
both-sided adhesive tape on the glass
sticking side before sticking the glass.
a When sticking the both-sided adhesive
tape, do not touch the cleaned surface as
long as possible.
a Take care that the both-sided adhesive
tape will not float at each corner of the
window frame.
a Do not lap the finishing end of both-sided
adhesive tape (3) over the starting end but
make clearance (a) of about 5 mm
between them.
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.
D155AX-6
4.
Install trim seals (4) to both door window

glasses (2).
Install each trim seal (4) so that its finishing end and starting end will be jointed at
position (c) and dimension (b) between
the corner and position (c) will be 90 mm.
D155AX-6
SEN01211-02
5.
Position the new window glass.

1) Using tool X1, set the window glass to the
sticking position. Check the clearance
between the window glass and the operator'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
the door window glass so that the
positional relationship between it and
door metal sheet will be even all
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 positioning 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.
SEN01211-02
6.
1)
Break aluminum seal (11) of the outlet of

adhesive cartridge (10) and install the
nozzle.
2)
Cut the tip of the adhesive nozzle (12) so

that dimensions (f) and (g) will be as follows.
q
Dimension (f) : 10 mm
q
Dimension (g): 15 mm
3)
Set adhesive cartridge (10) to caulking

gun [7].
a An electric caulking gun is more efficient.
Apply adhesive.
2
a
a
a
a
a
Adhesive:Sikaflex 256HV
manufactured by Sika Japan
Do not use primer.
The using limit of the adhesive is 6 months
after the date of manufacture. Do not use
the adhesive after this limit.
Keep the adhesive in a dark place where
the temperature is below 25C.
Never heat the adhesive higher than
30C.
When reusing the adhesive, remove the
all hardened part from the nozzle tip.
D155AX-6
4)
SEN01211-02
a
Remove release tape of the both-sided

adhesive tape (3a) on the glass side.
a
a
5)
Apply adhesive (13) to dimensions (h)

and (j) of both-sided adhesive tape
(3) of operator's cab (7).
q
Dimension (h): 10 mm
q
Dimension (j) : 15 mm
Apply adhesive (13) higher than bothsided adhesive tape (3).
Apply the adhesive evenly.
Apply adhesive (13) to the outside of bothsided adhesive tape (3) of the operator's
cab.
7.
D155AX-6
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.
SEN01211-02
3)
4)
Mask front window glass (1) and operator's cab (7) with masking tapes [8].
Fill the clearance between front window
glass (1) and operator's cab (7) with caulking material (14) all around the window.
2 Caulking material:
SEKISUI SILICONE SEALANT
a The usable period of the following
caulking material is 6 months after the
date of manufacture. Do not use the
caulking material after its usable
period.
8.
5)
10
After applying caulking material (14) to

front window glass (1), form it with the fingers as shown in the following figure.
a Use rubber spatula [9] to form the
caulking material around the handrail,
etc. where it is difficult to form with the
fingers.
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
adhesive tape.
a Press the corners of each window
glass firmly.
D155AX-6

a
SEN01211-02
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.
3)
Fill the clearance between each door window glass and trim in the range of dimension (k).
i) Mask the range of dimension (k) of
each door window glass.
ii) Fill clearance (m) between each door
window glass (2) and trim seal (4)
with caulking material.
a The usable period of the following
caulking material is 6 months after the
date of manufacture. Do not use the
caulking material after its usable
period.
a Apply the caulking material to joint (c)
of the trim seal, too.
2 Caulking material:
SEKISUI SILICONE SEALANT
D155AX-6
Fix the window glasses.

1) Using styrene foam blocks [10] and rubber
bands [11], fix the front window glass to fit
it completely.
a You may use sealing tapes to fix the
front window glass.
(The figure shows the operator's cab of a
hydraulic excavator.)
11
SEN01211-02
2)
Immediately after sticking both door window 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 operator's cab.
a Using white gasoline, wipe off the adhesive 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 humidity 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

frame assembly
1
SEN01211-02
5.
Disconnect heater hoses (2) and (3).
6.
Disconnect air conditioner hoses (4) and (5).

[*3]
7.
Remove duct flange mounting bolts (6).
8.
Lift off battery top cover (7).
Removal
k
k
a
a
k

In the case that you do not drain the coolant, 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.
Collect the air conditioner refrigerant
(R134a) from air conditioner circuit in
advance.
Ask professional traders for collecting and filling operation of refrigerant (R134a).
Never release the refrigerant (R134a) to the
atmosphere.
If refrigerant gas (R134a) gets in your eyes,
you may lose your sight. Accordingly, put
on protective goggles while you are collecting 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.

from air conditioner circuit. [*1]
2.

assembly".
3.
Remove control valve cover.
4.
Disconnect wiring harness connector WESL

(1). [*2]
D155AX-6
Cover: 75 kg
13
SEN01211-02
9.
Disconnect and remove hose and flange (8)

from flange (9).
14. Remove mounting bolts (17) in front of the floor

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).
13. Disconnect wiring harness connectors FSB

(13), PL1 (14), FD1 (15) and FD4 (16). [*4]
17. Sling pin (20), tighten the bolt to pull out pin
(21), and lift off pin (20).
18. Remove the pin on the other side at the rear
and the 2 pins at the front according to steps
16 and 17.
14
D155AX-6
19. Lift off operator's cab and floor frame assembly

(22).
a When removing, take care extremely that
the floor frame assembly will not interfere
with another part.
4
Floor frame assembly: 1,000 kg
SEN01211-02
Installation
q

removal.
[*1], [*3]
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}

(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
SEN01211-02
Removal and installation of air

conditioner unit assembly
5.
Remove cover (2).
6.
Disconnect air conditioner hoses (3) and (4).

[*2]
7.
Disconnect heater hoses (5) and (6).
8.
Remove the 4 mounting bolts of work equipment controller assembly (7) and disconnect
the assembly.
Removal
1.

from air conditioner circuit in advance. [*1]
a Ask professional traders for collecting and
filling operation of refrigerant.
a Never release the refrigerant to the atmosphere.
k If refrigerant gets in your eyes, you
may lose your sight. Accordingly, put
on protective goggles, gloves and
working suits with long sleeves while
you are collecting the refrigerant or filling the air conditioner circuit with the
refrigerant. Collecting and filling work
must be conducted by a qualified person.
2.
Remove the operator's cab assembly. For

details, see "Removal and installation of operator's cab".
3.
Remove the cover at the right lower part of the

operator's seat.
4.
Lift off operator's seat assembly (1).

4
16
Operator's seat assembly: 55 kg
D155AX-6
9.
SEN01211-02
Remove filter (8).
Installation
q
11. Disconnect wiring harness connectors AC01

(10) and AC02 (11).
12. Disconnect wiring harness clamp (12) and
move wiring harness (13) aside.

removal.
[*1], [*2]
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}
13. Disconnect 2 duct hoses (14).

14. Remove the 7 mounting bolts and air conditioner unit assembly (15).
D155AX-6

(R134a).
17
SEN01211-02
D155AX-6 Bulldozer
2009 KOMATSU
All Rights Reserved
18
D155AX-6
SEN02708-01
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine Model
Serial Number
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
SEN02708-01

engine controller assembly
Installation
Removal
k
1.

Open the left engine side cover and lift off side
cover assembly (1).
4
Side cover assembly: 40 kg
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).

removal.
a Before installing, remove foreign materials
(dirt, water, etc.) from the wiring harness
connector of the engine controller assembly.
[*1]
Connector mounting screw:

2.82 Nm {0.288 kgm}
D155AX-6
SEN02708-01
Removal and installation of power

train controller assembly
1
Removal and installation of work

equipment controller assembly 1
Removal
Removal


1.
Remove the left lower cover of the operator's

seat.
1.
Remove the right lower cover of the operator's

seat.
2.
Remove 4 mounting bolts (1) of the power train

controller assembly.
2.
Disconnect wiring harness connectors WEC

(1), WEC (2) and WEC (3). [*1]
3.
Move the controller, disconnect wiring harness

connectors STC1 (2), STC2 (3) and STC3 (4),
and remove power train controller assembly
(5). [*1]
3.
Remove 4 mounting bolts (4) and work equipment controller assembly (5).
Installation
q

removal.
connector of the work equipment controller assembly.
[*1]

2.82 Nm {0.288 kgm}
Installation
q

removal.
connector of the power train controller
assembly.
[*1]

2.82 Nm {0.288 kgm}
D155AX-6
SEN02708-01
D155AX-6 Bulldozer
2007 KOMATSU
All Rights Reserved
D155AX-6
SEN04683-01
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine Model
Serial Number
D155AX-6
80001 and up
80 Air conditioner
Structure, function, testing, adjusting,

and troubleshooting
Structure and function ..................................................................................................................................... 3
Air conditioner component ....................................................................................................................... 3
Configuration and function of refrigerating cycle ..................................................................................... 4
Outline of refrigerating cycle .................................................................................................................... 5
Air conditioner unit ................................................................................................................................... 7
Functions of major components in the air conditioner unit ...................................................................... 9
Control plate ...........................................................................................................................................11
Compressor ........................................................................................................................................... 13
Condenser ............................................................................................................................................. 14
Receiver drier ........................................................................................................................................ 15
Testing, adjusting and troubleshooting.......................................................................................................... 17
Caution about refrigerant ....................................................................................................................... 17
Troubleshooting procedure .................................................................................................................... 18
Block diagram ........................................................................................................................................ 19
D155AX-6
SEN04683-01
80 Air conditioner
Circuit diagram and arrangement of connector pins .............................................................................. 20

Detail of air conditioner unit ................................................................................................................... 22
Part and connector locations ................................................................................................................. 24
Testing air leakage (duct)....................................................................................................................... 31
Testing with self-diagnosis function........................................................................................................ 33
Testing temperature control ................................................................................................................... 36
Testing vent (mode) changeover............................................................................................................ 39
Testing Recirc/Fresh changeover .......................................................................................................... 42
Testing inner sensor............................................................................................................................... 44
Testing evaporator temperature sensor ................................................................................................. 45
Testing sunlight sensor .......................................................................................................................... 48
Testing (dual) pressure switch for refrigerant......................................................................................... 49
Testing relays and diodes ...................................................................................................................... 51
Troubleshooting chart 1 ......................................................................................................................... 53
Troubleshooting chart 2 ......................................................................................................................... 54
Troubleshooting for electrical system (E mode)..................................................................................... 57
E-1 Power supply system (Air conditioner does not operate)......................................................... 58
E-2 Compressor system (Air is not cooled) .................................................................................... 62
E-3 Blower motor system (No air comes out or air flow is abnormal)............................................. 65
E-4 Temperature cannot be controlled............................................................................................ 70
E-5 Vent (mode) cannot be changed over ...................................................................................... 72
E-6 Recirc/Fresh air cannot be changed over ................................................................................ 74
Troubleshooting with gauge pressure .................................................................................................... 76
Connection of service tool...................................................................................................................... 78
Precautions for connecting air conditioner piping .................................................................................. 79
Handling of compressor oil .................................................................................................................... 80
1. Control of compressor oil .......................................................................................................... 80
2. Adding of compressor oil .......................................................................................................... 80
3. Compressor replacement.......................................................................................................... 81
4. Applying compressor oil for O-ring............................................................................................ 81
D155AX-6
80 Air conditioner
SEN04683-01
Structure and function
Air conditioner component
1.
2.
3.
4.
5.
6.
7.
8.
9.
Condenser
Hot water return piping
Hot water piping
Front window defroster
Side window defroster
Air outlet for face
Air outlet for center
Air outlet for rear
10.
11.
12.
13.
14.
15.
16.
Air outlet for foot

Receiver drier
Refrigerant piping
Valve (hot water outlet)
Valve (hot water inlet)
(Dual) pressure switch
A.
B.
Fresh air filter

Recirculated air filter
Specifications
D155AX-6
Refrigerant
R134a
Refrigerant refilling level (g)
1200 50
SEN04683-01
80 Air conditioner
Configuration and function of refrigerating cycle
Component
Compressor
Condenser
Expansion valve
Evaporator
Engine compartment
Front of radiator
In operators cab
(In air conditioner unit)
In operators cab
(In air conditioner unit)
Item
Location
Function
Circulates refrigerant
gas and increases its
temperature and
pressure so that it can
be liquefied easily in
condenser.
Condenses refrigerant Lowers temperature and

to discharge heat
pressure of refrigerant
absorbed in evaporator. liquid and gas for easy
evaporation with throttle.
Controls flow rate, too.
(Compression of refrig- (condensation of refrig- (Throttle of refrigerant)

erant)
erant)
State of
refrigerant
Gas o Gas
Adiabatic compression
Gas o Liquid
Constant pressure
change
Liquid o Liquid and gas

Adiabatic expansion
Evaporates refrigerant
to absorb heat from (or
cool) air around
evaporator.
(Evaporation of refrigerant)
Liquid and gas o Gas
Constant pressure
change
D155AX-6
80 Air conditioner
Outline of refrigerating cycle
SEN04683-01
3.
Receiver drier
The refrigerant liquefied in the condenser is
reserved in the receiver drier temporarily so
that it can be supplied to the evaporator
according to the cooling load. A strainer and a
drying agent are sealed in the receiver drier to
remove dirt and water in the refrigerating
cycle.
If any water is in the refrigerating cycle, it is frozen in the small hole of the expansion valve
and retards the flow of the refrigerant.
It can cause a cooling trouble.
4.
Expansion (Expansion valve)

The pressure of the refrigerant liquid is lowered by the restricting action [*1] of the expansion valve to a level at which the refrigerant is
evaporated easily.
The action to lower the pressure of the refrigerant to a level at which the refrigerant is evaporated easily before the refrigerant is sent to the
evaporator is called expansion.
The expansion valve which performs this action
also controls the flow rate of the refrigerant.
In other words, the quantity of the refrigerant
liquid evaporated in the evaporator is decided
by the quantity of heat to be removed (refrigeration load) at the specified evaporation temperature (evaporation pressure), and the
expansion valve senses it and controls the
refrigerant flow rate properly.
[*1] Restricting action
If there is a suddenly narrowed part in a pipe in
which a liquid is flowing, there is resistance to
the flow. Since the sectional area is increased
suddenly through this part, the liquid expands
suddenly and its pressure and temperature
lower. No heat is exchanged between the
inside and outside of the pipe during this
action.
The refrigerating cycle performs the following four

actions. The refrigerant is liquefied and gasified
repeatedly while it is circulated in the cycle.
1.
2.
Compression (Compressor)
The refrigerant gas is compressed by the compressor to the state where it can be liquefied
easily at the normal temperature (ambient temperature).
The refrigerant evaporated in the evaporator is
sucked into the compressor.
This action is performed to keep the refrigerant
pressure in the evaporator low so that the
refrigerant liquid can continue evaporation
actively even if the ambient temperature is
close to 0C.
The refrigerant gas sucked into the compressor is compressed in the cylinder and its pressure and temperature are so changed that is
can be liquefied easily when it is cooled with
the external air at the normal temperature.
Condensation (Condenser)
The refrigerant gas in the condenser is cooled
to be liquefied with the external air.
The refrigerant gas of high temperature and
high pressure discharged from the compressor
is cooled to be liquefied with the external air
and then stored in the receiver drier.
The heat discharged from the refrigerant of
high temperature and high pressure discharged from the compressor is called the condensation heat, which is the total of the heat
that the refrigerant absorbed from the
operators cab through the evaporator (vaporization heat) and the work performed to compress the refrigerant (the value converted into
heat).
During condensation, the refrigerant gas and
refrigerant liquid are mixed together in the condenser. While the refrigerant gas changes to
the refrigerant liquid, the relationship between
the pressure (condensation pressure) and
temperature (condensation temperature) is
kept constant.
Reference: The pressure varies with the type
of refrigerant and the condensation temperature.
D155AX-6
SEN04683-01
5.
80 Air conditioner
Evaporation (Evaporator)
The refrigerant changes from liquid to gas
(superheated vapor) in the evaporator.
The refrigerant mist in the evaporator evaporates actively.
At this time, the refrigerant evaporates quickly,
absorbing heat necessary for evaporation
(latent heat of vaporization) from the air around
the cooling fins (air in the operators cab). The
cooled air is spread in the operators cab by
the fan to lower the tem per atur e in t he
operators cab.
The refrigerant mist sent through the expansion
valve and the evaporated refrigerant are mixed
together in the evaporator. While the refrigerant
liquid changes to the refrigerant gas, the relationship between the pressure (evaporation
pressure) and temperature (evaporation temperature) is kept constant. If the pressure is set,
the temperature is decided automatically.
That is, the relationship between the above
pressure and temperature is equal to the relationship between saturation pressure and saturation temperature.
To evaporate the refrigerant at lower temperature, the pressure in the evaporator must be
kept lower.
Accordingly, the evaporated refrigerant is
sucked into the compressor.
The refrigerant circulates in the refrigerating
cycle, repeating the above four actions, to
move the heat from the operators cab where
the temperature is low to the outside where the
temperature is high.
If the amount of the refrigerant is insufficient,
all of the refrigerant is evaporated while it is
passing through the evaporator and the evaporator capacity decreases. It can cause a cooling trouble.
To the contrary, if the amount of the refrigerant
is too much, a part of it is not evaporated in the
evaporator and is absorbed in the compressor.
As a result, the compressor compresses the
liquid and may be broken.
D155AX-6
80 Air conditioner

a
This air conditioner unit is auto temperature control type.
Inside temp. sensor is the same as inner (air temperature) sensor.
D155AX-6
SEN04683-01
SEN04683-01
80 Air conditioner
Outline
q
The air conditioner unit consists of the evaporator, heater core and fan (blower) and generates cool air and hot air.
q
Temperature control
The machine monitor sends temperature setting data to the control amplifier (See Control
plate) according to the temperature control
switch operation.
The control amplifier controls the air mix servomotor to adjust the angle of the cool door, hot
door and sub hot door for temperature control.
Over-cooling (Freezing) prevention

The evaporator temperature sensor senses
evaporator temperature by the change of resistance. The control amplifier converts the
change of resistance of the evaporator temperature sensor into a change of voltage and
detects the evaporator temperature by the
change of voltage.
The control amplifier turns OFF the compressor clutch relay so that the evaporator will not
be frozen.
Air flow adjustment

The machine monitor sends air flow data to the
control amplifier (described later) according to
the air flow adjustment switch.
The control amplifier controls the air flow with
the power transistor.
Vent (mode) changeover

The machine monitor sends mode data to the
control amplifier according to the vent selector
(mode) switch.
The control amplifier controls the blowing out
(mode) servomotor to adjust the angles of the
foot door, defroster door, front door and rear
door for vent changeover.
Automatic air conditioner

The inner temperature sensor senses the room
temperature by the change of resistance. The
control amplifier converts the change of resistance of the inner temperature sensor into a
change of voltage and detects the room temperature by the change of voltage.
The control amplifier checks the inner air temperature sensor voltage so that the room temperature will be kept at the temperature set
with the machine monitor.
The 5 A fuse for the air conditioner unit is

installed to the wiring harness.
The door is the same as the damper.
D155AX-6
80 Air conditioner
Functions of major components

in the air conditioner unit
1
q
Evaporator
Evaporator fins are cooled by low-pressure,
low-temperature refrigerant gas being sent
from the expansion valve. Air from the blower
motor is cooled and dehumidified when passing through the fins.
Heater core
Fins of the heater core are heated by the hot
water (cooling water) being sent from the
engine. Air from the blower motor is heated as
it passes through the fins.
Expansion valve
This valve converts high-pressure, high-temperature liquid refrigerant coming from the
receiver to low-pressure, low-temperature
misty refrigerant through the throttling function.
It controls the flow rate of the refrigerant by
changing the level of throttling depending on
the thermal load (temperature) in the operator's cab. As a result, temperature of the air
blown out of the grill is adjusted depending on
the volume of refrigerant circulated in evaporator.
1) Structure
The box-type expansion valve consists of
the diaphragm, thermosensing rod, needle
valve (ball), spring, etc. The outside of diaphragm (hatched part) is pre-enclosed
with refrigerant gas.
The spring is installed on the needle valve
(ball) side of the thermosensing rod. The
needle valve opening ratio is decided
when the constant force of the spring to
push the ball to the right is balanced with
the force (Fg) of the refrigerant gas to
push the thermosensing rod to the left
through the diaphragm. As a result, the
refrigerant flow rate to the evaporator is
decided and the temperature is controlled.
D155AX-6
SEN04683-01
2)
Operation
The thermosensing rod senses the temperature of the refrigerant which passed
the evaporator. The temperature at this
time is conducted through the thermosensing rod to the refrigerant gas in the
diaphragm chamber (hatched part). As the
pre-enclosed refrigerant gas temperature
changes, the gas pressure changes and
pressing force (Fg) also changes. The
thermosensing rod attached directly to the
diaphragm so moves that the constant
force of the spring to push the ball will be
balanced with variable force (Fg) to adjust
the needle valve opening ratio.
A: When the evaporator outlet temperature is high (at start of cooling (air is
not cooled yet))
The gas pressure in the diaphragm
chamber increases and the gas volume increases.
Pushing force (Fg) of the refrigerant
gas increases and the thermosensing
rod (ball) moves to the left and the
needle valve op ens wide . Mu ch
refrigerant is supplied to the evaporator and the cooling capacity
increases.
B.
When the evaporator outlet temperature is low (during cooling (air is

cooled already))
The gas pressure in the diaphragm
chamber decreases and the gas volume decreases. Since pushing force
(Fg) of the refrigerant gas is small,
the thermosensing rod (ball) moves to
the right and the needle valve is narrowed. Accordingly, refrigerant supply
and the cooling capacity decrease.
SEN04683-01
Power transistor (PTR)

It controls the blower motor speed by receiving
signal current from the air conditioner control
amplifier. (See Control plate.)
Servomotor
This servomotor is used for temperature control (AIR MIX) and blowing out (MODE).
1.
If the switch on the control panel is operated,

the control amplifier supplies 24 V power
across (6) and (7). (The rotation direction
changes according to the polarities of the supplied power.)
10
80 Air conditioner
2.
There is a variable resistor in the servomotor

and its resistance varies with the angle of the
motor shaft. The control amplifier applies 5 V
voltage to this variable resistor and judges the
rotation angle of the motor by the potential difference (PT).
When the door (damper) comes to the position
set with each switch, the control amplifier stops
supplying the power to the servomotor.
a Do not apply the power directly to the
motor terminal to drive the motor because
the motor output shaft is damaged or the
motor coil is broken.
3.
If the potential difference (PT) does not reach

the voltage set for the servomotor control, the
control amplifier notifies the error to the
machine monitor.
Then, the letters of A/C Controller Error are
displayed red on the air conditioner operation
screen of the machine monitor.
a The Recirc/Fresh changeover servomotor
does not have this potential difference
(PT). Accordingly, it does not have the
self-diagnosis function.
D155AX-6
80 Air conditioner
Control plate
1.
SEN04683-01
Control amplifier (CNTAMP)
A/C U: Air conditioner unit

AC01: Intermediate connector to air conditioner
control amplifier (CNTAMP)
(GND, sunlight sensor, pressure switch,
connectors for relay)
AC02: Intermediate connector to air conditioner
(24 V, CAN communication with machine
monitor)
D155AX-6
Functions of main component parts

q
Control amplifier (CNTAMP) (1)
1) Communicates with the machine monitor
through CAN communication system and
controls the air conditioner unit with the
switch inputs related to the air conditioner.
2) Controls the three servomotors in the air
conditioner unit to adjust the temperature,
changeover the vent (mode), and changeover the recirculated air or fresh air.
3) Turns ON and OFF blower main relay
(switch to blow air) and compressor clutch
relay (switch to operate the compressor).
See item 8 in Part and connector
locations.
a Control amplifier (CNTAMP) (1) controls compressor clutch relay on the
basis of following three (input) data.
1] A/C switch or AUTO switch
on the machine monitor
2] Evaporator temperature sensor
3] (Dual) pressure switch
4) Has the self-diagnosis function. If any
abnormality is detected, the control amplifier notifies it to the machine monitor by
the CAN communication.
Then, the letters of A/C Controller Error
are displayed red on the air conditioner
operation screen of the machine monitor.
5) Adjusts the room temperature to the set
temperature on the basis of the data of the
sunlight sensor and inner air sensor in the
automatic air conditioner mode.
11
SEN04683-01
80 Air conditioner
Input and output signals of control amplifier (CNTAMP)

Connector on controller side: ACCN AMP 040-36PM
Connector on wiring harness side: [1], [2]
[1] AMP 040-16PF
Pin
No.
Symbol
[2] AMP 040-20PF

Signal name
Symbol
17
CAN (+)
CAN communication +
Input/
Output
CAN communication
Input/
Output
Signal name
A/M P
POT 5V
Servo potentiometer 5V power supply Output
18
CAN ()
PRESS
SW
(Dual) pressure switch (Refrigerant

pressure)
19
R/F A
Recirculated air and fresh air servo

terminal A
Output
+24 V
Input
20
R/F B
Recirculated air and fresh air servo

terminal B
Output
Input
21
A/M A
A/M servo terminal A
Output
Output
22
A/M B
A/M servo terminal B
8
9
A/M servo potentiometer voltage
Power supply
BLOW F/B Blower feedback signal

PTR B
Power transistor control signal
Blowing out (mode) servo

MODE P
potentiometer voltage
10
11
THI
12
THEVA
13
14
15
SS
16
GND
Input
and
output
Pin
No.
Input
and
output
Input
Input
Input
MODE A Blowing out (mode) servo terminal A
Output
24
MODE B Blowing out (mode) servo terminal B
Output
25
Inner air temperature sensor
Input
26
Evaporator temperature sensor
Input
27
GND S
28
29
Sunlight sensor
Input
30
GND
Input
31
Sensor GND
Input
32
33
34
35
CCRL
Compressor clutch relay
36 BLOW RL Blower main relay

q
q
q
12
Output
23
Output
Output
A/M: Air mix

F/B: Feedback
R/F: Recirculation/Fresh
D155AX-6
80 Air conditioner
SEN04683-01
Compressor
A: Refrigerant inlet port from air conditioner unit

B: Refrigerant outlet port to condenser
C: Pulley
D: Relief valve
Function
q
Other than circulating the refrigerant, compressor compresses the refrigerant gas from the
evaporator to a high-pressure, high-temperature misty refrigerant so that it may be easily
regenerated (liquefied) at normal temperature.
q
The magnetic clutch in the compressor is
engaged depending on the evaporator temperature and refrigerant pressure.
If the magnetic clutch is engaged, the shaft in
the compressor rotates to operate the compressor.
Specifications
D155AX-6
Piston capacity (cc/rev)
157.3
Allowable maximum speed

(rpm)
6,000
Refrigerant oil used
Denso: ND-OIL8
(For R134a)
Refrigerant oil refilling volume

(cc)
180
13
SEN04683-01
80 Air conditioner
Condenser
1.
Condenser
A: Refrigerant inlet from compressor

B: Refrigerant outlet to receiver drier
Function
Condenser (1)
q
Condenser cools and liquefies the high-pressure, high-temperature misty refrigerant from
the compressor.
a
If the fins are crushed or clogged with dirt, heat

exchange efficiency is degraded and complete
liquefaction of refrigerant becomes unavailable. As a result, pressure in the refrigerant circulation circuit will be increased, applying extra
load to the engine or degrading the cooling
effect. Thus, care must be used in its handling
and daily inspection.
Specifications
Fin pitch (mm)
4.0
Height Width Thickness
357 540 16
Max. pressure used

(MPa {kg/cm2})
3.6 {36}
14
D155AX-6
80 Air conditioner
SEN04683-01
Receiver drier
1.
2.
Receiver drier
A:
B:
Refrigerant inlet from condenser

Refrigerant outlet to air conditioner unit
SG: Sight glass

Function
Receiver drier (1)
q
It is used to store liquefied high-pressure, hightemperature misty refrigerant from the condenser. It is capable of completely liquefying
the refrigerant even when bubbles are contained in the refrigerant due to the condenser
condition in heat dissipation.
q
It eliminates foreign substances in the circulation circuit and water content in the refrigerant
by use of the built-in filter and desiccating
agent.
q
Sight glass (1) allows inspection of the refrigerant flow.
Even if 5 minutes elapsed after engine start up
and turning ON of A/C switch, when bubbles
are seen through sight glass (1), the amount of
the refrigerant is insufficient.
If the amount of the refrigerant is proper, no
bubbles are seen there.
a If there is no (or excessive) refrigerant in
the refrigerating cycle, no bubbles are
seen through sight glass (1), too.
(Dual) pressure switch (2)

a Connector is AC05
If abnormally low or high pressure is generated
in the refrigerant circulation circuit, the (dual)
pressure switch is turned OFF. (it is normally
turned ON.) When the (dual) pressure switch
become OFF, the control amplifier turns the
compressor clutch relay OFF. So the magnetic clutch of the compressor is disengaged
and the devices related to the air conditioner
are protected.
LA: 0.20 MPa {2 kg/cm2}

LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
Specifications
Weight of desiccating agent (g)
D155AX-6
370
15
SEN04683-01
16
80 Air conditioner
D155AX-6
80 Air conditioner
SEN04683-01
Testing, adjusting and troubleshooting

Caution about refrigerant
k
a
a
k
Collect the air conditioner refrigerant

(R134a) from air conditioner circuit to
before disconnecting air conditioner hose
replace air conditioner unit, air conditioner
compressor or receiver drier and so on.
Ask a qualified shop for collecting, adding and
filling operation of refrigerant (R134a).
Never release the refrigerant (R134a) to the
atmosphere.
If refrigerant gas (R134a) gets in your eyes,
you may lose your sight. And if it touches
your skins, you may suffer from frostbite.
Accordingly, put on protective goggles,
gloves and working suits with long sleeves
while you are collecting the refrigerant
(R134a) or filling the air conditioner circuit
with the refrigerant (R134a). Collecting and
filling work must be conducted by a qualified person.
Refrigerant (R134a) filling up quantity:
1200 g 50 g
D155AX-6
17
SEN04683-01
80 Air conditioner
The air conditioner has a self-diagnosis function for inspecting the main component parts. With this function,
you can inspect the operation of sensors and servomotors in the system.
If a troubled section is detected, every part of that section must be inspected.
Troubleshooting procedure
1.
2.
3.
After basic check, find the troubled section according to the detected trouble of the air conditioner.
Find the troubled section with the self-diagnosis function (See Inspection with self-diagnosis).
If the air conditioner unit does not operate at all, check that the power supplied to the control amplifier is
normal and that CAN communication between machine monitor and the control amplifier is normal.
If any part of the air conditioner unit operates, the power supply and CAN communication do not need to
be checked.
After finding out the troubled section, inspect the component parts in that section and repair the troubled
part.
Basic flow of troubleshooting

Occurrence of trouble:
Examination,
confirmation of failure
Basic check
operate?
1. Battery voltage (24 V)

2. Tension of compressor belt
3. Oil stain at air conditioner hose joints (*2)
4. Abnormal sound check (*3)
Compressor, blower motor and air conditioner
hose (clamp)
E-1 Power supply system (Air
conditioner does not operate)
Inspection with self-diagnosis

function (*1) and with each switch
Troubleshooting with
troubleshooting chart 1
Troubleshooting with E mode
Troubleshooting with gauge

pressure
Inspection with
troubleshooting chart 2
*1: By error display or abnormal display on Abnormality Record screen on machine monitor.
*2: If refrigerant leaks, recirculating compressor oil in the air conditioner circuit always leaks, too.
*3: Start engine and then air conditioner switch ON.
18
D155AX-6
80 Air conditioner
Block diagram
a
SEN04683-01
This air conditioner unit is auto temperature control type.
D155AX-6
19
SEN04683-01
Circuit diagram and arrangement of connector pins
20
80 Air conditioner
D155AX-6
80 Air conditioner
a
a
SEN04683-01
INSIDE TEMP. SENSOR means Inner sensor on Abnormality Record screen: 03 Air-conditioning
System.
BLOWING OUT (MODE) SERVOMOTOR means BLOWING OUT (MODE) CHANGEOVER SERVOMOTOR.
D155AX-6
21
SEN04683-01
Detail of air conditioner unit
22
80 Air conditioner
D155AX-6
80 Air conditioner
D155AX-6
SEN04683-01
23
SEN04683-01
Part and connector locations

a
1.
2.
24
80 Air conditioner
3.
Remove foot duct (2).
4.
Remove cover (3).
There are a circuit breaker and a fuse. The circuit breaker is in the battery cover on the left
side of the machine and the fuse is wound onto
the wiring harness between the air conditioner
unit and control amplifier.
The air conditioner unit is at the rear of the
operator seat.
Open the battery cover on the left side of the
machine. (See the fuse locations in Troubleshooting Volume.)
q
Circuit breaker CB3 (5th from left) (20 A):
For power supply for air conditioner compressor and air conditioner unit (for all
devices related to air conditioner)
a If the reset button (RB) of the circuit
breaker is projected, the circuit is turned
OFF. In this case, push in the reset button
(RB). If it is kept pushed in, the circuit is
normal. If it is soon projected again, the
circuit may have a ground fault etc. (See
E-1.)
Remove recirculated air filter (1) from the rear

of the operator seat.
D155AX-6
80 Air conditioner
SEN04683-01
5.
State without cover (3)

q
q
CNTAMP: Control amplifier
q
[1] and [2]: Control amplifier connectors
q
AC01: Connector to air conditioner
unit for GND, compressor, pressure
switch, relay and sunlight sensor
q
AC02: Connector to air conditioner
unit for 24 V power supply and CAN
communication connector to monitor
panel (Communication circuit common to engine controller and pump
controller)
Disconnect connectors AC01 and AC02.
6.
Disconnect clamp (4).
7.
Remove bracket (5).

a Fu5A: Fuse 5 A is installed to the bracket
bottom of wiring harness (H).
For power supply for air conditioner unit
(including primary side of relays for blower
(fan) and air conditioner compressor)
q
Fuse part No.
Fu5A: ND93950-05003
q
[5]: Blowingout (Mode) servomotor
connector
q
[6]: Temperature control (Air mix) servomotor connector
D155AX-6
25
SEN04683-01
q
q
q
q
q
q
q
26
80 Air conditioner
[3]: Blower (Fan) motor connector

[4]: Power transistor (PTR) connector
[5]: Blowingout (Mode) servomotor
connector
[6]: Temperature control (Air mix) servomotor connector
[7]: Recirc/Fresh changeover servomotor connector
[8]: Recirculated air sensor connector
[9]: Evaporator temperature sensor
connector
D155AX-6
80 Air conditioner
8.
9.
Relays and diodes

The relays and diodes are at the left rear of the
operator seat.
q
AC03: Blower main relay connector --- For
turning fan motor ON/OFF
q
AC04: Compressor clutch relay connector
--- For turning air conditioner compressor
(clutch) ON/OFF
q
Diodes: ACD1 and ACD2 --- For cutting
back electromotive force generated in the
primary coils of the blower main relay and
compressor clutch relay. For protection of
IF: Recirculated air filter
SEN04683-01
q
q
q
AC05: Pressure switch connector

RD: Receiver drier
SG: Sight glass
Pressure switch
Open engine left cover (6) and remove covers
(7) (9).
D155AX-6
27
SEN04683-01
80 Air conditioner
10. Air conditioner compressor

q
ACC: Air conditioner compressor
q
A/C: Air conditioner compressor connector
q
ACS: Diode connector of air conditioner
compressor
q
GND09: Ground
q
A/C1: Intermediate connector of air conditioner compressor
28
D155AX-6
80 Air conditioner
11. Sunlight sensor connector SLS and machine

monitor connector CM02 (CAN communication
connector)
a If the machine monitor connector CM02 is
disconnected, the engine controller and
other controller(s) can not perform the
CAN communication. Accordingly, failure
code: [DAFRMC] is displayed.
If the screen changes to the air conditioner operation screen at this time, A/C
Controller error is displayed red. If the
above error is not displayed, no check is
necessary.
Note: A/C Controller error on the air
conditioner operation screen is also displayed when the vent cannot be changed,
when the temperature control is abnormal
or when the refrigerant pressure switch is
turned OFF. (A/C Controller error display for the refrigerant pressure switch is
turned OFF will be abolished in the
future.)
1) Remove dashboard cover (10).
2) Disconnect sunlight sensor (S) connector (SLS).
3)
4)
D155AX-6
SEN04683-01
5)
Float dashboard (14) and pull it out

toward you.
a Since the wiring harness is connected, pull out the dashboard
slowly.
q
DSH: Intermediate connector of
machine monitor
a Connector DSH is DRC-70.
Take care in handling it. See the
next page.
6)
Disconnect the following connectors.

q
(15): KEY
q
(16): BKSW --- Red band
q
(17): DCL --- Blue band
q
(18): BRK --- Yellow band
q
(19): FLSW
q
(20): RLSW
Remove duct (11).

Remove covers (12) and (13).
29
SEN04683-01
7)
Inspect connectors CM01, CM02,

CM03 and GPS from the backside of
dashboard (14).
a CM02 and CM03 can be connected reversely. Take care.
CM03 is green.
12. Intermediate connector

1) Open cover (21).
2)
3)
30
80 Air conditioner
How to disconnect connector DSH

Disconnect the connector straight slowly and
check the seal for breakage, peeling and sticking foreign matter.
a If the seal is damaged, replace it.
How to connect connector DSH

1) Check that the seal is correctly installed to
the plug.
2) Check that the key is positioned to be
matched to the groove of the receptacle
(key is not positioned oppositely).
3) Set the plug connector to the receptacle
straight (since the seal is projected) and fit
it a little, while check that the seal is not
rolled up.
4) Tighten the hexagon bolt at the center of
the connector by 2 3 turns.
5) Fit the plug connector to the end and
adjust it so that the clearance between it
and the fitted receptacle will be even when
seen from each direction.
6) Tighten the lock bolt to the specified
torque.
3 Hexagon lock bolt:
2.8 0.3 Nm {0.28 0.03 kgm}
a If the lock bolt is tightened to strongly,
it will be broken and cannot lock.
Take care.
Disconnect battery ground cable.

Inspect connectors FSB, FD1 and FD4.
D155AX-6
80 Air conditioner
Testing air leakage (duct)

1.
2.
SEN04683-01
3.
Remove cover (3).

4.
Remove cover (4).
5.
Ensure that the following are not removed.

1) Duct (5)
2) Front duct (FD)
3) Defroster duct (DD)
q
q
A1 and A2: Front blowingout route
q
C1, C2 and C3: Defroster blowingout
route
D155AX-6
31
SEN04683-01
6.
32
80 Air conditioner
For air leakage through the defroster blowingout route of C2 and C3, check each duct joint
for air leakage in the defroster mode at the
maximum air flow.
a When air does not come out of only C2
(Air comes out of C1 and C3)
1) Remove duct (6).
2) Check to see if air comes out of (P) in
the defroster mode at the maximum
air flow.
3) If no air comes out of (P), inspect duct
(7).
4) If air comes out of (P), remove dashboard (8), referring to Part and connector locations, Item 11.
5) Inspect duct (9).
D155AX-6
80 Air conditioner
Testing with self-diagnosis

function
SEN04683-01
Outline
On the air conditioner operation screen of the
machine monitor, the system performs self-diagnosis for the communication with the air conditioner
unit, temperature control, vent (mode) changeover
and refrigerant pressure with the pressure switch. If
any of these items has trouble, A/C Controller
error is displayed red to notify the trouble.
a A/C Controller error display for the refrigerant pressure switch is turned OFF will be
abolished in the future.
1.
While pressing numeral key [4] on the normal

screen, press [1], [2] and [3] in order.
2.
On the service menu screen, press [F3] (R)

once to select 02 Abnormality Record.
3.
Press [F6] (
Once a problem is detected, its indication is

not reset even if it becomes normal. The indication can be reset after the starting switch is
turned OFF.
On the air conditioner Abnormality Record

screen in the service mode of the machine monitor,
the system performs self-diagnosis for various sensors, in addition to the above items, and displays
Error red if any problem is detected.
a The system does not have self-diagnosis function for the Recirc/Fresh changeover servomotor.
q
Explanation of machine monitor operating procedure
) to confirm.
How to enter air conditioner Abnormality

Record screen in service mode of machine
monitor.
Outline of machine monitor operation

Normal screen
O
While pressing [4], press [1], [2] and [3] in
order.
Service menu (Mode)
O
Press [F3] once. Press [F6].
02 Abnormality Record
O
Press [F3] twice. Press [F6].
03 Air-conditioning system Abnormality Record
screen
D155AX-6
33
SEN04683-01
80 Air conditioner
4.
On the Abnormality Record screen, press

[F3] (R) twice to select 03 Air-conditioning
System.
5.
Press [F6] (
34
) to confirm.
Information displayed on Abnormality

Record screen: 03 Air-conditioning
System screen
(a): System/Component name
(b): Number of occurrence time
(c): Condition (Normal or abnormal)
(d): If CAN status is abnormal in condition,
CAN communication cannot be carried out
normally but air conditioner unit is disconnected. Accordingly, the conditions (d) of
other items are not displayed.
(e): If [E] is displayed on the left of a condition,
the abnormality is still occurring or clearing of it has not been confirmed.
q
[F2]: Clear Abnormality Record
q
[F5]: Return to Abnormality Record
screen
Clearing Abnormality Record by machine

monitor
While the Abnormality Record screen is displayed, press [F2], and the number of occurrence time of abnormality is reset. If it is
confirmed at this time that the abnormality has
been reset, the display changes to Normal.
Caution
Inner Sensor means inside temperature sensor on
block diagram or circuit diagram.
Ventilating Sensor is abnormal means that evaporator temperature sensor is short circuit or disconnected.
Sunlight Sensor is abnormal means that Sunlight
Sensor is short circuit only.
Ventilation is abnormal means servomotor for
blowing out changeover (mode) damper does not
rotate judging from the servomotor potentiometer
voltage.
a Damper is the same as door.
Air Mix is abnormal means servomotor
for Air Mix (temperature adjustment)
damper does not rotate judging from the
servomotor potentiometer voltage.
Refrigerant means refrigerant pressure
from (dual) pressure switch. Namely,
refrigerant is abnormal means that
(dual) pressure switch of refrigerant is
OFF.
1.
CAN Status (communication) is abnormal

The CAN communication between the
machine monitor and air conditioner control
amplifier (CNTAMP) is not carried out normally.
a If failure code [DAFRMC] (Error of CAN
communication with engine controller) is
displayed, all the communication circuit is
abnormal. In this case, see failure code
[DAFRMC] in Chapter 40. If [DAFRMC] is
not displayed, only the communication
between control amplifier (CNTAMP) and
machine monitor is abnormal.
(Check connectors CN-N10, CN-AC01, [1]
and [2] for disconnection. See Part and
connector locations 2., 3., and 6. or see
E-1.)
2.
Setting abnormal
The software of the air conditioner amplifier
does not match that of the monitor. Check the
part numbers of those components.
D155AX-6
80 Air conditioner
3.
Inner Sensor abnormal

a Inner Sensor is the same as inside temperature sensor on block diagram or
circuit diagram.
a There is a Disconnection or a short circuit
in the line between the control amplifier
and Inside temperature sensor.
a Action of air conditioner amplifier:
The air conditioner amplifier controls with
only the set temperature since the data of
the Inside temperature sensor are not
available.
a Trouble: The air conditioner does not function automatically but functions when
operated manually.
a See Testing Inner Sensor.
4.
Ventilating Sensor abnormal

a Ventilating Sensor is the same as evaporator temperature sensor.
a There is a disconnection or a short circuit
in the line between the control amplifier
and evaporator temperature sensor.
a Action of control amplifier:
The control amplifier stops outputting to
the compressor.
a Trouble: The air conditioner does not
work.
(See Testing evaporator temperature
sensor.)
5.
Sunlight Sensor abnormal

There is a short circuit between the control
amplifier and Sunlight Sensor.
The control amplifier controls without the
Sunlight Sensor.
a Trouble: The automatic air conditioner
does not work when the machine is
exposed to the direct sunlight in the automatic air conditioner mode.
a See Testing sunlight sensor.
SEN04683-01
6.
Ventilation is abnormal
Servomotor for blowing out changeover
(mode) damper does not rotate judging from
the servomotor potentiometer voltage.
a Trouble: Blowing out is not changed.
the servomotor for blowing out changeover (mode).
a Even if the link is disconnected and the
damper does not rotate, the self-diagnosis
system judges the damper normal since
the servomotor potentiometer voltage
changes normally.
(For mechanical troubles, see Testing
vent (mode) changeover.
7.
Air Mix is abnormal

Servomotor for Air Mix (temperature adjustment) damper does not rotate judging from the
servomotor potentiometer voltage.
a Trouble: The temperature control system
does not work.
the air mix servomotor.
a Even if the link is disconnected and the
damper does not rotate, the self-diagnosis
system judges the damper normal since
the servomotor potentiometer voltage
changes normally.
(For mechanical troubles, see Testing
temperature control.
8.
Refrigerant is abnormal
(Dual) pressure switch signal for refrigerant is
abnormal. Namely pressure switch for refrigerant is OFF.
a Trouble: The air conditioner does not
work.
the compressor.
k
D155AX-6
When replacing the pressure switch,

be sure to collect the refrigerant. See
Cautions about refrigerant.
See Testing (dual) pressure switch for
refrigerant.
35
SEN04683-01
Testing temperature control
80 Air conditioner
2.
3.
Remove cover (3).
State with cover (3) removed

q
q
CNTAMP: Control amplifier
4.
Check contacts of connector [6] of the air mix

servomotor (for disconnection).
Outline
q
Temperature is controlled by mixing ratio of the
hot air from the heater and cooled air from the
evaporator by changing the angles of the four
doors (dampers) in the air mix section. The
angle of each door (damper) is set changed by
the air mix servomotor through plate (P1),
lever 1 (L1) lever 6 (L6) and rod (RODAM).
Only rod (RODAM), lever 5 (L5) and lever 6
(L6) are seen from outside. (For the figure, see
item 5.)
a
1.
36
If lever 5 (L5) and lever 6 (L6) move smoothly

between COOL MAX and HOT MAX, plate
(P1) and lever 1 (L1) lever 4 (L4) operate
normally, too.
Control amplifier (CNTAMP) control temperature is automatically based on inside temperature sensor. So to operate between COOL
MAX and HOT MAX inside temperature sensor
connector may have to be disconnected.
To reset the self-diagnosis system (To clear the
air conditioner error displayed on the air conditioner screen of the machine monitor), the
starting switch must be turned OFF (While the
self-diagnosis system is indicating a problem,
no signals are output to the servomotor).
D155AX-6
80 Air conditioner
5.
Check the rod (RODAM) for disconnection.
6.
Start the engine and turn the air conditioner

power ON.
7.
Set the temperature to 18C and 32C on the

air conditioner screen of the monitor and check
visually that lever 5 (L5) and lever 6 (L6) move
smoothly between COOL MAX and HOT MAX.
a Figure is PC200-8 type, so duct is different
from this type.
a For COOL MAX and HOT MAX, see the
right.
When Lever 5 (L5) and Lever 6 (L6) do not

move between COOL MAX and HOT MAX.
1) Starting switch OFF.
2) Disconnect connector [8] under box
assembly (11).
3)
SEN04683-01
a
Plate (P1), lever 1 (L1) lever 4 (L4) are

not seen from outside.
Retry steps 6 and 7.

a After checking the operation and connect [8], confirm Inner sensor is
normal on Abnormality Record
screen: "03 Air-conditioning System"
screen.
D155AX-6
37
SEN04683-01
38
80 Air conditioner
When lever 5 (L5) and lever 6 (L6) do not

move smoothly through the range shown in
the figure
4)
Disconnect connectors [5] and [6] of the

servomotor.
5)
Make match marks on servomotors (5)

and (6) to show which connector has been
connected to which servomotor. (The servomotor will be exchanged with each
other later.)
6)
Remove servomotors (5) and (6).
7)
a
Remove cover (7).

Figure is PC200-8 type, so duct is different
from this type.
8)
Rotate plate (P1) with the hand between

COOL MAX and HOT MAX to see where
lever 1 (L1) lever 6 (L6) are hitched and
then repair.
a If the levers do not move smoothly,
clean them and apply grease to the
links.
2 Link: Molykote MH-62 Grease
(Dow Corning Toray Co. Ltd.)
9)
When plate (P1) is rotated with the hand

between COOL MAX and HOT MAX, if
lever 1 (L1) lever 6 (L6) move smoothly,
the servomotor may have trouble. In this
case, exchange servomotors (5) and (6)
and operate them.
a For electrical problems, see E-4
Temperature cannot be controlled.
D155AX-6
80 Air conditioner
SEN04683-01
Testing vent (mode) changeover 1

Outline
The vent (modes) are selected by changing the
angles of the 4 internal doors (dampers). The
angles of the doors (dampers) are changed by the
servomotor through plate (P2), defroster rod
(RODD), front face rod (RODF) and lever 7
(LEVER 7) lever 12 (LEVER 12). Only defroster
rod (RODD), front face rod (RODF), lever 7 (L7)
and lever 8 (L8) are seen from outside. (For the figure, see item 5.) Visually check the positions of the
levers and opening and closing operations of the
doors (dampers) of the front face and rear face.
The rear face door (damper) angle is changed by
the servomotor through lever (L13) and rod
(RODR). Since lever (L11) of the front face and
lever (L13) and rod (RODR) of the rear face are not
seen from outside, remove the duct and check the
revolution of the door (damper) directly.
a To reset the self-diagnosis system (To delete
the air conditioner error displayed on the air
conditioner screen of the machine monitor),
the starting switch must be turned OFF (While
the self-diagnosis system is indicating a trouble, no signals are output to the servomotor).
1.
Referring to Testing temperature control, 1.

3., remove recirculated filter (1), duct (2) and
cover (3).
2.
Check contacts of connector [5] of the servomotor (for disconnection).
3.
Check the defroster rod (RODD) and foot rod

(RODF) for disconnection.
4.

power ON.
5.
Press the vent selector switch on the air conditioner screen of the monitor and check visually
that lever 7 (L7) and lever 8 (L8) move
smoothly between the foot mode and defroster
mode shown in the figure.
6.
Stop the engine.
7.
Remove rear face duct (RFD).
8.
Referring to Testing for air leakage (ducts),

remove the ducts in order from the one on the
monitor side and remove front face duct (FFD).
D155AX-6
39
SEN04683-01
80 Air conditioner
9.

power ON.
10. Press the vent selector switch on the air conditioner screen of the monitor and check the
opening and closing operations of the front
face door and rear face door (damper).
When lever 7 (L7) and lever 8 (L8) do not

move smoothly through the range shown in the
figure or the front face door and rear face door
(damper) do not open or close
1)
2)
3)
4)
40
Disconnect connectors [5] and [6] of the

servomotor.
Make match marks on servomotors (5)
and (6) to show which servomotor has
been installed. (The servomotor will be
exchanged with each other later.)
Remove cover (7).
a Figure is PC200-8 type, so duct is different from this type.
D155AX-6
80 Air conditioner
5)
Rotate plate (P2) with the hand to see

where lever 7 (L7) lever 12 (L12) are
hitched and then repair.
a If the levers do not move smoothly,
clean them and apply grease to the
links.
2 Link: Molykote MH-62 Grease
(Dow Corning Toray Co. Ltd.)
6) When plate (P2) is rotated with the hand, if
lever 7 (L7) lever 12 (L12) move
smoothly, the servomotor may have trouble. In this case, exchange servomotors
(5) and (6) and operate them.
a The figures of the foot mode and
defroster mode are shown before.
For electrical problem, see E-5 Vent (mode)
cannot be changed over.
D155AX-6
SEN04683-01
a
F. Face door position will change from

OPEN to Half gradually when raising the
setting temperature from 18C to 32C gradually.
41
SEN04683-01
80 Air conditioner
Testing Recirc/Fresh
changeover
Outline
Recirculated air or fresh air is selected by changing
the door (damper) angle in the air conditioner unit
with the servomotor. Check the opening and closing operations of the door (damper) visually.
a The system does not have self-diagnosis function for the Recirc/Fresh changeover servomotor.
1.
Remove recirculation air filter from behind the

operator seat.
2.

power ON.
3.
Press the Recirc/Fresh selector switch on the

air conditioner screen of the monitor and check
visually that door (damper) (F/R D) opens and
closes.
4.
When door (damper) (F/R D) does not open

and close, check contacts of connector [7] of
the servomotor (for disconnection), referring to
Testing temperature control, 1. 3., recirculated filter (1), duct (2) and cover (3).
42
For electric problems, see E-6 Recirc/

Fresh cannot be changed over.
D155AX-6
80 Air conditioner
Reference
q
How to remove fresh air duct.
1. Remove duct (4).
D155AX-6
SEN04683-01
Method of replacing Recirc/Fresh changeover

servomotor
Remove fresh air duct in advance.
1) Disconnect connector [7]. (Explained
before)
2) Disconnect inner sensor connector [8].
3) Remove box assembly (11).
4) Remove the Recirc/Fresh changeover
servomotor from box assembly (11).
43
SEN04683-01
Testing inner sensor

a
80 Air conditioner
8.
Inner Sensor is the same as inside temperature sensor on block diagram or circuit
diagram.
If Inner Sensor abnormal is displayed by the
self-diagnosis (Abnormality Record screen
on machine monitor: 03 Air-conditioning
System), test the inner sensor.
To reset the self-diagnosis system (detection of
abnormality), the starting switch must be
turned OFF.
Check that the resistance between female connector [8] (2) (PB) (on the wiring harness side)
and connector [1] (11) (PB) (on the wiring harness side) is 1 z or below. (If not, the wiring
harness is defective.)
9.
Check that the resistance between female connector [8] (1) (BrR) (on the wiring harness side)
and connector [2] (27) (BrR) (on the wiring harness side) is 1 z or below. (If not, the wiring
1.

3., recirculated filter (1), duct (2) and cover
(3).
2.
Check contacts of inner sensor connector [8]

(for disconnection).
3.
Referring to Testing Recirc/Fresh changeover

door (damper), remove the fresh air duct.
4.
Referring to Method of replacing Recirc/Fresh

changeover servomotor, remove box assembly (11).
5.
Resistance between terminals on sensor side

of connector [8]:
Normal value:
0C ----- 1.6 kz
25C --- 5 kz
6.
Disconnect connectors [1] and [2] from control

amplifier (CNTAMP).
7.
Check that the female terminals (on the wiring

harness side) of connector [8] are not shorted
to each other. (If they are shorted, the wiring
44
10. Connect all the connectors.

11. Turn the starting switch ON and carry out selfdiagnosis (Abnormality Record screen on
the machine monitor: 03 Air-conditioning
System). If Inner Sensor abnormal is still
displayed, replace the control amplifier.
D155AX-6
80 Air conditioner
Testing evaporator temperature

sensor
1
q
SEN04683-01
6.
Disconnect connector [9].
7.
Measure the resistance between the mate

(female) of connector [9] and the terminal on
the evaporator temperature sensor side.
Normal value:
0C ----- 4.8 kz
15C --- 2.3 kz
If Ventilating Sensor abnormal is displayed

by the self-diagnosis (Abnormality Record
screen on machine monitor: 03 Air-conditioning System), test the evaporator temperature
sensor.
turned OFF.
1.
Remove recirculated air filter (1), duct (2) and

cover (3) according to Testing temperature
control, 1 3.
2.
Disconnect connectors AC01 and AC02 from

air conditioner unit (A/C U).
3.
Disconnect clamp (4).
4.
Remove control amplifier (CNTAMP) and its

bracket together.
8.
5.
Ensure contact of connector [9] along wiring

harness (H). (Check for disconnection.)
D155AX-6
If an error is detected by the self-diagnosis

and evaporator temperature sensor is normal, control amplifier (CNTAMP) or the
wiring harness is defective.
Disconnect connectors [1] and [2] from control

amplifier (CNTAMP). (Connect connector [9].)
Resistance between terminal (11) (PB) of connector [1] and (27) (BrR) of [2]:
Normal value:
0C ----- 4.8 kz
15C --- 2.3 kz
a If the result of 8. above is normal, control
amplifier (CNTAMP) is defective. If the
result of 8. above is abnormal, and the
result of 7. is normal, the wiring harness is
defective.
45
SEN04683-01
a
If the evaporator temperature sensor is defective, replace it according to the following procedure.
Replacing evaporator temperature sensor.

Remove air conditioner unit assembly (A/C U).
For details, see Shop Manual, Chapter 50,
Removal and installation of air conditioner
unit assembly.
1.
2.
Remove wiring harness. (For each connector,

see the Part and connector locations.)
3.
4.
Remove cover (4).
5.
Remove the link section. For details, see Shop

Manual, Chapter 60, Structure and function,
Air conditioner unit.
6.
Separate cases (5) and (6).
46
80 Air conditioner
D155AX-6
80 Air conditioner
7.
Remove the evaporator.
8.
Remove the holder from part (P) and remove

the evaporator temperature sensor.
SEN04683-01
Installation
1.
Install the evaporator temperature sensor to

the position shown in the previous figure with
the holder.
2.
Carry out the following installation in the

reverse order to removal.
D155AX-6
47
SEN04683-01
Testing sunlight sensor

q
1.
2.
48
80 Air conditioner
If Sunlight Sensor abnormal is displayed by

the self-diagnosis (Abnormality Record
screen on machine monitor: 03 Air-conditioning System), test sunlight sensor connector
SLS.
turned OFF.
a A short circuit between the terminals of
the sunlight sensor unit is a defect.
Whether the sunlight sensor is normal
cannot be checked by measuring resistance, etc., however. Accordingly, if the
wiring is normal, presume the sunlight
sensor to be abnormal and replace it. If
Sunlight Sensor abnormal is still displayed, replace the control amplifier.
Remove cover (10) and check connector SLS
of sunlight sensor (S) on the rear side of the
cover (for disconnection).
3.

3., recirculated filter (1), duct (2) and cover
(3).
4.
Referring to Testing evaporator temperature

sensor item 1, 5., disconnect connector [1]
from control amplifier (CNTAMP).
5.
Ensure that the terminals of female connector

SLS (on the wiring harness side) are not
shorted to each other. (If they are shorted, the
wiring harness is defective.)
6.
Check that the resistance between female connector SLS (2) (L) (on the wiring harness side)
and connector [1] (3) (YW) (on the wiring harness side) is 1 z or below. (If not, the wiring
a If the result of item 6 or item 7 is abnormal,
check the contact of connector CN-AC01.
(See Part and connector locations.)
7.
Check that the resistance between female connector SLS (1) (O) (on the wiring harness side)
and connector [1] (15) (RB) (on the wiring harness side) is 1 z or below. (If not, the wiring
8.
Connect all the connectors.
9.
Turn the starting switch ON and carry out selfdiagnosis (on the air conditioner fault history
screen of the machine monitor). If Sunlight
Sensor abnormal is still displayed, replace the
control amplifier.
Disconnect SLS connector and measure voltage between male terminals on sunlight sensor (S) at voltage range of tester because the
sensor (S) may be broken by measurement of
resistance at resistance range of tester.
q
Approximate voltage of sunlight sensor
unit
0.55 (V): direct sunlight
0.45 (V): cloudy
0.4 (V): in room
D155AX-6
80 Air conditioner
Testing (dual) pressure switch for

refrigerant
1
q
1.
If Refrigerant abnormal is displayed by the

self-diagnosis (Abnormality Record screen
on machine monitor: 03 Air-conditioning
System), test pressure switch connector
AC05.
turned OFF.
The pressure switch unit is turned ON when
the refrigerant pressure is normal and OFF
when the refrigerant pressure is abnormal.
The pressure switch unit may be OFF when
ambient temperature below 0C because the
refrigerant pressure becomes down. The pressure switch unit is not defective but normal.
SEN04683-01
3.
Ensure that the terminals on the switch side of

connector AC05 are shorted to each other
(ON). (When they are not shorted (OFF), the
pressure switch detects abnormal refrigerant
pressure.)
a When the pressure switch is OFF, connect
a pressure gauge to the high pressure
side of the air conditioner compressor and
check the refrigerant pressure.
See Connection of service tool and
Troubleshooting with gauge pressure.
a If refrigerant pressure is normal, the pressure switch is defective.
Open engine left cover (1) and remove covers

(2) (4).
LA: 0.20 MPa {2 kg/cm2}

LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
k
2.
Disconnect pressure switch connector AC05.

RD: Receiver drier
SG: Sight glass
D155AX-6
When replacing the pressure switch, be

sure to collect the refrigerant.
49
SEN04683-01
50
80 Air conditioner
When the terminals on the switch side of

connector AC05 are shorted (ON) (See E-2
for circuit)
1) Referring to Testing temperature control,
1., 3., recirculated filter (1), duct (2) and
cover (3).
2)
Disconnect connector [1] from control

amplifier (CNTAMP).
3)
Check that the resistance between female

connector AC05 (2) (B) (on the wiring harness side) and the ground is 1 z or below.
(If not, the wiring harness is defective.)
4)
Check that the resistance between female

connector AC05 (1) (G) (on the wiring harness side) and connector [1] (4) (GB) (on
the wiring harness side) is 1 z or below. (If
not, the wiring harness is defective.)
a If the result of item 4) is abnormal,
check the contact of connector CNAC01. (See Part and connector
locations.)
5)
Connect all the connectors.
6)
Turn the starting switch ON and carry out

self-diagnosis (Abnormality Record
screen on machine monitor: 03 Air-conditioning System). If Refrigerant
abnormal is still displayed, replace the
control amplifier.
D155AX-6
80 Air conditioner
Testing relays and diodes

a
a
SEN04683-01
If the air conditioner compressor is normal (air

is cooled) and air comes out, the relays are
normal. Accordingly, skip these relay tests.
Bring your ear to each relay to check its operation by sound.
There are two relays.

Blower main relay (connector AC03): Used to
turn the fan motor ON/OFF.
q
Compressor clutch relay (connector AC04):
Used to turn the air conditioner compressor
(clutch) ON/OFF
q
1.
Check contacts of connectors AC03 and AC04

(for disconnection) from left behind of operator
seat.
2.
Turn the starting switch ON (do not start the

engine) and turn the main power of the air conditioner ON. If the blower-off relay is normal, it
is turned ON. Check its click.
3.
If the air conditioner switch is turned ON at this

time, the compressor relay is turned ON if it is
normal. Check its click.
a Control amplifier (CNTAMP) does not turn
the compressor relay ON in the following
cases.
1) When the evaporator temperature is
below 3? (depending on the input
voltage from the evaporator temperature sensor).
2) When the pressure switch detects
abnormality (it is turned OFF).
a If the fan sound is too loud to hear the
compressor relay sound, disconnect connector AC03 with the starting switch in the
OFF position, and then check.
IF: Recirculated air filter
D155AX-6
Checking relay unit

a Since no T-adapter is available, it is
impossible to check the relay while the
voltage is applied to the coil actually.
Blower main relay (AC03)

1) The resistance of the coil between terminals (1) and (2) is 140 340 z.
2) While the voltage (DC20 30 V) is not
applied between terminals (1) (+) and (2),
terminals (3) and (4) are disconnected
from each other and terminals (3) and (5)
are connected to each other.
3) While the voltage (DC20 30 V) is applied
between terminals (1) (+) and (2), terminals (3) and (4) are connected to each
other and terminals (3) and (5) are disconnected from each other.
Compressor clutch relay (AC04)

1) The resistance of the coil between terminals (1) and (3) is 140 340 z.
2) Without voltage (DC20 30 V) applied
between terminals (1) (+) and (3), terminals (2) and (4) are disconnected from
each other.
3) With the voltage (DC20 30 V) applied
between terminals (1) (+) and (3), terminals (2) and (4) are connected to each
other.
51
SEN04683-01
52
80 Air conditioner
Testing diode units (ACD1) and (ACD2) (male)

a Measure with a circuit tester in the diode
range.
a Test ACD2 similarly to ACD1.
Between ACD1 (2) (+) and (1) ():
There is continuity.
Between ACD1 (2) () and (1) (+):
There is no continuity.
D155AX-6
80 Air conditioner
Troubleshooting chart 1
SEN04683-01
a
a
1.
The numbers in the boxes are the item numbers in the troubleshooting table.
E-2, E-3 means Troubleshooting for electrical system (E mode).
Cooling trouble
2.
Heating trouble
D155AX-6
53
SEN04683-01
80 Air conditioner
Troubleshooting chart 2
1.
Blower fan motor does not revolve or its speed is different from set value.
a See troubleshooting "E-3 Blower motor system (No air comes out or air flow is abnormal)" for troubleshooting for the electrical system.
Possible cause
Check method
Defective BLOWER MAIN RELAY See Testing relays and diodes
Remedy
Replace
Disconnection of wire or defective Check connector of blower fan motor for disconnec- Repair broken parts and conconnection
nect correctly
tion. See E-3 and Part and connector locations
Defective blower motor
Check two lead wires of motor with circuit tester. If

there is not continuity, motor is defective. See E-3
and Part and connector locations
Replace
Defective POWER TRANSISTOR

Move fan switches in sequence and check fan speed. Replace
(PTR)
Defective diode (ACD1)
2.
Check diode (ACD1).

See E-3 and Testing relays and diodes.
Replace
Blower fan motor is normal but air flow is insufficient.

Possible cause
Check method
Remedy
Large duct resistance
Check duct for crushing and filter for clogging
Repair
Air leakage
See Testing air leakage (duct)
Repair or replace
Obstruction on suction side of

evaporator
Check evaporator for stain and obstruction
Remove obstruction and clean
Defective evaporator temperature sensor, defective contact of

evaporator temperature sensor or
defective expansion valve
Evaporator is frozen. Check sensor clip. Check sensor for dirt.

Check the frost on the hose near pressure switch
(when freezing advances furthermore)
Repair or replace
(Evaporator temperature sensor and expansion valve are in
air conditioner unit)
Check method
Remedy
3.
Low/high pressure
Possible cause
Collect refrigerant, then

charge with proper quantity of
refrigerant again
Excessive or insufficient refrigerant
Insufficient refrigerant
If R-134a is used as refrigerant, its quantity cannot

be checked through sight glass.
Accordingly, check by connecting gauge manifold.
Purpose of sight glass is to check refrigerant flow.
Collect refrigerant, then

refrigerant again
Overcharge with refrigerant
Judgment by pressure at inlet/

outlet of compressor
54
Repair leaking part, then

refrigerant again
Normal pressure range

Low pressure:
Approx. 0.13 0.2 MPa {1.3 2.0 kg/cm2}
High pressure:
Appox. 1.5 1.7 MPa {15 17 kg/cm2}
These values are for following condition, however.
Temperature in cab: 30 35?
Engine speed: Appox. 1500 rpm
See Troubleshooting with

gauge pressure
D155AX-6
80 Air conditioner
4.
SEN04683-01
Compressor does not revolve at all or its speed is low.

a See "E-2 compressor system (Air is not cooled)" for troubleshooting for the electrical system.
Troubled part
Possible cause
Compressor belt Loosened compressor belt

Trouble in compressor
Compressor
Magnet clutch
Check method
Remedy
Vibration amplitude of belt is large Adjust tension

Slip of belt
Repair or replace
Insufficient compressor oil or seizure

Heating of compressor
in the compressor
See "Handling compressor oil"
Low battery voltage
Slip of clutch
Charge battery
Disconnection or short circuit in coil
Inspect with circuit tester (10

20 z)
Replace
Disconnection in wiring or defective Check ground wire and connecconnection of ground wire
tions
Repair
Relay
Defective compressor clutch relay
See Testing relays and

diodes.
Replace
Refrigerant
pressure
Low/high pressure
(Operation of pressure switch)

pressure

pressure
Pressure switch Defective pressure switch
See Testing (dual) pressure

switch for refrigerant and E-2
Replace
Diode
Check diode (ACD2).

See E-2 and Testing relays
and diodes.
Replace
5.
Defective diode (ACD2)
Blower fan motor is normal but air flow is insufficient.

Possible cause
Check method
Remedy
Large duct resistance
Check duct for crushing and filter for clogging
Repair
Air leakage through duct joints
Check duct joints for defective duct seal and disconnection of duct
Repair
Clogging of heater core fins
Check heater core fins for clogging
Repair
6.
Check of hot water

Possible cause
Check method
Remedy
Low engine coolant temperature
Warm up engine, and then check engine coolant

temperature
Find out cause
Low engine coolant level
Check coolant level in radiator
Add coolant
Insufficient circulation of engine

coolant
Check engine coolant piping for clogging (Hose,

pipe, and core)
Bleed air and repair
Contrary connection of IN and OUT

Check the destination of heater hoses
heater hoses
7.
Repair
Fan rotation speed

Possible cause
Fan rotation speed is low
D155AX-6
Check method
See "Checking and adjusting air conditioner compressor belt tension" in chapter 30 "Testing and
adjusting" of shop manual.
Remedy
Repair
55
SEN04683-01
8.
80 Air conditioner
Other items
Possible cause
Check method
Temperature cannot be adjusted
See "Testing temperature control" and "Troubleshooting for electrical system, E-4"
Vent (mode) cannot be changed

over
See "Testing vent (mode) changeover" and "Troubleshooting for electrical system, E-5"
Recirc/Fresh cannot be changed

over
See "Testing Recirc/Fresh changeover" and "Troubleshooting for electrical system, E-6"
Excessive compressor oil
See "Handling compressor oil"
Water leakage into the cab
Clogging of drain hole
Remark
Common to cooling and heating
Cooling only
56
D155AX-6
80 Air conditioner
SEN04683-01
Troubleshooting for electrical system (E mode)

a
The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before troubleshooting, understand the information fully.
Trouble
Related
information
Problem that appears on machine

Causes
Possible causes
and standard
value in normal
state
Procedure/Standard (normal) value/Remarks on troubleshooting
<Described contents>
Standard (value) required for judgement (Normal state value)
1 Assumed causes for trouble Remarks required for judgement
(The order number indicates
a serial number, not a priority <Notes on troubleshooting>
sequence. Perform trouble- (1) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus () leads
shooting according to these
as shown below unless otherwise specified.
2 numbers, however.)
Connect the plus (+) lead to pin or harness indicated in the
front.
Connect the minus () lead to a pin or harness indicated in
the rear.
(2) Example of troubleshooting by inspection of multiple items
3 - defective
a Normal in 1 but abnormal in 2
At this time - defective shown at left is applied
If a wiring harness is burnt, replace it.
<Phenomenon of defective harness>

Disconnection in wiring
The connector connection is defective or wiring harness is disconnected.
q
Ground fault
A harness not connected to the ground (earth) circuit comes into contact with the ground (earth) circuit
accidentally.
q
Hot short circuit
A harness not connected to the power (24 V) circuit comes into contact with the power (24 V) circuit
accidentally.
q
Short circuit
A harness of an independent circuit abnormally comes into contact with one of another circuit.
q

This is the excerpted circuit diagram related to troubleshooting
q
Connector No.: Indicates (Model No. of pins) (Color).
q
See Arrangement of connector pins and Arrangement of parts and connectors
q
The circuit diagram shows the size and colors of wires.
W: White, B: Black, R: Red, G: Green, Y: Yellow, L: Blue, V: Purple, P: Pink, O: Orange, Br: Brown,
Gr: Gray, Sb: Sky blue, Lg: Light green, Dg: Dark green, Ch: Dark brown
a When there are 2 colors
Example: WY: Yellow line on white background
a The number before the wire color indicates the wire size.
q
N.C.: Normally closed (Normally turned ON)
q
[1], [2],? are connector numbers.
q
Arrow (io ): Roughly indicates mounting place on machine.
D155AX-6
57
SEN04683-01
80 Air conditioner
E-1 Power supply system (Air conditioner does not operate)

Problem
Indication of
problem on
machine
Air conditioner does not operate due to power supply system failure.
A/C Controller Error is displayed red on air conditioner screen of machine monitor.
No air blows out (Blower motor does not rotate).
If failure code [DAFRMC] is displayed on machine monitor, see Chapter 40 Troubleshooting first and
repair so that [DAFRMC] will not be displayed.
a CAN communication is connected to machine monitor, engine controller, pump controller and air
conditioner controller.
Related
information
A/C Controller Error is displayed on air conditioner operation screen of machine monitor in following cases. In E-1, 1), 2) and 3) of following cases are explained.
1) Power is not supplied to control amplifier.
2) Control amplifier is broken.
3) Control amplifier (CNTAMP) cannot communicate with machine monitor.
4) Blowing out door (damper) servomotor does not rotate.
5) Temperature control (AIRMIX) door (damper) servomotor does not rotate.
6) Refrigerant pressure is abnormal.
Referring to Testing with self-diagnosis function, display Abnormality Record screen on
machine monitor: 03 Air-conditioning System and check to see if CAN Status is abnormal.
Abnormality of CAN Status indicates that control amplifier at rear of air conditioner unit cannot
communicate with machine monitor.
CAN Status is indicated as abnormal in any case of 1), 2) and 3) above.
Referring to Part and connector locations, ensure the following.
1) Circuit breaker CB3 is not OFF (Its reset button is not projected). (It is ON, if normal.)
2) Fuse Fu5A is not broken.
Ground cable of air conditioner is grounded together with that of machine wiring harness for electrical equipment of machine.
For each connector and relay, see Part and connector locations.
If fuse is broken when A/C switch is pressed, see E-2.
T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220
a T-adapter is not prepared for other connectors.
Causes
Possible causes
and standard
value in normal
state
Between (16) (black) on wiring harness side

of connector [1] ground
2
58
Defective wiring harness

(ground cable)

1) Turn starting switch OFF.
2) Disconnect battery ground cable.
3) Disconnect connector [1] from control amplifier and carry out
troubleshooting without turning starting switch ON.
Circuit breaker CB3 is OFF,

broken fuse
Resistance
Max. 1 z

2) Referring to Part and connector locations, check circuit
breaker CB3 is not OFF (Its reset button is not projected) and
check fuse Fu5A.
D155AX-6
80 Air conditioner
SEN04683-01
Causes

a If fuse described in related information is broken, replace it.
3) Disconnect connectors [1] and [2] from control amplifier.
4) Turn starting switch ON and carry out troubleshooting.
Between (6) (red) (16) (B) on
wiring harness side of connector
[1]
3 Defective wiring harness
Possible causes
and standard
value in normal
state
Ground fault in wiring

4 harness (Contact with GND
circuit)
D155AX-6
harness
Voltage
20 30 V
a If fuse is broken again in test A above, perform following procedure. (Replace broken fuse.)
3) Disconnect control amplifier connector [1] and carry out
a If fuse is broken again in test A above and results B and C below
are normal, blower motor circuit may be cause of trouble. See E3.
Between (6) (red) (16) (black)
wiring harness side of connector
[1]
Resistance
Min. 1 Mz
Between (6) (red) on wiring

harness side of connector [1]
ground
Resistance
Min. 1 Mz
a If fuse is broken again in test A for cause 3 and result of B or C is

abnormal, identify wiring harness having ground fault.
3) Disconnect connectors AC01, AC02 and [1].
4) Connect T-adapter to wiring harness side of connector [1] and
carry out troubleshooting without turning starting switch ON.
a If result D or E below is abnormal: Short circuit in air conditioner
wiring harness (on plate)
a If result F or G below is abnormal: Short circuit in machine wiring
harness
Between (6) (red) (16) (black)
on wiring harness side of
connector [1]
Resistance
Min. 1 Mz
Between (6) (red) on wiring

ground
Resistance
Min. 1 Mz
Between connector AC02

(female) (4) AC01 (female) (5)
(black)
Resistance
Min. 1 Mz

(female) (4) (red) (5) (black)
Resistance
Min. 1 Mz
a If fuse described in related information is not broken and test

result A for cause 3 is abnormal, check with circuit diagram.
59
SEN04683-01
80 Air conditioner
Causes

a If CAN communication circuit has short circuit or ground fault,
[DAFRMC] error is displayed.
a Terminal resistors of about 120 z are in machine monitor and on
engine. Since they are connected in parallel, combined resistance is about 60 z.
3) Disconnect control amplifier connectors [1] and [2] and connect
T-adapter to wiring harness side.
4) Carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in CAN
communication circuit
6 (Communication between
control panel and control
amplifier is defective)
Between connector [2] (17)

(18)
Approx.
60 z
a If result H above is abnormal, perform following procedure.

a If result H above and J below are abnormal, operator cab wiring
harness is abnormal.
a If result H above is abnormal and J below is normal, air conditioner wiring harness (on plate) is abnormal.
a Terminal resistors of about 120 z are in machine monitor and on
engine. Since they are connected in parallel, combined resistance is about 60 z.
3) Disconnect control amplifier connectors [1] and [2] and connect
T-adapter to wiring harness side.
(female) (1) (2)
60
Resistance
Resistance
Approx.
60 z
7 Defective control amplifier
When test results for causes 1, 2, result A for cause 3 and result H
for cause 6 are normal, replace control amplifier.
When test results for causes 1 7 are normal, machine monitor is

defective.
D155AX-6
80 Air conditioner
SEN04683-01
D155AX-6
61
SEN04683-01
80 Air conditioner
E-2 Compressor system (Air is not cooled)

Problem
Air is not cooled due to compressor system failure.
Indication of
problem on
machine
When engine is started and A/C switch is pressed on air conditioner screen of machine monitor, air is
not cooled as displayed on screen.
Air conditioner compressor does not operate.
A/C Controller Error may be displayed red on air conditioner screen of machine monitor. Causes of
this phenomenon are 1) 6). For 1) 5), see Related information in E-1.
Related
information
In E-2, 6) Refrigerant pressure is abnormal of Related information in E-1 is explained.

Referring to Testing with self-diagnosis function, display air conditioner fault history screen on
machine monitor and check to see if refrigerant pressure is abnormal. If refrigerant pressure is abnormal, compressor is not turned ON and air is not cooled consequently.
a Abnormal refrigerant pressure indicates that Signal (connector [1] (4)) from pressure switch is not
grounded.
Air conditioner may not be turned ON even when ambient temperature is below 5C (Normal).
For each connector, see Part and connector locations.
Causes
1 Defective pressure switch

a If A/C Controller Error is displayed red on air conditioner operation screen of machine monitor, perform following procedure.
2) Disconnect battery ground terminal.
3) Disconnect pressure switch connector P17 and carry out
a Pressure switch may operate normally and turn off itself. Accordingly, if following is abnormal (if switch is turned OFF), install pressure gauge to low pressure side of air conditioner compressor
and check refrigerant pressure.
Between (1) (2) on pressure switch side of
connector AC05
k
Possible causes
and standard
value in normal
state
2
Defective air conditioner

compressor
Resistance
Max. 1 z
Before replacing pressure switch, collect refrigerant.

2) Disconnect connector A/C from air conditioner compressor and
carry out troubleshooting without turning starting switch ON.
a Ensure connection of air conditioner compressor ground cable
and GND09. (See Part and connector locations.)
Between (1) on air conditioner compressor
side of connector A/C ground (Air
conditioner compressor coil resistance)
Resistance
Approx.
15 z

2) Disconnect connectors ACS, ACD2 and carry out troubleshooting
a Test at diode range.
3 Defective Diode
62
Between ACS (male) (1) (+) (2) ()
There is no continuity
Between ACS (male) (1) () (2) (+)
There is continuity
Between ACD2 (male) (1) (+) (2) ()
Between ACD2 (male) (1) () (2) (+)
There is continuity
D155AX-6
80 Air conditioner
SEN04683-01
Causes

2) Disconnect connectors [1], AC04 and ACS and carry out
a Ensure that test result for cause 1 is normal (pressure switch is
turned ON) and that for cause 2 is normal (air conditioner compressor is normal) and that cause 3 is normal.
harness
Between connector [1] (4) ground

(Pressure switch is turned ON)
Resistance
Max. 1 z
Between connector AC04 (female) (2)

ground (Air conditioner compressor coil
resistance)
Resistance
Approx.
15 z
Between connector ACS (male) (2) ground
Resistance
Max. 1 z
Referring to Testing relays, check

sound made when compressor clutch
relay is turned ON.
a If blower sound is too large to hear operating sound of compressor clutch relay, turn
starting switch OFF temporarily and disconnect connector R30.
Click is
heard.
a If A above and B below are abnormal and C is normal (relay is

normal), go to causes 7 and 8.
5
Possible causes
and standard
value in normal
state
Defective compressor clutch 1) Turn starting switch OFF.

2) Disconnect connector AC04.
relay (Does not turn ON)
3) Short (2) (white) and (4) (green) of
connector AC04 (on wiring harness side)
wire. (Turn compressor ON forcibly without
using relay.)
4) Turn starting switch ON.
Air is
cooled.

2) Disconnect connector AC04 and carry out troubleshooting without
turning starting switch ON.
Between AC04 (relay side) (1)
(3) (coil resistance)

circuit)
Resistance
Approx.
140
340 z
a If fuse is not broken, skip troubleshooting.

2) Disconnect connector AC04 and carry out troubleshooting without
a Ensure that test result for cause is normal.
Between (2) on machine wiring harness side
of connector AC04 ground (Air conditioner
compressor coil resistance)
Resistance
Approx.
15 z

2) Disconnect connector AC04 and [2] and carry out troubleshooting
Short circuit in wiring
7 harness (with another wiring a Ensure that test result for cause 2 is normal.
harness)
Between (3) (1) on machine wiring harness
ResisMin. 1 Mz
side of connector AC04
tance
8
harness
Check with circuit diagram.

2) Disconnect connectors [1] and [2] and insert T-adapter in wiring
harness side.
4) Display air conditioner operation screen on machine monitor and
press A/C switch.
Between connector [2] (35) [1] (16)
10
D155AX-6

(Defective switch)
Voltage
Max. 1 V

2) Display air conditioner operation screen on machine monitor.
Press A/C switch.
A/C ON is
displayed.
63
SEN04683-01
80 Air conditioner
64
D155AX-6
80 Air conditioner
SEN04683-01
E-3 Blower motor system (No air comes out or air flow is abnormal)
Problem
No air comes out or air flow is abnormal due to blower motor system failure.
Indication of
problem on
machine
LCD of machine monitor on air conditioner operation screen lights normally but air does not come
out.
Air flow does not match fan switch setting on air conditioner operation screen.
Related
information
This trouble is not checked with self-diagnosis function.

If air flow becomes abnormal after a while in cooling mode, evaporator may be frozen. Possible
causes for this trouble are as follows.
1) Compressor clutch relay is defective (Stuck closed). (See E-2, 5, A.)
2) Evaporator temperature sensor mounting holder has come off. (Remove and disassemble air
conditioner unit.)
3) Expansion valve is adjusted improperly. (Remove air conditioner unit and replace expansion
valve.)
If air comes out, fuse and relay are normal and wiring harness is seldom abnormal.
If air comes out but its flow is abnormal in heating mode, replace power transistor first.
For each connector, relay, and power transistor, see Part and connector locations.
Causes

2) Disconnect connector [3] and carry out troubleshooting without
1 Defective blower (fan) motor
Between wiring harness terminals on blower
There is continuity
motor side of connector [3]
a If power transistor is normal, all of following are normal. Reverse
is not always true, however (Transistor itself cannot be checked if
transistor unit is removed).
Possible causes
and standard
value in normal
state
2 Defective power transistor
D155AX-6
Between (2) (+) (1) of connector [4] (male)

(power transistor) (Internal fuse and resistor
must not be broken)
a If test result is abnormal, overcurrent has
flowed. In this case, replace blower motor,
too.
Approx. 11 kz
Between (3) (4) of connector [4] (male)

(power transistor) (Internal resistor must not
be broken)
Approx. 2.2 kz
Between (1) (+) (3) () of connector [4]

(male) (power transistor)
There is continuity
* Diode range

(male) (power transistor)
* Diode range
65
SEN04683-01
80 Air conditioner
Causes

Referring to Testing relay, check turnon sound of blower main relay.
Click is
heard.
a If test results A above and B below are abnormal and C is normal

(relay is normal), go to causes 8-J and 10.
Defective blower main relay

(Does not turn ON)

2) Disconnect connector AC03.
3) Short (3) (red/yellow) and (4) (red/blue) of connector AC03
(wiring harness side) with wire. (Turn blower ON forcibly without
using relay.)
Operate fan on air conditioner operation
screen.
Air comes
out.
a If air does not come out even when blower is turned ON forcibly
without using relay, cause is part other than relay.
2) Disconnect connector AC03 and carry out troubleshooting
Between (1) (2) of AC03 (relay
side) (coil resistance)
4 Defective Diode
Possible causes
and standard
value in normal
state
5
Defective wiring harness

(ground)
Resistance
Approx.
140
340 z

2) Disconnect connector ACD1 and carry out troubleshooting
a Test at diode range.
Between ACD1 (male) (1) (+) (2) ()
Between ACD1 (male) (1) () (2) (+)
There is continuity

Between (1) (black) on wiring harness side
of connector [4] ground
Resistance
Max. 1 z
Blower motor input voltage

2) Disconnect connector [3].
4) Press fan switch on air conditioner operation screen. (Air flow
may be set to any position.)
a If result is abnormal, go to causes 8-J and 10.
Between (1) (red/yellow) on wiring harness
side of connector [3] ground
Check of input and output

voltages
Approx.
24 V
Voltage
Power transistor input voltage

2) Disconnect connector [4].
(Since no current flows to blower motor, blower motor does not
rotate.)
4) Press fan switch on air conditioner operation screen. (Air flow
may be set to any position.)
a If D below is abnormal, go to G below.
a If E below is abnormal, go to causes (9) and (10).
Between (2) (brown/black) (1)
(black) on wiring harness side of
connector [4]
Voltage
Max. 2 V
Between (3) (black/blue) (1)

(black) on wiring harness side of
connector [4]
Voltage
Approx.
24 V
*1
*1: At blower main relay ON
66
D155AX-6
80 Air conditioner
SEN04683-01
Causes
Check of input and output

voltages
7 Defective blower (fan) motor
Possible causes
and standard
value in normal
state
Control amplifier
2) Disconnect connectors [1] and [2] and insert T-adapter.
4) Press fan switch on air conditioner operation screen.
(Air flow may be set to any position.)
a If F below is abnormal, go to causes 7-J and 9.
a If G below is abnormal, go to causes (9) and (10).
Between (36) (16) of connector
[2]
Voltage
Max. 1 V
Between (8) (16) of connector

[1]
Voltage
Max. 2 V
When test results D for cause 6 are normal (voltage is normal but
motor does not rotate), blower (fan) motor is defective.
2) Disconnect connectors AC03 and [1] and carry out
Short circuit in wiring

8 harness (with another wiring Between (2) (1) on wiring
harness side of connector AC03
harness)
Between (6) (7) on wiring
circuit)
10
harness

12
(Defective switch)
D155AX-6
Resistance
Resistance
Min. 1 Mz
Min. 1 Mz

2) Disconnect connectors [1] and [4] and carry out troubleshooting
Between (2) (1) on wiring
Resistance
Min. 1 Mz

Control amplifier is defective in following cases.
1) F for cause 6 is abnormal, J for cause 8 is normal, and cause 10
is normal.
2) G for cause 6 is abnormal and causes 9 and 10 are normal.
Press fan switches from MIN to
MAX.
LCD display of air flow changes

from MIN to MAX.
67
SEN04683-01
80 Air conditioner
68
D155AX-6
80 Air conditioner
D155AX-6
SEN04683-01
69
SEN04683-01
80 Air conditioner
E-4 Temperature cannot be controlled

Problem
Temperature cannot be controlled.
Indication of
problem on
machine
A/C Controller Error may be displayed red on air conditioner screen of machine monitor. (See E-1.)
While air conditioner operation screen of machine monitor is displayed, temperature does not
change even if temperature control switch is operated.
Related
information
a Temperature control means Air Mix of cooled air and hot air.
machine monitor: 03 Air-conditioning System and check to see if Air Mix is abnormal and
Inner sensor is abnormal.
See Testing inner sensor when Inner sensor is abnormal.
Even if rod etc. is disconnected (See Testing temperature control), if current is supplied to air mix
servomotor by operating switches and potentiometer in servomotor reaches normal voltage, selfdiagnosis function judges system normal.
Referring to Testing temperature control, check that there is not contact of connector [6] or
mechanical trouble (removal or interference of link, etc.)
Air mix servomotor and air blowing out (mode) servomotor are same part number. Operating angle of
temperature control (air mix) is less, however. Accordingly, do not test servomotor to see if it rotates
by connecting connector [5] to connector [6]. It is allowed, however, to exchange air mix servomotor
and blowing out (mode) servomotor to see if they are normal.
Air mix servomotor can be checked for trouble by connecting new servomotor to connector [6] and
see if it operates normally.
a Since T-adapter is not prepared for other connectors, check signals with control amplifier during
operation.
Causes

Between (6) (7) of connector [6] (on

servomotor side) (There must not be
Defective air mix servomotor disconnection or short circuit)
1
(Unit test)
disconnection or short circuit)
Possible causes
and standard
value in normal
state
70
Resistance
400
3000 z
Resistance
4 k 8 kz
Resistance
4 k 8 kz

Voltage
5V

4) Set temperature control switch on air conditioner operation
screen to COOL MAX.
Defective air mix servomotor 5) Set temperature control switch on air conditioner operation
screen to HOT MAX.
2 or defective air conditioner
a Voltage appears across (21) and (22) of connector [2] for about 3
wiring harness
seconds (only while door moves).
a Voltage across connectors [1] (2) and [2] (27) changes for about 3
seconds (only while door moves) (It is stabilized after door stops).
a If temperature is changed from HOT MAX
to COOL MAX, voltage polarities are
reversed.
Voltage
Approx.
24 V
Between connector [1] (2) (+) [2] (27) ()
Voltage
Change
below 5 V
D155AX-6
80 Air conditioner
SEN04683-01
Causes
3
Possible causes
and standard
value in normal
state

wiring harness

5
(Defective switch)

a When test result for cause 1 is normal and that for cause 2 is
abnormal, perform following procedure.
abnormal and that for cause 3 is normal, control amplifier is
defective.
Press temperature control switch.
LCD display changes

from 18 to 32 C.
D155AX-6
71
SEN04683-01
80 Air conditioner
E-5 Vent (mode) cannot be changed over

Problem
Indication of
problem on
machine
Vent (mode) cannot be changed over.

A/C Controller Error may be displayed red on air conditioner screen of machine monitor. (See E-1.)
When vent selector switch on air conditioner operation screen of machine monitor is operated, vent
does not change.
machine monitor: 03 Air-conditioning System and check to see if Ventilating sensor is
abnormal.
Even if rod etc. is disconnected (See Testing vent (mode) changeover), if current is supplied to
blowing out (mode) servomotor by operating switches and potentiometer in servomotor reaches normal voltage, self-diagnosis function judges system normal.
Related
information
Referring to Testing vent (mode) changeover, check that there is not contact of connector [5] or
mechanical trouble (removal or interference of link, etc.)
Air mix servomotor and blowing out (mode) servomotor are same. Operating angle of temperature
control (air mix) is less, however. Accordingly, do not test servomotor to see if it rotates by connecting connector [5] to connector [6]. It is allowed, however, to exchange air mix servomotor and blowing out (mode) servomotor to see if they are normal.
Blowing out servomotor can be checked for trouble by connecting new servomotor to connector [5]
and see if it operates normally.
operation.
Causes


Defective blowing out (mode) disconnection or short circuit)
1
servomotor (Unit test)
Possible causes
and standard
value in normal
state
72
Resistance
400
3000 z
Resistance
4 k 8 kz
Resistance
4 k 8 kz

Voltage
5V

4) Set vent selector switch on air conditioner operation screen to
FACE.
Defective blowing out (mode) 5) Set vent selector switch on air conditioner operation screen to
2 servomotor or defective air
DEFROST.
conditioner wiring harness
a Voltage appears across (24) and (23) of connector [2] for about 3
seconds (only while door moves).
a Voltage across connectors [1] (9) and [2] (27) changes for about 3
seconds (only while door moves) (It is stabilized after door stops).
a If vent is changed from DEFROST to
FACE, voltage polarities are reversed.
Voltage
Approx.
24 V
Between connector [1] (9) (+) [2] (27) ()
Voltage
Changes
below 5 V
D155AX-6
80 Air conditioner
SEN04683-01
Causes
3
Possible causes
and standard
value in normal
state

wiring harness

abnormal, perform following procedure.
abnormal and that for cause 3 is normal, control amplifier is
defective.

(Defective switch)
Operate air outlet switch and change LCD

display to FACE, FACE and REAR, FOOT,
FACE and REAR, FOOT, FOOT and
DEFRSOT, and DEFROST.
LCD display changes

to each mode
D155AX-6
73
SEN04683-01
80 Air conditioner
E-6 Recirc/Fresh air cannot be changed over

Problem
Recirc/Fresh air cannot be changed over.
Indication of
problem on
machine
When Recirc/Fresh selector switch of machine monitor is operated, recirculated or fresh air does not
changeover (Recirc/Fresh changeover door (damper) does not rotate).
Related
information
Recirc/Fresh changeover is not checked with self-diagnosis function.

Referring to Testing Recirc/Fresh changeover, operate Recirc/Fresh selector switch and check
that there is not mechanical trouble (removal or interference of link, etc.) in Recirc/Fresh changeover
door.
Operating angle of Recirc/Fresh changeover servomotor is 90.
operation.
Causes
Defective Recirc/Fresh
changeover servomotor
1
(Unit test) or defective air
conditioner wiring harness

wiring harness

a Since connector [7] cannot be disconnected easily, test on control
amplifier side.
2) Disconnect connectors [1] and [2] and connect T-adapter to
wiring harness side.
Between connector [1] (wiring harness side)
(6) connector [2] (wiring harness side) (19)
(There must not be disconnection or short
circuit)
Resistance
400
3000 z
Between connector [1] (wiring harness side)

(6) connector [2] (wiring harness side) (20)
(There must not be disconnection or short
circuit)
Resistance
400
3000 z
a When test result for cause 1 is abnormal, perform following procedure.

4) Set Recirc/Fresh selector switch on air conditioner operation
screen to Recirc.
screen to Fresh.
a Voltage appears across connector [1] (6) and connector [2] (20)
for about 3 seconds (only while door moves to Fresh position).
Possible causes
and standard
value in normal
state
Defective control amplifier or Between connector [1] (6) (+) and connector
Approx.
Voltage
3 defective Recirc/Fresh
24 V
[2] (20) ()
See 1) 3) above.
screen to Fresh.
screen to Recirc.
a Voltage appears across connector [1] (6) and connector [2] (19)
for about 3 seconds (only while door moves to Recirc position).
Between connector [1] (6) (+) and connector
[2] (19) ()
Defective Recirc/Fresh
4
74
Voltage
Approx.
24 V
a When test result for cause 1 is abnormal and that for cause 2 is
normal, Recirc/Fresh changeover servomotor is defective.
(If all test results for causes 1, 2 and 3 are normal, cause may be
mechanical trouble such as hitch.)
D155AX-6
80 Air conditioner
SEN04683-01
Causes
Possible causes
and standard
value in normal
state

6
(Defective switch)

a When test results for causes 1 and 2 are normal and that for
cause 3 is abnormal, control amplifier is defective.
Press Recirc/Fresh selector switch.
Display of Recirc/
Fresh changes.
D155AX-6
75
SEN04683-01
80 Air conditioner
Troubleshooting with gauge pressure
Referring to Connection of service tool, carry out

troubleshooting by reading the high and low gauge
pressures of the cooling cycle.
<Measurement condition for pressure>

Atmospheric temperature
20 50?
The gauge pressure varies largely with the

weather condition and operating condition of
the machine. Take care.
Engine speed
Low idle
ON
Fan switch
Hl
High pressure is too high:

Above approx. 2.5 MPa {25 kg/cm2}
High pressure is too low:
Below approx. 1 MPa {10 kg/cm2}
Low pressure is too high:
Above approx. 0.3 MPa {3 kg/cm2}
Low pressure is too low:
Below approx. 0.05 MPa {0.5 kg/cm2}
Set temperature
Full cool
q
q
q
q
Item
Dual pressure switch

Normally "ON", abnormal pressure "OFF" for
compressor.
(Dual) pressure switch on high pressure side

protects air conditioner circuit with OFF:
See right
LA: 0.20 MPa {2 kg/cm2}
LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
Indicated gauge pressure
Pressure is normal
Cause
Check method
Both high pressure and low

pressure are too low
Remedy
Air conditioner cycle is operating normally.

If there is any trouble (cooling trouble), there is another
cause.
High pressure: Approx. 1.5 1.7 MPa {15 17 kg/cm2}
Low pressure: Approx. 0.13 0.2 MPa {1.3 2.0 kg/cm2}
Insufficient refrigerant
Collect refrigerant, then fill

Bubble can be seen in the
up with proper quantity of
sight glass
(*1)
refrigerant again
(*2)
Clogging of receiver drier
There is a temperature difference between inlet and

Replace
outlet pipes of receiver drier.
Tank is frosty
Clogging of expansion valve Expansion valve is frosty

Gas leakage at heat sensing tube of expansion valve
Low pressure becomes vacDefective evaporator sensor

uum
or defective contact of sensor (removal of mounting
clip)
(*2)
Clean or replace
(*2)
Low pressure gauge

becomes vacuum
Replace
Evaporator is frozen
Air flow is down by freezing
(At cool max. and HI speed
of fan, later it becomes not to
cold.)
Repair or replace
Replace receiver drier
refrigerant again
(*2)
Piping between receiver

drier and compressor is
Clogging or flattening or pip- clogged or flattened. If
ing
clogged completely, low
gauge pressure becomes
vacuum
76
Condition value
(*2)
Clean or replace
(*2)
D155AX-6
80 Air conditioner
SEN04683-01
Indicated gauge pressure
Cause
Check method
Filling too much with refrigerConnect gauge manifold

ant

pressure are too high
High pressure is too high

and low pressure is too low
Remedy
refrigerant again
(*2)
Defective cooling of condenser
Stain of condenser, clogging Clean, repair fins, or repair

or crushing of fins, or defec- or replace condenser
tive revolution of cooling fan
(*2)
expansion valve (Valve is
opened too wide)

sight glass
Air in cycle

sight glass
Replace
(*2)
Evacuate and then fill up
with proper quantity of refrigerant again
(*2)
Clogging or flattening of pip- There is a remarkable tem- Clean inside of cycle or

ing between compressor and perature difference between replace
condenser
before and after clogged part
(*2)

Defective compressor (Com- pressure are balanced while
High pressure is too low and
Replace
pression trouble of compres- compressor is in operation.
low pressure is too high
sor)
Compressor has seized and
is extremely hot.
*1
(*2)
If refrigerant leaks, internal oil always leaks, too. So perform the check mainly on pipe joints and parts which are
stained with oil. Increase tightening of the joints or replace parts.
*2.
k When replacing a cooling cycle part, see Caution about refrigerant and collect refrigerant. After replacing it,
fill up the air conditioner system with refrigerant again.
Sight glass (SG) is on the receiver drier (RD).
D155AX-6
77
SEN04683-01
80 Air conditioner
Connection of service tool

Symbol
X
Part No.
799-703-1200
Part name
Service tool kit
Use the service tool kit for R134a.
Service tool kit

1. Gauge manifold
2. High pressure charging hose (red)
3. Low pressure charging hose (blue)
4. Quick joint (Hi) (Large diameter)
5. Quick joint (Lo) (Small diameter)
a. The thread is rough. So be careful not to loosen.
78
Connect the gauge manifold, hoses and other service tools according to the following procedure.
1.
2.
3.
4.
Close the high-pressure valve (HI) and lowpressure valve (LO) of gauge manifold (1).
Connect red charging hose (2) to the (HI) side
and blue charging hose (3) to the (LO) side.
Connect quick joints (4) and (5) to each hose.
Connect the quick joints to the service valves
of the high and low-pressure pipings.
D155AX-6
80 Air conditioner
Precautions for connecting air

conditioner piping
q
SEN04683-01
When connecting the piping, apply compressor

oil NDOIL-8 for R134a to the O-rings. (See
item 4. in Handling of compressor oil)
Do not apply oil to the threads of a bolt, nut or
union, however.
Once an O-ring is used, it is deformed and
deteriorated. Accordingly, do not reuse it.
When removing it, use a soft tool (such as a
toothpick) so that the piping will not be damaged.
Push in each pipe to the stopper (until it clicks)
and tighten the bolt or nut fully with your fingers.
Be sure to use two wrenches to tighten each
nut (Apply a torque wrench to the tightening
side). Place one wrench and tighten the nut
with the other wrench to the specified torque.
Refrigerant piping diagram
Table of tightening torque for refrigerant piping adapter and installation

Unit: Nm {kgm}
Screw size
D155AX-6
Tightening torque
M6 1.0
8 12 {0.8 1.2}
M16 1.5
12 15 {1.2 1.5}
M24 1.5
30 35 {3.1 3.6}
79
SEN04683-01
80 Air conditioner
Handling of compressor oil

1.
Control of compressor oil

(Denso: ND-OIL8: For R134a)
Compressor oil does not need to be checked
or added so frequently as engine oil. Insufficiency or excess of compressor oil can cause
the following troubles.
Condition
Contents
Insufficiency of oil
Lubrication trouble and seizure

of compressor
Excess of oil
Cooling trouble (Excessive oil

stick to parts and lower heat
exchange performance)
Accordingly, compressor oil must be filled to

the specified level, similarly to refrigerant.
2.
Adding of compressor oil

k
80
Since refrigerant is dangerous and bad

for environment, collect the refrigerant
before disconnecting the air conditioner hose. See Caution about
refrigerant.
If refrigerant gets in your eyes, you
may lose your sight. (Put on protective
goggles.)
If oil for CFC-12 (R-12) is used, lubrication
trouble will occur and the compressor may
be broken or seized.
Be sure to use the specified oil for R134a
(Denso: ND-OIL8)
Oil for R134a absorbs moisture very easily. Accordingly, fit the cap immediately
after using oil to stop the atmosphere.
Store the oil can in a dry and ventilated
place.
Precautions for using oil
Oil for R134a (Denso: ND-OIL8 in particular) may dissolve acrylic resin and polystyrene (excluding baked polystyrene paint
film).
Accordingly, do not stick oil to those plastics.
Check compressor oil in the following cases,

and then add new oil if necessary.
q
When much refrigerant is discharged
because of leakage.
q
When the compressor is troubled and
replaced.
q
When a cycle parts such as the air conditioner unit, condenser, receiver drier,
evaporator unit, etc. is replaced.
Quantity of oil to be added when cycle part is
replaced
Air conditioner part
Quantity to be added
(cm3)
Air conditioner unit,

evaporator
Approx. 40
Condenser
Approx. 40
Receiver drier
Approx. 20
Hose (Compressor
Condenser)
Approx. 10
Hose (Condenser
Receiver)
Approx. 20
Each hose (Compressor

M24 joint Cab)
Approx. 15
Hose (Cab Receiver)
Approx. 10
D155AX-6
80 Air conditioner
3.
Compressor replacement
q
In case of compressor seizure or breakage.

Metal chips will circulate through the air
conditioner circuit and contaminate the
compressor oil extremely.
In this case, flush the air conditioner circuit
and replace the compressor and receiver
drier.
The compressor oil is removed from the
air conditioner circuit by flushing.
Accordingly, install a new compressor with
the oil of the specified quantity (180 cc)
filled in it.
Other cases
New compressor has 180 cc compressor
oil in it. So drain excessive compressor oil
before installing new compressor in the
following.
1) Prepare an oil pan and drain oil from
old compressor.
2) Measure the quantity of the drained
oil with a graduated cylinder, and note
the quantity or mark the level.
3)
D155AX-6
SEN04683-01
4.
Applying compressor oil for O-ring

When connecting a pipe or hose, apply oil
(Denso: ND-OIL8) to its O-ring to prevent
refrigerant leakage.
k When discarding a can which still has
some oil in it, make a hole on it to discharge gas and oil.
Drain below-mentioned quantity of oil

from new compressor.
180 cc the noted quantity.
EX. If drained oil quantity from
removed compressor is 30cc,
drain oil of 180 30 cc = 150 cc
from new one.
81
SEN04683-01
80 Air conditioner
D155AX-6 Bulldozer
2009 KOMATSU
All Rights Reserved
82
D155AX-6
SEN00616-03
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up

Power train hydraulic circuit diagram .............................................................................................................. 3
Hydraulic circuit diagram (1/2) Serial No.: 80001 80806 ............................................................................. 5
Hydraulic circuit diagram (2/2) Serial No.: 80001 80806 ............................................................................. 7
Hydraulic circuit diagram (1/2) Serial No.: 80807 and up ............................................................................... 9
Hydraulic circuit diagram (2/2) Serial No.: 80807 and up ..............................................................................11
D155AX-6
SEN00616-03
D155AX-6
Power train hydraulic circuit diagram
D155AX-6
SEN00616-03
Power train hydraulic circuit diagram

D155AX-6
Hydraulic circuit diagram (1/2)

Serial No.: 80001 80806
D155AX-6

D155AX-6
SEN00616-03

Serial No.: 80001 80806
D155AX-6

D155AX-6
SEN00616-03

D155AX-6

D155AX-6
SEN00616-03

D155AX-6

D155AX-6
SEN00616-03
11
D155AX-6
SEN00616-03
13
SEN00616-03
D155AX-6 Bulldozer
2008 KOMATSU
All Rights Reserved
14
D155AX-6
SEN00617-05
BULLDOZER
1SHOP MANUAL
D155AX-6
Machine model
Serial number
D155AX-6
80001 and up

Electrical circuit diagram (1/12)....................................................................................................................... 3
Electrical circuit diagram (5/12)......................................................................................................................11
Electrical circuit diagram (6/12)..................................................................................................................... 13
Electrical circuit diagram (10/12)................................................................................................................... 21
Electrical circuit diagram (11/12) ................................................................................................................... 23
Electrical circuit diagram (12/12)................................................................................................................... 25
Electrical circuit diagram for inside cab......................................................................................................... 27
Connectors table and arrangement drawing ................................................................................................. 29
D155AX-6
SEN00617-05
D155AX-6
Electrical circuit diagram (1/12)

D155AX-6
SEN00617-05
D155AX-6

D155AX-6
SEN00617-05
D155AX-6

D155AX-6
SEN00617-05
D155AX-6

D155AX-6
SEN00617-05
D155AX-6

D155AX-6
SEN00617-05
D155AX-6
11

D155AX-6
SEN00617-05
D155AX-6
13

D155AX-6
SEN00617-05
D155AX-6
15

D155AX-6
SEN00617-05
D155AX-6
17

D155AX-6
SEN00617-05
D155AX-6
19

D155AX-6
SEN00617-05
D155AX-6
21

D155AX-6
SEN00617-05
D155AX-6
23

D155AX-6
SEN00617-05
D155AX-6
25
Electrical circuit diagram for inside cab
D155AX-6
SEN00617-05
Electrical circuit diagram for inside cab

D155AX-6
27
Connectors table and arrangement drawing D155AX-6

Connector
No.
250
255
256
260
270
280
A/C
A/C1
AC01
AC02
AC03
AC04
AC05
ACCN
ACD1
ACD2
ACS
ACT
AF1
AL/B
AL/R
ASUS
AT11
AT12
AT21
AT22
AUX0
B30L
B30S
B105HL
B105HS
B105L
B105S
BKA
BKAL
BKSW
BNSL
BNSU
BNSW
BP
BRB
BRC
BRE
BRK
BVRV
CA1
CB1
CB2
CB3
CB4
CB5
CB6
CB7
CB8
CB9
CB30
CB105
CB105H
CBPW
CK01
CK02
CM01
CM02
CM03
CM04
CM05
CN1
CN2
CN3
CN4
CN5
CN6
DCL
DIAL
DSH
E22
EG1
EG2
EGC1
EGC2
EGC3
EGPW
EGR
EHL
ESD
F105
F1T
F2T
F3T
F30
FAC
FAR
FBRL
FBRR
FD1
FD2
FD3
FD4
FFT
FLSW
FLUC
FLV
FRT
FS11
FS12
FS21
FS22
FSB
FSTC
FTK
G
GND
GND03
GND06
GND07
GND08
GND09
GND11
GND12
GND20
HDT
Type of
Number
Location
connector
of pin
Terminal
1
Starting switch (Terminal B)
Terminal
1
Starting switch (Terminal R1)
Terminal
1
Starting switch (Terminal R2)
Terminal
1
Starting switch (Terminal BR)
Terminal
1
Starting switch (Terminal ACC)
Terminal
1
Starting switch (Terminal C)
DT
2
DT
2
Intermediate conncector
YAZAKI
8
SUMITOMO4
4
Relay
5
Air conditioner blower relay
Relay
4
Air conditioner compressor relay
S090
2
Air conditioner gas pressure sensor
040
36
Air conditioner controller
DT
2
Diode
DT
2
Diode
DT
2
Diode
Relay
5
Engine ACC signal cut relay
DT
2
Air cleaner clogging switch (If equipped)
Terminal
1
Alternator terminal B
Terminal
1
Alternator terminal R
DT
2
Service connector (for air suspension seat)
1
Machine monitor
1
GPS antenna
1
KOMTRAX communication module
1
ORBCOMM antenna
1
Terminal
1
Circuit breaker (30A)
Terminal
1
Terminal
1
Terminal
1
Terminal
1
Terminal
1
Relay
5
Backup alarm relay
DT
2
Backup alarm
DT
3
Brake pedal switch
3
Blade float switch
3
Blade pitch switch
DT
6
Blade control lever (knob switch)
DT
2
Bypass valve solenoid
Terminal
1
Battery relay (Contact input terminal)
Terminal
3
Battery relay (Contact output terminal)
Terminal
1
Battery relay (Coil ground terminal)
DT
3
Brake pedal potentiometer
DT
2
Transmission bevel speed sensor
DT
3
CAN terminal resistance
1
1
1
1
1
1
1
1
1
2
2
2
DTP
4
Intermediate connector
070
14
070
10
070
18
Machine monitor
070
12
Machine monitor
070
18
Machine monitor
070
12
Machine monitor
070
8
Machine monitor
DT
2
Injecter #1
DT
2
Injecter #2
DT
2
Injecter #3
DT
2
Injecter #4
DT
2
Injecter #5
DT
2
Injecter #6
DT
3
Decelerator pedal potentiometer
M
3
Fuel control dial
DRC-70A
70
DT
6
DTP
2
DT-B
12
DRC-60
60
Engine controller
DRC-50
50
Engine controller
DTP
4
Engine controller
DTP
2
DT
2
EGR valve solenoid
5
Engine hold relay
DT
3
Service connector (for engine option)
DTHD
1
DT
2
Transmission 1st clutch ECMV (Fill switch)
DT
2
Transmission 2nd clutch ECMV (Fill switch)
DT
2
Transmission 3rd clutch ECMV (Fill switch)
DTHD
1
DT
2
Fan pump control valve
DT
2
Fan reverse solenoid valve
DT
2
Left brake ECMV (Fill switch)
DT
2
Right brake ECMV (Fill switch)
24-31
31
DT-C
12
DT
6
24-31
31
DT
2
Transmission F clutch ECMV (Fill switch)
SWP
6
Headlamp switch
DT
2
Torque converter lockup clutch ECMV (Fill switch)
DT
2
Fuel level sensor
DT
2
Transmission R clutch ECMV (Fill switch)
5
Fuse box
5
Fuse box
5
Fuse box
5
Fuse box
24-21
21
DT
2
Torque converter stator clutch ECMV (Fill switch)
DT
12
SUMITOMO
3
Engine Bkup speed sensor
Terminal
1
Ground (ROPS)
Terminal
6
Ground (ROPS)
Terminal
4
Ground (Fender)
Terminal
1
Ground (Bulkhead)
Terminal
4
Ground (Guard) [Additional headlamp specification]
Terminal
1
Ground (Engine)
Terminal
6
Ground (Floor)
Terminal
6
Ground (Floor)
Terminal
2
Ground (Engine)
DT
2
Hydraulic oil temperature sensor
Connectors table and arrangement drawing

D155AX-6
Address
R-9
R-8
R-8
R-8
R-9
R-9
AE-1
F-7, AG-8
K-8, AB-8
K-9, AB-7
AB-5
AB-4
I-1
L-8
AB-2
AB-2
AE-2
D-8
E-7
AC-4
AC-5
AA-8
F-8
I-9
H-8
I-9
K-2
L-2
L-2
M-3
M-3
M-3
M-2
A-8
M-5
P-6
T-7
T-7
V-9
AD-6
N-3
M-3
N-1
P-6
AN-7
AH-3
C-6
C-6
C-6
B-6
B-6
B-6
B-6
A-6
D-6
L-2
M-3
M-3
X-9
Z-9
Y-9
R-6
R-5
R-5
AC-4
AC-5
AD-7
AE-7
AE-7
AH-7
P-6
AB-8
P-2, V-1
AG-2
H-1, AH-5
H-1, AH-5
AH-4
AH-4
AG-3
L-3
AC-5
D-9
U-2
K-2
AL-9
AK-8
AK-8
L-3
AI-3
C-1
AL-7
AM-7
K-2, AB-4
L-3
M-3
J-2, AB-3
AM-9
P-5
AJ-1
M-4
AL-9
A-8
A-8
A-7
A-7
B-9, AB-4
AK-1
M-7
AD-2
M-3
M-5
J-1
G-1
AE-2
AB-6
AB-6
AF-2
AI-2
Connector
Type of
Number
Location
No.
connector
of pin
HHP
DT
3
Work equipment and HSS pump pressure sensor
HNSW
DT
2
Horn switch
HRN
1
Horn
HSL
DT
2
HSS left EPC valve
HSR
DT
2
HSS right EPC valve
HSS
DT
6
HT
Terminal
2
Heater relay (Terminal C)
HT/A
Terminal
1
Heater relay (Terminal A)
HT/B
Terminal
1
Heater relay (Terminal B)
HTD
DT
2
Diode
J1939
DT
3
Service connector
JM01
6
Junction wiring harness
JM02
7
JM03
4
JM04
3
JM05
3
JM06
3
JM07
5
JM08
7
KEY
DT
6
Starting switch
LHD
DT
2
LHDL
DT
2
Left headlamp
LHDL1
DT
2
Additional left headlamp [Additional headlamp specification]
LHDL2
DT
2
Additional left headlamp [Additional headlamp specification]
LHDR
DT
2
Right headlamp
LHDR1
DT
2
Additional right headlamp [Additional headlamp specification]
LHDR2
DT
2
Additional right headlamp [Additional headlamp specification]
LMD1
DT
2
Diode
LMD2
DT
2
Diode
LMFL
Relay
5
Left headlamp relay
LMFR
Relay
5
Right headlamp relay
LMRE
Relay
5
Rear lamp relay
LMRP
Relay
5
Ripper lamp relay
LREL
DT
2
Left rear lamp
LRER
DT
2
Right rear lamp
LRP1
DT
2
Ripper lamp
LRP2
DT
3
NE
FRAMATONE
3
Engine Ne speed sensor
NSF
Relay
5
Neutral safety relay
OPPW
DT
2
PAMB
FRAMATONE
4
Ambient pressure sensor
PBD
DT
2
Diode
PBS
DT
2
Pedal brake solenoid
PCV1
SUMITOMO
2
Supply pump #1
PCV2
SUMITOMO
2
Supply pump #2
PEVA
CANNON
4
EGR inlet pressure sensor
PFUEL
AMP
3
Common rail pressure sensor
PHR
Relay
5
Preheat relay
PIM
CANNON
4
Charge pressure sensor
PKD
DT
2
Diode
PKS
DT
2
Parking brake solenoid
PKSW
DT
3
Parking brake lever switch
PL1
DRC-70A
70
PLSW
DT
2
Pin puller switch
POIL
CANNON
4
Engine oil pressure sensor
PPL
DT
2
Pin puller solenoid valve
PRE
DT
2
Pre-lubrication connector
PRT
DT-A
12
PT1
DT
3
Pitch angle sensor
PUMP
DT-A
12
QDP
DT
2
Blade quick drop solenoid valve
RDG
DT-A
12
RES
DT
2
Service connector
RHT
Terminal
1
Intake air heater (Electrical intake air heater)
RLSW
SWP
6
Rear lamp switch
RSD
DT
2
Diode
S1T
DT
2
Transmission 1st clutch ECMV (Solenoid)
S2T
DT
2
Transmission 2nd clutch ECMV (Solenoid)
S3T
DT
2
Transmission 3rd clutch ECMV (Solenoid)
SBP
DT
4
Bypass valve lift sensor
SBRL
DT
2
Left brake ECMV (Solenoid)
SBRR
DT
2
Right brake ECMV (Solenoid)
SEGR
DT
4
EGR valve lift sensor
SFT
DT
2
Transmission F clutch ECMV (Solenoid)
SFTD
3
Shift-down switch
SFTU
3
Shift-up switch
SLS
050
2
Daylight sensor
SLUC
DT
2
Torque converter lockup clutch ECMV (Solenoid)
SRT
DT
2
Transmission R clutch ECMV (Solenoid)
SRV
DT-A
12
Service connector (for CAN communication)
SSP
DT
2
Sudden stop prevent valve
SSTC
DT
2
Torque converter stator clutch ECMV (Solenoid)
ST
DT
2
Starting motor (Terminal R, S)
ST/B
Terminal
1
Starting motor (Terminal B)
STC1
DRC26-24
24
STC2
DRC26-40A
40
STC3
DRC26-40B
40
SW
Terminal
1
Battery relay (Coil signal terminal)
TCT
DT
2
Torque converter oil temperature sensor
TFUEL
PACKARD
2
Fuel temperature sensor
TIM
PACKARD
2
Charge temperature sensor
TIP
DT
3
Torque converter inlet pressure sensor
TLV1
DT-B
8
Steering/directional/gearshift lever (Potentiometer)
TLV2
DT
6
Steering/directional/gearshift lever (Shift switch)
TMV
24-23
23
TOP
DT
3
Torque converter outlet pressure sensor
TVC
DT
2
Work equipment and HSS pump TVC valve
TWTR
PACKARD
2
Engine coolant temperature sensor
WEC1
DRC26-24
24
WEC2
DRC26-40A
40
WEC3
DRC26-40B
40
WELK
DT
3
Work equipment lock lever switch
WEP1
DT
2
Blade lift raise EPC valve
WEP2
DT
2
Blade lift lower EPC valve
WEP3
DT
2
Blade left tilt head EPC valve
WEP4
DT
2
Blade left tilt bottom EPC valve
WEP5
DT
2
Blade right tilt head EPC valve
WEP6
DT
2
Blade right tilt bottom EPC valve
WEP7
DT
2
Ripper lift raise EPC valve
WEP8
DT
2
Ripper lift lower EPC valve
WEP9
DT
2
Ripper tilt in EPC valve
WEPA
DT
2
Ripper tilt back EPC valve
WEPW
DT
2
Service connector (Power supply for driving work equipment in emergency)
WESL
DRC-40A
40
WLK
DT
2
Work equipment lock solenoid valve
WLV
DT
2
Radiator coolant level sensor
WLV1
DT-B
8
Blade control lever (Potentiometer)
WLV2
DT-B
8
WSH
DT
4
WSH1
DT
6
Window washer tank (Front, left)
WSH2
DT
6
Window washer tank (Rear, right)
Address
AI-4
V-9
C-2
T-8
U-9
U-9, AJ-8
A-5
B-5
A-4
H-1
AF-8
AH-4
AH-3
AH-3
AG-2
AH-5
AH-5
AF-8
AG-8
R-6
C-3
C-3
C-4
Q-8
Q-8
C-9
C-9
A-9
D-7
M-7
I-9
M-6
M-4
AH-4
C-9
V-1
AH-3
AB-6
AL-7
AD-2
AD-2
AC-6
AF-2
B-9
AH-6
AB-6
AL-7
L-8, AB-5
AB-4, AN-6
W-9
AG-2
M-4
W-1
E-7
D-6
T-7, AI-8
C-2
C-5
AG-7
AC-6
P-4
AA-1
AK-9
AK-8
AK-8
AD-6
AM-7
AM-7
AC-3
AL-7
X-1
Y-1
P-7
AK-1
AK-8
V-1
AN-2
AK-1
AC-3
AD-7
Z-1
Z-1
AA-1
N-1
AM-2
AH-7
AH-6
AM-2
Y-1
Y-1
AN-3
AM-2
AI-3
AF-8
T-2
T-3
T-5
W-9
T-9
T-9
T-9
T-9
U-9
T-8
U-9
T-8
U-9
T-8
T-8
T-6
AJ-6
C-2
T-6
V-9
X-9
J-2
I-1
SEN00617-05
D155AX-6
29
D155AX-6
SEN00617-05
31
SEN00617-05
D155AX-6 Bulldozer
2010 KOMATSU
All Rights Reserved
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D155AX-6

D155ax 61

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SEN00596-14

00 Index and foreword

00 Index and foreword

Composition of shop manual

Shop Manual, contents binder, binder label and tabs

00 Index and foreword

10 Structure, function and maintenance standard

20 Standard value table

30 Testing and adjusting

00 Index and foreword

Troubleshooting by failure and error codes, Part 6

50 Disassembly and assembly

90 Diagrams and drawings

00 Index and foreword

00 Index and foreword

00 Index and foreword

Brake ECMV ............................................................................................................................... 64

00 Index and foreword

Measuring exhaust gas color ...................................................................................................... 12

00 Index and foreword

Check before troubleshooting .....................................................................................................

00 Index and foreword

Failure code [CA324] Inj #3 (L#3) Open/Short Error ................................................................... 50

00 Index and foreword

Failure code [DB95KK] WE controller: Source voltage reduction............................................

00 Index and foreword

Failure code [DH21KB] Weq pressure sensor: Short circuit ....................................................... 50

00 Index and foreword

Failure code [DXH7KA] R clutch ECMV: Disconnection.......................................................... 11

00 Index and foreword

E-5 Precaution item lights up while engine is running ................................................................. 14

00 Index and foreword

S-7 Exhaust gas is black (incomplete combustion).....................................................................

50 Disassembly and assembly

00 Index and foreword

Disassembly and assembly of carrier roller assembly ................................................................ 38

00 Index and foreword

Troubleshooting chart 2 ...........................................................................................................

90 Diagrams and drawings

00 Index and foreword

00 Index and foreword

Foreword and general information

00 Index and foreword

Important safety notice

If welding repairs are needed, always

Prohibition of operation and handling by

6 Safety check before starting work

Wearing protective goggles

Wearing shielding goggles and protectors

9 Good physical condition and preparation

Precautions against work which you are

00 Index and foreword

Preparations for work

Precautions during work

When removing a cover which is under

Precautions for sling work and making

00 Index and foreword

When installing wire ropes to an angular

11) Do not use twisted or kinked wire ropes.

00 Index and foreword

If the load is unstable or the wire rope

Precautions for using mobile crane

Selecting wire ropes