Shop D155A-6 PDF

SEN02854-06
BULLDOZER D155A -6
SERIAL NUMBERS 85001 and up
SEN02856-06
BULLDOZER 1SHOP MANUAL
D155A-6
Machine model Serial number

D155A-6 85001 and up
00 Index and foreword 1

Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 4
D155A-6 1
SEN02856-06 00 Index and foreword
Composition of shop manual 1

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN02854-06
00 Index and foreword SEN02855-06

Index SEN02856-06 q
Foreword and general information SEN02857-03
01 Specification SEN02858-02
Specification and technical data SEN02859-02
10 Structure, function and maintenance standard SEN02860-03

Engine and cooling system SEN02861-01
Power train, Part 1 SEN02862-01
Undercarriage and frame SEN02864-00
Hydraulic system SEN02865-02
Work equipment SEN02866-00
Cab and its attachments SEN02867-00
Electrical system SEN02868-02
20 Standard value table SEN02869-00

Standard service value table SEN03199-00
30 Testing and adjusting SEN02870-03

Testing and adjusting, Part 1 SEN03200-02 q
Testing and adjusting, Part 4 SEN03203-00
40 Troubleshooting SEN02871-02
Failure code table and fuse locations SEN03204-02 q
General information on troubleshooting SEN03205-02 q
Troubleshooting by failure and error codes, Part 1 SEN03206-00
Troubleshooting by failure and error codes, Part 3 SEN03208-01 q
Troubleshooting of electrical system (E-mode) SEN03210-01
2 D155A-6
Troubleshooting of hydraulic and mechanical system (H-mode) SEN03211-00

Troubleshooting of engine (S-mode) SEN03212-01
50 Disassembly and assembly SEN02872-02

General information on disassembly and assembly SEN03366-02 q
Engine and cooling system SEN03367-02 q
Power train, Part 2 SEN03369-01 q
Electrical system SEN03376-01 q
60 Air conditioner SEN04441-00

Structure, function, testing, adjusting, and troubleshooting SEN04442-00
90 Diagrams and drawings SEN02873-02

Hydraulic diagrams and drawings SEN02875-01
Electrical diagrams and drawings SEN02874-01
D155A-6 3
Table of contents 1
00 Index and foreword
Index SEN02856-06
Composition of shop manual....................................................................................................... 2
Table of contents ......................................................................................................................... 4
Foreword and general information SEN02857-03

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
Specification and technical data SEN02859-02
Specification dimension drawings ............................................................................................... 2
Specifications .............................................................................................................................. 3
Weight table ................................................................................................................................ 9
Table of fuel, coolant and lubricants ............................................................................................ 12
10 Structure, function and maintenance standard

Radiator, oil cooler....................................................................................................................... 2
Engine mount .............................................................................................................................. 9
Cooling fan pump ........................................................................................................................ 10
Cooling fan motor ........................................................................................................................ 18
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
Transmission ............................................................................................................................... 18
Transmission ECMV.................................................................................................................... 34
Main relief valve and torque converter relief valve ...................................................................... 40
Lubricating oil relief valve ............................................................................................................ 42
Scavenging pump........................................................................................................................ 44
Power train and steering lubrication pump .................................................................................. 46
Work equipment pump ................................................................................................................ 2
Work equipment cooler bypass valve.......................................................................................... 15
Steering, brake control ................................................................................................................ 16
Steering unit ................................................................................................................................ 18
Steering control valve .................................................................................................................. 32
Steering clutch ECMV, steering brake ECMV ............................................................................. 34
Parking brake solenoid valve ...................................................................................................... 40
Sudden stop prevention valve ..................................................................................................... 42
Final drive.................................................................................................................................... 45
Sprocket ...................................................................................................................................... 50
4 D155A-6

Track frame ................................................................................................................................. 2
Recoil spring ............................................................................................................................... 4
Idler ............................................................................................................................................. 6
Track roller .................................................................................................................................. 8
Carrier roller ................................................................................................................................ 10
Track shoe................................................................................................................................... 12
Main frame .................................................................................................................................. 18
Suspension ................................................................................................................................. 20
Work equipment hydraulic piping diagram .................................................................................. 2
Work equipment control piping diagram...................................................................................... 6
Work equipment control .............................................................................................................. 8
Hydraulic tank and filter............................................................................................................... 10
Accumulator ................................................................................................................................ 12
PPC valve ................................................................................................................................... 13
Work equipment lock valve ......................................................................................................... 26
Control valve ............................................................................................................................... 28
Work equipment cylinder............................................................................................................. 50
Piston valve................................................................................................................................. 52
Quick drop valve ......................................................................................................................... 54
Self pressure reducing valve....................................................................................................... 55
Cylinder stay ............................................................................................................................... 2
Blade ........................................................................................................................................... 4
Cutting edge, end bit ................................................................................................................... 6
Ripper.......................................................................................................................................... 8
Cab mount + ROPS pin............................................................................................................... 2
ROPS cab ................................................................................................................................... 3
ROPS floor .................................................................................................................................. 4
Air conditioner ............................................................................................................................. 5
Engine control ............................................................................................................................. 2
Engine control system................................................................................................................. 3
Deceleration potentiometer ......................................................................................................... 4
Monitor system............................................................................................................................ 6
Sensors ....................................................................................................................................... 25
Palm command control system ................................................................................................... 28
KOMTRAX system ...................................................................................................................... 31
20 Standard value table

Standard service value table SEN03199-00
Standard value table for engine .................................................................................................. 2
Standard value table for machine................................................................................................ 3
30 Testing and adjusting

Tools for testing, adjusting, and troubleshooting ......................................................................... 3
Sketches of special tools............................................................................................................. 7
Measuring engine speed............................................................................................................. 8
Measuring intake air pressure (boost pressure).......................................................................... 10
Measuring exhaust temperature ................................................................................................. 12
Measuring exhaust gas color ...................................................................................................... 14
Adjusting valve clearance ........................................................................................................... 15
Measuring compression pressure ............................................................................................... 16
D155A-6 5
Measuring blow-by pressure ....................................................................................................... 18

Measuring engine oil pressure .................................................................................................... 19
Handling fuel system parts .......................................................................................................... 20
Releasing residual pressure from fuel system ............................................................................ 20
Measuring fuel pressure.............................................................................................................. 21
Measuring fuel return rate and fuel leakage................................................................................ 22
Bleeding air from fuel circuit ........................................................................................................ 26
Measuring fuel circuit for leakage................................................................................................ 28
Testing and adjusting alternator belt tension ............................................................................... 29
Testing and adjusting air conditioner compressor belt tension.................................................... 30
Measuring fan speed................................................................................................................... 31
Measuring fan circuit oil pressure................................................................................................ 32
Bleeding air from fan pump ......................................................................................................... 33
Bleeding air from work equipment pump..................................................................................... 34
Adjusting fuel control dial and decelerator pedal......................................................................... 35
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 .................................................................................... 22
Measuring and adjusting work equipment oil pressure ............................................................... 23
Measuring control circuit basic pressure ..................................................................................... 26
Measuring work equipment lock solenoid valve output pressure (PPC valve basic pressure) ... 27
Measuring PPC valve output pressure........................................................................................ 28
Adjusting play of work equipment PPC valve.............................................................................. 30
Measuring ripper pin puller solenoid valve output pressure ........................................................ 31
Testing parts which cause hydraulic drift of blade and ripper ...................................................... 32
Measuring internal leakage of work equipment cylinder ............................................................. 33
Releasing residual pressure from work equipment cylinder........................................................ 34
Bleeding air from work equipment cylinder ................................................................................. 34
Adjusting work equipment lock lever ........................................................................................... 35
Adjusting blade............................................................................................................................ 36
Adjusting operator's cab .............................................................................................................. 38
Special functions of machine monitor (EMMS)............................................................................ 2
Handling of power supply circuit of engine controller .................................................................. 2
Preparation work for troubleshooting of electrical system........................................................... 3
Pm Clinic ..................................................................................................................................... 5
40 Troubleshooting
Failure code table and fuse locations SEN03204-02
Failure codes table ...................................................................................................................... 2
Fuse locations ............................................................................................................................. 8
General information on troubleshooting SEN03205-02
Points to remember when troubleshooting.................................................................................. 2
Sequence of events in troubleshooting ....................................................................................... 3
Check before troubleshooting ..................................................................................................... 4
Classification and procedures for troubleshooting ...................................................................... 5
Information in troubleshooting table ............................................................................................ 8
Connection table for connector pin numbers............................................................................... 10
T-branch box and T-branch adapter table ................................................................................... 46
6 D155A-6

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 [2201L1] When right steering clutch oil pressure command current is OFF,
fill signal is ON ..................................................................................................................... 14
Failure code [2201LH] When right steering clutch oil pressure command current is ON,
fill signal is OFF ................................................................................................................... 16
Failure code [2202L1] When left steering clutch oil pressure command current is OFF,
fill signal is ON ..................................................................................................................... 18
Failure code [2202LH] When left steering clutch oil pressure command current is ON,
fill signal is OFF ................................................................................................................... 20
Failure code [2300KM] Stall in 1st gear speed............................................................................ 22
Failure code [2301L1] Right brake: Fill high................................................................................ 23
Failure code [2301LH] Right brake: Fill low ................................................................................ 24
Failure code [2302L1] Left brake: Fill high .................................................................................. 25
Failure code [2302LH] Left brake: Fill low................................................................................... 26
Failure code [7RFAKA] ECM HOLD RELAY: Disconnection....................................................... 28
Failure code [AA10NX] Air Cleaner Clogging ............................................................................. 30
Failure code [AB00MA] Battery Charge Abnormal...................................................................... 32
Failure code [B@BAZG] Eng Oil Press Low ............................................................................... 34
Failure code [B@BCNS] Eng Water Overheat............................................................................ 34
Failure code [B@BCZK] Eng Water Level Low........................................................................... 35
Failure code [B@CENS] T/C Oil Overheat ................................................................................. 35
Failure code [B@HANS] Hyd Oil Overheat................................................................................. 36
Failure code [CA111] EMC Critical Internal Failure ..................................................................... 38
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ........................................................ 40
Failure code [CA122] Chg (boost) Air Press Sensor High Error ................................................. 42
Failure code [CA123] Chg (boost) Air Press Sensor Low Error .................................................. 44
Failure code [CA131] Throttle Sensor High Error ....................................................................... 46
Failure code [CA132] Throttle Sensor Low Error ........................................................................ 48
Failure code [CA135] Eng Oil Press Sensor High Error.............................................................. 50
Failure code [CA141] Eng Oil Press Sensor Low Error .............................................................. 52
Failure code [CA144] Coolant Temp Sens High Error................................................................. 54
Failure code [CA145] Coolant Temp Sens Low Error ................................................................. 56
Failure code [CA153] Chg (boost) Air Temp Sensor High Error.................................................. 58
Failure code [CA154] Chg (boost) Air Temp Sensor Low Error .................................................. 60
Failure code [CA187] Sens Supply 2 Volt Low Error................................................................... 60
Failure code [CA221] Ambient Press Sens High Error ............................................................... 62
Failure code [CA222] Ambient Press Sens Low Error ................................................................ 64
Failure code [CA227] Sens Supply 2 Volt High Error.................................................................. 66
Failure code [CA234] Eng Overspeed ........................................................................................ 3
Failure code [CA238] Ne Speed Sens Supply Volt Error ............................................................ 4
Failure code [CA263] Fuel Temp Sensor High Error................................................................... 6
Failure code [CA265] Fuel Temp Sensor Low Error.................................................................... 8
Failure code [CA271] PCV1 Short Error ..................................................................................... 9
Failure code [CA272] PCV1 Open Error ..................................................................................... 10
Failure code [CA273] PCV2 Short Error ..................................................................................... 11
Failure code [CA274] PCV2 Open Error ..................................................................................... 12
D155A-6 7
Failure code [CA322] Inj #1 Open/Short Error ............................................................................ 14

Failure code [CA342] Calibration Code Incompatibility ............................................................... 26
Failure code [CA351] Injectors Drive Circuit Error ...................................................................... 28
Failure code [CA352] Sens Supply 1 Volt Low Error................................................................... 30
Failure code [CA386] Sens Supply 1 Volt High Error .................................................................. 32
Failure code [CA441] Battery Voltage Low Error......................................................................... 34
Failure code [CA442] Battery Voltage High Error ........................................................................ 34
Failure code [CA449] Rail Press Very High Error........................................................................ 35
Failure code [CA451] Rail Press Sensor High Error ................................................................... 36
Failure code [CA452] Rail Press Sensor Low Error .................................................................... 38
Failure code [CA553] Rail Press High Error................................................................................ 38
Failure code [CA554] Rail Press Sensor In Range Error ............................................................ 39
Failure code [CA559] Rail Press Low Error................................................................................. 40
Failure code [CA689] Eng Ne Speed Sensor Error ..................................................................... 44
Failure code [CA731] Eng Bkup Speed Sens Phase Error ......................................................... 46
Failure code [CA757] All Continuous Data Lost Error ................................................................. 46
Failure code [CA778] Eng Bkup Speed Sensor Error ................................................................. 48
Failure code [CA1633] KOMNET Datalink Timeout Error ........................................................... 50
Failure code [CA2185] Throt Sens Sup Volt High Error .............................................................. 52
Failure code [CA2186] Throt Sens Sup Volt Low Error ............................................................... 54
Failure code [CA2249] Rail Press Very Low Error ...................................................................... 54
Failure code [CA2555] Grid Htr Relay Volt Low Error ................................................................. 55
Failure code [CA2556] Grid Htr Relay Volt High Error ................................................................ 56
Failure code [D110KA] Battery relay: Disconnection................................................................... 58
Failure code [D110KB] Battery Relay: Drive Short Circuit........................................................... 60
Failure code [D130KA] Neutral relay: Disconnection .................................................................. 62
Failure code [D130KB] Neutral relay: Short circuit...................................................................... 64
Failure code [D161KA] Back-up alarm relay: Disconnection....................................................... 66
Failure code [D161KB] Back-up alarm relay: Short circuit .......................................................... 68
Failure code [D190KA] ACC signal relay: Disconnection............................................................ 70
Failure code [D190KB] ACC signal relay: Short circuit ............................................................... 72
Failure code [D5ZKKX] Throttle Dial: Out of normal range ......................................................... 4
Failure code [DAFRKR] CAN Disconnection (Monitor) ............................................................... 6
Failure code [DB2RKR] CAN Disconnection (Engine controller) ................................................ 8
Failure code [DB90KR] PT 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 [DGT1KA] T/C oil temp sensor: Abnormal.............................................................. 40
Failure code [DGT1KX] T/C oil temp sensor: Abnormal.............................................................. 42
Failure code [DH21KA] Weq pressure sensor: Disconnection .................................................... 44
8 D155A-6
Failure code [DH21KB] Weq pressure sensor: Short circuit ....................................................... 46

Failure code [DK10KX] Fuel control Dial: Out of normal range................................................... 48
Failure code [DK30KA] ST lever 1: Disconnection...................................................................... 50
Failure code [DK30KB] ST lever 1: Short circuit ......................................................................... 52
Failure code [DK30KX] ST lever 1: Out of normal range ............................................................ 54
Failure code [DK30KZ] RL lever: Disconnection or short circuit ................................................. 54
Failure code [DK30L8] ST lever: Signal mismatch...................................................................... 55
Failure code [DK31KA] ST lever 2: Disconnection...................................................................... 56
Failure code [DK31KB] ST lever 2: Short circuit ......................................................................... 58
Failure code [DK40KA] Brake potentiometer: Disconnection...................................................... 60
Failure code [DK40KB] Brake potentiometer: Short circuit ......................................................... 62
Failure code [DK55KX] FR lever: Out of normal range ............................................................... 64
Failure code [DK55KZ] FR lever: Disconnection or short circuit ................................................. 64
Failure code [DK55L8] FR lever: Signal mismatch ..................................................................... 65
Failure code [DK56KA] FR lever 1: Disconnection ..................................................................... 66
Failure code [DK56KB] FR lever 1: Short circuit ......................................................................... 68
Failure code [DK57KA] FR lever 2: Disconnection ..................................................................... 4
Failure code [DK57KB] FR lever 2: Short circuit ......................................................................... 6
Failure code [DKH1KA] Pitch angle sensor: Disconnection........................................................ 8
Failure code [DKH1KB] Pitch angle sensor: Short circuit ........................................................... 10
Failure code [DLT3KA] T/M out-speed sensor: Disconnection.................................................... 12
Failure code [DLT3KB] T/M out-speed sensor: Abnormal........................................................... 13
Failure code [DW7BKA] Fan rev EPC: Disconnection ................................................................ 14
Failure code [DW7BKB] Fan rev EPC: Short circuit.................................................................... 15
Failure code [DWN3KA] Ssp solenoid: Disconnection................................................................ 16
Failure code [DWN3KB] Ssp solenoid: Short circuit ................................................................... 18
Failure code [DWN3KY] Ssp solenoid: Short circuit ................................................................... 20
Failure code [DWN5KA] Fan pump solenoid: Disconnection...................................................... 22
Failure code [DWN5KB] Fan pump solenoid: Short circuit ......................................................... 23
Failure code [DXH4KA] 1st clutch ECMV: Disconnection ........................................................... 24
Failure code [DXH4KB] 1st clutch ECMV: Short circuit............................................................... 25
Failure code [DXH4KY] 1st clutch ECMV: Short circuit............................................................... 26
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection.......................................................... 27
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit ............................................................. 28
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit ............................................................. 29
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection........................................................... 30
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit .............................................................. 31
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit .............................................................. 32
Failure code [DXH7KA] R clutch ECMV: Disconnection ............................................................. 33
Failure code [DXH7KB] R clutch ECMV: Short circuit................................................................. 34
Failure code [DXH7KY] R clutch ECMV: Short circuit................................................................. 35
Failure code [DXH8KA] F clutch ECMV: Disconnection.............................................................. 36
Failure code [DXH8KB] F clutch ECMV: Short circuit ................................................................. 37
Failure code [DXH8KY] F clutch ECMV: Short circuit ................................................................. 38
Failure code [DXH9KA] Right steering clutch ECMV disconnection ........................................... 40
Failure code [DXH9KB] Right steering clutch ECMV short circuit............................................... 42
Failure code [DXH9KY] Right steering clutch ECMV hot short ................................................... 44
Failure code [DXHAKA] Left steering clutch ECMV disconnection ............................................. 46
Failure code [DXHAKB] Left steering clutch ECMV short circuit................................................. 48
Failure code [DXHAKY] Left steering clutch ECMV hot short ..................................................... 50
Failure code [DXHBKA] Right brake ECMV: Disconnection ....................................................... 52
Failure code [DXHBKB] Right brake ECMV: Short circuit ........................................................... 54
Failure code [DXHBKY] Right brake ECMV: Short circuit ........................................................... 56
Failure code [DXHCKA] Left brake ECMV: Disconnection.......................................................... 58
Failure code [DXHCKB] Left brake ECMV: Short circuit ............................................................. 60
Failure code [DXHCKY] Left brake ECMV: Short circuit ............................................................. 62
Failure code [DXJ4KA] Weq lock Sol.: Disconnection ................................................................ 64
Failure code [DXJ4KB] Weq lock Sol.: Short circuit .................................................................... 65
D155A-6 9
Troubleshooting of electrical system (E-mode) SEN03210-01

Before carrying out troubleshooting for electrical system............................................................ 3
E-1 When starting switch turned ON, machine monitor displays nothing.................................... 8
E-2 When starting switch turned ON (before starting engine), basic check item lights up .......... 10
E-3 Engine does not start (Engine does not turn) ....................................................................... 12
E-4 Preheater does not operate .................................................................................................. 15
E-5 Precaution item lights up while engine is running................................................................. 18
E-6 Emergency stop item lights up while engine is running ........................................................ 20
E-7 Engine coolant temperature gauge does not indicate normally............................................ 22
E-8 Fuel level gauge does not indicate normally......................................................................... 23
E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally....................... 25
E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally ............................ 26
E-11 Contents of display by machine monitor are different from applicable machine ................. 28
E-12 Machine monitor does not display some items................................................................... 28
E-13 Function switch does not work............................................................................................ 28
E-14 Operation mode does not change ...................................................................................... 29
E-15 Gearshift mode does not change........................................................................................ 29
E-16 Customize function does not operate normally................................................................... 30
E-17 Customize memory function does not normally.................................................................. 30
E-18 Alarm buzzer cannot be stopped ........................................................................................ 31
E-19 Air conditioner does not operate normally (including air conditioner fault history).............. 32
E-20 When starting switch is turned OFF, service meter is not displayed................................... 46
E-21 Machine monitor cannot be set in service mode ................................................................ 46
E-22 Ripper pin puller cylinder does not operate ........................................................................ 48
E-23 Backup alarm does not sound or does not stop ................................................................. 50
E-24 Headlamp, rear lamp, and ripper point lamp do not light up............................................... 52
E-25 Windshield wiper and window washer do not operate........................................................ 57
E-26 KOMTRAX terminal does not operate normally.................................................................. 73
E-27 Fan does not reverse.......................................................................................................... 74
E-28 Gear cannot be shifted ....................................................................................................... 76
E-29 Electric priming pump does not operate or does not stop automatically ............................ 78
Troubleshooting of hydraulic and mechanical system (H-mode) SEN03211-00
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 Steering is not possible......................................................................................................... 9
H-7 Steering is possible only on one side ................................................................................... 10
H-8 Steering overrun occurs........................................................................................................ 11
H-9 Brake does not work............................................................................................................. 12
H-10 Power train oil is overheated .............................................................................................. 13
H-11 Speed of all work equipment is low..................................................................................... 14
H-12 No work equipment moves ................................................................................................. 15
H-13 Blade lift speed or power is low .......................................................................................... 16
H-14 Blade tilt speed or power is low .......................................................................................... 17
H-15 Ripper lift speed or power is low......................................................................................... 18
H-16 Ripper tilt speed or power is low......................................................................................... 19
H-17 Hydraulic drift of blade lift is large....................................................................................... 19
H-18 Hydraulic drift of blade tilt is large....................................................................................... 20
H-19 Hydraulic drift of ripper lift is large ...................................................................................... 20
H-20 Ripper pin puller cylinder does not operate ........................................................................ 21
H-21 Abnormal sound comes out from around work equipment pump ....................................... 22
H-22 Fan speed is abnormal
(Sound and/or vibration are abnormally large or engine over heats) ................................... 23
10 D155A-6
Troubleshooting of engine (S-mode) SEN03212-01

Method of using troubleshooting chart ........................................................................................ 3
S-1 Starting performance of engine is poor................................................................................. 6
S-2 Engine does not start............................................................................................................ 7
S-3 Engine does not pick up smoothly........................................................................................ 10
S-4 Engine stops during operation .............................................................................................. 11
S-5 Engine does not rotate smoothly .......................................................................................... 12
S-6 Engine lack output (or lacks power) ..................................................................................... 13
S-7 Exhaust gas is black (incomplete combustion)..................................................................... 14
S-8 Oil consumption is excessive (or exhaust gas is blue) ......................................................... 15
S-9 Oil becomes dirty quickly...................................................................................................... 16
S-10 Fuel consumption is excessive........................................................................................... 17
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................. 18
S-12 Oil pressure drops .............................................................................................................. 19
S-13 Oil level rises (Entry of coolant or fuel)............................................................................... 20
S-14 Coolant temperature becomes too high (Overheating) ...................................................... 21
S-15 Abnormal noise is made ..................................................................................................... 22
S-16 Vibration is excessive ......................................................................................................... 23
S-17 Air cannot be bled from fuel circuit ..................................................................................... 24
50 Disassembly and assembly

General information on disassembly and assembly SEN03366-02
How to read this manual ............................................................................................................. 2
Coating materials list................................................................................................................... 4
Special tool list ............................................................................................................................ 7
Sketches of special tools............................................................................................................. 13
Removal and installation of fuel supply pump assembly............................................................. 2
Removal and installation of fuel injector assembly ..................................................................... 7
Removal and installation of cylinder head assembly .................................................................. 13
Removal and installation of radiator assembly............................................................................ 24
Removal and installation of aftercooler assembly ....................................................................... 27
Removal and installation of engine assembly ............................................................................. 30
Removal and installation of engine hood assembly .................................................................... 35
Removal and installation of engine front seal ............................................................................. 37
Removal and installation of engine rear seal .............................................................................. 41
Removal and installation of fuel tank assembly .......................................................................... 46
Removal and installation of fan drive assembly .......................................................................... 48
Removal and installation of fan motor assembly......................................................................... 49
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 ...................................................... 16
Disassembly and assembly of PTO assembly ............................................................................ 2
Disassembly and assembly of torque converter assembly ......................................................... 9
Disassembly and assembly of transmission assembly ............................................................... 14
Disassembly and assembly of steering case assembly .............................................................. 31
Removal and installation of final drive assembly ........................................................................ 2
Disassembly and assembly of final drive assembly .................................................................... 4
Removal and installation of track frame assembly ...................................................................... 3
Removal and installation of idler assembly ................................................................................. 6
Disassembly and assembly of idler assembly............................................................................. 7
D155A-6 11
Removal and installation of recoil spring assembly..................................................................... 11

Disassembly and assembly of recoil spring assembly ................................................................ 12
Removal and installation of track roller assembly ....................................................................... 17
Disassembly and assembly of track roller assembly................................................................... 18
Removal and installation of carrier roller assembly..................................................................... 20
Disassembly and assembly of carrier roller assembly ................................................................ 21
Removal and installation of pivot shaft assembly........................................................................ 25
Spreading and installation of track shoe assembly ..................................................................... 27
General disassembly and assembly of track shoe ...................................................................... 30
Disassembly and assembly of 1 link in field ................................................................................ 44
Disassembly and assembly of master link .................................................................................. 48
Removal and installation of equalizer bar assembly ................................................................... 51
Disassembly and assembly of equalizer bar assembly............................................................... 53
Removal and installation of segment teeth ................................................................................. 55
Removal and installation of hydraulic tank assembly .................................................................. 2
Removal and installation of hydraulic pump assembly................................................................ 4
Disassembly and assembly of hydraulic cylinder assembly........................................................ 7
Removal and installation of blade assembly ............................................................................... 2
Disassembly and assembly of multi-shank ripper ....................................................................... 4
Removal and installation of operator's cab assembly ................................................................. 2
Removal and installation of operator's cab glass (Stuck glass)................................................... 4
Removal and installation of operator's cab and floor frame assembly ........................................ 13
Removal and installation of air conditioner unit assembly........................................................... 2
Removal and installation of engine controller assembly ............................................................. 4
Removal and installation of power train controller assembly ...................................................... 5
Removal and installation of KOMTRAX assembly ...................................................................... 5
60 Air conditioner
Structure, function, testing, adjusting, and troubleshooting SEN04442-00
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
12 D155A-6
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
90 Diagrams and drawings

Hydraulic diagrams and drawings SEN02875-01
Power train hydraulic circuit diagram .......................................................................................... 3
Hydraulic circuit diagram Serial No.: 85001 – 85024 .................................................................. 5
Hydraulic circuit diagram Serial No.: 85025 and up .................................................................... 7
Electrical diagrams and drawings SEN02874-01
Electrical circuit diagram (Cab spec.).......................................................................................... 3
Electrical circuit diagram (Cab less spec.) .................................................................................. 5
Electrical circuit diagram for inside cab....................................................................................... 7
Connectors table and arrangement drawing ............................................................................... 9
D155A-6 13
D155A-6 Bulldozer
Form No. SEN02856-06
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 06-09
14 D155A-6
SEN02857-03
D155A-6

D155A-6 85001 and up
00 Index and foreword 1

Foreword and general information
Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling 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
D155A-6 1
Safety notice 1
(Rev. 2008/08)
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before weld in g wo rk , al way s wear wel din g
operating the machine. In addition, gloves, apron, shielding goggles, cap and
read this manual and understand its other clothes suited for welding work.
contents before starting the work. 8) Before starting work, warm up your body
1) Before carrying out any greasing or thoroughly to start work under good condi-
repairs, read all the safety labels stuck to tion.
the machine. For the locations of the 9) Avoid continuing work for long hours and
safety labels and detailed explanation of take rests at proper intervals to keep your
precautions, see the Operation and Main- body in good condition. Take rests in
tenance Manual. specified safe places.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always Safety points
keep the tools and parts in their correct
places. Always keep the work area clean 1 Good arrangement
and make sure that there is no dirt, water, 2 Correct work clothes
or oil on the floor. Smoke only in the areas 3 Following work standard
provided for smoking. Never smoke while
working. 4 Making and checking signs
3) When carrying out any operation, always Prohibition of operation and handling by
5
wear safety shoes and helmet. Do not unlicensed workers
wear loose work clothes, or clothes with 6 Safety check before starting work
buttons missing.
Wearing protective goggles
q Always wear safety glasses when hit- 7
(for cleaning or grinding work)
ting parts with a hammer.
q Always wear safety glasses when Wearing shielding goggles and protectors
8
grinding parts with a grinder, etc. (for welding work)
4) When carrying out any operation with 2 or 9 Good physical condition and preparation
more workers, always agree on the oper- Precautions against work which you are
ating procedure before starting. Always 10
not used to or you are used to too much
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, fork-
lift, service car, etc.
2 D155A-6
2. Preparations for work 6) When removing a cover which is under

1) Before adding oil or making any repairs, internal pressure or under pressure from a
park the machine on a hard and level spring, always leave 2 bolts in diagonal
ground, and apply the parking brake and positions. Loosen those bolts gradually
block the wheels or tracks to prevent the and alternately to release the pressure,
machine from moving. and then remove the cover.
2) Before starting work, lower the work 7) When removing components, be careful
equipment (blade, ripper, bucket, etc.) to not to break or damage the electrical wir-
the ground. If this is not possible, insert ing. Damaged wiring may cause electrical
the lock pin or use blocks to prevent the fires.
work equipment from falling. In addition, 8) When removing piping, stop the fuel or oil
be sure to lock all the control levers and from spilling out. If any fuel or oil drips
hang warning signs on them. onto the floor, wipe it up immediately. Fuel
3) When disassembling or assembling, sup- or oil on the floor can cause you to slip
port the machine with blocks, jacks, or and can even start fires.
stands before starting work. 9) As a general rule, do not use gasoline to
4) Remove all mud and oil from the steps or wash parts. Do not use it to clean electri-
other places used to get on and off the cal parts, in particular.
machine. Always use the handrails, lad- 10) Be sure to assemble all parts again in their
ders or steps when getting on or off the original places. Replace any damaged
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 parts and parts which must not be reused
machine. If it is impossible to use the with new parts. When installing hoses and
handrails, ladders or steps, use a stand to wires, be sure that they will not be dam-
provide safe footing. aged by contact with other parts when the
machine is operated.
3. Precautions during work 11) When installing high pressure hoses,
1) Before disconnecting or removing compo- make sure that they are not twisted. Dam-
nents of the oil, water, or air circuits, first aged tubes are dangerous, so be
release the pressure completely from the extremely careful when installing tubes for
circuit. When removing the oil filler cap, a high pressure circuits. In addition, check
drain plug, or an oil pressure pickup plug, 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
loosen it slowly to prevent the oil from installed.
spurting out. 12) When assembling or installing parts,
2) The coolant and oil in the circuits are hot always tighten them to the specified
when the engine is stopped, so be careful torques. When installing protective parts
not to get scalded. Wait for the oil and such as guards, or parts which vibrate vio-
coolant to cool before carrying out any lently or rotate at high speed, be particu-
work on the oil or water circuits. l a r ly c a r e fu l t o c he c k t h a t t h e y ar e
3) Before starting work, stop the engine. installed correctly.
When working on or around a rotating 13) When aligning 2 holes, never insert your
part, in particular, stop the engine. When fingers or hand. Be careful not to get your
checking the machine without stopping fingers caught in a hole.
the engine (measuring oil pressure, 14) When measuring hydraulic pressure,
revolving speed, temperature, etc.), take check that the measuring tools are cor-
extreme care not to get rolled or caught in rectly assembled.
rotating parts or moving parts. 15) Take care when removing or installing the
4) Before starting work, remove the leads tracks of track-type machines. When
from the battery. Always remove the lead removing the track, the track separates
from the negative (–) terminal first. suddenly, so never let anyone stand at
5) When raising a heavy component (heavier either end of the track.
than 25 kg), use a hoist or crane. Before 16) If the engine is operated for a long time in
starting work, check that the slings (wire a place which is not ventilated well, you
ropes, chains, and hooks) are free from may suffer from gas poisoning. Accord-
damage. Always use slings which have ingly, open the windows and doors to ven-
ample capacity and install them to proper tilate well.
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.
D155A-6 3
4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is 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.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
4 D155A-6
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven- 18 28.6 2.9
tion earth leakage breaker, crane collision 20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
30 79.6 8.1
2) Observe the signs for sling work.
40 141.6 14.4
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
D155A-6 5
8. Precautions for disconnecting and con- a Example of O-ring (Fitted to every joint of
necting hoses and tubes in air conditioner hoses and tubes)
circuit
1) Disconnection
k For the environment, the air condi-
tioner 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 dis-
connecting the refrigerant gas cir-
cuit and then reuse it.
a Ask professional traders for collecting a For tightening torque, see the precautions for
and filling operation of refrigerant installation in each section of "Disassembly
(R134a). and assembly".
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 recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
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.
6 D155A-6
How to read the shop manual 1
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
1. Composition of shop manual

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

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

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

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

This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
D155A-6 7
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 …)
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving stan-

a Caution
dards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
8 D155A-6
Explanation of terms for maintenance standard 1

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 tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the “standard size” and the range of differ-
ence from the standard size is called the
“tolerance”.
q The tolerance with the symbols of + or – is
indicated on the right side of the standard
size.
Example:
Standard size Tolerance
–0.022
120
–0.126
a The tolerance may be indicated in the text

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

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
D155A-6 9
2. Standard clearance and standard value 5. Clearance limit

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

able 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 prod-
uct 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 vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
10 D155A-6
Handling of electric equipment and hydraulic component 1

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

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

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

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
D155A-6 11
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector

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

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
12 D155A-6
3. Removing, installing, and drying connec-

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

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

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

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
D155A-6 13
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
14 D155A-6
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
D155A-6 15
4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as fol-
lows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oi l a nd wa ter fr om t he c om -
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
16 D155A-6
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
D155A-6 17
Points to remember when handling hydraulic equipment

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

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

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

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
18 D155A-6
5. Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
D155A-6 19
Handling of connectors newly used for engines 1

a Mainly, following engines are object for follow- 2. Pull lock type (PACKARD-2)
ing connectors. q 95 – 170, 12V140 engines
q 95E-5 q Various temperature sensors
q 107E-1 Example)
q 114E-3 Intake air temperature sensor in
q 125E-5 intake manifold: TIM
q 140E-5 Fuel temperature sensor: TFUEL
q 170E-5 Oil temperature sensor: TOIL
q 12V140E-3 Coolant temperature sensor: TWTR,
etc.
1. Slide lock type Disconnect the connector by pulling lock
(FRAMATOME-3, FRAMATOME-2) (B) (on the wiring harness side) of connec-
q 95 – 170, 12V140 engines tor (2) outward.
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)
Disconnect connector (1) according to the fol-

lowing procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connec-
tor (1) toward you.
a Even if lock (L2) is pressed, connec-
tor (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screw-
driver while press lock (L2), and then
pull out connector (1) toward you.
20 D155A-6
3. Push lock type

q 95, 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the fol-

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

flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
D155A-6 21
q 95, 125 – 170, 12V140 engines 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure sensor in common rail: 1) Disconnect connector (6) according to the
PFUEL etc. (AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
2) Connect the connector according to the

following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it “clicks”.
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22 D155A-6
How to read electric wire code 1

a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.

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

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

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
D155A-6 23
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.
24 D155A-6
3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
D155A-6 25
Precautions when carrying out operation 1

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

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

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
26 D155A-6
2. Precautions when carrying out installation work

q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 – 3 drops of adhesive.
q When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, “Bleeding air”.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see “Disassembly and assembly”.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
D155A-6 27
4) Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly
and assembly”.
28 D155A-6
Method of disassembling and connecting push-pull type coupler 1

k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
D155A-6 29
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
contacts contact surface (a) of the hexag-
30 D155A-6
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
D155A-6 31
Standard tightening torque table 1

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

mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 157 – 196 16 – 20
16 24 245 – 309 25 – 31.5
18 27 343 – 427 35 – 43.5
20 30 490 – 608 50 – 62
22 32 662 – 829 67.5 – 84.5
24 36 824 – 1,030 84 – 105
27 41 1,180 – 1,470 120 – 150
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a The following table applies to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 12 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 17 74.5 – 90.2 7.6 – 9.2
a Fig. A 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 D155A-6
2. Table of tightening torques for split flange bolts

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

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

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

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

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

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
D155A-6 33
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal

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

diameter across Nominal No. – Thread diameter
of pipe flats Range Target Number of threads, (mm)
(mm) (mm) type of thread (Reference)
8 19 14 – 16 {1.4 – 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 – 27 {2.4 – 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 (27) 43 – 47 {4.4 – 4.8} 45 {4.6} 13/16-16UN 20.6
15 (16) 30 (32) 60 – 68 {6.1 – 6.8} 64 {6.5} 1-14UN 25.4
22 (20) 36 90 – 95 {9.2 – 9.7} 92.5 {9.4} 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
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
34 D155A-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 Tightening torque

mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
9. 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.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
D155A-6 35
Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.

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

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

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
36 D155A-6
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
D155A-6 37
Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
38 D155A-6
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
D155A-6 39
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

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

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

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

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

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

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
40 D155A-6
D155A-6 41
D155A-6 BULLDOZER
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 02-09 (02)
42 D155A-6
SEN02859-02
D155A-6

D155A-6 85001 and up
01 Specification 1
Specification and technical data
Specification dimension drawings ................................................................................................................... 2
Specifications .................................................................................................................................................. 3
Weight table .................................................................................................................................................... 9
Table of fuel, coolant and lubricants.............................................................................................................. 12
D155A-6 1
SEN02859-02 01 Specification
Specification dimension drawings
Semi U-tilt dozer + Variable Sigma-tilt dozer + Variable

Item Unit
multiple shank ripper multiple shank ripper
A Overall length mm 8,325 8,275
B Overall height (with ROPS) mm 3,510 3,510
C Overall width mm 4,130 4,060
Semi U-tilt dozer + Variable Sigma-tilt dozer + Variable

Item Unit
giant ripper giant ripper
A Overall length mm 8,680 8,630
B Overall height (with ROPS) mm 3,510 3,510
C Overall width mm 4,130 4,060
2 D155A-6
Specifications
Machine model D155A-6
Serial number 85001 and up

• Bare tractor 31,200
• With semi U-tilt dozer + variable giant ripper +
Weight
ROPS cab + air conditioner + 560mm HD shoe kg 41,700

+ side cover
• With multi ripper 42,080
Minimum turning radius (F1, center of machine) mm 2.1
Gradeability deg. 30
Stability (front, rear, left, right) deg. 35
1st 3.9
Transmission speed ranges
Forward
2nd 5.7
km/h
3rd (low speed) 7.5
Performance
3rd 11.4
1st 4.7
Reverse
2nd 6.8
km/h
3rd (low speed) 9.2
3rd 13.7
Overall height Overall width Overall length Ground pressure
• Bare tractor 86.73 {0.88}

• With semi U-tilt dozer + variable giant rip-
per + ROPS cab + air conditioner + kPa 113.97 {1.16}
{kg/cm2}
560mm HD shoe + side cover
• With multi ripper 115.13 {1.17}
Bare tractor 4,875
With semi U-tilt dozer + tractor 6,225
mm
With semi U-tilt dozer + variable giant rip-
8,680
per
Bare tractor 2,765
Dimensions
With semi U-dozer + tractor 4,130

mm
With Sigma-tilt dozer + variable multi-shank
ripper 4,060
To blade lift cylinder 3,510

To top of cab 2,210
mm
With ROPS cab installed 3,395
D155A-6 3

Track gauge 2,140
Dimensions
Length of track on ground 3,150

Track shoe width (Standard) mm 560
Minimum ground clearance
500
(To bottom surface of undercover)
Name SAA6D140E-5
4-cycle, water-cooled, in-line, vertical type,
Type of engine
direct injection, with turbocharger, aftercooler
No. of cylinders - Bore x Stroke mm 6 – 140 x 165
Piston displacement l {cc} 15.24 {15,240}
Flywheel horsepower kW {HP}/rpm 239 {320}/1,900
Performance
Max. torque Nm {kgm}/rpm 1,834 {187}/1,300

Engine
Max. speed at no load rpm 2,100

Min. speed at no load rpm 740
Min. fuel consumption ratio g/kWh {g/HPh} 193 {142}
Starting motor 24V, 11kW
Alternator 24V, 50A
Battery 12V, 136Ah x 2
Radiator core type Rectangle wave fin
Torque converter 3-element, 1-stage, 2-phase
Planetary gear, multiple disc clutch,
hydraulically actuated, (electrically type)
Transmission force-feed lubrication gear pump,
forward 3-speed, reverse 3-speed,
electrically actuated type
Power train system
Spiral bevel gear, force-feed lubrication

Bevel gear shaft
gear pump
Wet type, multiple disc clutch type, spring-
Steering clutch boosted type, hydraulic actuation type
(manual type), brake linkage type
Wet type, multiple disc clutch type, spring-
boosted type, hydraulic actuation type
Steering brake
(foot operation, manual type),
clutch linkage type
Final drive Spur gear 1-stage, planetary gear 1-stage,

splash type lubrication
4 D155A-6

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

Track roller 7 each side
Assembly type, single grouser,
Track shoe (shoe width: 560 mm)
41 each side, pitch: 228.6 mm
Lubrication pump + power train (tandem) Gear type (SAR(3)100 + (2)40)
85001 – 85024 Gear type (SAR(4) + 125)
Scavenging pump (tandem)
85025 and up Gear type (SAR(3) + 125)
MPa Variable swash plate type (HPV112)
{kg/cm2} Max. delivery pressure: 27.5 {280}
Hydraulic pump
l/min/rpm Theoretical delivery: 216/2,250
1+1+2 tandem spool type,
Variable multi-shark ripper type
hydraulically assisted type
Control valve
• For ripper tilt + Ripper tilt

• For ripper lift + Ripper lift
• For blade lift
+ (Blade lift + blade tilt)
• For blade tilt
Type Reciprocal, piston type
Dimensions of blade lift
Cylinder bore mm 110
Piston rod outer diameter mm 75

Work equipment hydraulic system
Max. piston stroke mm 1,404
Max. distance between pins mm 2,093
Min. distance between pins mm 687.5

Dimensions of blade tilt Dimensions of blade tilt

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

(For semi U-dozer)
D155A-6 5

giant ripper tilt cylinder multi ripper lift cylinder (For sigma-tilt dozer tilt and pitch)

Dimensions of blade

Dimensions of variable Dimensions of variable

Work equipment hydraulic system

Hydraulic cylinder

Dimensions of ripper tilt
Hydraulic tank Box type (control valve externally installed)

Fan drive system
MPa Variable swash plate (LPV45)

Cooling fan pump {kg/cm2} Max. delivery pressure: 31.9 {325}
l/min Theoretical delivery pressure: 103/2,296
MPa Fixed swash plate (LMF65)
Cooling fan motor
{kg/cm2} Max. delivery pressure: 31.9 {325}
6 D155A-6

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

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

Blade capacity (SAE) m3 9.4
Dimensions
Blade width mm 4,060

Blade height mm 1,850
Blade cutting angle deg. 46
Work equipment
Performance

Semi U-tilt dozer
Max. blade tilt mm 935

Dimensions

Performance

Max. blade tilt mm 970
Full U-dozer

Dimensions

D155A-6 7

Variable multi-shank ripper
Dimensions Performance Dimensions Performance
Max. digging depth mm 835
Max. lifting height mm 890
Ripping angle of point deg. 30 – 70
Max. beam width mm 2,320

Work equipment
Shank positions No. of holes 2
Max. digging depth mm 1,370

Variable giant ripper
Max. lifting height mm 900
Ripping angle of point deg. 30 – 70
Max. beam width mm 1,520
Shank positions No. of holes 4
8 D155A-6
Weight table
k This weight table is for reference in handling or transporting components.

Engine, damper assembly 1,900
• Engine assembly 1,725
• Damper assembly 120
• Universal joint 18
• Engine mount parts (wiring) 3
Radiator assembly
333
(including built-in oil cooler hydraulic cooler and codenser)
Air flow control grid 81
Fuel tank assembly (when empty) 383
Fuel tank assembly (when full) 913
Power train unit assembly 2,412
• Torque converter, PTO assembly 410
• Transmission assembly 634
• C & B assembly 1,038
• Brake valve assembly 63
• Power train filter assembly 16.5
• Scavenging pump 20
• Power train, lubrication pump 28
• Hydraulic pump 145
Final drive assembly 1,395 x 2
Sprocket teeth (12 x 9) x 2
Hull frame assembly 4,440
Track group assembly (each side) 3,900
• Track frame 1,607
• Idler assembly 458
• Recoil spring assembly 449
• Track roller assembly (single flange x1) 112 x 2
(double flange x1) 124 x 5
• Carrier roller assembly 48 x 2
D155A-6 9

Track shoe assembly (560 mm, wet type) 2,280 x 2
Pivot shaft assembly (Left) 126
Pivot shaft assembly (Right) 142
Equalizer bar 231
Hydraulic tank assembly (including hydraulic filter) 99
Control valve
104
(Blade lift + blade tilt + ripper lift + ripper tilt + steering)
Engine underguard 248
Transmission underguard 285
Operatorís seat 68
Sigma 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
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
• Tilt cylinder assembly 130
Blade lift cylinder assembly 187 x 2
Multi-shank ripper assembly 4,330
• Bracket, beam, arm 2,300
• Shank 266 x 3
• Lift cylinder assembly 184 x 1
• Tilt cylinder assembly 252 x 1
10 D155A-6

Giant ripper assembly 3,950
• Bracket, beam, arm 2,975
• Shank 446 x 1
• Lift cylinder assembly 188 x 1
• Tilt cylinder assembly 252 x 1
• Pin puller cylinder assembly 7
Cab assembly 410
Dashboard 54
Floor frame (including air conditioner unit) 611
Side cover 20
Air conditioner unit assembly 10
D155A-6 11
Table of fuel, coolant and lubricants

a For details of the notes (Note 1, Note 2 - - -) in the table, see Operation and Maintenance Manual.
12 D155A-6
Unit: l
Hydraulic system
Engine oil Power train Damper Fainal drive Cooling
(with blade, without Fuel tank
pan case case case system
ripper)
(each left
Specified capacity (l) 45 105 1.5 and right) 240 625 82
31
(each left
Refill capacity (l) 37 70 1.5 and right) 85 — —
31
D155A-6 13
D155A-6 Bulldozer
© 2008 KOMATSU
All Rights Reserved
14 D155A-6
SEN02861-01
D155A-6

D155A-6 85001 and up
10 Structure, function and

maintenance standard 1
Engine and cooling system
Radiator, oil cooler .......................................................................................................................................... 2
Engine mount.................................................................................................................................................. 9
Cooling fan pump.......................................................................................................................................... 10
Cooling fan motor.......................................................................................................................................... 18
D155A-6 1
SEN02861-01 10 Structure, function and maintenance standard
Radiator, oil cooler 1

Radiator (without sand protection grill)
2 D155A-6
1. Overflow hose
2. Air bleed hose
3. Inlet hose
4. Coolant filler cap
5. Radiator core assembly
6. Reservoir tank
7. Inlet hose (for circulating at low coolant
temperature)
8. Outlet hose
9. Lower tank (power train oil cooler built-in)
10. Fan
11. Drain plug
12. Cushion
13. Breather cap
14. Pressure valve
a: Aftercooler
b: Aftercooler outlet hose
c: Aftercooler inlet hose
Outline
q The reservoir tank is provided for radiator.
q The power train oil cooler is built in the lower
tank of the radiator.
D155A-6 3
Oil cooler
1. Hydraulic cooler A: Power train oil cooler inlet port

2. Power train oil cooler B: Power train oil cooler outlet port
Outline
4 D155A-6
D155A-6 5
Radiator (with sand protection grill)
6 D155A-6
1. Overflow hose
2. Air bleed hose
3. Inlet hose
4. Coolant filler cap
5. Radiator core assembly
6. Reservoir tank
7. Inlet hose (for circulating at low coolant
temperature)
8. Outlet hose
9. Lower tank (power train oil cooler built-in)
10. Fan
11. Drain plug
12. Cushion
13. Breather cap
14. Pressure valve
a: Aftercooler
b: Aftercooler outlet hose
c: Aftercooler inlet hose
Outline
q The reservoir tank is provided for radiator.
D155A-6 7
Oil cooler (sand protection grill)
1. Hydraulic cooler A: Power train oil cooler inlet port

2. Power train oil cooler B: Power train oil cooler outlet port
3. Sand protection grill
Outline
8 D155A-6
Engine mount 1
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between bracket size Shaft Hole clearance limit
1
and cushion
–0.1 +0.046 0.1 –
60 — Replace
–0.3 +0.046 0.346
Standard clearance Clearance limit
2 Free height of mount rubber
86 84
D155A-6 9
Cooling fan pump 1

Type: LPV45
P1: Pump discharge port 1. Servo valve

PAEPC: EPC output pressure pickup plug 2. Air bleeder
PEPC: EPC valve basic pressure input port
PS: Pump suction port
TO: Drain port
10 D155A-6
1. Shaft
2. Oil seal
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Spring
10. Servo piston
D155A-6 11
Function q Cylinder block (7) seals the pressurized oil to

q The pump converts the engine rotation trans- valve plate (8) and carries out relative rotation.
mitted to its shaft to oil pressure and delivers q This surface is designed so that the oil pres-
pressurized oil corresponding to the load. sure balance is maintained at a suitable level.
q It is possible to change the delivery by chang- q The oil inside each cylinder chamber of cylin-
ing the swash plate angle. der block (7) is suctioned and discharged
through valve plate (8).
Structure
q Cylinder block (7) is supported to shaft by
spline (11).
q Shaft (1) is supported with front and 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 bear-
ing.
q Shoe (5) is kept pressed against plane (A) of
rocker cam (4) and slid circularly.
q Rocker cam (4) slides around ball (13).
q Piston (6) carries out relative movement in the
axial direction inside each cylinder chamber of
cylinder block (7).
12 D155A-6
Operation of pump q With the condition of center line (X) of rocker

q Cylinder block (7) rotates together with shaft cam (4) has swash plate angle (a) to axial
(1), and shoe (5) slides on flat surface (A). direction of cylinder block (7), flat surface (A)
q At this time, rocker cam (4) slants around ball functions as cam against shoe (5).
(13). As a result, angle (a) between center line q In this way, piston (6) slides on the inside of
(X) of rocker cam (4) and the axis of cylinder cylinder block (7), so a difference between vol-
block (7) changes. umes (E) and (F) is created inside cylinder
q Angle (a) is called the swash plate angle. block (7).
q A single piston (6) sucks and discharges the oil
by the amount (F) - (E).
q As cylinder block (7) rotates and the volume of
chamber (E) becomes smaller, the pressurized
oil is discharged.
q On the other hand, the volume of chamber (F)
grows larger and, in this process, the oil is suc-
tioned.
D155A-6 13
q As center line (X) of rocker cam (4) matches Control of delivery

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

pump delivery.
14 D155A-6
D155A-6 15
Servo valve
P: EPC valve basic pressure 1. Plug

PE: Control piston pressure 2. Lever
PH: Pump discharge pressure 3. Retainer
T: Drain port 4. Seat
5. Spool
6. Piston
7. Sleeve
8. Spring
16 D155A-6
Function q Then, the land of the servo piston pressure

q The servo valve controls the current input to passage is connected to the pump discharge
the EPC valve and the pump delivery (Q) so passage by the notch of spool (5) and the dis-
that they will be related as shown in the dia- charge pressure is led to the servo piston.
gram. q When the rocker cam is pushed up by the
servo piston, a position feedback is applied
and lever (2) moves to compress spring (8).
q When spool (5) is pushed back, the pump dis-
charge circuit and the servo piston circuit are
cut off.
q Pressure in the servo piston chamber drops
and the rocker cam returns in the direction of a
maximum swash plate angle.
q These processes are repeated until the swash
plate is fixed to a position where the EPC out-
put pressure is balanced with spring (8) force.
q The greater the EPC output pressure, the
smaller the swash plate angle. Conversely, the
smaller the EPC output pressure, the greater
q The output pressure of the EPC valve flows in the swash plate angle.
the piston chamber to push piston (6).
q Piston (6) pushes spool (5) until it is balanced
with the spring.
D155A-6 17
Cooling fan motor 1

Type: LMF75(65)
P: From fan pump Specifications

T: From cooler to tank Type: LMF75(65)
TC: To tank Capacity: 65.1 cc/rev
Rated speed: 1,250 rpm
Rated flow: 81.4 l/mm
Check valve crack pressure: 78.5 kPa {0.8 kg/cm2}
18 D155A-6
1. Output shaft 7. End cover

2. Case 8. Center spring
3. Thrust plate 9. Check valve
4. Piston assembly 10. Pilot valve
5. Cylinder block 11. Spool for reversible valve
6. Valve plate 12. Safety valve
Unit: mm
Standard size Repair limit
Free length x Installation Installation Free Installation
13 Spool return spring outer diameter length load length load Replace spring
146 N 117 N if damaged or
62.66 x 19.8 53.5 —
{14.9 kg} {11.9 kg} deformed.
13.7 N 11.0 N
14 Check valve spring 16.4 x 8.9 11.5 —
{1.4 kg} {1.12 kg}
D155A-6 19
1. Hydraulic motor
Function
q This hydraulic motor is called a swash plate-
type axial piston motor. It converts the energy
of the pressurized oil sent from the hydraulic
pump into rotary motion.
Principle of operation
q The oil sent from the hydraulic pump flows
through valve plate (7) into cylinder block (5).
This oil can flow on only one side of the (Y-Y)
line connecting the top dead center and bottom
dead center of the stroke of piston (4).
q The oil sent to one side of cylinder block (5)
presses piston (4) [4 or 5 pieces], and gener-
ates force (F1)[F1 = P x xD2/4].
q This force is applied to thrust plate (2). Since
thrust plate (2) is fixed to the angle of (a°)
degrees to the output shaft(1), the force is
divided into components (F2) and (F3).
q The radial component (F3) generates torque [T
= F3 x ri] against the (Y-Y) line connecting the
top dead center and bottom dead center.
q The result of this torque [T = (F3 x ri)] rotates
cylinder block (5) through the piston.
q Since this cylinder block (5) is splined to the
output shaft, the output shaft revolves to trans-
mit the torque.
20 D155A-6
2. Suction valve
Function 2) When the pump is stopped

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

q If the pressurized oil from the pump is supplied
to port (P) and the pressure on (MA) side rises
and starting torque is generated in the motor,
the motor starts revolution.The pressurized oil
on the motor outlet (MB) side of the motor
returns through port (T) to the tank.
D155A-6 21
3. Operation of reversible valve
1) When the ON-OFF solenoid is de-energized. 2) When the ON-OFF solenoid is energized.
q If ON-OFF solenoid (1) is “de-energized“, the q If ON-OFF solenoid (1) is “energized“, ON-
pressurized oil from the pump is blocked by OFF selector valve (2) changes to let the pres-
ON-OFF selector valve (2), and port (C) opens surized oil from the pump flow through port (C)
for the tank circuit. into spool chamber (D).
q Spool (3) is pushed to the right by spring (4). q The pressurized oil in chamber (D) pushes
q Motor port (MA) opens and pressurized oil valve spool (3) to the left against spring (4).
flows in to revolve the motor in forward (clock- q Motor port (MB) opens and pressurized oil
wise). flows in to revolve the motor in reverse (coun-
terclockwise).
22 D155A-6
4. Safety valve
Function
q When the engine is started, the pressure in
port (P) of the fan motor is heightened in some
cases.
q Safety valve (1) is installed to protect the fan
system circuit.
Operation
q If the pressure in port (P) rises above the
cracking pressure of safety valve (1), valve (2)
of safety valve (1) opens to release the pres-
surized oil into port (T).
q By this operation, generation of abnormal pres-
sure in port (P) is prevented.
D155A-6 23
D155A-6 Bulldozer
© 2007 KOMATSU
All Rights Reserved
24 D155A-6
SEN02862-01
D155A-6

D155A-6 85001 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
Transmission................................................................................................................................................. 18
Transmission ECMV ..................................................................................................................................... 34
Main relief valve and torque converter relief valve........................................................................................ 40
Lubricating oil relief valve.............................................................................................................................. 42
Scavenging pump ......................................................................................................................................... 44
Power train and steering lubrication pump.................................................................................................... 46
D155A-6 1
Power train skeleton 1
Outline
q The power generated by engine (1) has its tor- q The power transmitted to the bevel gear shaft
sional vibration dampened by damper (2), and is transmitted to divided at right angles to the
then passes through universal joint (3), and is left and right and transmitted to the respective
transmitted to torque converter (8). steering clutches (11).
q The power from the engine is transmitted The power transmitted from the bevel gear
through the oil by torque converter (8) to the shaft to the final drive is used to steer the
transmission input shaft (turbine shaft) in machine by engaging or disengaging steering
accordance with the change in load. (with L/U) clutch (11).
q Transmission (9) uses a combination of a plan- The steering lever is operated to disengage
etary gear system and hydraulic clutches to the steering clutch on the side to which the
reduce the speed and shift the gears (3 for- machine is to be steered in order to change the
ward gears and 3 reverse gears). It connects direction of travel. The side of the turning
2 sets of clutches selected according to the radius id controlled by steering brake (12)
change in load, and transmits the power to installed to the outside of the steering clutch.
bevel gear (10) from the bevel pinion at the Steering brake (12) uses the same disc system
rear end of the transmission. that is used for the steering clutch.
The power sent from steering brake (12) is
transmitted to final drive (13).
q Final drive (13) consists of a single-stage spur
gear and a single-stage planetary gear system.
It reduces the speed and rotates sprocket (14)
to drive track shoe (15) and move the machine.
It also rotates cooling fan motor (17) with the
oil discharged from cooling fan pump (16)
driven with PTO (6).
2 D155A-6
1. Engine (SAA6D140E-5) 10. Bevel gear

2. Damper 11. Steering clutch
3. Universal joint 12. Steering brake
4. Scavenging pump (SAR(4)125) 13. Final drive
5. Hydraulic pump (HPV112) 14. Sprocket
6. PTO 15. Track shoe
7. Power train, lubricating pump (SAR(3)100+40) 16. Cooling fan pump (LPV45)
8. Torque converter 17. Cooling fan motor (LMF65)
9. Transmission
D155A-6 3
Overall drawing of power train unit 1
4 D155A-6
1. Steering brake Outline

2. Transmission q The power train unit can be broadly divided
3. Power train, lubricating pump (SAR(3)100+40) into torque converter, PTO (7), transmission
4. Power train oil strainer (2), and steering brake (1).
5. Main relief, torque converter relief valve So, a fter the power train unit h as be en
6. Torque converter, PTO removed, it can be disassembled into the
7. Scavenging pump (SAR(4)125) torque converter, PTO (7), transmission (2),
8. Cooling fan pump (LPV45) and steering brake (1).
9. Hydraulic pump (HPV112) q Steering clutch consists of the bevel pinion
10. Brake control valve unit, bevel gear shaft, and steering brake.
D155A-6 5
Power train hydraulic piping drawing 1
6 D155A-6
1. Hydraulic pump (HPV112)

2. Centralized pressure detection port
3. Power train, lubrication pump
(SAR(3)100+(3)40)
4. Brake control valve
5. Main relief, torque converter relief valve
6. Power train oil filter
7. Scavenging pump (SAR(4)125)
8. Power train oil cooler
(built in radiator lower tank)
A: Left brake oil pressure pickup port (LB)

B: Right brake oil pressure pickup port (RB)
C: 3rd transmission clutch oil pressure pickup port
(3RD)
D: 2nd transmission clutch oil pressure pickup
port (2ND)
E: 1st transmission clutch oil pressure pickup port
(1ST)
F: Reverse transmission clutch oil pressure pickup
port (R)
G: Forward transmission clutch oil pressure pickup
port (F)
H: Transmission main relief oil pressure pickup
port (TM)
J: Left clutch oil pressure pickup port (LC)
K: Right clutch oil pressure pickup port (RC)
L: Torque converter oil pressure pickup port (IN)
M: Torque converter oil pressure pickup port (OUT)
D155A-6 7
Damper, universal joint 1
8 D155A-6
1. Breather
2. Dipstick
3. Drain plug
4. Output shaft
5. Flywheel
6. Outer body
7. Coupling
8. Universal joint
9. Cover
10. Rubber coupling
11. Inner body
Unit: mm
Clearance between flywheel size Shaft Hole clearance limit
12
housing and cover
–0.022 +0.070 0.022 –
511.18 0.2
–0.092 +0.070 0.162
Clearance between flywheel –0.020 +0.063 0.020 – Replace
13 466.72 0.2
and damper –0.083 +0.070 0.146
Standard size Tolerance Repair limit
Outside diameter of coupling
14 –0.087
oil seal contact surface 90 89.8
–0.087
Outline
q The damper, dampens the torsional vibration
caused by the change in engine torque and
the impact torque generated when accelerat-
ing suddenly or when carrying out heavy-duty
digging. In this way, it acts to protect the torque
converter, transmission, and other parts of the
power train.
q The damper has few component parts: it uses
a rubber coupling, so the vibration is absorbed
by the damping effect of the rubber material.
Operation
q The motive force from the engine passes
through flywheel (5) and is transmitted to outer
body (6).
The torsional vibration of the engine is absorbed
by rubber coupling (10), and the power is trans-
mitted to inner body (11). It passes through uni-
versal joint (8), and is then transmitted to the
torque converter and transmission.
D155A-6 9
Torque converter, PTO 1

a PTO: Abbreviation for Power Take Off
A: To power train oil cooler D: To transmission case

B: From main relief valve E: From power train oil cooler
C: From transmission case
10 D155A-6
D155A-6 11
1. Work equipment pump mounting port

2. Cooling fan pump mounting port
3. Scavenging pump mounting port
4. Power train and steering lubrication pump
mounting port
5. Torque converter case
6. Coupling
7. Input transfer drive gear (Number of teeth: 58)
8. PTO idler gear (Number of teeth: 66)
9. PTO idler gear shaft
10. Turbine
11. Drive case
12. Rase
13. Stator
14. Pump
15. Retainer
16. Stator shaft
17. Transmission input shaft
18. Turbine boss
19. PTO gear A (Number of teeth: 49)
20. PTO gear B (Number of teeth: 48)
21. Scavenging pump drive gear
(Number of teeth: 56)
22. Power train oil strainer
23. Sleeve
12 D155A-6
General
q 3-element, 1-stage and 2-phase type is
employed for the torque converter. It is inte-
grated with the transmission.
q Pump (14) is integrated with coupling (6), input
shaft (7) and drive case (11), and rotated by
the power from the engine.
q Turbine (10) is integrated with turbine boss
(18) and transmission input shaft (17), and
rotates using the oil from pump (14) as the
medium.
q Stator (13) is integrated with stator shaft (16),
and fixed to torque converter case (5).
q The PTO system is consisted of input shaft (7),
PTO idler gear (8), PTO gear A (19), PTO gear
B and scavenging pump drive gear (21).
D155A-6 13
14 D155A-6
Unit: mm
Outside diameter of coupling oil
1 seal contact surface -0.054 Repair by hard
100 99.8
-0.054 chromium-plat-
ing or replace
Inside diameter of stator shaft 65 +0.030 65.1
seal ring contact surfac +0.025
-0.01
2 Wear on seal ring Width 3 -0.03 2.7
of the transmission Replace
input shaft Thickness 2.7 ±0.1 2.55
Inside diameter of retainer seal +0.040 Repair by hard

3 ring contact surface 150 +0.040 150.5 chromium-plat-
ing or replace
4 Backlash between input shaft 0.198 – 0.484

and PTO idler gear
5 Backlash between PTO idler 0.198 – 0.484

gear and PTO gear A
6 Backlash between PTO idler 0.198 – 0.484

gear and PTO gear B
Backlash between input shaft
7 and scavenging pump drive 0.198 – 0.484
gear

size Shaft Hole clearance limit
Tolerance for fit-
8 ness of PTO idler Outside 140 -0.018 -0.008 0.033 – —
gear bearing diameter -0.018 -0.033 0.010
Inside 80 -0.019 -0.015 0.015 – —
diameter -0.019 -0.015 0.019
Outside -0.018 +0.026 0.014 –
diameter 140 -0.018 -0.014 0.044 —
(Cover side)
Tolerance for fit- Outside -0.015 +0.022 0.013 –
ness of drive gear diameter 120 -0.015 -0.013 0.037 —
bearing on work (Case side)
9 Replace
equipment, power Inside
train and steering +0.030 -0.015 0.045 –
diameter 65 +0.011 -0.015 0.011 —
lubrication pump (Cover side)
Inside +0.030 -0.015 0.045 –

diameter 65 +0.011 -0.015 0.011 —
(Case side)
Outside -0.015 +0.022 0.013 –
diameter 120 -0.015 -0.013 0.037 —
(Cover side)
Outside -0.015 +0.022 0.013 –
diameter 120 -0.015 -0.013 0.037 —
Tolerance for fit- (Case side)
10 ness of fan pump
drive gear bearing Inside +0.030 -0.015 0.045 –
diameter 55 +0.011 -0.015 0.011 —
(Cover side)
Inside +0.030 -0.015 0.045 –
diameter 65 +0.011 -0.015 0.011 —
(Case side)
Tolerance for fit- Outside 85 -0.015 +0.010 0.025 – —

diameter -0.015 -0.025 0.025
11 ness of scaveng-
ing pump drive Inside +0.018 -0.012 0.030 –
gear bearing 45 —
diameter +0.002 -0.012 0.002
D155A-6 15
Power transmitting route Oil flow
Power generated from engine q The oil flows through the main relief valve and
O its pressure is reduced to less than the set
Damper pressure by the torque converter relief valve,
O then it flows through inlet port (A) and oil pas-
Universal joint sage of torque converter case (1), stator shaft
O (2), retainer (3), to pump (4).
Input coupling (1) q The oil is given a centrifugal force by pump (4),
O and then it enters turbine (5) to transmit its
Input shaft (2) energy to turbine (5).
O q The oil from turbine (5) is sent to stator (6), and
Drive case (3) and pump (4) rotate integral to each then returned to pump (4). Part of this oil is
other sent to the power train oil cooler through stator
O (6) and outlet port (B).
Oil is used as medium
O
Turbine (5)
O
Transmission input shaft (6)
16 D155A-6
D155A-6 17
Transmission 1
18 D155A-6
A: 1st clutch pressure pickup port (1ST) K: To torque converter

B: 3rd clutch pressure pickup port (3RD) L: To scavenging pump
C: R clutch oil pressure pickup port (R) M: To torque converter case
D: 2nd clutch pressure pickup port (2ND) N: From torque converter case
E: F clutch oil pressure pickup port (F) P: To R clutch
F: From power train pump R: To 3rd clutch
G: To brake control valve S: To 1st clutch
H: From steering case T: To 2nd clutch
J: From power train oil cooler U: To F clutch
D155A-6 19
20 D155A-6
1. Transmission ECMV General

2. Main relief valve and torque converter relief q The transmission consists of planetary gear
valve systems and disc clutches and has "3 forward
3. Transmission case gear speeds and 3 reverse gear speeds".
4. Sleeve q Among the 5 sets of planetary gear system
5. Transmission input shaft and disc clutches of the transmission, 2
6. Tie bolt clutches are fixed hydraulically with the ECMV
7. R ring gear (hub) to select 1 rotating direction and gear speed.
8. R planetary pinion (number of teeth: 26) q The transmission transfers the power received
9. R ring gear (number of internal teeth: 86) by the transmission input shaft to the output
10. F planetary pinion (number of teeth: 24) shaft while changing the gear speed (forward
11. F ring gear (number of internal teeth: 91) 1st-3rd or reverse 1st-3rd) by any combination
12. 3rd planetary pinion (number of teeth: 35) of the F, R clutches and 3 speed clutches.
13. 3rd ring gear (number of internal teeth: 89)
14. 2nd planetary pinion (number of teeth: 31) Number of plates and discs used
15. 2nd ring gear (number of internal teeth: 91)
Number of
16. 1st ring gear (number of internal teeth: 91) Clutch No.
plates
Number of discs
17. 1st planetary pinion (number of teeth: 27)
R clutch 6 6
18. Transmission output shaft
(3rd sun gear)(number of teeth: 19) F clutch 6 7
19. 1st clutch housing 3rd clutch 3 4
20. 1st clutch piston 2nd clutch 3 4
21. 1st sun gear (number of teeth: 37)
1st clutch 2 3
22. 1st carrier
23. 2nd clutch housing
24. 2nd clutch piston
25. 2nd sun gear (number of teeth: 29) Combinations of clutches at respective gear
26. 2nd carrier speeds and reduction ratio
27. 3rd clutch housing Reduction
28. 3rd clutch piston Gear speed Operated clutches
ratio
29. 3rd carrier Forward 1st F x 1st 1.705
30. F clutch housing
Forward 2nd F x 2nd 1.151
31. F clutch piston
32. F carrier Forward 3rd F x 3rd 0.540
33. R clutch housing Neutral * —
34. F sun gear (number of teeth: 44) Reverse 1st R x 1st 1.406
35. R clutch piston
Reverse 2nd R x 2nd 0.949
36. Washer spring
37. Clutch plate Reverse 3rd R x 3rd 0.445
38. Clutch disc *: The 1st, 2nd, or 3rd clutch is filled with low-pressure
39. Piston return spring oil.
40. R carrier
41. Front housing
42. R sun gear (number of teeth: 34)
D155A-6 21
22 D155A-6
Unit: mm
Installed Installed Installed
Free length Free length
1 R clutch spring (12 springs) length load load
59.8 N 51.0 N
81.7 72.4 76.8
{6.1 kg} {5.2 kg}
34.3 N 29.4 N
2 F clutch spring (12 springs) 81.7 76.4 76.8
{3.5 kg} {3.0 kg}
97.1 N 82.4 N
3 3rd clutch spring (12 springs) 70.0 50.2 65.8
{9.9 kg} {8.4 kg}
90.2 N 76.5 N
4 2nd clutch spring (12 springs) 70.0 51.6 65.8
{9.2 kg} {7.8 kg}
66.7 N 56.9 N
5 1st clutch spring (12 springs) 66.0 51.8 62.0
{6.8 kg} {5.8 kg}
Total assembled thickness of 6
6
disks and 6 plates for R clutch 51.6 ±0.35 48.4

7 57.0 ±0.36 53.3
disks and 6 plates for F clutch
8 31.2 ±0.26 29.1
disks and 3 plates for 3rd clutch
9 31.2 ±0.26 29.1
disks and 3 plates for 2nd clutch
10 22.6 ±0.22 21.0
disks and 2 plates for 1st clutch Replace
11 Thickness of clutch disk 5.4 ±0.1 4.9
12 Thickness of clutch plate 3.2 ±0.1 2.9
-0.01
Width 3.0 2.70
Wear of input shaft -0.03
13
seal ring
Thickness 2.7 ±0.1 2.55
Wear of seal ring on -0.01

Width 4.0 3.60
the front housing, F -0.04
14
clutch housing and
3rd carrier Thickness 5.0 ±0.15 4.85
-0.01
Width 4.0 3.60
Wear of seal ring -0.04
15
(large) on 2nd carrier
Thickness 4.0 ±0.15 3.85
-0.01
Width 4.0 3.60
16
(small) on 2nd carrier
Thickness 4.0 ±0.15 3.85
-0.01
Width 4.0 3.60
17
(large) on 1st carrier
Thickness 4.0 ±0.15 3.85
D155A-6 23
Unit: mm
-0.01
Wear of seal ring Width 4.0 3.60
18 -0.04
(small) on 1st carrier
Thickness 5.0 ±0.15 4.85
R, F,
Backlash between 0.14 – 0.35
3rd, 1st
19 sun gear and plane-
Replace
tary pinion 2nd 0.13 – 0.32
R 0.15 – 0.39
Backlash between
F, 2nd,
20 planetary pinion and 0.15 – 0.38
1st
ring gear
3rd 0.16 – 0.42
Disc clutch
Structure Operation
When clutch is "engaged" (fixed)
q The disc clutch consists of piston (2), plates

(3), discs (4), pin (5), return spring (6) etc. to fix q The oil sent from the ECMV flows through the
ring gear (1). oil passage in clutch housing (7), is pressure-
q Inside teeth of disc (4) are engaged with out- fed to the back side of piston (2), and pushes
side teeth of ring gear (1). piston (2) to the left.
q Plate (3) is assembled to clutch housing (7) q Piston (2) contacts plate (3) closely against
with pin (5). disc (4) to stop rotation of disc (4) by use of the
friction force generated between them.
q Since inside teeth of disc (4) are engaged with
outside teeth of ring gear (1), move of ring gear
(1) is stopped.
24 D155A-6
When clutch is "disengaged" (released) Oil passage in speed clutch

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

pushed back rightward by return spring (6).
q The friction force between plates (3) and discs q When the steering/directional/gear shift lever is
(4) is released and ring gear (1) is released. set in the "neutral" position, the 1st, 2nd, or 3rd
speed is selected.
q The piston chamber of the clutch correspond-
ing to the selected gear speed is filled with oil
by electronically controlling the hydraulic circuit
of each clutch.
q When the steering/directional/gear shift lever is
shifted from the "neutral" position to the"for-
ward" or "reverse" position, the pump is
required to supply oil of quantity to fill the pis-
ton chamber of the F clutch or R clutch.
q When the gear speed is changed from "for-
ward 1st" to "forward 2nd", the pump is
required to supply oil of only quantity to fit the
plate and disc of the 2nd clutch together since
the F clutch has been filled with the oil.
q The time lag in the gear shifting operation is
reduced by controlling the oil in the clutch cir-
cuit as explained above.
D155A-6 25
Power transmitting route

Forward 1st speed
26 D155A-6
F ring gear (4) of F clutch and 1st ring gear (19) of 1st clutch are fixed with oil pressure.
Power from torque converter

O
Input shaft (1)
O
F sun gear (2)
O
F planetary pinion (3)
O
F carrier (10)
O
3rd carrier (11)
O
3rd planetary pinion (12)
O
3rd ring gear (13)
O
2nd carrier (14)
O
2nd planetary pinion (15)
O
2nd ring gear (16)
O
1st carrier (17)
O
1st planetary pinion (18)
O
1st sun gear (20) 2nd sun gear (21)
O
Output shaft (22)
D155A-6 27
Forward 2nd speed
28 D155A-6
F ring gear (4) of F clutch and 2nd ring gear (16) of 2nd clutch are fixed with oil pressure.

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)
D155A-6 29
Forward 3rd speed
30 D155A-6
F ring gear (4) of F clutch and 3rd ring gear (13) of 3rd clutch are fixed with oil pressure.

O
Input shaft (1)
O
F sun gear (2)
O
O
F carrier (10)
O
3rd carrier (11)
O
O
Output shaft (22)
D155A-6 31
Reverse 1st speed
32 D155A-6
R ring gear (7) of R clutch and 1st ring gear (19) of 1st clutch are fixed with oil pressure.

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 =
R ring gear (9) rotates in reverse with
regard to input shaft (1)
Not translated
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 2nd sun gear (21)
1st sun gear (20)
O
Output shaft (22)
D155A-6 33
Transmission ECMV 1
a ECMV: Abbreviation for Electronic Control Modulation Valve
a Don't try to disassemble it since adjustment for maintaining the performance will be needed.
34 D155A-6
AF: To F clutch Operation table of ECMV

AR: To R clutch ECMV
A1: To 1st clutch Gear F R 1st 2nd 3rd
A2: To 2nd clutch speed
A3: To 3rd clutch N Q Q Q
P: From power train pump
F1 Q Q
T: Drain
Dr: Drain F2 Q Q
PF: F clutch oil pressure pickup port F3 Q Q
PR: R clutch oil pressure pickup port
R1 Q Q
P1: 1st clutch oil pressure pickup port
P2: 2nd clutch oil pressure pickup port R2 Q Q
P3: 3rd clutch oil pressure pickup port R3 Q Q
1. 3rd clutch proportional solenoid a When the directional lever is in (neutral) posi-
2. 1st clutch proportional solenoid tion, the speed clutch of the speed selected by
3. R clutch proportional solenoid gear shift lever activates.
4. F clutch proportional solenoid
5. 2nd clutch proportional solenoid
6. 3rd clutch fill switch
7. 2nd clutch fill switch
8. 1st clutch fill switch
9. R clutch fill switch
10. F clutch fill switch
11. Transmission oil filter
12. Connector for 1st clutch proportional solenoid
13. Connector for 3rd clutch fill switch
14. Connector for 3rd clutch proportional solenoid
15. Connector for R clutch proportional solenoid
16. Connector for 2nd clutch fill switch
17. Connector for 2nd clutch proportional solenoid
18. Connector for F clutch proportional solenoid
19. Connector for 1st clutch fill switch
20. Connector for R clutch fill switch
21. Connector for F clutch fill switch
D155A-6 35
1. Fill switch
2. Pressure control valve
3. Body (upper)
4. Body (lower)
5. Proportional solenoid
6. Filter
7. Pressure detection valve
8. Sleeve
36 D155A-6
Outline of ECMV ECMV and proportional solenoid

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

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

Range B: During filling ECMV and fill switch
Range C: Pressure regulation q For each ECMV, 1 fill switch is installed.
Range D: During filling (During triggering) If the clutch is filled with oil, the fill switch is
Point E: Start of filling turned "ON" by the pressure of the clutch. The
Point F: Finish of filling oil pressure is built up according to this signal.
a The logic is so made that the controller will not
recognize completion of filling even if the fill
switch is turned "ON" during triggering (Range
D).
D155A-6 37
Operation of ECMV Before shifting gear (when draining) (Range A

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

sent to the proportional solenoid (1), pressure
control valve (3) drains the oil from clutch port
(A) through drain port (T).
Also at this time, fill switch (5) is turned "OFF"
because oil pressure is not applied to pressure
Range A: Before shifting gear (When draining) detection valve (4).
Range B: During filling
Range C: Pressure regulation
Range D: During filling (During triggering)
Point E: Start of filling
Point F: Finish of filling
a The logic is so made that the controller will not
recognize completion of filling even if the fill
switch is turned "ON" during triggering (Range
D).
q When gear is shifted with gear shift switch, the
clutch is compressed by piston. If high pres-
sure is suddenly applied, the piston suddenly
engages clutch, causing sudden start of
machine and excessive shock.
ECMV reduces a shock at the start of the
machine by increasing the oil pressure applied
to the piston gradually to set pressure, and
puts clutch smoothly "engaged". It aims to
increase durability of power transmitting route
and enhances an operator comfort.
38 D155A-6
During filling (Range B in chart) Pressure adjustment (Range C in chart)
q If current is supplied to proportional solenoid q If current flows in proportional solenoid (1), the
(1) with no oil in the clutch, the oil pressure solenoid generates thrust in proportion to the
force balanced with the solenoid force is current. This thrust of the solenoid is balanced
applied to chamber (B) and pushes pressure with the sum of the thrust generated by the oil
control valve (3) to the right. As a result, pump pressure in clutch port and the repulsion of
port (P) and clutch port (A) are opened and oil pressure control valve spring (2) to regulate
starts filling the clutch. If the clutch is filled with the pressure.
oil, fill switch (5) is turned "on".
D155A-6 39
Main relief valve and torque converter relief valve 1
Unit: mm
Clearance between main relief size Shaft Hole clearance limit
1
valve and body
-0.035 +0.013 0.035 –
28 0.078
-0.045 +0.013 0.058
Clearance between the torque con- -0.035 +0.013 0.035 –
2 22 0.078
verter relief valve and the body -0.045 +0.013 0.058
Replace
Installation Installation Installation
Main relief valve spring Free length Free length
3 length load load
(outside)
481 N 457 N
122 78.0 118.3
{49 kg} {46.6 kg}
Main relief valve spring 368 N 349 N
4 108 78.0 104.8
(inside) {37.5 kg} {35.6 kg}
Torque converter relief valve 182 N 174 N
5 50 40.5 48.5
spring {18.6 kg} {17.7 kg}
6. Body A: Drain (Torque converter relief)

7. Piston B: Drain
8. Torque converter relief valve C: From pump
9. Piston D: Drain
10. Main relief valve E: To torque converter
P1: Main relief oil pressure pickup port
P8a: Torque converter relief oil pressure pickup
port
P8b: Torque converter inlet oil pressure pickup
port
40 D155A-6
General Operation of main relief valve
Torque converter relief valve

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

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

the set pressure, the oil conducted to chamber
(F) pushes piston (2) and the resulting reaction
force pushes main relief valve (1) leftward,
opening ports (C) and (E).
Above operation conducts the oil from port (E)
to the torque converter.
q 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).
q As the oil pressure to the torque converter
rises beyond the set pressure, the oil con-
ducted to chamber (G) pushes piston (4) and
the resulting reaction force pushes torque con-
verter relief valve (3) rightward, opening ports
(E) and (A).
As a result, the oil in port (E) is drained through
port (A).
D155A-6 41
Lubricating oil relief valve 1
Unit: mm
1 Lubrication relief valve spring length load load Replace
12.5 N 11.9 N
26 23.6 25.2
{1.27 kg} {1.21 kg}
2. F clutch housing General

3. R clutch housing q The oil leaving the torque converter passes
4. Piston through the power train oil cooler built in the
radiator lower tank. It then goes through the
A: From oil cooler lubrication relief valve and lubricates the trans-
B: Drain mission and PTO.
C: Drain q The lubrication relief valve is installed to the
right side face of the F clutch housing. It keeps
the lubricating oil pressure below the set pres-
sure.
s Specified value
Normal pressure 0.14 ± 0.05
(MPa{kg/cm2}) {1.4 ± 0.5}
Cracking pressure 0.30 ± 0.03
(MPa{kg/cm2}) {3.0 ± 0.3}
42 D155A-6
D155A-6 43
Scavenging pump 1
Type: SAR(4)125
Serial No.: 85001 – 85024
Unit: mm
1 Side clearance
0.11 – 0.16 0.19
Clearance between plain bear-
2 ing inner diameter and gear 0.06 – 0.14 0.20
shaft outer diameter Replace

3 Pin driving depth -0.5
21 —
-0.5
4 Spline shaft rotating torque 9.8 - 14.7 Nm {1.0 - 1.5 kgm}
Standard Discharge
Delivery amount Rotation speed Delivery pressure discharge amount
—
– Oil: SAE10WCD (rpm) MPa{kg/cm2} amount limit
Oil temperature: 45 – 55°C (l/min) (l/min)
2,200 2.94{30} 264 234
General
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.
44 D155A-6
Type: SAR(3)125
Serial No.: 85025 and up
Unit: mm
1 Side clearance
0.10 – 0.15 0.19
Clearance between plain bear-
2 ing inner diameter and gear 0.078 – 0.149 0.20
shaft outer diameter Replace

3 Pin driving depth -0.5
14 —
-0.5
4 Spline shaft rotating torque 6.9 - 11.8 Nm {0.7 - 1.2 kgm}
Standard Discharge
Delivery amount Rotation speed Delivery pressure discharge amount
—
– Oil: SAE10WCD (rpm) MPa{kg/cm2} amount limit
Oil temperature: 45 – 55°C (l/min) (l/min)
2,000 2.94{30} 240.7 213.1
General
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.
D155A-6 45
Power train and steering lubrication pump 1

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

2. Steering lubrication pump q The power train pump and the steering lubrica-
tion pump are installed to the torque converter
case. They are driven by the power from the
engine to supply the oil pressure to the torque
converter, the transmission and the steering
unit.
46 D155A-6
Unit: mm
Type Standard clearance Clearance limit
3 Side clearance SAR(3)100
0.10 – 0.15 0.19
SAR(3)40
Clearance between plain bear- SAR(3)100
4 ing inner diameter and gear 0.06 – 0.15 0.20 Replace
shaft outer diameter SAR(3)40
Type Standard size Tolerance Repair limit
5 Pin driving depth SAR(3)100 -0.5
14 —
SAR(3)40 -0.5
6 Rotating torque of spline shaft 13.7 – 23.5 Nm {1.4 – 2.4 kgm}
Delivery Standard Discharge
Rotation
pressure discharge amount
Type speed
Delivery amount (MPa{kg/ amount limit —
(rpm)
– Oil: SAE10WCD cm2}) (l/min) (l/min)
Oil temperature: 45 – 55°C
SAR(3)100 2,500 2.94{30} 241 96
SAR(3)40 2,500 2.94{30} 239 85
D155A-6 47
D155A-6 Bulldozer
© 2008 KOMATSU
All Rights Reserved
48 D155A-6
SEN02863-00
D155A-6

D155A-6 85001 and up

Power train, Part 2
Work equipment pump .................................................................................................................................... 2
Work equipment cooler bypass valve ........................................................................................................... 15
Steering, brake control .................................................................................................................................. 16
Steering unit .................................................................................................................................................. 18
Steering control valve.................................................................................................................................... 32
Steering clutch ECMV, steering brake ECMV ............................................................................................... 34
Parking brake solenoid valve ........................................................................................................................ 40
Sudden stop prevention valve....................................................................................................................... 42
Final drive ..................................................................................................................................................... 45
Sprocket ........................................................................................................................................................ 50
D155A-6 1
Work equipment pump 1

Type: HPV95 (112)
2 D155A-6
Outline
q The pump unit is composed of the variable
capacity swash plate type piston pump and LS
valve.
PA: Pump discharge port

PB: Pump pressure input port
PC: Pump discharge pressure pickup port
PD1: Case drain port
PD2: Drain plug
PEN: Control pressure pickup port
PLS: Load pressure input port
PLSC: Load pressure pickup port
PS: Pump suction port
1. Main pump
2. LS valve
D155A-6 3
1. Shaft
2. Cradle
3. Front case
4. Rocker cam
5. Shoe
6. Piston
7 Cylinder block
8. Valve plate
9. End cap
10. Servo piston
4 D155A-6
Function q Piston (6) carries out relative movement in the

q The pump converts the engine and torque rota- axial direction inside each cylinder chamber of
tion transmitted to its shaft to oil pressure and cylinder block (7).
delivers pressurized oil corresponding to the q Cylinder block (7) seals the pressurized oil to
load. valve plate (8) and carries out relative rotation.
q It is possible to change the delivery by chang- q This surface is designed so that the oil pres-
ing the swash plate angle. sure balance is maintained at a suitable level.
q The oil inside each cylinder chamber of cylin-
Structure der block (7) is suctioned and discharged
q Cylinder block (7) is supported to shaft (1) by through valve plate (8).
spline (12).
q Shaft (1) is supported with bearings (13).
q The end of piston (6) has a spherical hollow
and is combined with shoe (5).
q Piston (6) and shoe (5) form a spherical bear-
ing.
q Rocker cam (4) has flat surface (A), and shoe
(5) is always pressed against this surface while
sliding in a circular movement.
q Rocker cam (4) conducts high pressure oil to
cylinder surface (B) with cradle (2), which is
secured to the case, and forms a static pres-
sure bearing when it slides.
D155A-6 5
Operation of pump q As center line (X) of rocker cam (4) matches

q Cylinder block (7) rotates together with shaft the axial direction of cylinder block (7) (swash
(1), and shoe (5) slides on flat surface (A). plate angle (a) = 0), the difference between
q When this happens, rocker cam (4) moves volumes (E) and (F) inside cylinder block (7)
along cylindrical surface (B), so angle (a) becomes 0.
between center line (X) of rocker cam (4) and q Suction and discharge of pressurized oil is not
the ax ial di rec tio n of cy li nder b loc k (7) carried out in this state. Namely pumping
changes. action is not performed. (Actually, however, the
q Angle (a) is called the swash plate angle. swash plate angle is not set to 0)
q With center line (X) of rocker cam (4) at swash

plate angle (a) in relation to the axial direction
of cylinder block (7), flat surface (A) acts as a
cam in relation to shoe (5).
q In this way, piston (6) slides on the inside of
cylinder block (7), so a difference between vol-
umes (E) and (F) is created inside cylinder
block (7).
q A single piston (6) sucks and discharges the oil
by the amount (F) – (E).
q As cylinder block (7) rotates and the volume of
chamber (E) becomes smaller, the pressurized
oil is discharged.
q On the other hand, the volume of chamber (F)
grows larger and, in this process, the oil is suc-
tioned.
6 D155A-6
Control of delivery
q If 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 Servo piston (10) is used for changing swash
plate angle (a).
q Servo piston (10) carries out linear reciprocal
movement according to the signal pressure
from the LS valve.
q This linear 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 Space of the pressure receiving area of servo
piston (10) are not identical on the left side and
right side. Main pump discharge pressure (self
pressure) (PP) is always brought to the pres-
sure chamber of the small diameter piston
side.
q Output pressure (PEN) of the LS valve is
brought to the chamber receiving the pressure
at the large diameter piston end.
q The relationship in the size of pressure (PP) at
the small diameter piston end and pressure
(PEN) at the large diameter piston end, and
the ratio between the area receiving the pres-
sure of the small diameter piston and the large
diameter piston controls the movement of
servo piston (10).
D155A-6 7
LS valve
PA: Pump port 1. Sleeve

PDP: Drain port 2. Piston
PLP: LS control pressure output port 3. Spool
PLS: LS pressure input port 4. Spring
PP: Pump port 5. Seat
PSIG: Drain port 6. Sleeve
7. Plug
8. Locknut
Function
q The LS (load sensing) valve detects the load
and controls the delivery.
q This valve controls pump delivery (Q) accord-
ing to differential pressure (dPLS)
[ = (PP) – (PLS)] (called LS differential pres-
sure) between pump discharge pressure (PP)
and control valve outlet port pressure (PLS).
q Main pump pressure (PP), pressure (PLS)
(called the LS pressure) coming from the con-
trol valve output enter this valve.
8 D155A-6
D155A-6 9
Operation
1) When the control valve is situated at neutral
10 D155A-6
q The LS valve is a 3-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 (1).
q Magnitude of the force resulting from this LS
pressure (PLS), force of spring (4) and the
pump discharge pressure (self pressure) (PP)
determine the position of spool (3).
q Before starting engine, servo piston (10) is
pressed to the right. (See the figure to the
right)
q If the control lever is in neutral at start of the
engine, LS pressure (PLS) is set to 0 MPa {0
kg/cm2}. (It is connected with the drain circuit
through the control valve spool.)
q Spool (3) is pushed to the right, and port (C)
and port (D) will be connected.
q Pump discharge pressure (PP) enters the
large diameter side of the piston from port (K).
q Pump pressure (PP) is present in port (J) on
the small diameter side of the piston.
q According to the difference in the areas on
servo piston (10), servo piston (10) moves in to
the direction of minimizing the swash plate
angle.
D155A-6 11
2) Action for the direction of maximizing the pump delivery
q When the difference between pump discharge q The pressure at the large diameter end of
pressure (PP) and LS pressure (PLS), in other servo piston (10) becomes drain pressure
wo r ds , L S d iff er e nti a l p re s s ur e (dP L S) (PT), and pump pressure (PP) enters port (J)
becomes smaller [for example, when the area at the small diameter end, so servo piston (10)
of opening of the control valve becomes larger is pushed to the left side. Therefore, servo pis-
and pump discharge pressure (PP) drops], ton (10) is moved in the direction to make the
spool (3) is pushed to the left by the combined delivery larger.
force of LS pressure (PLS) and the force of
spring (4).
q When spool (3) moves, port (D) and port (E)
are interconnected and connected to the drain
port.
12 D155A-6
3) Action for the direction of minimizing the pump delivery
q If LS differential pressure (dPLS) becomes

larger (for example, when the area of control
valve opening becomes smaller and the pump
pressure (PP) increases), spool (3) is pressed
to the right by the force of pump pressure (PP).
q As a result of the movement of spool (3), pump
discharge pressure (PP) flows from port (C) to
port (D), then from port (K) to the large diame-
ter side of the piston.
q While main pump pressure (PP) is present in
port (J) of the smaller diameter side of the pis-
ton, servo piston (10) is pressed to the right by
its area difference between the larger and the
smaller diameter sides. As the result, servo
piston (10) moves in the direction to minimize
the swash plate angle.
D155A-6 13
4) When servo piston is balanced
q Let us take the area receiving the pressure at q And the swash plate of the pump will be held in
the large diameter end of the piston as (A1), an intermediate position. [Spool (3) will be
the area receiving the pressure at the small stopped at a position where the distance of the
diameter end as (A0), and the pressure flowing opening from port (D) to port (E) and the dis-
into the large diameter end of the piston as tance from port (C) to port (D) is almost the
(PEN). same.]
q If the main pump pressure (PP) of the LS valve q The formula (A0) : (A1) = 3 : 5 represents the
and the combined force of spring (4) and LS relation of pressure receiving areas across the
pressure (PLS) are balanced, and the relation- end of servo piston (10). And (PP) : (PEN) C 5 :
ship is (A0) × (PP) = (A1) × (PEN), servo pis- 3 represents the pressure applied across the
ton (10) will stop in that position. piston when balanced.
q The force of spring (4) is adjusted to determine
the balanced stop position of this spool (3) at
the center of the standard when (PP) – (PLS) =
2.0 MPa {20 kg/cm2}.
14 D155A-6
Work equipment cooler bypass valve 1
1. Body Outline
2. Valve q This valve is installed in the oil cooler inlet cir-
3. Spring cuit. If any abnormal pressure is generated in
the oil flowing to the oil cooler, this valve acts
A: Hydraulic oil cooler inlet to return the oil directly to the hydraulic tank.
B: To hydraulic tank
Set pressure
Cracking pressure ( MPa {kg/cm })
2 0.5 {5.1}
D155A-6 15
Steering, brake control 1

a Regarding the transmission-related description of the operation of the PCCS lever, see Transmission
control.
a PCCS: Palm Command Control System
16 D155A-6
1. Potentiometer Outline
2. Lock lever q PCCS lever (3) sends electric signals to power
3. PCCS lever (Steering) train controller (5). Upon receiving those sig-
4. Limit switch nals, power train controller (5) sends signals to
5. Power train controller the EPC valve of the control valve.
6. Rod (From brake pedal) q Brake pedal (7) receives signals from potenti-
7. Brake pedal ometer (1) through rod (6). Then, power train
controller (5) sends signals to the brake valve
Positions of levers and pedals to operate the brake.
A: Neutral q Lock lever (2) is connected to limit switch (4)
B: Forward straight and used as the parking brake lever, too.
C: Reverse straight When it is in lock position "J", power train con-
D: Left turn troller (5) does not send turning signals to the
E: Right turn EPC valve of the control valve.
F: Brake OFF
G: Brake ON
H: Free
J: Lock
D155A-6 17
Steering unit 1
(Bevel gear shaft, steering clutch and steering brake)
18 D155A-6
A: To transmission case
B: From scavenging pump and steering lubrication pump
C: R.H. brake oil pressure pickup port (RB)
D: L.H. brake oil pressure pickup port (LB)
E: From pin puller solenoid valve (drain)
F: R.H. steering clutch oil pressure pickup port (RC)
G: L.H. steering clutch oil pressure pickup port (LC)
D155A-6 19
20 D155A-6
D155A-6 21
1. Bevel gear rotation sensor

2. Drain plug
3. Drain valve
4. Steering clutch and brake control valve
5. Case
6. Brake cylinder
7. Brake spring
8. Brake piston
9. Brake plate
10. Brake disk
11. Brake drum
12. Brake hub
13. Tube
14. Bevel gear shaft
15. Bevel gear (Number of teeth: 32)
16. Clutch hub
17. Clutch plate
18. Clutch disk
19. Clutch piston
20. Clutch spring
21. Clutch cylinder
22. Clutch drum
23. Clutch stopper
24. Shim B (For bevel gear adjustment)
25. Bevel gear shaft bearing B
26. Bevel gear shaft bearing A
27. Shim A (For bevel gear adjustment)
28. Retainer
29. Spacer
30. Shim C (For bevel pinion adjustment)
31. Gauge
32. Bevel pinion bearing
33. Nut (For bevel pinion)
34. Bevel pinion (Number of teeth: 17)
22 D155A-6
General
Bevel gear shaft Steering brake

q Using the meshing of bevel pinion (34) and q The steering brake being connected to the
bevel gear (15), the bevel gear shaft system R.H. and L.H. steering clutches damps the
directs the power being transmitted through machine by damping the power from the steer-
the engine, torque converter and transmission ing clutch to the final drive.
orthogonally in the right and left directions and, q The wet type multi-disk clutch and spring-
at the same time, reduces the revolution. boosted type are employed for the steering
q A spiral bevel gear is employed for bevel pin- clutch. It hydraulically actuates steering brake
ion (34) and bevel gear (15) on the bevel gear control valve (4) through the operation of its
shaft system. And as for the lubrication, spat- brake pedal.
tering by use of the oil from the steering lubri- q The forced lubrication approach employed for
cation pump and scavenging pump is the lubrication conducts the oil from the steer-
employed. ing lubrication pump and scavenging pump to
q The bevel gear shaft system is consisted of brake disk (10) and brake plate (9) through
bevel pinion (34), bearing (32) and cage (31) passage in the steering case, case (5) and
supporting the bevel pinion, bevel gear (15) to brake drum (11).
be meshed with the bevel pinion, bevel gear q When the engine is stopped, back pressure of
shaft (14) and bearings (25) and (26) and brake piston (8) drops without pressing the
retainer (28) supporting the bevel gear shaft. brake piston, setting the steering brake to
"actuated" state. However, if the engine is
Steering clutch restarted and oil pressure in the circuit
q The steering clutch is connected to both ends increases, the brake is "released". Thus, the
of bevel gear shaft (14) through the spline. It parking brake must be set to the "lock" posi-
changes the machine turn direction by con- tion.
necting or disconnecting the power from bevel q The steering brake is consisted of clutch cylin-
gear shaft (14) to the final drive. der (21), clutch drum (22) (connected to brake
q The wet type multi-disk clutch and spring- hub (12)), brake disk (10), brake plate (9),
boosted type are employed for the steering brake drum (11), brake piston (8), brake spring
clutch. It is hydraulically actuated, in conjunc- (21) and brake cylinder (6) supporting above
tion with the brake, by the pressurized oil from components. Brake drum (11) is fixed to the
the steering clutch valve. steering case.
q The lubrication system employed the forced
lubrication approach by use of the oil from the
steering lubrication pump and scavenging
pump.
q The steering clutch is consisted of clutch hub
(16) (connected to the bevel gear shaft), clutch
disk (18), clutch plate (17), clutch drum (22),
clutch piston (19), cluch spring (20), and clutch
cylinder (21) supporting above components.
Clutch drum (22) and the clutch cylinder being
connected to the brake hub transmit the power
from the bevel gear shaft to the output shaft
through brake hub (12).
D155A-6 23
24 D155A-6
Unit: mm
Replace
Thickness 4.5 ±0.1 4.0
1 Steering brake disk
Repair or
Strain — 0.05 0.14
replace
Thickness 2.9 ±0.1 2.6 Replace

2 Steering brake plate
Repair or
Strain — 0.05 0.15
replace
3 disks and 5 plates for steering 41.5 ±0.33 38.3
brake Replace
Thickness 4.5 ±0.1 4.1
4 Steering clutch disk
Repair or
Strain — 0.05 0.14
replace
Thickness 2.9 ±0.1 2.6 Replace

5 Steering clutch plate
Repair or
Strain — 0.05 0.15
replace
6 disks and 5 plates for steering 37.0 ±0.32 34.3
clutch
Inside diameter of brake cylin- +0.040
125 125.5
der seal ring contact surface +0.035
7 –0.08
Width 5 4.2
Wear of brake hub –0.13
seal ring
Thickness 4.5 ±0.15 4.05
Large
+0.081
Inside diameter of diamete 280 280.1
+0.081
contact surface of portion
8
seal ring on steering Small
brake piston +0.072
diameter 220 220.1
+0.081
portion
Large
+0.081
Inside diameter of diamete 280 280.1 Replace
+0.081
contact surface of portion
9
seal ring on steering Small
clutch piston +0.072
diameter 220 220.1
+0.081
portion
Steering brake spring (2 springs Free length Free length
10 length load load
make up a set)
35.7 kN 33.9 kN
33 19.6 32.0
{3,640 kg} {3,460 kg}
Steering clutch spring (2 springs 35.7 kN 33.9 kN
11 33 19.6 32.0
make up a set) {3,640 kg} {3,460 kg}
Clearance between bevel gear size Shaft Hole clearance limit
12
and reamer bolt
+0.019 +0.027 -0.019 –
16 0.026
+0.001 +0.027 0.026
D155A-6 25
Unit: mm
Backlash between brake hub
13 0.23 – 0.42
and disk
Backlash between brake drum
14 0.23 – 0.42
and plate
Replace
Backlash between clutch hub
15 0.23 – 0.42
and disk
Backlash between clutch drum
16 0.23 – 0.42
and plate
Standard shim thickness of
17 2.0
retainer A Adjustment of
Standard shim thickness of shims
18 2.0
retainer B
Rotary torque: 4.2 – 5.1 Nm {0.43 – 0.52 kgm}
Preload of bevel gear shaft
19 (22.6 – 26.5 Nm {2.3 – 2.7 kgm} at the bevel gear addendum Adjusting
bearings A and B
when the bevel pinion gear is not meshed)
26 D155A-6
Unit: mm
Backlash between bevel gear Adjust or
1 0.25 – 0.33
and bevel pinion replace
Standard shim thickness of Adjustment of
2 2.0
cage shims
D155A-6 27
Operation of the steering clutch
When the steering clutch is turned "on" When the steering clutch is turned "off"
Oil pressure to the back side of clutch piston (19) is Oil being pressure-fed to the back side of clutch
stopped, and the repulsion of clutch spring (20) is piston (19) releases clutch hub (16).
used for fixing clutch hub (16).
Power from transmission
Power from transmission O
O Bevel pinion
Bevel pinion O
O Bevel gear
Bevel gear O
O Bevel gear shaft (14)
Bevel gear shaft (14) O
O Clutch hub (16)
Clutch hub (16)
O
Clutch drum (22)
O
Brake hub (12)
O
Output shaft
O
Final drive
28 D155A-6
Operation of steering brake
When the steering brake is "released" When the steering brake is "actuated"
(When PCCS lever is in "operation")
q When the PCCS lever is set to the "neutral"

position and the brake pedal is not pressure, q As the PCCS lever is operated in the right or
the brake pressure alone is set to the maxi- left, the steering clutch is "disengaged" by the
mum pressure by the steering control valve. steering control valve and, at the same time,
Thus, oil pressure works on the back side of draining of oil to the back side of brake piston
brake piston (8) as soon as the steering clutch (8) is started.
is "engaged". q At this point, brake piston (8) is pushed back
q At this point, brake piston (8) compresses and rightward by the tension of brake spring (7),
moves brake spring (7) leftward with the pressure-bonding disk (10) and plate (9)
increased oil pressure, relieving the pressure- against brake drum (11).
bonding force of disk (10) and plate (9). q Brake piston (8) and brake drum (11) are fixed
q The power being transmitted from bevel gear to the steering case.
shaft (14) to brake hub (12) through the steer- q Pressure-bonding disk (10) and plate (9) stops
ing clutch is then transmitted to the final drive the inertia-based rotation of brake hub (12)
through the output shaft. and output shaft even if the steering clutch is
"disengaged".
q Adjustment of the turn radius and swing
becomes available by adjusting the braking
force through controlling the oil pressure to the
back side of brake piston (8) corresponding to
the rightward and leftward stroke of the PCCS
lever.
D155A-6 29
When the steering brake is "applied"

(When the PCCS lever is in "neutral" and brake
pedal is "depressed")
q If the brake pedal is pressed while the PCCS

lever is at "neutral", the steering control valve
starts draining the oil on the back side of brake
piston (8), "engaging" the steering clutch and
actuating the steering brake. Thus, rotation of
the output shaft is stopped.
q Adjusting the braking force becomes available
by controlling the oil pressure to the back side
of brake piston (8) corresponding to the stroke
of the brake pedal.
30 D155A-6
D155A-6 31
Steering control valve 1
32 D155A-6
P: From power train pump General

L: Scavenging pump q The steering control valve controls the steering
From steering lubrication pump clutch and steering brake by use of 4 ECMVs,
PS: To pin puller solenoid valve parking brake solenoid valve and sudden stop
LB: To L.H. steering brake prevention valve installed on the valve seat.
LL: To L.H. steering brake lubrication q The steering control valve is provided in the
LC: To L.H. steering clutch circuit across the power train pump, steering
RB: To R.H. brake clutch and steering brake piston. It is consisted
RL: To R.H. brake lubrication of the steering clutch ECMV (R.H. and L.H.)
RC: To R.H. steering clutch and steering brake ECMV (R.H. and L.H.).
BSL: To bevel gear shaft and bearing lubrication q The steering control valve conducts the oil
BGL: To bevel gear lubrication from the power train pump to the steering
DLB: Drain (L.H. steering brake) clutch and steering brake to control the R.H.
DRB: Drain (R.H. steering brake) and L.H. disk clutches and the disk brake.
DLC: Drain (L.H. steering clutch) q If the PCCS lever is leaned to the right or left,
DRC: Drain (R.H. steering clutch) the steering clutch is disengaged. The steering
DB: Drain (Sudden stop prevention valve) brake will operate by further leaning the PCCS
DPB: Drain (Parking brake) lever.
PLB: L.H. steering brake oil pressure pickup port q The controller sends signals to each ECMV
PRB: R.H. steering brake oil pressure pickup port according to the right or left stroke of the
PLC: L.H. steering clutch oil pressure pickup port PCCS lever and adjusts the gradual or sharp
PRC: R.H. steering clutch oil pressure pickup port turns.
q As the brake pedal is pressed, the controller
1. L.H. steering brake ECMV sends the command, corresponding to the
2. R.H. steering brake ECMV pedal stroke, to the steering brake ECMV to
3. L.H. steering clutch ECMV actuate the R.H. and L.H. brakes and, thus, to
4. R.H. steering clutch ECMV apply braking to the machine.
5. Steering oil filter q The controller, which is electrically connected
6. Valve seat to the PCCS lever and brake pedal, operates
7. Parking brake solenoid valve the steering clutch and steering brake by con-
8. Sudden stop prevention valve trolling each ECMV and solenoid valve.
9. Check valve q The sudden stop prevention valve is installed
to prevent the machine from stopping sud-
denly, when an abnormality takes place in the
electric system.
q As the parking brake lever is set to the "lock"
position, the controller sends the signal to the
parking brake solenoid valve to drain the oil
between the R.H. and L.H. steering brake
ECMVs and brake piston in order for actuating
the brake. The parking brake solenoid valve is
electrically connected to the brake pedal, too.
D155A-6 33
Steering clutch ECMV, steering brake ECMV 1

a ECMV: Abbreviation for Electronic Control Modulation Valve
a Don't try to disassemble it since adjustment for maintaining the performance will be needed.
A: To clutch or brake General

P: From pump q Each ECMV keeps the steering clutch oil pres-
S: To parking brake solenoid valve sure and steering brake oil pressure to the set
T: Drain pressure and furthermore changes the circuit
DR: Drain to the piston chamber of the steering clutch
P1: Brake oil pressure pickup port and steering brake.
1. Fill switch connector

2. Proportional solenoid connector
3. Pressure detection valve
4. Fill switch
5. Proportional solenoid
6. Pressure control valve
7. Name plate (*1)
*1:
The clutch used Name plate stamp
Steering clutch,
R*******
Steering brake
34 D155A-6
Outline of ECMV
q The ECMV consists of 1 pressure control valve
and 1 fill switch.
q Pressure control valve
A proportional solenoid in this valve receives a
current sent from the controller and this valve
converts it to an oil pressure.
q Fill switch
This is a switch to detect that a clutch or brake
is filled with oil and has the following functions.
1. At the moment when the clutch or brake is
filled with oil, the fill switch outputs the signal
(fill signal) to the controller to notify the finish-
ing of filling.
2. While the oil pressure is applied to the clutch
or brake, the fill switch outputs the signal (fill
signal) to the controller to notify the presence
of the oil pressure.
ECMV and proportional solenoid

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

q For each ECMV, 1 fill switch is installed.
If the clutch is filled with oil, the fill switch
is turned "ON" by the pressure of the
clutch. The oil pressure is built up accord-
ing to this signal.
Operation of ECMV
q The ECMV is controlled by the command
current from the controller to the propor-
tional solenoid and the fill switch output
signal.
D155A-6 35
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 are "released", parking brake is "released")
q When the PCCS lever is in "neutral" position q The oil in port (Pb) of the brake ECMV flows in
and the brake pedal is "released", proportional port (E) and pushes valve (7) to the left to con-
solenoid (1) of the clutch ECMV is demagne- nect port (Pb) with port (B) and disconnect port
tized and the sealing part of ball (2) is opened. (B) from port (Dr). At this time, the oil flows in
q The oil from the power train pump flows the back pressure port of the brake piston. As
through port (Pc) of the clutch ECMV to orifice the oil pressure rises, the brake piston is
(a), then it is drained through the sealing part pushed to the left to compress the brake
of ball (2). spring, then the brake is "released".
q Valve (3) is moved to the right by the tension of q When the parking brake lever is set in the
spring (4) to disconnect port (Pc) from port (C), "free" position, the pilot pressure of brake
and connect port (C) with port (Dr). At this ECMV port (S) remains, because the parking
time, the oil from the back pressure port of the brake solenoid valve is de-energized.
clutch piston is drained through port (C) and
the clutch is turned "on" by the tension of the
clutch spring.
q The oil pressure in the brake circuit, etc. is
secured by orifice (a).
q Proportional solenoid (5) of the brake ECMV is
energized and pushes ball (6) to the left and
closes the sealing part.
36 D155A-6
When the PCCS lever is "operated to the left halfway", brake pedal is "released", and parking brake
lever is in "free" position: Gradual left turn
(L.H. brake is "half released", R.H. brake is "released", parking brake is "released")
q When the PCCS lever is "operated to left half- solenoid (5) according to the stroke of the
way" and the brake pedal is "released", propor- PCCS lever.
tional solenoid (1) of the L.H. clutch ECMV is q Proportional solenoid (5) generates the propul-
energized and the sealing part of ball (2) is sion force in proportion to the command cur-
closed. rent. This propulsion force is balanced with the
q The oil from the power train pump flows sum of the propulsion force generated by the
through port (C) of the clutch EMCV and orifice oil pressure in the back pressure port of the
(a) to port (F) and pushes valve (3) to the left to brake piston and the tension of spring (8), then
connect port (Pc) with port (C) and disconnect the brake pressure is set up to adjust the brake
port (C) from port (Dr). At this time, the oil flows force.
in the back pressure port of the clutch piston. q Accordingly, if the stroke of the PCCS lever is
As the oil pressure rises, the clutch piston is short, the oil pressure after port (B) is set high
pushed to the left to compress the clutch and the brake is turned from "released" to "half
spring, then the clutch is turned "off". released". If the stroke of the PCCS lever is
q Proportional solenoid (5) of the brake ECMV is long, the oil pressure after port (B) is set low
energized and pushes ball (6) to the left and and the brake is turned from "half released" to
closes the sealing part. "applied".
q The oil in port (Pb) of the brake ECMV flows in q When the parking brake lever is set in the
port (E) and pushes valve (7) to the left. As for "free" position, the pilot pressure of brake
the oil pressure after port (B), the controller ECMV port (S) remains, because the parking
outputs the command current to proportional brake solenoid valve is de-energized.
D155A-6 37
When the PCCS lever is "operated fully to the left", brake pedal is "released", and parking brake lever
is in "free" position: Sharp left turn
(L.H. clutch is turned "off", L.H. brake is "applied", R.H. clutch is turned "on", R.H. brake is "released", and
parking brake is "released".)
q When the PCCS lever is shifted from "operated q When the parking brake lever is set in the
to left halfway" to "operated to left fully", pro- "free" position, the pilot pressure of brake
portional solenoid (5) of the L.H. brake ECMV ECMV port (S) remains, because the parking
is demagnetized and the sealing part of ball (6) brake solenoid valve is de-energized.
is fully opened.
q Since the oil in port (E) is drained through the
sealing part, valve (7) is moved to the right by
the tension of spring (8) to disconnect port (Pb)
from (B) and connect port (B) with port (Dr). At
this time, the oil from the back pressure port of
the brake piston is drained through port (B)
and the brake is turned "applied" by the ten-
sion of the brake spring.
q The oil from the power train pump flows
through port (Pb) of the brake ECMV and ori-
fice (b), then it is drained through sealing part
of ball (6).
q The oil pressure in the clutch circuit, etc. is
secured by orifice (b).
38 D155A-6
When the PCCS lever is in "neutral", brake pedal is "depressed", and parking brake lever is in "free"
position: Stop
(L.H. and R.H. brake are "operated", parking brake is "released")
q When the brake pedal is depressed fully, pro- q When the brake pedal is depressed fully, the
portional solenoids (5) of L.H. and R.H. brake brake pedal switch is turned "ON", and the
ECMV are demagnetized to open the sealing parking brake solenoid valve is energized to
part of ball (6). drain the pilot pressure of the brake ECMV port
q The controller outputs the command current to (S).This carries out the same function as when
proportional solenoids (5) according to the the parking brake lever is set at the "lock" posi-
brake pedal stroke. tion.
q Proportional solenoid (5) generates the propul-
sion force in proportion to the command cur-
rent. This propulsion force is balanced with the
sum of the propulsion force generated by the
oil pressure in the back pressure port of the
brake piston and the tension of spring (8), then
the brake pressure is set up to adjust the brake
force.
q Since the PCCS lever is in "neutral" position,
proportional solenoids (1) of L.H. and R.H.
clutch ECMV are demagnetized and L.H. and
R.H. clutch are turned "on".
D155A-6 39
Parking brake solenoid valve 1
P: From brake ECMV

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

2. Brake pedal solenoid valve
3. Connector for parking brake lever solenoid valve
4. Connector for brake pedal solenoid valve
Solenoid valve
5. Coil (ON-OFF type)
6. Push pin
7. Spring
8. Spool
9. Body
40 D155A-6
When PCCS lever is in "neutral" position, brake pedal is "released", and parking brake lever is in
"lock" position: Parking
(L.H. and R.H. brake are "operated", parking brake is "operated")
q When the parking brake lever is in the "lock" q When the parking brake lever is in the "free"
position, the parking brake lever switch is position, the parking brake lever switch is
turned "ON" and coil (1) of the parking brake "OFF" and coil (1) of the parking brake sole-
solenoid valve is energized. noid valve is de-energized.
q Spool (3) is pushed to the right direction by q Spool (3) is returned to the left, and close port
push pin (2), then port (P) and (T) are opened (P) and (T) to remain the pilot pressure of the
to drain the pilot pressure of the L.H. and R.H. L.H. and R.H. brake ECMV.
brake ECMV. q The oil pressure from the brake ECMV is
q The oil which had flown into the brake piston applied to the back pressure port of the brake
back pressure port is drained through the piston, and brake is "released".
brake ECMV.
q The oil pressure in the back pressure port of
the brake piston continues to decrease, then
the brake is fully "applied" and that situation is
kept.
q When the engine is started again, as port (P)
and (T) are still opened, the brake is continu-
ously "applied".
D155A-6 41
Sudden stop prevention valve 1
A: From power train pump

B: From brake ECMV
dr1: Drain
dr2: Drain
1. Sudden stop prevention valve
EPC valve
2. Coil (proportional type)
3. Push pin
4. Valve
5. Ball
6. Spool
7. Body
42 D155A-6
General
q The sudden stop prevention valve is installed
to prevent the machine from stopping suddenly
when an abnormality takes place in the electric
system.
q Sudden stop prevention valve (1) is installed in
the drain circuit of the brake ECMV so that the
sudden oil pressure drop of port (DR) and con-
sequently the sudden brake can be avoided
when coil (2) of brake ECMV is de-energized.
q If an abnormality takes place in the electric
system, also coil (3) of the sudden stop pre-
vention valve (1) is de-energized. Then, the oil
of port (DR) is drained through orifice (a) so
that the brake is applied gradually.
D155A-6 43
44 D155A-6
Final drive 1
Outline
q The final drive is a single stage spur gear, sin-
gle stage planetary gear reduction type. The
lubrication is of splash type using the rotation
of the gears. The final drive can be removed
and installed as a single unit.
q Floating seal (1) is installed to the rotating slid-
ing portion of the sprocket to prevent the entry
of dirt or sand and to prevent leakage of lubri-
cating oil.
D155A-6 45
46 D155A-6
1. Floating seal 10. No.1 pinion

2. Sun gear 11. Final drive case
3. Carrier 12. Bearing cage
4. Sprocket boss 13. No.1 gear
5. Sprocket teeth 14. No.1 gear hub
6. Cover 15. Shaft
7. Planetary gear 16. Wear guard
8. Ring gear 17. Pivot shaft
9. Cover
Unit: mm
Backlash between No.1 pinion Standard clearance Clearance limit
18
and No.1 gear 0.25 – 0.77 0.77
Backlash between sun gear Replace
19 0.20 – 0.55 0.55
and planetary gear
Backlash between planetary
20 0.22 – 0.71 0.71
gear and ring gear
Outside diameter of No.1 pin- Repair or
21 –0.087
ion oil seal contact surface 95 94.913 replace
–0.087
Thickness of thrust collar of
22 23 22.95
inner body roller bearing
Clearance between outer size clearance limit
Shaft Hole
diameter of planet gear shaft
23
and inner diameter of carrier (Max.
–0.015 –0.009 - 0.024 – Replace
hole. (Small diameter) 68.262 clearance)
–0.034 –0.039 + 0.025
+ 0.025
Clearance between outer
diameter of planet gear shaft –0.036 –0.066 - 0.065 –
24 90 – 0.008
and inner diameter of carrier –0.058 –0.101 - 0.008
hole.(Large diameter)
Standard shim thickness for
25 2 Adjust
No.1 pinion bearing cage
Standard size Repair limit Repair or
26 Wear of wear guard
67 21 replace
D155A-6 47
Path of power transmission
q The power from the bevel gear shaft and steer- Then, the rotating force of sun gear (2) forms
ing clutch is transmitted to 1st pinion (10) to the rotating force of carrier (3), which supports
rotate 1st gear (13) meshed with the 1st pinion the planetary gear (7), via shaft (15), and is
and sun gear (2) meshed with the 1st gear. transmitted to sprocket boss (4).
The rotation of sun gear (2) is transmitted to The rotating direction of carrier (3) is the same
planetary gear (7). Since ring gear (8) meshed with sun gear (2).
with the planetary gear is fixed to cover (6), the The rotational force transmitted to sprocket
planetary gear (7) rotates along the ring gear boss (4) is further transmitted to sprocket teeth
(8) and revolves around the sun gear (2). (5).
48 D155A-6
D155A-6 49
Sprocket 1
Unit: mm
Standard clearance Repair limit
1 Wear of sprocket tooth tip
351 339
2 Wear of sprocket tooth root 21.7 15.5
Rebuid or
Wear of width of sprocket replace
3 83 75
tooth tip
Wear of width of sprocket
4 105 95
tooth root
50 D155A-6
Sprocket tooth shape of full scale
D155A-6 51
D155A-6 Bulldozer
© 2007 KOMATSU
All Rights Reserved
52 D155A-6
SEN02864-00
D155A-6

D155A-6 85001 and up

Undercarriage and frame
Track frame ..................................................................................................................................................... 2
Recoil spring ................................................................................................................................................... 4
Idler ................................................................................................................................................................. 6
Track roller ...................................................................................................................................................... 8
Carrier roller .................................................................................................................................................. 10
Track shoe .................................................................................................................................................... 12
Main frame .................................................................................................................................................... 18
Suspension ................................................................................................................................................... 20
D155A-6 1
Track frame 1
1. Equalizer bar Outline

2. Pivot shaft q The track rollers are mounted on an K-shaped
3. Idler bogie. This increases the actual ground con-
4. Track frame tact area between the track shoes and the
5. Carrier roller ground on rough surfaces, and helps increase
the drawbar pull.
6. Sprocket
q The K-shaped bogies are equipped with rubber
7. Sprocket cover guard pads to absorb the shock from the ground sur-
8. Track roller face.
Track roller, bogie

Track roller flange type arrangement
1st 2nd 3rd 4th 5th 6th 7th
S D D D D D S
D: Double
S: Single
2 D155A-6
Unit: mm
Item Repair limit
Curvature 7 (over length of 3,000) Correct or
4 Deformation of track frame
Twisting 3 (over length of 300) replace
Dents (pipe portion) 12
D155A-6 3
Recoil spring 1
1. Yoke Outline
2. Dust seal q Recoil spring (4) is used to adjust the track ten-
3. Rod sion by pumping in or releasing grease from
4. Recoil spring lubricator (6) to move rod (3) forward or back-
5. Wear ring ward. The recoil spring also acts to dampen
any sudden shock brought to bear on the idler.
6. Lubricator
7. Nut
8. Housing
9. Cylinder
10. Holder
11. Bushing
4 D155A-6
Unit: mm
Press-fitting force for
1 392 kN {40 ton} Adjust
idler yoke
Clearance between rod size Shaft Hole clearance limit
11
and bushing
–0.036 +0.277 0.098 –
110 1.0
–0.090 +0.062 0.367
Standard size Repair limit Replace
4 Recoil spring length load load
298 kN 274 kN
734 597 687
{30,388 kg} {27,900 kg}
D155A-6 5
Idler 1
6 D155A-6
Unit: mm
No. C heck item Criteria Remedy
1 Outer diameter of protrusion
850 —
2 Outer diameter of tread 800 781
Rebuild or
3 Depth of tread 25 34.5
replace
4 Thickness of tread 21 11.5
5 Overall width 245 —
6 Width of tread 62 —
Clearance between shaft size Shaft Hole clearance limit
7
and bushing
–0.210 +0.255 0.430 –
85 —
–0.260 +0.220 0.515 Replace
Tolerance bushing
Standard Standard Interference
Interference between idler size Shaft Hole interference limit
8
and bushing
+0.130 +0.100 0.02 –
135 —
+0.080 –0.050 0.18
9 Shaft flange width
–0 — Replace
20 –0.05
10 Play of shaft in axial direction 0.49 – 0.72
D155A-6 7
Track roller 1
8 D155A-6
Unit: mm
No. C heck item Criteria Remedy
Outer diameter of flange Standard size Repair limit
1
(outside flange) 298 —
Outer diameter of flange
2 282 —
(inside flange)
3 Outer diameter of tread 255 230
4 Thickness of tread 60 47.5
5 Overall width 294 —
Rebuild or
Width of tread
6 64 — replace
(single flange)
Width of tread
7 62 —
(double flange)
Flange width
8 25 —
(outside of double flange)
Flange width
9 22 —
(inside of double flange)
10 Shaft flange width 20 —

Clearance between shaft size Shaft Hole clearance limit Replace
11
and bushing bushing
–0.210 +0.255 0.430 –
85 —
–0.260 +0.220 0.515
Standard Tolerance Standard Interference
Interference between bushing size Shaft Hole interference limit
12 Replace
and roller
+0.130 +0.063 0.017 –
135 —
+0.080 –0.020 0.150
Standard size Clearance limit Adjust or
13 End play
0.5 – 0.75 — replace
D155A-6 9
Carrier roller 1
10 D155A-6
Unit: mm
1 Outer diameter of flange
220 —
2 Outer diameter of tread 190 167 Rebuild or
3 Width of tread 63 — replace
4 Thickness of tread 37.5 26
5 Width of flange 21 —
Tolerance Standard
Standard size
Interference between Shaft Hole interference
6
shaft and ring
+0.166 +0.030
70 0.090 – 0.166
+0.120 +0.030
Tolerance Standard
Standard size Replace
Clearance between Shaft Hole clearance
7
shaft and support
–0.2 +0.300
68 0 – 0.5
–0.2 +0.030
Standard clearance
8 Play of roller in axial direction
0.010 – 0.230
D155A-6 11
Track shoe 1
Dry type
a P portion shows the link of bushing press fitting end.
12 D155A-6
Unit: mm
1 Link pitch 231.9 (Heavy-duty areas)
228.9
233.9 (Standard areas)
When turned Reverse or
Standard size replace
2 Bushing outside diameter Normal load Impact load
81 75.0 77.0
3 Thickness of bushing metal 15.8 9.8 11.8
4 Link height
144 128 Repair or
replace
Thickness of link metal
5 45.5 29.5
(bushing press-fitting portion)
Tightening torque Additional tightening
6 Shoe bolt (Nm {kgm}) angle (deg.) Retighten
590 ± 60 {60 ± 6} 120 ± 10
Tolerance Standard
Standard size
Interference between Shaft Hole interference
7
bushing and link
+0.404 +0.074
77.0 0.230 – 0.404
+0.304 +0.074
Interference between +0.484 –0.038
8a 48.5 0.372 – 0.584 Adjust or
regular pin and link +0.334 –0.100
replace
8b 48.5 0.238 – 0.330
master pin and link +0.200 –0.100
Standard clearance
9 Clearance between links One side Both side
1.4 2.8
D155A-6 13
Sealed and lubricated track
a P portion shows the link of bushing press fitting end.
14 D155A-6
Unit: mm
1 Link pitch
228.9 231.9
When turned Reverse or
Standard size
2 Bushing outside diameter Normal load Impact load replace
81 72.5 75.0
3 Thickness of bushing metal 15.8 7.3 9.8
4 Link height
144 128 Repair or
replace
Thickness of link metal
5 45.5 29.5
(bushing press-fitting portion)
Tightening torque Additional tightening
a. Regular link (Nm {kgm}) angle (deg.)
6 Shoe bolt Retighten
590 ± 60 {60 ± 6} 120 ± 10
b. Master link 590 ± 60 {60 ± 6} 180 ± 10
Standard Tolerance Standard
Interference between size Shaft Hole interference
7
bushing and link
+0.404 +0.074
77.0 0.230 – 0.404
+0.304 +0.074
Adjust or
8 48.5 0.372 – 0.584 replace
regular pin and link +0.334 –0.100
Standard clearance
9 Clearance between links One side Both side
1.4 2.8
D155A-6 15
Single shoe, heavy duty shoe
Unit: mm
Height of
1 single 80 30
grouser
Repair or
heavy duty 80 30
replace
Overall height single 97 47
2
of shoe heavy duty 99 49
16 D155A-6
D155A-6 17
Main frame 1
18 D155A-6
1. Main frame
2. Cage
3. Clamp
4. Cover
5. Seal
6. Coupling
7. Cap
8. Plate
Unit: mm
Clearance between size clearance limit
Shaft Hole
9 equalizer bar shaft Replace
and bushing –0.036 +0.213 0.165 –
95 1.0
–0.090 +0.129 0.303
Press-fitting force for
10 equalizer bar shaft 29.42 – 68.65 kN {3 – 7 ton} Adjust
mounting bushing
D155A-6 19
Suspension 1
20 D155A-6
1. Equalizer bar 6. Pivot shaft

2. Pivot shaft assembly 7. Seal cage
3. Cover 8. Seal
4. Thrust plate 10. Side pin
5. Thrust plate 11. Center pin
Unit: mm
Press-fitting force for side
9 pin bushing 27.46 – 64.7 kN {2.8 – 6.6 ton}
—
Press-fitting force for center
12 pin bushing 47.07 – 131.41 kN {4.8 – 13.4 ton}

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

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

shaft and seal stopper ring +0.043 –0.093 0.176

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

shaft and bushing (inner) –0.208 +0.025 0.303
Outline
q The front of the track frame rocks up and down
using the rear pivot shafts (6) as a fulcrum.
Equalizer bar (1) rocks using center pin (11) as
a fulcrum. The left and right track frames are
connected by side pin (10).
D155A-6 21
D155A-6 Bulldozer
© 2007 KOMATSU
All Rights Reserved
22 D155A-6
SEN02865-02
D155A-6

D155A-6 85001 and up

Hydraulic system
Work equipment hydraulic piping diagram ...................................................................................................... 2
Work equipment control piping diagram ......................................................................................................... 6
Work equipment control .................................................................................................................................. 8
Hydraulic tank and filter ................................................................................................................................ 10
Accumulator .................................................................................................................................................. 12
PPC valve ..................................................................................................................................................... 13
Work equipment lock valve ........................................................................................................................... 26
Control valve ................................................................................................................................................. 28
Work equipment cylinder .............................................................................................................................. 50
Piston valve................................................................................................................................................... 52
Quick drop valve ........................................................................................................................................... 54
Self pressure reducing valve......................................................................................................................... 55
D155A-6 1
Work equipment hydraulic piping diagram 1

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

2. R.H. blade lift cylinder 6. Hydraulic pump
3. Accumulator 7. L.H. blade lift cylinder
4. Control valve 8. Oil cooler
2 D155A-6
Multi-shank ripper
1. Control valve
2. Divider block
3. Ripper lift cylinder
4. Ripper tilt cylinder
D155A-6 3
Giant ripper
1. Control valve
2. Divider block
3. Ripper lift cylinder
4. Pin puller cylinder
5. Ripper tilt cylinder
6. Pin puller solenoid valve
4 D155A-6
D155A-6 5
Work equipment control piping diagram 1

Blade, ripper control
Serial No.: 85001 – 85024
1. Accumulator 3. Work equipment lock valve

2. Control valve 4. Self pressure reducing valve
6 D155A-6
Serial No.: 85025 and up
1. Accumulator 4. Self pressure reducing valve

2. Control valve 5. Filter
3. Work equipment lock valve
D155A-6 7
Work equipment control 1
3
4
2
1
AJG00278
8 D155A-6
1. Work equipment lock lever

2. Blade PPC valve
3. Ripper PPC valve
4. Work equipment lock switch
5. Control valve
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
(with variable ripper)
L : Ripper INCREASE TIP ANGLE
(with variable ripper)
M : FREE
N : LOCK
Outline
q The work equipment control employs a PPC
system which uses a PPC valve to move the
spools of the control valve.
D155A-6 9
Hydraulic tank and filter 1
1. Pressure valve 7. Strainer

2. Drain valve 8. Suction valve
3. Drain plug 9. Spring
4. Cover 10. Hydraulic filter element
5. Cover 11. Oil filler cap
6. Hydraulic tank 12. Sight gauge
10 D155A-6
Specified
value
Tank capacity (l) 125
Hydraulic Hi (l) 95
Level
tank inside Center (l) 85
tank
Low (l) 75
Cracking pressure 16.7 ± 2.5
(kPa {kg/cm2}) {0.17±0.025}
Breather
Vacuum valve actuating 2 ± 0.3
pressure (kPa {kg/cm2}) {0.02±0.003}
Cracking pressure 147 ± 29.4
(kPa {kg/cm2}) {1.5±0.31}
Hydraulic Mesh size (µ m) 20/10/5
filter
Filtering area (cm2) 13,600
Filtering oil flow (l/min) 550
Mesh size (µ m) 105
Strainer
Filtering area (cm2) 1,850
D155A-6 11
Accumulator 1 Function
q The accumulator is installed between the
For EPC valve redusing valve and the EPC valve. Even if the
engine is started with the work equipment still
raised, the pressure of the nitrogen gas com-
pressed inside the accumulator sends the pilot
pressure to the control valve to actuate it and
enable the work equipment to move down
under its own weight.
Operation
q After the engine is stopped, when the EPC
valve is at neutral, chamber (A) inside the blad-
der is compressed by the oil pressure in cham-
ber (B).
q When the EPC valve is operated, the oil pres-
sure in chamber (B) goes below 2.9 MPa {30
kg/cm2}, and the pressure of the nitrogen gas
in chamber (A) expands the bladder, so the oil
in chamber (B) acts as the pilot pressure and
actuates the main control valve.
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications
Type of gas: Nitrogen
Gas volume: 300 cc
Max. actuation pressure: 3.14 MPa {32 kg/cm2}
Min. actuation pressure: 1.18 MPa {12 kg/cm2}
12 D155A-6
PPC valve 1
Blade PPC valve
P: From self pressure reducing valve P3: To blade tilt valve (LEFT TILT)
P1: To blade lift valve (LOWER, FLOAT) P4: To blade tilt valve (RIGHT TILT)
P2: To blade lift valve (RAISE) T: To tank
D155A-6 13
1. Spool 6. Plate
2. Piston 7. Retainer
3. Disc 8. Body
4. Nut (For connecting lever) 9. Filter
5. Joint
14 D155A-6
Unit: mm
Free length Installed
Installed Installed
Metering spring x Outside Free length
10 length load load
(For ports P3 and P4) diameter
16.7 N 13.3 N
26.53 x 8.15 24.9 —
{1.7 kg} {1.36 kg}
Centering spring 107.9 N 86.3 N Replace
11 48.57 x 15.5 32.5 —
(For ports P3 and P4) {11 kg} {8.8 kg} spring If
Metering spring 16.7 N 13.3 N damaged or
12 26.3 x 8.15 24.1 —
(For port P2) {1.7 kg} {1.36 kg} deformed.
Centering spring 78.5 N 62.8 N
13 43.2 x 15.5 34 —
(For port P2) {8 kg} {6.4 kg}
Centering spring 94 N 75.3 N
14 34.0 x 15.5 31.9 —
(For port P1) {9.6 kg} {7.68 kg}
Metering spring 16.7 N 13.3 N
15 29.27 x 8.15 25.4 —
(For port P1) {1.7 kg} {1.36 kg}
D155A-6 15
Operation
1. When in neutral
1) For lifting blade 2) For tilting blade
q Ports (A) and (B) of the blade lift valve of the- q Ports (C) and (D) of the blade tilt valve of the
control valve and ports (P1) and (P2) of the control valve and ports (P3) and (P4) of the
PPC valve are connected through fine control PPC valve are connected through fine control
hole (f) of spool (1) to drain chamber (D). hole (f) of spool (1) to drain chamber (D).
16 D155A-6
2. When in fine control

(Neutral o Fine control)
q If piston (2) is pushed by disc (3), retainer (7) is
pushed and spool (1) is also pushed down
through metering spring (15).
q Accordingly, fine control hole (f) is discon-
nected from drain chamber (D) and connected
to pump pressure chamber (PP) almost simul-
taneously, and then the pilot oil flows from port
(P1) through fine control hole (f) to port (B).
q If the pressure in port (P1) rises, spool (1) is
pushed back and fine control hole (f) is discon-
nected from pump pressure chamber (PP) and
connected to drain chamber (D) almost simul-
taneously to release the pressure in port (P1).
q As a result, spool (1) moves up and down to
balance the force of metering spring (15) with
the pressure in port (P1).
q The positional relationship between spool (1)
and body (8) [where fine control hole (f) is
between drain chamber (D) and pump pres-
sure chamber (PP)] does not change until
retainer (7) comes in contact with spool (1).
q Since metering spring (15) is compressed in
proportion to the stroke of the control lever, the
pressure in port (P1) rises in proportion to the
stroke of the control lever.
q Accordingly, the control valve spool moves to a
position at which the pressure in port (B) [equal
to the pressure in port (P1)] is balanced with
the force of the control valve spool return
spring.
D155A-6 17
3. When in fine control 4. When lever is operated to stroke end

(When control lever is returned) q If disc (3) pushes down piston (2) and retainer
q If disc (3) begins to return, the force of center- (7) pushes down spool (1), fine control hole (f)
ing spring (14) and the pressure in port (P1) is disconnected from drain chamber (D) and
push up spool (1). connected to pump pressure chamber (PP).
q As a result, fine control hole (f) is connected to q Accordingly, the pilot oil flows through fine con-
drain chamber (D) and the oil in port (P1) is trol hole (f) and port (P1) into port (B) and
released. pushes the control valve spool.
q If the pressure in port (P1) lowers too much, q The oil returning from port (A) flows through
spool (1) is pushed down by metering spring port (P2) and fine control (f’) into drain cham-
(15) and fine control hole (f) is disconnected ber (D).
from drain chamber (D) and connected to
pump pressure chamber (PP) almost simulta-
neously. Then, the pump pressure is applied
until the pressure in port (P1) is restored to the
level corresponding to the position of the lever.
q When the control valve spool returns, the oil in
drain chamber (D) flows in through fine control
hole (f’) of the valve which is not in operation
and then flows through port (P2) into port (A).
18 D155A-6
5. When blade is “floated” 6. When “FLOAT” state of blade is reset

q If piston (2) on the “LOWER” side of port (P1) q Disc (3) is pushed down with a force larger
is pushed down by disc (3), ball (18) touches than the oil pressure in chamber (E) to return
projection (a) of the piston in the middle of the from the “FLOAT” position.
stroke (The detent starts to operate). q As a result, chamber (E) is disconnected from
q If piston (2) is pushed in further, ball (18) passage (d) and connected to the drain cham-
pushes up collar (17) supported on detent ber. Accordingly, the oil pressure in chamber
spring (16) and escapes out to go over projec- (E) is lost and the “FLOAT” state is reset.
tion (a) of the piston.
q At this time, piston (2') on the opposite side is
pushed up by spring (19).
q As a result, the oil in chamber (F) flows
through (b) and (c) to chamber (E) and piston
(2') follows disc (3). Since passage (d) is con-
nected to port (P1), almost the same pressure
is applied to passage (d) and port (P1).
q Chamber (E) is normally connected to drain
chamber (D). If ball (18) goes over projection
(a) of the piston, passage (d) and chamber (E)
are connected and the oil starts flowing.
q At this time, the control valve moves to the
“FLOAT” position and the blade is floated.
q Since piston (2') is pushed up by the pressure
in chamber (E), the “FLOAT” state is kept even
if the lever is released.
D155A-6 19
Ripper PPC valve
P : From self pressure reducing valve

P1 : To ripper tilt valve (OUT)
P2 : To ripper tilt valve (IN)
P3 : To ripper lift valve (LOWER)
P4 : To ripper lift valve (RAISE)
T : To tank
20 D155A-6
D155A-6 21
22 D155A-6
1. Spool
2. Piston
3. Disc
4. Nut (for connecting lever)
5. Joint
6. Plate
7. Retainer
8. Body
9. Filter
Unit: mm
Free length
Centering spring × Outside Free length
10 length load load
(For ports P3 and P4) diameter
Replace spring
55.9 N 44.7 N
50.35 × 15.5 34 — if damaged or
{5.7 kg} {4.56 kg}
deformed.
Centering spring 71.4 N 57.1 N
11 50.05 × 15.5 34 —
(For ports P1 and P2) {7.28 kg} {5.8 kg}
16.7 N 13.3 N
12 Metering spring 26.53 × 8.15 24.9 —
{1.7 kg} {1.36 kg}
D155A-6 23
Operation q Since metering spring (2) is compressed in

1. When in neutral proportion to the stroke of the control lever, the
q Ports (A) and (B) of the control valve and ports pressure in port (P1) rises in proportion to the
(P1) and (P2) of the PPC valve are connected stroke of the control lever.
through fine control hole (f) of spool (1) to drain q Accordingly, the control valve spool moves to a
chamber (D). position at which the pressure in chamber (A)
[equal to the pressure in port (P1)] is balanced
with the force of the control valve spool return
spring.
2. When in fine control

(Neutral o Fine control)
q If piston (4) is pushed by disc (5), retainer (9) is
pushed and spool (1) is also pushed down
through metering spring (2).
q Accordingly, fine control hole (f) is discon-
nected from drain chamber (D) and connected
to pump pressure chamber (PP) almost simul-
taneously, and then the pilot oil flows from port
(P1) through fine control hole (f) to port (A).
q If the pressure in port (P1) rises, spool (1) is
pushed back and fine control hole (f) is discon-
nected from pump pressure chamber (PP) and
connected to drain chamber (D) almost simul-
taneously to release the pressure in port (P1).
q As a result, spool (1) moves up and down to
balance the force of metering spring (2) with
the pressure in port (P1). The positional rela-
tionship between spool (1) and body (10)
[where fine control hole (f) is between drain
chamber (D) and pump pressure chamber
(PP)] does not change until retainer (9) comes
in contact with spool (1).
24 D155A-6
3. When in fine control 4. When lever is operated to stroke end

(When control lever is returned) q If disc (5) pushes down piston (4) and retainer
q If disc (5) begins to return, the force of center- (9) pushes down spool (1), fine control hole (f)
ing spring (3) and the pressure in port (P1) is disconnected from drain chamber (D) and
push up spool (1). connected to pump pressure chamber (PP).
q As a result, fine control hole (f) is connected to q Accordingly, the pilot oil flows through fine con-
drain chamber (D) and the oil in port (P1) is trol hole (f) and port (P1) into chamber (A) and
released. pushes the control valve spool.
q If the pressure in port (P1) lowers too much, q The oil returning from chamber (B) flows
spool (1) is pushed down by metering spring through port (P2) and fine control (f') into drain
(2) and fine control hole (f) is disconnected chamber (D).
from drain chamber (D) and connected to
pump pressure chamber (PP) almost simulta-
neously. Then, the pump pressure is applied
until the pressure in port (P1) is restored to the
level corresponding to the position of the lever.
q When the control valve spool returns, the oil in
drain chamber (D) flows in through fine control
hole (f') of the valve which is not in operation
and then flows through port (P2) into chamber
(B).
D155A-6 25
Work equipment lock valve 1
1. Solenoid
2. Body
3. Spool
Outline
q The work equipment lock valve is installed
between the basic pressure valve and control
valve in the work equipment control circuit. If
the work equipment lock lever is set in the
FREE position, the work equipment lock switch
operates and the work equipment lock valve
opens the work equipment control circuit so
that the operator can operate the work equip-
ment.
Operation
q The solenoid is operated by the electric signal
to move the spool. As a result, the circuit
between port (A) connected to the basic pres-
sure valve and port (B) connected to the con-
trol valve is opened.
26 D155A-6
D155A-6 27
Control valve 1
General view
28 D155A-6
A: Pump pressure pick-up port

A1: To blade tilt cylinder head
A2: To blade lift cylinder head
A3: To ripper lift cylinder head
A4: To ripper tilt cylinder bottom
B: LS pressure pick-up port
B1: To blade tilt cylinder bottom
B2: To blade lift cylinder bottom
B3: To ripper lift cylinder bottom
B4: To ripper tilt cylinder head
C: PPC main pressure port
LS: To pump LS valve
P: From pump
PA1: From blade PPC valve
PA2: From blade PPC valve
PA3: From ripper PPC valve
PA4: From ripper PPC valve
PB1: From blade PPC valve
PB2: From blade PPC valve
PB3: From ripper PPC valve
PB4: From ripper PPC valve
T: To tank
D155A-6 29
Sectional view
(1/3)
30 D155A-6
1. Valve block 5. Blade tilt spool

2. Ripper tilt spool 6. Valve body
3. Ripper lift spool 7. Load check valve
4. Blade lift spool 8. Pressure compensation valve
Unit: mm
Free length
x Outside Free length
9 Spool return spring length load load
diameter
224N 178N
76.3 x 30 68.5 —
{22.8kg} {18.2kg}
If damaged or
140N 112N
10 Spool return spring 51.7 x 31.3 50 — deformed,
{14.3kg} {11.4kg}
replace spring
217N 174N
11 Spool return spring 54.7 x 36.5 33.5 —
{22.1kg} {17.7kg}
12.7N 9.8N
12 Load check valve spring 20.8 x 12.2 13.5 —
{1.3kg} {1.0kg}
193N 154N
13 Unload valve spring 86.7 x 30 66 —
{19.63kg} {15.7kg}
D155A-6 31
(2/3)
32 D155A-6
1. LS check valve 4. Unload valve

2. Main relief valve 5. Suction valve
3. LS relief valve 6. Check valve (built in spool)
Unit: mm
Free length
Installed Installed Installed If damaged or
7 Suction valve spring length load load deformed,
diameter
replace spring
6.37N 5.1N
64.9 x 12.5 56 —
{0.65kg} {0.52kg}
D155A-6 33
(3/3)
34 D155A-6
1. Suction valve
2. Preset check valve
3. LS bypass valve
Unit: mm
Free length
Installed Installed Installed If damaged or
4 Suction valve spring length load load deformed,
diameter
replace spring
5.49N 4.41N
46.8 x 7.5 40.6 —
{0.56kg} {0.45kg}
D155A-6 35
Operation of control valve
Function q When (FO) becomes larger than set load (FS)

q When the main spool is at the HOLD position, of spring (2), the spool moves to the right and
it drains the excess oil discharged by the connects the passage between chamber (A)
pump, and prevents the pressure from being and chamber (B), so the oil from the pump is
formed in the circuit from rising. drained. Therefore, spool (1) is balanced at a
q Use of the CLSS circuit (Closed Center Load position that matches the supply of oil from the
Sensing System) makes it possible to control pump.
the oil flow by adjusting the area of opening of Actually, the amount of oil supplied from the
the spool driven by the PPC valve, regardless pump is small, so the pressure in the circuit is
of the load. almost the same as the set load of spring (2).
Operation of unload valve

q When the main spool is at the HOLD position,
the pump pressure passes from chamber (A)
through oriffice (4) to chamber (D). Chambers
(C) and (C') are connected to the drain circuit.
q When oil is supplied from the pump, the pres-
sure in chamber (D) rises, and spool (1) is
pushed to the right by pressure (FO) which is
determined by the cross-sectional area of pis-
ton (3) receiving the pressure.
36 D155A-6
Control of oil flow

1. At HOLD
a The diagram shows blade right tilt cylinder cir-
cut
Operation
q When the spool is at the HOLD position, the load of spring (4) and moves to the right to the
pump pressure is sent from chamber (A) maximum stroke position. In this condition, the
through the notch in spool (3) of the pressure area of the opening to spool (1) of the blade tilt
compensation valve, and passes through valve is at its minimum.
chamber (B) to chamber (C). Chamber (G) is
drained through chamber (H) to chamber (F).
When this happens, the pump pressure is act-
ing on the left end of spool (3) of the pressure
compensation valve, so it pushes against the
D155A-6 37
2. At blade right tilt
Operation
q When the tilt lever is operated to right tilt, pilot q PLS = differential pressure between ports
pressure (PB1) acts on the right end of spool (K) and (J) = 1.96 MPa {20kg/cm2}
(1) through the PPC valve, and when the pres- q PLS' = differential pressure between ports
sure becomes greater than the set load of (I) and (D)
spring (2), the spool starts to move to the left. It q PLS C PLS'
is balanced at a position corresponding to PPC
output pressure (PB1).
38 D155A-6
q Chamber (C) and chamber (D) are connected, q In addition, pump servo valve (7) is controlled
and the oil from the pump flows through ports so that the differential pressure between pump
(A), (B), (C), and (D) to tilt cylinder (6). At the pressure (P) and LS pressure (LS) (LS differ-
same time, the load pressure in chamber (D) ential pressure: ( PLS) remains constant, so
passes through LS orifice (5) and chamber (H), a suitable amount of oil flows to ensure that the
and is sent to chamber (G). It is also sent from loss of pressure at the control valve ( PLS') is
the LS circuit (O) to pump servo valve (7). equal to ( PLS). The loss of pressure in the
q The condition of the pressure of spool (3) is control valve is determined by the area of the
chamber (B) pressure C chamber (C) pressure, opening of the main spool, so the oil flow
and chamber (G) pressure C chamber (D) matches the opening of the spool.
pressure, so spool (3) is controlled by the dif- q The return oil flow from the tilt cylinder passes
ferential pressure of spool (1) (chamber (C) through chamber (E) and chamber (F), and is
pressure – Chamber (D) pressure), and bal- drained.
ances with spring (4).
In other words, if the oil flow is too large, the
differential pressure of spool (1) becomes
larger, so spool (3) moves in the direction to
throttle the oil flow; on the other hand, if the oil
flow is too small, spool (3) moves in the direc-
tion to increase the oil flow.
D155A-6 39
3. Meter-out control when blade moves down under its own weight
(work equipment lever at LOWER)
40 D155A-6
Operation
q In the case where the blade falls owing to the
weight of the blade, the return flow from a cyl-
inder is controlled according to the opening
area of main spool (1).
q Oil flows from the suction valve (2) to a cylin-

der so that it prevents the circuit from being
evacuated.
q When a spool port opens with PPC output

pressure at (PA2), oil on the cylinder head side
passes through ports (A), (B) and (D) and then
drains into the tank owing to the weight of the
blade. At this time, the opening area between
ports (A) and (B) squeezes the return flow from
a lift cylinder in order to control the drop speed.
q In the case where the blade falls owing to the
weight of the blade, oil on the cylinder head
side passes through a drain circuit and the
suction valve (2) and then it is supplied to the
cylinder bottom side. At the same time, the out-
put flow from the pump passes through ports
(A1), (B1), (C1), (D1) and (E1) and then it is
supplied to the cylinder bottom side.
D155A-6 41
4. Meter-out control when blade moves down under its own weight
(work equipment lever at FLOAT)
42 D155A-6
Operation
q When the lift valve is at FLOAT, the cylinder
port and drain port are connected to put the cir-
cuit in a no-load condition.
q When the 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.
q When the work equipment control lever is at
t h e F L O AT p o s i t i o n , i f p r e s s u r e ( PA 3 )
becomes 3.4 MPa (35 kg/cm 2 ) or more, lift
spool (1) is moved to the maximum stroke
position.
q In this condition, ports (A3) and (B3) and the
LS passage (O) are all connected to the drain
circuit, so there is no load on the lift cylinder.
q If the cylinder is driven by the weight of the
blade, the oil entering from (A3) flows to ports
(A), (B), (B1) and (A1), while the rest of the oil
flows through port (D), and is drained. The oil
from suction valve (9) flows to port (B3). When
this happens, the oil flow is throttled by the
area of opening between ports (A) and (B) of
spool (1), and the cylinder speed is controlled.
q The pump circuit chamber (E) and ports (A3)
and (B3) are separated, and pump pressure
(P) is formed, so it is possible to carry out com-
pound operations with other control valves.
D155A-6 43
5. At relief
(Blade lift, blade tilt, ripper lift, ripper tilt)
a The diagram shows the condition at relief for work equipment LS relief valve (5) with blade tilt stroke
end.
q P1 = P3 + P4 = Differential pressure q P4 = Differential pressure between ports (B)

between ports (M) and (P) and (P)
q P2 = Differential pressure between ports (P) q LS = P1 + P2 = Differential pressure
and (N) between ports (M) and (N) = 1.96 MPa {20 kg/
q P3 = Differential pressure between ports (M) cm2}
and (B)
44 D155A-6
Operation
q If blade tilt valve (1) is moved, and the pres-
sure of tilt cylinder (8) becomes higher, work
equipment LS relief valve (5) will crack and oil
will be drained from LS circuit (O). (Ports (P),
(F), (G), (J), and (K)). As a result, there will be
a drop in pressure in LS passage (O) starting
from LS sensing hole (F), and ( P2) will
become larger.
q For the same reason, if the pressure in cham-
ber (I) and (H) drops, 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 between 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 pres-
sure ( LS). When this happens, pump LS
valve (6) detects the differential pressure gen-
erated by LS relief valve (5), and moves the
pump swash plate from the maximum to the
minimum position where the LS differential
pressure is 1.96 MPa {20 kg/cm2}.
q When the pump is at the minimum swash plate
angle (minimum oil flow), if the minimum oil
flow is greater than the LS relief oil flow + leak-
age at any part, the pressure is confined in the
pump circuit (the pump and chambers (A) and
chamber (B) through pressure compensation
valve (7)), so the LS differential pressure rises.
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.
D155A-6 45
6. Compound operation of work equipment valve

a The diagram shows the condition when the blade lift and tilt valves are operated at the same time.
46 D155A-6
q It consists of a parallel circuit, so when com-

pound operations are carried out, the oil flow is
divided according to the size of each spool
opening.
q Tilt spool (1) and lift spool (2) are actuated by

PPC valve output pressure (PA1) and (PB2),
and each is balanced at a position that
matches its own pilot pressure.
1) When pump pressure (P2) Z (P3)

q Lift valve load pressure (P3) is sent to pump
LS valve (4) through LS passage (O).
(1) When pump swash plate does not

reach maximum angle
q When the maximum flow of oil from the
pump is greater than the total of the oil
flow demanded by the tilt valve and lift
valve, an oil flow that matches the opening
of the spool flows to both the tilt valve and
lift valve.
(2) When pump swash plate is at maxi-

mum angle
q When the maximum flow of oil from the
pump is smaller than the total of the oil
flow demanded by the tilt valve and lift
valve, the flow of oil to the tilt valve and lift
valve is divided according to differential
pressure (PO) – (P2) and differential pres-
sure (PO) – (P3). In other words, more oil
flows to (P2) where the load is small.
q In cases where the blade is raised in the

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

(P3)
q (P) – (P2) C (P) – (P3), so an oil flow propor-
tional to the size of the spool opening is distrib-
uted to each spool.
D155A-6 47
7. Unload valve preset system

a The diagram shows the condition with preset check valve (3) open immediately after blade lift valve is
operated.
48 D155A-6
q This improves the response of the system

including the pump swash plate and pressure
compensation valve by sending the pilot pres-
sure (basic pressure of PPC valve) to the LS
circuit, and compensating the rise of the LS cir-
cuit pressure.
q When lift spool (1) is at the HOLD position,

pilot pressure (P1) (basic pressure of PPC
valve) is sent through preset check valve (3) to
the chamber (F) of the pressure compensation
valve. This pressure is called preset pressure
(P2). At the same time, unload pressure (P) is
being sent to chamber (B), but (P1) + (FO) >
(P) ((FO): load of spring (4)), so pressure com-
pensation spool (2) moves to the left and the
size of the opening between (A) and (B)
becomes the maximum.
q When spool (1) is switched, unload pressure

(P) flows immediately through chamber (A),
(B), (C), (D), and (E) to lift cylinder (8), so the
pressure at the port starts to rise and the time
lag becomes smaller.
q At the same time, preset pressure (P2) is sup-

plied to LS circuit (O) by the timing of the
spool, and the pressure in the LS circuit rises.
Because of this, unload valve (7) closes, and
oil is sent further to pump LS valve (6) 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.
Check valve (5) is built in the spool to prevent
preset pressure (P2) from venting in force from
the cylinder port.
q When cylinder port pressure (P3) rises and

becomes greater than preset pressure (P2), it
pushed up check valve (5), and oil is sent to
chamber (F) of the pressure compensation
valve and pump LS valve (6) to give the basic
( PLS) control.
When this happens, pressure (P3) at the cylin-
der port is prevented from entering the PPC
pump circuit by preset check valve (3).
D155A-6 49
Work equipment cylinder 1

Blade lift cylinder
Blade tilt cylinder
Ripper cylinder
a The piping of the lift cylinder and tilt cylinder of the variable multi-shank ripper is different from the
above.
50 D155A-6
Unit: mm
size Shaft Hole clearance limit
Blade -0.030 +0.279 0.095 –
75 0.666
LIFT -0.076 +0.065 0.355
Clearance between
1 piston rod and bush- Blade 90
-0.036 +0.270 0.097 –
0.695
ing TILT -0.090 +0.061 0.330
Ripper -0.036 +0.257 0.105 –
100 0.675
LIFT -0.090 +0.047 0.375
Ripper -0.036 +0.261 0.105 –
110 0.675
TILT -0.090 +0.047 0.375
Clearance between
piston rod support Blade +0.3
2 85 — — 1.0
shaft and blade LIFT +0.3
ball portion
Clearance between Replace
Blade -0.100 0.100 –
3 cylinder support 85 — 0.5
LIFT -0.174 0.228
shaft and bushing
Clearance between
Blade -0.200
4 piston rod spherical 115 — — —
TILT -0.300
surface and cap
Blade -0.030 +0.174 0.130 –
60 1.0
TILT -0.050 +0.100 0.224
Clearance between
cylinder bottom sup- Ripper -0.036 +0.207 0.156 –
5 90 1.0
port shaft and bush- LIFT -0.090 +0.120 0.297
ing
Ripper -0.036 +0.201 0.156 –
100 1.0
TILT -0.090 +0.119 0.291
Clearance between Ripper -0.036 +0.207 0.156 –
90 1.0
cylinder rod sup- LIFT -0.090 +0.120 0.297
6
port shaft and bush- Ripper -0.036 +0.201 0.156 –
ing 100 1.0
TILT -0.090 +0.119 0.291
D155A-6 51
Piston valve 1 2. Piston valve OPEN

Just before piston rod (1) reaches the end of
For blade lift cylinder its stroke, the tip of valve (6) contacts the cylin-
Outline der bottom, so valve (6) and piston valve (3)
q The piston valve is installed on the piston in stop at that position and do not move further.
the blade lift cylinder. When the piston reaches Only piston (2) moves further.
its stroke end, the valve releases the oil from When this happens, the oil at the cylinder
the hydraulic pump to reduce the oil pressure head, which was sealed by piston valve (3),
being exerted on the piston. escapes from piston valve seats (4) and (5),
When the blade is tilted, the blade is subject to and the pressure inside the cylinder stops ris-
a tortional force owing to the uneven position ing.
of the pistons in the two cylinders; that is the
piston on one side is still moving while the pis-
ton on the other side has reached its stroke
end.
The piston valves are installed to prevent the
tortional force from occurring. When one of the
pistons reaches its stroke end, its piston valve
opens to relieve the oil pressure.
In addition the piston valve relieves the shock
which occurs when the piston comes into con-
tact with the cylinder head or the bottom and
serves to reduce the subsequent surge pres-
sure in the cylinder by letting the oil escape
from the cylinder before the piston reaches its
stroke end.
Operation
1. Piston valve CLOSED
Pressurized oil from the hydraulic pump acts
on piston (2) and piston valve (3).
The piston valve (3) is pushed in the direction
of the arrow until piston valve seat (4) comes
into snug contact with the tapered section,
thereby, this causing the pressure in the cylin-
der to rise and moving piston (2) in the direc-
tion of the arrow.
52 D155A-6
D155A-6 53
Quick drop valve 1

(Blade lift cylinder)
Structure
The quick drop valve consists of valve body (1),
spool (2), check valve (3), and spring (4).
The quick drop valve serves to increase the blade
lowering speed and to reduce the occurrence of
vacuum when the blade is lowering, thereby short-
ening the time lag before digging is started.
The blade lowering speed, which is generally deter-
mined by the pump discharge, can be made faster
with the quick drop valve.
2. While lowering
Pressurized oil from the cylinder head flows
into port (C) through port (B).
At this time, the oil flow is restricted by an ori-
fice (a) provided along the way, causing a dif-
ferential pressure before and after the orifice.
When the differential pressure becomes
greater than the force of spring (4), it com-
presses the spring and moves spool (2) and
check valve (3) to the right.
When the spool and the check valve have
moved, part of the oil flowing from the cylinder
1. Valve body head to tank enters the passage to the cylinder
2. Spool bottom together with the oil from the control
3. Check valve valve.
4. Spring Thus, the blade lowering speed increases in
accordance with the amount of oil that flows to
Operation the bottom of the cylinder and reduces the for-
1. Start of lowering mation of vacuum at the bottom of the cylinder.
When the blade lever is operated to LOWER,
the oil from the control valve enters the cylin-
der bottom through port (A) and pushes the
piston. In the meantime, the oil in the cylinder
head is pushed out into the piston, enters valve
port (B), and flows into the tank from port (C).
54 D155A-6
Self pressure reducing valve 1
T: To hydraulic tank
P1: From cooling fan pump
P2: To cooling fan motor
PR: Supply to PPC valve and EPC valve
D155A-6 55
1. Sequence valve 5. Poppet

2. Valve 6. Ball
3. Filter
4. Screw
Unit: mm
Free length
Installation Installation Free Installation
x outer
7 Valve return spring length load length load
diameter
If damaged or
250 N 200 N
70.9 x 18 56 — deformed,
{25.5 kg} {20.4 kg}
replace spring
61.8 N 49.0 N
8 Ball return spring 16.1 x 7.8 13.4 —
{6.3 kg} {5.0 kg}
19.6 N 15.7 N
9 Valve return spring 19.2 x 7.2 16.1 —
{2.0 kg} {1.6 kg}
56 D155A-6
Operation
At engine stop (total low pressure)
q Spring (6) pushes the poppet (5) to the seat,

and the circuit between ports (PR) and (T) is
closed.
q Spring (7) pushes valve (8) to the left side, and
the circuit between port (P1) and port (PR) is
open.
q Spring (3) pushes the valve (2) to the upper
side, and the circuit between ports (P1) and
(P2) is closed.
Function
q The self pressure reducing valves reduce the
discharge pressure of the fan pump and sup-
plies it to the PPC valve, the EPC valve, etc. as
the control pressure.
D155A-6 57
2. When the load pressure P2 is lower than the output pressure PR of the self pressure reducing
valve.
q The spring (3) and the (PR) pressure (0 MPa q Therefore, there will occur a differential pres-
{0 kg/cm2} at the time of engine stop) pushes sure around the hold a in the spool (8) and the
the valve (2) in the direction to close the circuit spool will move in the direction to close the
between the ports (P1) and (P2). When the port (P1) and the (PR) opening. Then, the (P1)
hydraulic oil enters the (P1) port, the expres- pressure is reduced and adjusted to a certain
sion ((P1) pressure Spring (7) force + (ø(d) pressure (set pressure) with the opening and is
area x (PR) pressure)) holds, and the self pres- supplied as the (PR) pressure.
sure reducing valve will adjust the openings of
the ports (P1) and (P2) so that the (P1) pres-
sure can be maintained higher than the (PR)
pressure.
q When the (PR) pressure rises above the set
pressure, the poppet (5) will open and the
hydraulic oil flows through the route from the
(PR) port, the hole a in the spool (8), the pop-
pet (5) opening to the tank port (T).
58 D155A-6
3. At raise of load pressure P2
q When the load pressure (P2) rises due to dig- q When the (PR) pressure rises above the set
ging or other operations, the pump delivery will pressure, the poppet (5) will open and the
increase and the (P1) pressure will rise. hydraulic oil will flow through the route from the
Then, the expression ((P1) pressure > Spring (PR) port, the hole (a) in the spool (8), the pop-
(7) force + ( (d) area x (PR) pressure)) will pet (5) opening to the tank port (T).
hold, and the valve (2) will move to the right q Therefore, there will occur a differential pres-
side till the stroke end. As a result, the open- sure around the hold (a) in the spool (8) and
ing between the ports (P1) and (P2) will the spool will move in the direction to close the
increase, the passage resistance will become port (P1) and the (PR) opening. Then, the (P1)
smaller to reduce engine loss horsepower. pressure is reduced and adjusted to a certain
pressure (set pressure) with the opening and is
supplied as the (PR) pressure.
D155A-6 59
4. At occurrence of abnormal high pressure
q When the (PR) pressure of the self pressure

reducing valve rises abnormally high, the ball
(10) will separate from the seat against the
spring (9) force to flow the hydraulic oil to the
output ports (PR) (T) so as to reduce the
(PR) pressure. Then, the equipment (PPC
valve, etc.), to which the oil pressure is sup-
plied, is protected from the abnormal high
pressure.
60 D155A-6
D155A-6 61
D155A-6 Bulldozer
© 2008 KOMATSU
All Rights Reserved
62 D155A-6
SEN02866-00
D155A-6

D155A-6 85001 and up

Work equipment
Cylinder stay ................................................................................................................................................... 2
Blade............................................................................................................................................................... 4
Cutting edge, end bit....................................................................................................................................... 6
Ripper ............................................................................................................................................................. 8
D155A-6 1
Cylinder stay 1
1. Yoke
2. Dust seal
3. Bushing
4. Bushing
5. Grease nipple
2 D155A-6
Unit: mm
Clearance between cylinder size Shaft Hole clearance limit
6
yoke and bushing
–0.172 +0.063 0.172 –
125 —
–0.235 +0.046 0.298
Replace
Clearance between cylinder –0.170 +0.054 0.170 –
7 100 —
yoke and bushing –0.224 +0.046 0.278
Clearance between bushing
–0.172 +0.054 0–
8 of cylinder support shaft and 110 0.5
–0.035 +0.046 0.089
yoke
D155A-6 3
Blade 1
Sigma-tilt dozer, semi-U blade
4 D155A-6
Sigma-tilt, semi-U blade common parts mark

Unit: mm
Clearance between brace size Shaft Hole clearance limit
1 Replace
and pin
–0.3 +0.174 0.4 –
60 2
–0.5 +0.100 0.674
Clearance between brace –0.3 +0.5 Adjust shims
2 60 0.5 – 1.0 2 or replace
pin and bracket –0.5 +0.2
Clearance between brace –0.2 +0.3
3 115 0.2 – 0.6 1
spherical surface and cap –0.3 +0.6
Clearance between –0.3 +0.3
4 90 0.4 – 0.8 2
brace pin and bracket –0.5 +0.1
Clearance between brace –0.3 +0.5
5 90 0.6 – 1.0 2
pin and brace –0.5 +0.3
Clearance between joint –0.2 +0.5
6 140 0.5 – 1.2 2 Replace
and blade bracket –0.7 +0.3
Clearance between frame –0.5 +0.3
7 70 0.5 – 0.9 3
pin and joint –0.6 +0.6
Clearance between blade –0.5 +0.3
8 70 0.5 – 0.9 3
bracket pin and blade bracket –0.6 +0.6
Clearance between blade –0.5 +0.3
9 70 0.5 – 0.9 3
bracket pin and joint –0.6 +0.6
Clearance between center
–0.2 +0.3 Adjust shims
10 brace spherical surface 165 0.2 – 0.6 1
–0.3 +0.6 or replace
and cap
Clearance between trunnion
–0.5 +0.5
11 spherical surface and cap 160 0.5 – 1.5 8
–1.0 +0.0
(Left)
Replace
Clearance between trunnion
–0.5 +0.5
12 spherical surface and cap 195 0.5 – 1.5 8
–1.0 +0.0
(Right)
D155A-6 5
Cutting edge, end bit 1

For semi-U blade
Unit: mm
1 Height of outside of end bit
315 235
Replace
2 Width of end bit 540 440
3 Height of inside of end bit 254 215
Turn
4 Height of cutting edge 254 215 (175 to turning)
or replace
6 D155A-6
For sigma-tilt blade
Unit: mm
Standard size Repair limit Turn
1 Height of cutting edge
330 260 (215 to turning) or replace
2 Height of outside of end bit 300 235
3 Height of inside of end bit 330 260 Replace
4 Width of end bit 640 500
D155A-6 7
Ripper 1
Variable multi-shank ripper
8 D155A-6
Unit: mm
Clearance between arm size clearance limit
Shaft Hole
1,7 mounting pin and mounting
bracket or beam bracket –0.036 +0.207 0.156 –
110 1.5
–0.090 +0.120 0.297
Clearance between arm –0.036 +0.529 0.499 –
2,8 110 1.5
mounting pin and bushing –0.090 +0.463 0.619
Clearance between tilt cylin-
–0.036 +0.207 0.156 –
3,9 der mounting pin and mount- 100 1.5
–0.090 +0.120 0.297
ing bracket or beam bracket
Clearance between tilt cylin- –0.036 +0.201 0.155 –
4,10 100 1.5
der mounting pin and bushing –0.090 +0.119 0.291
Clearance between lift cylinder
–0.036 +0.207 0.156 –
5,11 mounting pin and mounting 90 1.5 Replace
–0.090 +0.120 0.297
bracket or beam bracket
–0.036 +0.207 0.156 –
6,12 mounting pin and shank bush- 90 1.5
–0.090 +0.120 0.297
ing
Clearance between shank
Shaft 80 +0.300 +0.300 1.400 –
13 mounting pin and shank 10.0
Hole 82 –0.300 –0.300 2.600
holder
Clearance between shank Shaft 80 +0.300 +1.000 3.700 –
14 15.0
mounting pin and shank hole Hole 88 –0.300 –1.000 6.300
15 Wear of point
335 225
16 Wear of protector 115 90
D155A-6 9
Variable giant ripper
10 D155A-6
Unit: mm
Clearance between arm size clearance limit
Shaft Hole
1,7 mounting pin and mounting
bracket or beam bracket –0.036 +0.207 0.156 –
110 1.5
–0.090 +0.120 0.297
Clearance between arm –0.036 +0.529 0.499 –
2,8 110 1.5
mounting pin and bushing –0.090 +0.463 0.619
Clearance between tilt cylin-
–0.036 +0.207 0.156 –
3,9 der mounting pin and mount- 100 1.5
–0.090 +0.120 0.297
ing bracket or beam bracket
Clearance between tilt cylin- –0.036 +0.201 0.155 –
4,10 100 1.5
der mounting pin and bushing –0.090 +0.119 0.291
–0.036 +0.207 0.156 –
5,11 mounting pin and mounting 90 1.5 Replace
–0.090 +0.120 0.297
bracket or beam bracket
–0.036 +0.207 0.156 –
6,12 mounting pin and shank bush- 90 1.5
–0.090 +0.120 0.297
ing
Clearance between shank
Shaft 75 +0.300 +0.300 1.400 –
13 mounting pin and shank 10.0
Hole 77 –0.300 –0.300 2.600
holder
Clearance between shank Shaft 75 +0.300 +1.000 3.700 –
14 15.0
mounting pin and shank hole Hole 80 –0.300 –1.000 6.300
15 Wear of point
335 225
16 Wear of protector 115 90
D155A-6 11
D155A-6 Bulldozer
© 2007 KOMATSU
All Rights Reserved
12 D155A-6
SEN02867-00
D155A-6

D155A-6 85001 and up

Cab and its attachments
Cab mount + ROPS pin .................................................................................................................................. 2
ROPS cab ....................................................................................................................................................... 3
ROPS floor...................................................................................................................................................... 4
Air conditioner ................................................................................................................................................. 5
D155A-6 1
Cab mount + ROPS pin 1

Cab spec.
1. Support Outline
2. Damper mount (front) q Viscous mounts are installed at two places at
3. Damper mount (rear) the front and two places at the rear to secure
4. ROPS pin (front) the floor frame and cab.
5. ROPS pin (rear) q An oil-filled damper mount is used to absorb
the vibration.
q The ROPS pins are installed to 2 places each
at the front and rear sections to fix the ROPS
(built in the cab) when the machine rolls over.
2 D155A-6
ROPS cab 1
Cab assembly
1. Front wiper
2. Front glass
3. Rear wiper
4. Door
5. ROPS sub (built in CAB)
D155A-6 3
ROPS floor 1
Cab less spec.
1. ROPS floor
4 D155A-6
Air conditioner 1
Air conditioner piping
1. Condenser 10. Air outlet for foot

2. Hot water return piping 11. Receiver tank
3. Hot water pick-up piping 12. Refrigerant piping
4. Front window defroster 13. Valve (hot water outlet)
5. Side window defroster 14. Air conditioner compressor
6. Air outlet for face 15. Valve (hot water inlet)
7. Air outlet for center
8. Air outlet for rear A: Fresh air
9. Air conditioner unit B: Recirculated air
D155A-6 5
D155A-6 Bulldozer
© 2007 KOMATSU
All Rights Reserved
6 D155A-6
SEN02868-02
D155A-6

D155A-6 85001 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
D155A-6 1
Engine control 1
1. Decelerator pedal Outline

2. Decelerator potentiometer q The throttle signals of the fuel control dial are
3. Starter switch sent to the power train controller and pro-
4. Fuel control dial cessed together with the 3rd throttle signal,
5. Battery relay and then sent as the throttle commands
together with the throttle signals of the deceler-
6. Battery
ator pedal to the engine throttle controller. The
7. Power train controller engine throttle controller controls the engine
8. Starter according to the commands.
9. Fuel supply pump
2 D155A-6
Engine control system 1
Outline q The information of the engine throttle controller

q The engine throttle controller receives the fuel is possessed jointly by the other controllers
control dial signal of the 1st throttle, decelera- through the network and used for the optimum
tor pedal signal of the 2nd throttle, and 3rd control of the engine and machine body.
throttle signal which is the control signal from q The auto deceleration is a function of setting
the power train controller, and then controls the the engine speed low temporarily when the
fuel supply pump according to the command travel direction is changed from F3, R3, F2,
signal having the lowest engine speed. and R2 (to protect the transmission clutch).
The control signals of the 3rd throttle are as q The neutral deceleration is a function of limit-
follows. ing the high idle speed when the transmission
(1) Auto deceleration (F3, R3, F2, R2) is set in neutral.
(2) Neutral deceleration
q The power train controller calculates a proper
engine speed from information items (1), (2),
etc.
and sends it as the 3rd throttle signal to the
engine throttle controller.
D155A-6 3
Deceleration potentiometer 1
1. Connector Outline
2. Lever q The deceleration potentiometer is installed to
3. Body the inside of the dashboard and connected to
4. Potentiometer the decelerator pedal by linkage.
5. Cuppling q If the decelerator pedal is pressed, it rotates
6. Shaft the throttle potentiometer shaft through the
7. Stopper linkage and the potentiometer resistance
changes.
Constant voltage is applied between pins (A)
and (C) of the potentiometer and a voltage sig-
nal is sent through pin (B) to the engine con-
troller according to the position of the
decelerator pedal.
4 D155A-6
D155A-6 5
Monitor system 1
q The monitor system monitors the machine con- q The CPU (Central Processing Unit) in the mon-
dition with the sensors installed to various itor panel displays and outputs various infor-
parts of the machine and processes and dis- mation items processed by the power train
plays the obtained information on the panel controller. The display unit is LCD (Liquid Crys-
quickly to notify the operator of the machine tal Display)
condition.
The main display sections and functions of the
panel are as follows.
1) Monitor unit which turns on the alarm
when the machine has a trouble.
2) Gauge unit which constantly displays the
machine condition (coolant temperature,
torque converter oil temperature, fuel
level, etc.)
3) Function of displaying error codes.
4) Function of monitoring the current and
voltage of the sensors and solenoids,
6 D155A-6
Processing in machine monitor (Common to all specifications)

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

1. The communication conditions of each sensor, each so-
lenoid, and CAN are displayed.
• The item Nos. and device conditions are notified to
CAN
the machine monitor by CAN. Each sensor-controller-machine
• The machine monitor displays the items and each monitor
value.
2. Each items is selected by using the cursor switches and
CAN
confirmation switch.
Other items
01 Monitoring
02 Trouble history
03 Maintenance history
04 Maintenance mode change
05 Telephone number set
06 Default
07 Adjustment
08 PM clinic
09 Reduced cylinders mode operation – –
10 No injection cranking
11 Fuel consumption display
12 —
13 Service message display
88 Screen adjustment a
89 —
a See testing and adjusting, special functions of machine monitor.
D155A-6 7
Machine monitor
Outline Precautions on the machine monitor display

q The machine monitor has the functions to dis- q The liquid crystal display panel may have black
play various items and the functions to select spots (which do not light up) or bright spots
modes and electric parts. (which stay on).
q The machine monitor has a CPU (Central Pro- Products having 10 or less black or bright
cessing Unit) in it to process, display, and out- spots conform the product specification; such
put the information. the condition is quite normal.
q The monitor display employs an LCD (Liquid q Battery voltage may suddenly drop at engine-
Crystal Display). The switches are flat sheet start due to ambient temperature or the condi-
switches. tion of the battery. The machine monitor dis-
play may temporarily disappear if it happens; it
is quite normal.
q Continuous operation of the machine monitor
may display blue bright spots on the screen
having a black background; it is quite normal.
The screen normally displayed on the monitor
has a blue or white background. For this rea-
son, blue spots will not cause any problem
(since the liquid crystal lights up red, blue, and
green spots when displaying white).
8 D155A-6
Input and output signals CN-CM03

Pin No. Signal name Input/
CN-CM01 output
Input/ 1 RS232C CD for communication terminal Input
Pin No. Signal name
output 2 RS232C RXD for communication terminal Input
1 Battery power (+24V constantly) Input 3 RS232C SG for communication terminal —
2 Battery power (+24V constantly) Input Signal GND for communication terminal
4 control
—
3 Battery power GND —
4 Battery power GND — 5 Communication terminal selection signal Input
Input/ 6 RS232C RTS for communication terminal Output
5 Wake-up Output 7 RS232C TXD for communication terminal Output
6 Relay output Output 8 RS232C DTR for communication terminal Output
7 Chassis signal GND — 9 RS232C DTR for communication terminal Input
8 Hydraulic oil pressure — 10 RS232C CTS for communication terminal Input
9 Fuel level Input 11 RS232C RI for communication terminal Input
10 NC(*) — 12 Power GND for communication terminal —
11 Charge amount Input Input CH1 for communication terminal
13 status
Input
12 Chassis analog signal GND —
13 Light switch Input Output for communication terminal
14 power control
Output
14 Key switch (ACC) Input Output CH1 for communication terminal
15 Key switch (C) Input 15 control
Output
16 Preheating Input 16 Output CH2 for communication terminal
Output
control
17 NC(*) —
Input CH2 for communication terminal
18 NC(*) — 17 status Input
*: Never connect to NC or malfunctions or failures will Electric power supply for communication
occur. 18 terminal
Output
CN-CM02 CN-CM04
Input/ Input/
Pin No. Signal name output Pin No. Signal name output
1 NC(*) — 1 NC(*) —
2 NC(*) — 2 NC(*) —
3 Coolant level sensor Input 3 NC(*) —
4 NC(*) — 4 NC(*) —
5 NC(*) — 5 NC(*) —
6 NC(*) — 6 NC(*) —
7 Chassis signal GND — 7 NC(*) —
8 CAN terminating resistance — 8 NC(*) —
9 CAN_H Input/ 9 NC(*) —
Output
10 NC(*) —
10 CAN_L Input/
Output 11 NC(*) —
11 NC(*) — 12 NC(*) —
12 NC(*) — *: Never connect to NC or malfunctions or failures will
occur.
*: Never connect to NC or malfunctions or failures will
occur.
CN-CM05
Input/
Pin No. Signal name
output
1 Electric power supply for camera Output
2 Camera NTSC signal input 1 Input
5 Electric power supply GND for camera —
6 Camera signal GND1 —
D155A-6 9
Monitor control, display portion
1. Gear shift mode selector switch 9. Fuel level

2. Buzzer cancel switch 10. Travel gear speed gear shift mode preset
3. Working mode selector switch 11. Guidance icon
4. Engine coolant temperature 12. Function switch
5. Multi gauge 13. Custom switch
6. Pilot display 14. Custom memory switch
7. Service meter, clock 15. Air conditioner switch
8. Hydraulic mode display
10 D155A-6
D155A-6 11
Machine monitor display

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

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

Check
Display when normal: OFF

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

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

engine coolant
temperature gauge
Engine coolant tempera-
Above 102°C:
ture Displays when starting switch is ON
Symbol ON
and engine is running
Caution
Above 105°C:
Symbol ON + buzzer Display when normal: OFF
When at highest level on Display when abnormal: ON
engine coolant Alarm buzzer sounds
temperature gauge
Torque converter oil tem-
Above 120°C:
perature
Symbol ON
Above 130°C:
Symbol ON + buzzer
Above 100°C:
Symbol ON
Hydraulic oil temperature
Above 110°C:
Symbol ON + buzzer
When replacement time

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

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

heat by setting starting switch at pre-
heat position (turning it
counterclockwise).
12 D155A-6
Display
Symbol Display item Display range Display method
category
Engine coolant
temperature
Torque converter oil

Indicative applicable temperature
temperature
Gauges
Fuel level Indicative applicable level
Service meter
From 0 to 99999 Actuated when the engine is rotating
(Hours meter)
D155A-6 13
Gauge
The gauge pointer disappears when information on coolant temperature or hydraulic oil temperature cannot
be obtained due to disconnection of CAN.
Temperature or vol-
Gauge Range ume Indicator Buzzer sound
A1 105 Red Q
A2 102 Red
Engine coolant A3 100 Off
temperature
(°C) A4 85 Off
A5 60 Off
A6 30 White
B1 130 Red Q
B2 120 Red
Power train oil B3 118 Off
temperature
(°C) B4 90 Off
B5 50 Off
B6 0 White
C1 110 Red Q
C2 100 Red
Hydraulic oil C3 98 Off
temperature
(°C) C4 70 Off
C5 20 Off
C6 0 White
D1 565 Off
D2 425 Off
D3 310 Off
Fuel level (l)
D4 220 Off
D5 150 Off
D6 75 Red
14 D155A-6
Machine speed Battery voltage
1. 0 km/h 3. 10 km/h 1. 0 V 4. 25 V
2. 5 km/h 4. 15 km/h 2. 17 V 5. 30 V
3. 20 V 6. 31 V
Hydraulic oil pressure Engine speed
1. 0 MPa 4. 30 MPa 1. 500 rpm 4. 2,000 rpm

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

2. 0.2 MPa 5. 0.5 MPa 2. 0.2 W 5. 0.8 W
3. 0.3 MPa 6. 0.7 MPa 3. 0.4 W 6. 1.0 W
D155A-6 15
Guidance icon and function switch

The function switches differ depending on the screen display. Each guidance icon shows the function of the
switch below it.
Switches with no guidance icon are disabled.
The functions shown by the guidance icons are as shown in the table below.
Symbol Switch Item Function
F6 Enter Enters selected/set item.
F5 Return Returns to previous screen.
F4 Select service meter/clock Selects service meter and clock alternately.
F5 Select maintenance screen Selects maintenance screen.
F6 Select user mode screen Selects user mode screen.
Selects item on left side (Selects right end item after left
F3 Select item
end item).
Selects item on right side (Selects left end item after right
F4 Select item
end item).
Selects item on lower side (Selects top item after bottom

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

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

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

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

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

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

F1 Stop
consumption on fuel consumption display screen.)
F1/F2 Clear Clears selected/displayed item
F1 Set Executes setting.
F2 Change multi gauge Change of multi gauge items
16 D155A-6
Air conditioner control switch

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

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

conditioner control screen displayed, the window
returns to the normal window.
a When communication with the air conditioner
is disconnected, or “spurting-out damper”,
“A/M damper”, or “refrigerant” has a problem,
the following screen appears.
D155A-6 17
Maintenance function
q Pressing F5 on the normal screen switches to
the maintenance screen.
F5 : Cancels the reset to return to the maintenance

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

and replacement intervals. The time remaining
to maintenance is reduced as the machine is
operated.
Replacement interval
No. Item
(Hours)
01 Engine oil 500
02 Engine oil filter 500
03 Fuel main filter 1000
F1 : Displays the next page. 41 Fuel pre filter 500
Displays the top page when the last page is 04 Hydraulic filter 2000
displayed.
06 Corrosion resistor 1000(*)
F2 : Displays the previous page.
07 Damper case oil 2000
Displays the last page when the top page is
08 Final drive case oil 1000
displayed.
10 Hydraulic oil 2000
F3 : Selects (highlights) an item one down.
19 P/L oil 1000
F4 : Selects (highlights) an item one up.
F5 : Returns to the normal screen. 20 P/L oil filter 500
F6 : Switches to the maintenance time reset screen. *: If equipped (To be determined)
P/L: Power train
mal screen.
q The content of the caution display differs
according to the remaining time. The relation-
q If the remaining time on the maintenance table
ship is as shown in the table below.
screen is less than 30 hours, the relevant items
are highlighted in yellow, and if 0 hours, they Display Condition
are done in red. Remaining time for mainte-
q On the maintenance time reset screen, reset None nance for all items is more
the remaining time for the selected item to than 30 hours.
return to the default. There is one or more items
Notice display (black sym-
with less than 30-hour
bol displayed on yellow
remaining time for mainte-
background)
nance.
There is one or more items
Warning display (white
with less than 0-hour
symbol displayed on red
remaining time for mainte-
background)
nance.
18 D155A-6
q To reset the maintenance time carelessly, it is User mode 1

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

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

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

q If utility screen select is selected with switch
F6, (1) Standard Display, (2) Load Display, or
(3) Body Pitch Display can be selected.
q Select an item with switch F3 or F4 and con-
firm that item with switch F6.
D155A-6 19
Multi gauge select

q On this screen, the gauges displayed at the
center can be selected.
q Select an item with switch F3 or F4 and con-
firm that item with switch F6.
Standard display
q The normal screen is selected.
Load display
q The horizontal axis indicates the time and the
vertical axis indicates the traction force. The
operation should be carried out in the green q The following items can be selected.
range.
No. Selected item Remarks
q The graph on the screen is updated and
scrolled to the left at intervals of several sec- 1 Power train oil Temperature With caution
onds. 2 HYD oil temperature With caution
3 Vehicle Speed —
4 HYD Pressure —
5 ENG Oil Pressure With caution
6 Battery Voltage —
7 Engine Speed —
8 Traction Force —
9 Clock —
10 ENG coolant temperature For Utility Screen Select
11 Fuel For Utility Screen Select
Body Pitch Display

q The horizontal axis indicates the time and the
vertical axis indicates the pitch angle of the
body.
q The graph on the screen is updated and
scrolled to the left at intervals of several sec-
onds.
20 D155A-6
Screen adjustment F6 : Moves to the setup items of the selected (high-

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

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

F3 : Advances the clock one hour.
F4 : Sets the clock back one hour.
F5 : Cancels changes you made before
confirming them with F6 to return to
F4 : Selects (highlights) an item one up. the user menu.
F5 : Cancels changes you made before confirming F6 : Confirms the changes and moves to
them with F6 to return to the menu screen. minute setting.
D155A-6 21
The minute display part is highlighted.

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

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

a system to lead a life according to
the one-hour advanced time in order
to make efficient use of daylight time.
Language setting
q Selecting the Language from the user menu
screen and pressing F6 switches to the lan-
guage setting screen.
q From this menu, you can change the language
to be displayed on the monitor. Available lan-
guages are as follows.
English, Japanese, Chinese, French, Spanish,
Portuguese, Italian, German, Russian, and
Turkish
22 D155A-6
q Press F6 to enter user mode and select “Mes- Fan reverse mode
sage display” and you can view (open) the q In this mode, the fan is driven in reverse to
messages. clean the radiator core.
q While the starting switch is OFF, select an item
with switch F3 or F4 and confirm that item with
switch F6.
q While screen (A) is displayed, press switch F6,
and the fan is ready to run in reverse.
q While screen (B) is displayed, start the engine.
F6 : Returns to the user mode screen.
q Under messages that accept replies, “Value to

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

a q In this mode, the fan cannot be reversed
while the engine is running.
q When running the fan in reverse, set
q Messages will be deleted when their validity
the travel lock in the LOCK position.
expire or a new message is received.
q While the fan is running in reverse, the
q When no message has not been received, “No
machine cannot travel.
message” appears at the blue part of the top of
q When resetting the reverse running,
the screen.
turn the starting switch OFF to stop the
q Separately from the message display for users
engine.
above, the service menu is provided with mes-
q When using this mode, warm up the
sage display for service.
engine sufficiently. If the engine is not
warmed up, air may not be supplied
sufficiently.
D155A-6 23
Service meter check function Display LCD check function

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

goes out.
a Continuous operation of the machine monitor q Pressing any function switch returns to the pre-
may display blue bright spots on this screen; it vious screen.
is quite normal.
24 D155A-6
Sensors 1
Type of sensor Sensor method When normal When abnormal
Engine oil pressure Contact OFF ON
Engine coolant temperature Resistance — —
Torque converter oil temperature Resistance — —
Hydraulic oil temperature Resistance — —
Coolant level Contact ON OFF
Fuel level Resistance — —
Engine speed sensor Resistance — —
Bevel gear speed sensor Resistance — —
Pitch angle sensor Resistance — —
Engine oil pressure sensor
1. Plug 4. Diaphragm
2. Contact ring 5. Spring
3. Contact 6. Terminal
Engine coolant temperature sensor

Torque converter oil temperature sensor
Hydraulic oil temperature sensor
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
D155A-6 25
Coolant level sensor
1. Float 4. Wire
2. Sensor 5. Connector
3. Tube
Fuel level sensor
1. Connector Function
2. Float q The fuel sensor is installed to the side face of
3. Arm the fuel tank. The float moves up and down
4. Body according go the fuel level. This movement of
5. Spring the float is transmitted by the arm and actuates
6. Contact a variable resistance. This sends a signal to
7. Spacer the monitor panel to indicate the remaining fuel
level.
26 D155A-6
Engine speed sensor

Bevel gear speed sensor
1. Magnet 4. Boots
2. Terminal 5. Connector
3. Case
Pitch angle sensor
1. Body 3. Wire
2. Tube 4. Connector
D155A-6 27
Palm command control system 1
1. Machine monitor (Multi-information)

2. Preset mode switch
3. Engine throttle controller
4. Power train controller
5. Engine speed sensor
6. Transmission control valve
7. Steering control valve
8. Transmission output shaft speed sensor
28 D155A-6
Gearshift mode function

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

q Set a gear by pressing (a) or (b) of the steer-
ing/directional/gearshift lever.
(a) Shift-up switch
(b) Shift-down switch
Display of screen
The gearshift mode is displayed in the gearshift
mode display section of the monitor panel as
shown below.
A: Auto gearshift mode
1. Gear speed used currently
2. Preset (gear speed at start) and maximum
gear speed during travel
3. Mark of AUTO (which indicates auto gear-
shift mode)
4. Mark of Dozing (which indicates auto
gearshift mode)
B: Manual gearshift mode
5. Gear speed used currently
6. Preset (gear speed at start)
7. Mark of Ripping (which indicates manual
gearshift mode)
D155A-6 29
Setting preset with shift switches in neutral Changing gear speed with gearshift switches
q Set the preset (gear speed at start) and the during travel
maximum gear speed during travel (for only q The maximum gear speed during travel (in the
the auto gearshift mode) with the gearshift auto gearshift mode) or the gear speed used
switches in neutral. during travel (in the manual gearshift mode)
A: Auto gearshift mode can be changed with the gearshift switches
2. Setting preset (gear speed at start) and while the machine is traveling.
maximum gear speed during travel) A: Auto gearshift mode
2. Changing maximum speed during travel
During forward travel: The maximum gear
speed can be set to F1 – F3.
During reverse travel: The maximum gear
speed can be set to R1 – R3.
Shift-up switch: Each time this switch is

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

B: Manual gearshift mode 5. Changing maximum speed during travel
6. Setting preset (gear speed at start) During forward travel: The maximum gear
speed can be set to F1 – F3.
During reverse travel: The maximum gear
speed can be set to R1 – R3.
Shift-up switch: Each time this switch is

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

auto gearshift mode ([F1 – R1]) is set. When
the gearshift mode is changed, [F1 – R1] is
selected initially.
30 D155A-6
KOMTRAX system 1
q The KOMTRAX system consists of a KOMTRAX

terminal, communication antenna, machine
monitor, and GPS antenna.
q This system transmits various kinds of
machine information wirelessly. Persons to
operate the KOMTRAX can refer to the infor-
mation at office to provide various kinds of ser-
vices for customers.
q Information transmittable from the KOMTRAX
system includes the following.
1. Operation map
2. Service meter
3. Position information
4. Error history
and others.
a To provide the services, you need to make an
arrangement for starting the KOMTRAX ser-
vice separately.
D155A-6 31
KOMTRAX terminal 1
TH300
q For japan / For other countries

q Using satellite wave
1. Communication antenna connection

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

q The KOMTRAX terminal is a wireless commu- Connector A
nication device to transmit various kinds of Input/
machine information or GPS position informa- Pin No. Signal name
output
tion the monitor obtains from network signals A-1 Power (12V) Input
or input signals in the machine. The terminal A-2 NC(*1) —
can transmit information via the communica- A-3 NC(*1) —
tion antenna. A-4 Electric power supply switching Output
q Use of KOMTRAX terminal must be limited for A-5 NC(*1) —
the countries in which such communication is A-6 NC(*1) —
allowed. A-7 GND —
q When using TH300 in Japan or in other coun-
A-8 GND —
tries, the satellite communication company to
A-9 NC(*1) —
contract is different. So, part numbers of
A-10 NC(*1) —
TH300 are different in Japan or in other coun-
A-11 NC(*1) —
tries. Also, when using TH300 in countries
A-12 NC(*1) —
other than Japan, you must notify the name of
the country. A-13 NC(*1) —
A-14 NC(*1) —
Connector B
Input/
Pin No. Signal name
output
B-1 Serial signal DCD Output
B-2 Serial signal RXD Output
B-3 Serial signal TXD Input
B-4 Serial signal DTR Input
B-5 Serial signal SGND —
B-6 Serial signal DSR Output
B-7 NC(*1) —
B-8 NC(*1) —
B-9 NC(*1) —
B-10 NC(*1) —
*1: Never connect to NC or malfunctions or failures
will occur.
32 D155A-6
D155A-6 33
D155A-6 Bulldozer
© 2009 KOMATSU
All Rights Reserved
34 D155A-6
SEN03199-00
D155A-6

D155A-6 85001 and up
20 Standard value table 1

Standard service value table
Standard value table for engine ...................................................................................................................... 2
Standard value table for machine ................................................................................................................... 3
D155A-6 1
SEN03199-00 20 Standard value table
Standard value table for engine 1
Engine SAA6D140E-5
Cate- Standard value for

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

• Engine coolant
Speed temperature: Within Low idle rpm 740 (+40/0) 740 (+40/0)
operating range
Rated speed rpm 1,900 1,900
• Engine coolant temperature: Within

operating range
Intake air pressure kPa Min. 85 72
• Power train oil temperature: Within
(Boost pressure) {mmHg} {Min. 640} {540}
operating range
• Torque converter: Stalled
Exhaust • Whole speed range
°C 670 720
temperature (Outside temperature: 20°C)
At sharp
%
acceleration Max. 30 40
• Engine coolant (Bosch
(Low idle o (Max. 3.0) {4.0}
Exhaust gas color temperature: Within index)
High idle)
operating range
(Bosch
High idle Max. 1.0 2.0
index)
Intake valve mm 0.35 —

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

• Engine oil pressure {kg/cm2} {Min. 42} {29}
Compression
temperature:
pressure Engine
40 – 60°C rpm 200 – 250 200 – 250
speed
operating range
kPa Max. 2.94 3.92
Blow-by pressure • Power train oil temperature: Within
{mmH2O} {Max. 300} {400}
operating range
• Torque converter: Stalled
• SAE0W30EOS,
MPa Min. 0.34 0.21
SAE5W40EOS, High idle
{kg/cm2} {Min. 3.5} {2.1}
SAE10W30DH,
Engine oil pressure SAE15W40DH
SAE30DH Oil MPa Min. 0.10 0.08
• Engine oil temperature: Low idle {kg/cm2} {Min. 1.0} {0.8}
Min. 80 °C
Oil temperature • Whole speed range (In oil pan) °C 90 – 110 120
• Between water pump pulley –

Alternator belt alternator pulley
mm 13 – 16 13 – 16
tension • Deflection under finger pressure of
98 N {10 kg}
• Between compressor pulley – fan
Air compressor belt pulley
mm Approx. 10 Approx. 10
tension • Deflection under finger pressure of
59 N {6 kg}
2 D155A-6
Standard value table for machine 1

gory new machine
operating range
Decelerator pedal • Power train oil temperature: Within
rpm 875 ± 25 875 ± 25
speed operating range
• Hydraulic oil temperature: Within
operating range
• Engine: High idle
Auto deceleration • Decelerator pedal speed:
Press pedal rpm 1,875 ± 50 1,875 ± 50
speed
• Auto deceleration speed:
Engine speed
Set all levers in neutral

operating range
Torque converter • Power train oil temperature: Within rpm 1,665 ± 50 1,450
stall speed operating range
operating range
Torque converter • Select P mode
stall speed + Work • Torque converter stall speed: F3
rpm 1,630 ± 50 1,395
equipment relief • Torque converter stall speed + Work
speed equipment relief speed: F3 + Ripper
raise
• Hydraulic oil
temperature: Within
operating range
Min. speed rpm — —
• Fan: Set in 100%
mode
• Engine: Low idle
Fan motor speed
Cooling fan
• Hydraulic oil
temperature: Within
operating range
Max. speed rpm 1,100 ± 5 % 1,100 ± 5 %
• Fan: Set in 100%
mode
Fan pump circuit operating range MPa
pressure • Fan: Set in 100% mode {kg/cm2}
No
mm 30 ± 5 30 ± 5
Forward/ Forward
Reverse travel No
PCCS lever
Stroke of control lever/pedal
mm 30 ± 5 30 ± 5
• Stop engine Reverse
• Center of lever grip
N o Left mm 40 ± 5 40 ± 5
Steering
N o Right mm 40 ± 5 40 ± 5
• Stop engine
Decelerator pedal mm 50 ± 10 50 ± 10
• Center of pedal
All stroke mm 79 ± 10 79 ± 10
Brake pedal
• Center of pedal Stroke to 0 of
mm 54 ± 4 54 ± 4
oil pressure
D155A-6 3

gory new machine
N o Raise mm 60 ± 10 72 ± 10
N o Lower mm 60 ± 10 72 ± 10
• Stop engine
Stroke of control lever/pedal
Blade control lever

• Center of lever knob
N o Left tilt mm 53 ± 10 53 ± 10
No
mm 53 ± 10 53 ± 10
Right tilt
N o Raise mm 77 ± 10 75 ± 10
N o Lower mm 77 ± 10 75 ± 10
• Stop engine
Ripper control lever
• Center of lever knob
N o In mm 79 ± 10 80 ± 10
N o Out mm 79 ± 10 80 ± 10
No N 56.9 ± 6.9 56.9 ± 6.9

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

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

• Engine: Low idle N 411.6 ± 78.4 411.6 ± 78.4
Brake pedal
• Center of pedal {kg} {42.0 ± 8.0} {42.0 ± 8.0}
N 39.2 ± 5.9 39.2 ± 5.9
N o Raise
{kg} {4.0 ± 0.6} {4.0 ± 0.6}
N 39.2 ± 9.8 39.2 ± 9.8
N o Lower
{kg} {4.0 ± 1.0} {4.0 ± 1.0}
• Stop engine
Lower o N 82 ± 9.8 82 ± 9.8
Blade control lever • Center of lever knob
Float {kg} {8.4 ± 1.0} {8.4 ± 1.0}
• Lower o Float
N 28.4 ± 5.9 28.4 ± 5.9
N o Left tilt
{kg} {2.9 ± 0.6} {2.9 ± 0.6}
No N 28.4 ± 5.9 28.4 ± 5.9
Right tilt {kg} {2.9 ± 0.6} {2.9 ± 0.6}
N 19.6 ± 4.9 19.6 ± 4.9
N o Raise
{kg} {2.0 ± 0.5} {2.0 ± 0.5}
N 19.6 ± 4.9 19.6 ± 4.9
N o Lower
• Stop engine {kg} {2.0 ± 0.5} {2.0 ± 0.5}
• Center of lever knob N 24.5 ± 4.9 24.5 ± 4.9
N o In
{kg} {2.5 ± 0.5} {2.5 ± 0.5}
N 24.5 ± 4.9 24.5 ± 4.9
N o Out
{kg} {2.5 ± 0.5} {2.5 ± 0.5}
4 D155A-6

gory new machine
MPa 0.05 – 0.49 0.05 – 0.49
Low idle
Torque converter {kg/cm2} {0.5 – 5.0} {0.5 – 5.0}
inlet pressure • Power train oil temper- MPa Max. 1.0 Max. 1.0
ature: Within operating High idle {kg/cm2} {Max. 10.0} {Max. 10.0}
range
• PCCS lever: Neutral MPa 0.05 – 0.29 0.05 – 0.29
Low idle
Torque converter • Display by monitoring {kg/cm2} {0.5 – 3.0} {0.5 – 3.0}
outlet pressure MPa 0.29 – 0.69 0.29 – 0.69
High idle
{kg/cm2} {3.0 – 7.0} {3.0 – 7.0}
• Power train oil temper-
ature: Within operating Low idle MPa 2.81 – 3.11 Min. 2.62
range {kg/cm2} {28.7 – 31.7} {Min. 26.7}
Transmission main
• PCCS lever: Neutral
relief pressure
(Main relief pressure) MPa 3.04 – 3.33 Min. 2.84
• Brake pedal: Press High idle
{kg/cm2} {31.0 – 34.0} {Min. 29.0}
(Other than above)
Transmission F MPa 2.55 – 2.94 Min. 2.35
Low idle
clutch pressure {kg/cm2} {26.0 – 30.0} {Min. 24.0}
(When operating MPa 2.65 – 3.04 Min. 2.45
N1 o F1) High idle
{kg/cm2} {27.0 – 31.0} {Min. 25.0}
Transmission R MPa 2.60 – 2.99 Min. 2.40
Low idle
N1 o R1) High idle
{kg/cm2} {28.0 – 32.0} {Min. 26.0}
Transmission 1st MPa 2.81 – 3.11 Min. 2.62
Power train oil pressure
• Power train oil temper- Low idle

clutch pressure ature: Within operating {kg/cm2} {28.7 – 31.7} {Min. 26.7}
(When operating range MPa 3.04 – 3.33 Min. 2.84
N1 o F1) High idle
• PCCS lever: Neutral {kg/cm2} {31.0 – 34.0} {Min. 29.0}
(Main relief pressure) MPa 2.55 – 2.94 Min. 2.35
Transmission 2nd Low idle
• Brake pedal: Press {kg/cm2} {26.0 – 30.0} {Min. 24.0}
clutch pressure
(Other than above)
N1 o F2) High idle
{kg/cm2} {27.5 – 31.5} {Min. 25.5}
Transmission 3rd MPa 2.81 – 3.11 Min. 2.62
Low idle
F2 o F3) High idle
{kg/cm2} {31.0 – 34.0} {Min. 29.0}
Transmission lubri-
MPa 0.098 – 0.25 0.098 – 0.25
cating oil pressure High idle
{kg/cm2} {1.0 – 2.5} {1.0 – 2.5}
(Reference)
MPa 3.04 – 3.33 3.04 – 3.33
Low idle
Steering right brake {kg/cm2} {31.0 – 34.0} {31.0 – 34.0}
pressure • Power train oil MPa 3.04 – 3.33 3.04 – 3.33
temperature: Within High idle
{kg/cm2} {31.0 – 34.0} {31.0 – 34.0}
operating range
• PCCS lever: Neutral MPa 3.04 – 3.33 3.04 – 3.33
Low idle
Steering left brake • Brake pedal: Release {kg/cm2} {31.0 – 34.0} {31.0 – 34.0}
pressure MPa 3.04 – 3.33 3.04 – 3.33
High idle
{kg/cm2} {31.0 – 34.0} {31.0 – 34.0}
MPa 2.3 – 2.6 2.3 – 2.6
• Power train oil Low idle
Steering right {kg/cm2} {23.5 – 26.5} {23.5 – 26.5}
temperature: Within
clutch pressure operating range MPa 2.3 – 2.6 2.3 – 2.6
High idle
• Gear speed: N {kg/cm2} {23.5 – 26.5} {23.5 – 26.5}
• PCCS lever: Right MPa 2.3 – 2.6 2.3 – 2.6
stroke end Low idle
Steering left clutch {kg/cm2} {23.6 – 26.5} {23.6 – 26.5}
pressure • PCCS lever: Left
MPa 2.3 – 2.6 2.3 – 2.6
stroke end High idle
{kg/cm2} {23.6 – 26.5} {23.6 – 26.5}
D155A-6 5

gory new machine
• Flat ground F1 km/h 3.8 ± 0.2 3.8 ± 0.2
• Engine coolant
temperature: Within F2 km/h 7.5 ± 0.4 7.5 ± 0.4
Power train performance
operating range
• Power train oil F3L km/h 7.5 ± 0.4 7.5 ± 0.4
temperature: Within
operating range F3 km/h 11.6 ± 0.6 11.6 ± 0.6
Travel speed • Select manual
gearshift mode R1 km/h 4.6 ± 0.2 4.6 ± 0.2
• Approach run: R2 km/h 6.8 ± 0.4 6.8 ± 0.4
10 – 30 m
• Measuring distance: R3L km/h 9.2 ± 0.5 9.2 ± 0.5
20 m
(Converted into km/h) R3 km/h 14.0 ± 0.7 14.0 ± 0.7
• Hydraulic oil tempera- MPa
Low idle — —
ture: Within operating {kg/cm2}
Unload pressure range
MPa 2.45 (+1.37/0) 2.45 (+1.37/0)
• All levers: High idle
Set in neutral {kg/cm2} {25 (+14/0)} {25 (+14/0)}
Blade lift relief MPa 27.5 ± 1.5 27.5 ± 1.5
pressure {kg/cm2} {280 ± 15} {280 ± 15}
Work equipment oil pressure
Blade tilt relief MPa 27.5 ± 1.5 27.5 ± 1.5

pressure • Hydraulic oil temperature: Within {kg/cm2} {280 ± 15} {280 ± 15}
operating range
Ripper lift relief MPa 27.5 ± 1.5 27.5 ± 1.5
pressure {kg/cm2} {280 ± 15} {280 ± 15}
• Cylinder of measured circuit:
Ripper tilt relief Stroke end MPa 27.5 ± 1.5 27.5 ± 1.5
pressure {kg/cm2} {280 ± 15} {280 ± 15}
Work equipment LS MPa 25.0 ± 0.98 25.0 ± 0.98
relief pressure {kg/cm2} {255 ± 10} {255 ± 10}
Control circuit basic operating range MPa 3.97 (+0.49/0) 3.78 – 4.46
pressure • Engine: High idle {kg/cm2} {40.5 (+5/0)} {38.5 – 45.5}
• All levers: Set in neutral
Control valve PPC operating range
MPa 3.82 – 4.12 3.53
valve output • Engine: High idle
{kg/cm2} {39 – 42} {36}
pressure • Lever of measured circuit: Stroke
end
• Hydraulic oil tempera-
ture: Within operating
Work equipment speed
range Raise sec 3.0 – 4.0 3.0 – 4.0

Work equipment

• Select P mode
• Apply no load to blade.
Blade lift • Measure time required
to move blade from
ground level to raise
stroke end Lower sec 1.0 – 1.7 1.0 – 1.7
• For measuring posture,
see Fig. 1
6 D155A-6

gory new machine
• Hydraulic oil
temperature: Within
operating range Left tilt sec 1.8 – 2.8 3.1
• Select P mode
Blade tilt • Apply no load to blade
• Measure time required
to move blade from left
tilt end to right tilt end Right tilt sec 1.8 – 2.8 3.1
see Fig. 2
• Hydraulic oil
temperature: Within
Work equipment speed
operating range
• Engine: High idle Raise sec 2.5 – 3.5 4.0
• Select P mode
• Apply no load to ripper
Ripper lift (Shank hole: Lowest)
to move ripper from
ground level to raise Lower sec 2.5 – 3.5 4.0
end
see Fig. 3
Work equipment
• Hydraulic oil tempera-

ture: Within operating
range Tilt in sec 4.5 – 5.5 6.2
• Select P mode
Ripper tilt • Apply no load to ripper
to move ripper from tilt
in end to tilt back end Tilt back sec 3.3 – 4.3 5.7
see Fig. 4
operating range
• Select P mode.
Blade • Blade control lever: Set to stroke end sec Max. 1.7 2.5
• Lower blade from max. rising position
and measure time after blade comes
in contact with ground until idler is
lifted
Time lag

operating range
• Select P mode
• Ripper control lever: Set to stroke
Ripper sec Max. 1.5 1.5
end
• Lower ripper from max. rising posi-
tion and measure time after ripper
comes in contact with ground until
sprocket is lifted
D155A-6 7

gory new machine
operating range
Hydraulic drift • Stop engine Max. 150/15
mm 200/15 minutes
of lifted blade • Measure reduction of blade bottom minutes
height h in 15 minutes
• For measuring posture, see Fig. 5
Hydraulic drift of work equipment

operating range
Hydraulic drift
• Stop engine
of machine mm Max. 50/5 minutes 70/5 minutes
• Measure reduction of idler center
lifted by blade
operating range
Work equipment
Hydraulic drift
• Stop engine
• Measure reduction of idler center
tilted by blade
operating range
Hydraulic drift
• Stop engine
• Measure reduction of sprocket center
lifted by ripper
Leakage from cylinder
Blade lift
cc/min Max. 3.0 12
cylinder
operating range
Ripper lift
• Engine: High idle cc/min Max. 2.7 11
cylinder
• Measure leakage from relieved
cylinder in 1 minute
Ripper tilt
cc/min Max. 2.7 11
cylinder
8 D155A-6
Postures and procedures for measuring performance
Fig. 1: Blade lift speed Fig. 4: Ripper tilt speed
Fig. 2: Blade tilt speed Fig. 5: Hydraulic drift of lifted blade
Fig. 3: Ripper lift speed Fig. 6: Hydraulic drift of machine lifted by blade
D155A-6 9
Fig. 7: Hydraulic drift of machine tilted by blade
Fig. 8: Hydraulic drift of machine lifted by ripper
10 D155A-6
D155A-6 11
D155A-6 Bulldozer
© 2007 KOMATSU
All Rights Reserved
12 D155A-6
SEN03200-02
D155A-6

D155A-6 85001 and up
30 Testing and adjusting 1

Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting............................................................................................. 3
Sketches of special tools ................................................................................................................................ 7
Measuring engine speed................................................................................................................................. 8
Measuring intake air pressure (boost pressure) ........................................................................................... 10
Measuring exhaust temperature ................................................................................................................... 12
Measuring exhaust gas color ........................................................................................................................ 14
Adjusting valve clearance ............................................................................................................................. 15
Measuring compression pressure................................................................................................................. 16
Measuring blow-by pressure......................................................................................................................... 18
Measuring engine oil pressure...................................................................................................................... 19
Handling fuel system parts............................................................................................................................ 20
Releasing residual pressure from fuel system .............................................................................................. 20
Measuring fuel pressure ............................................................................................................................... 21
Measuring fuel return rate and fuel leakage ................................................................................................. 22
Bleeding air from fuel circuit.......................................................................................................................... 26
Measuring fuel circuit for leakage ................................................................................................................. 28
D155A-6 1
SEN03200-02 30 Testing and adjusting
Testing and adjusting alternator belt tension................................................................................................. 29

Testing and adjusting air conditioner compressor belt tension...................................................................... 30
Measuring fan speed..................................................................................................................................... 31
Measuring fan circuit oil pressure ................................................................................................................. 32
Bleeding air from fan pump ........................................................................................................................... 33
Bleeding air from work equipment pump....................................................................................................... 34
Adjusting fuel control dial and decelerator pedal .......................................................................................... 35
2 D155A-6
Tools for testing, adjusting, and troubleshooting 1
Sym-
Q'ty
Testing and adjusting item Part No. Part name Remarks
bol
– 101 – 200 kPa
Measuring intake air pres- 799-201-2202 Boost gauge kit 1
A {– 760 – 1,500 mmHg}
sure (boost pressure)
799-401-2220 Hose 1 Straight type quick coupler
Measuring exhaust
B 799-101-1502 Digital thermometer 1 – 99.9 – 1,299°C
temperature
1 799-201-9001 Handy smoke checker 1
Measuring exhaust gas
C Commercially Bosch index: 0 – 9
color 2 Smoke meter 1
available
Commercially Air intake: 0.35 mm,
Adjusting valve clearance D Thickness gauge 1
available Exhaust: 0.57 mm
1 795-502-1590 Compression gauge 1 0 – 7.0 MPa {0 – 70 kg/cm2}
Measuring compression
E 795-471-1330 Adapter 1
pressure 2 For 140E-5 engine
6261-71-6150 Gasket 1
Measuring blow-by
F 799-201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mmH2O}
pressure
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6.0, 40, 60 MPa
1 {25, 60, 400, 600 kg/cm2}
Measuring engine oil Pressure gauge: 60 MPa
G
pressure 790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
Pressure gauge: 1.0 MPa
2 799-401-2320 Hydraulic tester 1
{10 kg/cm2}
Pressure gauge:
1 {25, 60, 400, 600 kg/cm2}
Pressure gauge: 60 MPa
790-261-1204 Digital hydraulic tester 1
Measuring fuel pressure H {600 kg/cm2}
Pressure gauge: 1.0 MPa
2 799-401-2320 Hydraulic tester 1
{10 kg/cm2}
795T-471-2010 Adapter 1
3 8 × 1.25 mm o R1/8
07005-00812 Gasket 1
1 6151-51-8490 Spacer 1 Inside diameter: 14 mm
2 6206-71-1770 Joint 1 Inside diameter of joint: 10 mm
Commercially
3 Hose 1 ø5 mm × 2 – 3 m
available
Measuring fuel return rate Commercially
J 4 Hose 1 ø15 mm × 2 – 3 m
and fuel leakage available
Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
Measuring fan speed K 795-205-1100 Tachometer kit 1 6.0 – 99999.9 rpm
Pressure gauge:
1 {25, 60, 400, 600 kg/cm2}
Measuring fan circuit Pressure gauge: 60 MPa

L 790-261-1204 Digital hydraulic tester 1
pressure {600 kg/cm2}
2 799-401-3400 Adapter 1 Size: 05
799-101-5220 Nipple
3 1 Size: 10 × 1.25 mm
07002-11023 O-ring
D155A-6 3
Sym-
Q'ty
bol
Pressure gauge:
Measuring power train oil {25, 60, 400, 600 kg/cm2}
M
pressure
{600 kg/cm2}
Adjusting brake pedal N 79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
Emergency escape 19M-06-32820 Switch assembly 1

1
method when power train P 17A-06-41410 Wiring harness 1
has trouble 2 790-190-1601 Pump assembly 1
Pressure gauge:
1 {25, 60, 400, 600 kg/cm2}
Measuring and adjusting
work equipment oil pres- Q Pressure gauge: 60 MPa
sure {600 kg/cm2}
799-101-5220 Nipple 2
2 Size: 10 × 1.25 mm
07002-11023 O-ring 2
Pressure gauge:
1 {25, 60, 400, 600 kg/cm2}
Measuring control circuit Pressure gauge: 60 MPa
R 790-261-1204 Digital hydraulic tester 1
basic pressure {600 kg/cm2}
799-401-3200 Adapter 1
2 Size: 03
02896-11009 O-ring 1
Pressure gauge:
1 {25, 60, 400, 600 kg/cm2}
Testing work equipment
lock solenoid valve output S Pressure gauge: 60 MPa
791T-643-1010 Elbow 1
2
07002-11423 O-ring 1
Pressure gauge:
1 {25, 60, 400, 600 kg/cm2}
PPC valve output pres- {600 kg/cm2}
T
sure 799-401-3100 Adapter 1
2 Size: 02
02896-11008 O-ring 1
799-401-3200 Adapter 1
3 Size: 03
02896-11009 O-ring 1
Pressure gauge:
1 {25, 60, 400, 600 kg/cm2}
Measuring ripper pin puller
solenoid valve output U Pressure gauge: 60 MPa
799-401-3200 Adapter 1
2 Size: 03
02896-11009 O-ring 1
21mm deep socket
Commercially
Removal and installation – Socket 1 (MITOLOY 4ML 21 or equivalent)
available
of engine coolant temper- Applied engine: 530056 – 534132
ature sensor 19 mm deep socket
– 795T-981-1010 Socket 1
Applied engine: 534133 –
4 D155A-6
Sym-
Q'ty
bol
Measuring internal leak-
Commercially
age of work equipment V Measuring cylinder 1
available
cylinder
Measuring coolant
temperature and oil — 799-101-1502 Digital thermometer 1 – 99.9 – 1,299°C
temperature
Testing operating effort 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
—
and pressing force 79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
Measuring stroke and Commercially
— Ruler 1
hydraulic drift available
Measuring work equip- Commercially
— Stopwatch 1
ment speed available
Measuring voltage and Commercially
— Circuit tester 1
resistance available
799-601-4101
or T-adapter assembly
799-601-4201
For DRC60 • ECONO*² (Max 60P)
799-601-4350 • T-box 1 (Does not include in assembly
No.799-601-4201)
For engine (CRI-T3) coolant temper-
ature sensor (PACKARD 2P)
For engine (CRI-T3) fuel temperature
795-799-5530 • Socket 1
sensor (PACKARD 2P)
For engine (CRI-T3) oil temperature
sensor (PACKARD 2P)
For engine (CRI-T3) boost tempera-
795-799-5540 • Socket 1
ture sensor (PACKARD 2P)
For engine (CRI-T3) ambient pres-
799-601-4240 • Socket 1
sure sensor (AMP 3P)
For engine (CRI-T3) boost pressure
799-601-4110 • Socket 1
sensor (SUMITOMO 3P)
For engine (CRI-T3) G (Bkup) sensor
799-601-4330 • Socket 1
(SUMITOMO 3P)
For engine (CRI-T3) supply pump
Engine related controller, 799-601-9430 • Socket 1 PCV1 • supply pump PCV sensor
sensor and actuator diag- — (SUMITOMO 3P)
nosis
For engine (CRI-T3) NE sensor
799-601-4130 • T-adapter 1
(FRAMATOME 3P)
For engine (CRI-T3) oil pressure sen-
799-601-4150 • T-adapter 1
sor (FRAMATOME 3P)
For engine (CRI-T3) common rail
799-601-9420 • T-adapter 1
pressure sensor (AMP 3P)
For engine controller (DRC26-50P)
799-601-4211 • T-adapter 1 (Does not include in assembly No.
799-601-4201)
For engine controller DRC26-60P
799-601-4220 • T-adapter 1 (Does not include in assembly No.
799-601-4201)
For engine controller (DTP-4P)
799-601-4260 • T-adapter 1 (Include in assembly No. 799-601-
9000 and 799-601-9100, too)
For DT 4P
9000 and 799-601-9200, too)
For DT 2P
9000 and 799-601-9200, too)
D155A-6 5
Sym-
Q'ty
bol
799-601-9000
or
799-601-9100 T-adapter assembly
or
799-601-9300
799-601-9200 • T-box 1 For ECONO*¹ (Max 24P)
799-601-4350 • T-box 1 For DRC60 • ECONO*² (Max 60P)
799-601-7000
or
799-601-7100
799-601-7400
or
799-601-8000
For ECONO*³ (Max 21P)
799-601-2600 • T-box 1 (Does not include in assembly No.
799-601-7000.)
799-601-7210 • T-adapter 1 For AMP040 16P
799-601-7110 • T-adapter 1 For M 3P
For SWP 6P (Does not include in
799-601-7050 • T-adapter 1
assembly No. 799-601-8000.)
Mashine related controller 799-601-7530 • T-adapter 1 For AMP070 14P
and sensors/wiring har- —
nesses diagnosis
799-601-9000
799-601-9200
For DT 4P
4101 and 799-601-4201, too.)
799-601-9020 • T-adapter 1 For DT 2P
799-601-9030 • T-adapter 1 For DT 3P
799-601-9050 • T-adapter 1 For DT 6P
799-601-9060 • T-adapter 1 For DT 8P
799-601-9070 • T-adapter 1 For DT 8P
799-601-9110 • T-adapter 1 For DT 12P (Gray)
799-601-9120 • T-adapter 1 For DT 12P (Black)
799-601-9130 • T-adapter 1 For DT 12P (Green)
799-601-9140 • T-adapter 1 For DT 12P (Brown)
799-601-9280 • T-adapter 1 For HD36 24-24P
799-601-9290 • T-adapter 1 For HD36 24-31P
(Does not include in assembly
No.799-601-9200.)
(Include in assembly No. 799-601-
9100, too.)
799-601-9360 • T-adapter 1 For pump controller (DRC26-24P)
799-601-9350 • T-adapter 1 For pump controller (DRC26-40P)
6 D155A-6
Sketches of special tools 1

Note) Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
H3 Adapter
S2 Elbow
D155A-6 7
Measuring engine speed 1

k Stop the machine on level ground, lower
the work equipment to the ground, stop the
engine, and set the parking brake lever and
work equipment lock lever in the lock posi-
tion.
a Measure the engine speed under the following
conditions.
q Engine coolant temperature: Within oper-
ating range
q Power train oil temperature: Within operat-
ing range
q Hydraulic oil temperature: Within operat-
ing range 2. Measuring low idle speed
q Working mode: P mode 1) Start the engine and set the fuel control
q Gearshift mode: Either Auto or Manual dial in the low idle (MIN) position.
2) Set the PCCS lever, blade control lever,
1. Preparation work and ripper control lever in neutral and
Measure the engine speed with the Adjustment measure the engine speed.
function in the service mode of the machine a The parking brake lever and work
monitor. equipment lock lever may be kept in
a For the operating method of the machine the LOCK position.
monitor, see Special functions of machine
monitor (EMMS). 3. Measuring high idle speed
1) Measuring low idle speed, decelerator 1) Start the engine and set the fuel control
pedal speed, auto-deceleration speed, dial in the high idle (MAX) position.
torque converter stall speed, and torque 2) Set the PCCS lever, blade control lever,
converter stall speed + work equipment and ripper control lever in neutral and
relief speed (full stall speed): measure the engine speed.
q Adjustment code: 0530 (Stall mode) a The parking brake lever and work
a When stalling the torque converter for equipment lock lever may be kept in
a purpose other than measuring the the LOCK position.
engine speed, be sure to use this a When measuring the high idle speed,
adjustment code, too. be sure to select adjustment code
[0007] (If adjustment code [0530] is
selected, the auto-deceleration speed
is measured).
4. Measuring decelerator pedal speed

1) Start the engine and set the fuel control
dial in the high idle (MAX) position.
and ripper control lever in neutral, press
the decelerator pedal to the stroke end,
and measure the engine speed.
a The parking brake lever and work
equipment lock lever may be kept in
the LOCK position.
2) Measuring high idle speed:
q Adjustment code: 0007 (Reset engine
5. Measuring auto-deceleration speed
deceleration)
a Only when this code is selected, the
dial in the high idle (MAX) position.
engine can be operated and tested
with the auto-decelerator reset.
and ripper control lever in neutral and
measure the engine speed.
8 D155A-6
a The parking brake lever and work a The preset mode display section (at
equipment lock lever may be kept in the right bottom of the screen) can be
the LOCK position. set to [F3-R3] only while the Adjust-
ment function is selected.
6. Measuring torque converter stall speed 3) Set the work equipment lock lever in the
1) Start the engine and set the fuel control free position and operate the ripper control
dial in the low idle (MIN) position. lever to set the ripper lift cylinder to the
2) Operate the shiftup (UP) switch of the raise stroke end.
PCCS lever and set the preset mode dis- 4) While pressing the brake pedal securely,
play section to [F3-R3]. set the parking brake lever in the free
a The preset mode display section (at position and set the direction of PCCS
the right bottom of the screen) can be lever in the forward position.
set to [F3-R3] only while the Adjust- a Before going to the next step, check
ment function is selected. that [F3] is displayed in the gear
3) While pressing the brake pedal securely, speed display section (at the right
set the parking brake lever in the free bottom of the screen).
position and set the direction of PCCS a Keep the steering system in neutral.
lever in the forward position. 5) Press the decelerator pedal and set the
a Before going to the next step, check fuel control dial in the high idle (MAX)
that [F3] is displayed in the gear position.
speed display section (at the right 6) Return the decelerator pedal slowly to stall
bottom of the screen). the torque converter with the engine at
a Keep the steering system in neutral. high idle.
4) Press the decelerator pedal and set the k Keep pressing the brake pedal se-
fuel control dial in the high idle (MAX) curely and keep your right foot on the
position. decelerator pedal for safety until the
5) Return the decelerator pedal slowly to stall work is finished.
the torque converter with the engine at 7) Just after the power train oil temperature
high idle. gauge (T/C TEMPERATURE) indicates
k Keep pressing the brake pedal se- 118 – 120 °C, return the direction of PCCS
curely and keep your right foot on the lever to neutral.
decelerator pedal for safety until the a The top of the green range of the
work is finished. power train oil temperature gauge
6) Just after the power train oil temperature indicates about 118 – 120 °C.
gauge (T/C TEMPERATURE) indicates 8) Repeat above steps 4) – 7) 3 times.
118 – 120 °C, return the direction of PCCS 9) Perform steps 4) – 6) again, operate the
lever to neutral. ripper control lever to relieve the ripper
a The top of the green range of the raise system, and measure the engine
power train oil temperature gauge speed about 5 seconds after the power
indicates about 118 – 120 °C. train oil temperature gauge (T/C TEM-
7) Repeat above steps 3) – 6) 3 times. PERATURE) indicates 118 – 120 °C.
8) Perform steps 3) – 5) again and measure a Immediately after finishing measure-
the engine speed about 5 seconds after ment, return the direction of PCCS
the power train oil temperature gauge (T/C lever to neutral and lower the power
TEMPERATURE) indicates 118 – 120 °C. train oil temperature with the engine
a Immediately after finishing measure- at high idle.
ment, return the direction of PCCS
lever to neutral and lower the power
train oil temperature with the engine
at high idle.
7. Measuring torque converter stall + work

equipment relief speed (Full stall speed)
dial in the low idle (MIN) position.
2) Operate the shiftup (UP) switch of the
PCCS lever and set the preset mode dis-
play section to [F3-R3].
D155A-6 9
Measuring intake air pressure 4. Run the engine at a medium or higher speed
(boost pressure) 1 and drain the oil from the test hose.
a Insert the connecting parts of the gauge
a Measuring instruments for intake air pressure and hose about a half and open the self-
(boost pressure) seal on the hose side repeatedly, and the
Symbol Part No. Part name oil will be drained.
a If Pm kit (A) is available, you may drain
799-201-2202 Boost gauge kit
A the oil by using the oil draining coupling
799-401-2220 Hose
(790-261-1130) in that kit.
k Stop the machine on level ground, lower a If oil is left in the hose, the gauge does not
the work equipment to the ground, stop the work. Accordingly, be sure to drain the oil.
5. Turn the starting switch ON and set the
machine monitor to Adjustment function of the
tion.
service mode.
k Be careful not to touch any hot part of the
q Adjustment code: 0530 (Stall mode)
engine when removing or installing the
a For the operating method, see Special
measuring tools.
functions of machine monitor (EMMS).
a Measure the intake air pressure (boost pres-
sure) under the following conditions.
ating range
ing range
ing range
1. Open the engine left side cover.
2. Remove intake air pressure pickup plug (1)
from the rear of the air intake connector.
6. While running the engine at high idle, stall the

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

nect gauge [2].
10 D155A-6
7. After finishing measurement, remove the mea-

suring instruments and return the removed parts.
q Remove the gasket sealant sticking to the
threaded part of the removed plug with a
wire brush, apply adhesive or gasket seal-
ant to it, and install it.
2 Plug: LT-2 or LG-5
3 Plug: 9.8 – 19.6 Nm {1.0 – 2.0 kgm}
(Air intake connector made of FC)
6.9 – 14.7 Nm {0.7 – 1.5 kgm}
(Air intake connector made of Al)
D155A-6 11
Measuring exhaust temperature 1

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

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

periodically for preventive maintenance (Pm
3. Install sensor [1] of digital thermometer B and clinic)
connect them to meter [2]. a If the torque converter is stalled simply,
a Clamp the wiring harness of the digital the torque converter oil is overheated
thermometer so that it will not touch a hot before the exhaust temperature is stabi-
part during measurement. lized. Accordingly, measure according to
the following procedure.
1) Turn the starting switch ON and set the
machine monitor to Adjustment function of
the service mode.
a For the operating method, see Spe-
cial functions of machine monitor
(EMMS).
12 D155A-6
2) Start the engine and set the fuel control 8) Under the condition of step 7), stop reliev-
dial in the low idle (MIN) position. ing the ripper raise system and lower the
3) Operate the shiftup (UP) switch of the exhaust temperature by only stalling the
PCCS lever and set the preset mode dis- torque converter (Condition (b) in the fig-
play section to [F3-R3]. ure).
a The preset mode display section (at a If the exhaust temperature does not
the right bottom of the screen) can be lower but rises, set the temperature
set to [F3-R3] only while the Adjust- high in step 7).
ment function is selected. 9) After the exhaust temperature is lowered
4) Set the work equipment lock lever in the and stabilized, measure the exhaust tem-
free position and operate the ripper control perature (Condition (c) in the figure).
lever to set the ripper lift cylinder to the
raise stroke end. k Just after the power train oil tem-
5) While pressing the brake pedal securely, p eratu re (T/C TEMPERAT URE)
set the parking brake lever in the free reaches about 120 °C, return the
position and set the direction of PCCS direction of PCCS lever to neutral
lever in the forward position. and lower the power train oil tem-
a Before going to the next step, check perature with the engine at high
that [F3] is displayed in the gear idle.
speed display section (at the right a The border between the green range
bottom of the screen). and red range of the power train oil
a Keep the steering system in neutral. temperature gauge indicates about
6) Press the decelerator pedal and set the 120 °C.
fuel control dial in the high idle (MAX)
position.
7) Return the decelerator pedal slowly to stall
the torque converter and relieve the ripper
raise system to raise the exhaust temper-
ature to about 650 °C (Condition (a) in the
figure) with the engine at high idle.
k Keep pressing the brake pedal
securely and keep your right foot
on the decelerator pedal for safety
until the work is finished.

suring instruments and return the removed
parts.
q Clean the threaded part of the removed
plug, apply anti-seizure compound to it,
and tighten it.
2 Plug: Anti-seizure compound (LC-G)
3 Plug: 2.9 – 5.9 Nm {0.3 – 0.6 kgm}
D155A-6 13
Measuring exhaust gas color 1

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

tion.
k Be careful not to touch any hot part of the 2) Connect the probe hose, receptacle of the
engine when removing or installing the accelerator switch, and air hose to smoke
measuring tools. meter C2.
a If an air source and an electric power source a Limit the supplied air pressure to 1.5
are not available in the field, use handy smoke MPa {15 kg/cm²}.
checker C1. When recording official data, use 3) Connect the power cable to a receptacle
smoke meter C2. of AC 100 V.
a Measure the exhaust gas color under the fol- a Before connecting the cable, check
lowing condition. that the power switch of the smoke
q Engine coolant temperature: Within oper- meter is turned OFF.
ating range 4) Loosen the cap nut of the suction pump
1. Measuring with handy smoke checker C1 and fit the filter paper.
1) Stick a sheet of filter paper to smoke a Fit the filter paper securely so that the
checker C1. exhaust gas will not leak.
2) Insert the exhaust gas intake pipe in 5) Turn power switch of smoke meter C2
exhaust pipe (1). ON.
3) Start the engine.
4) Accelerate the engine suddenly or run it at
high idle and operate the handle of smoke
checker C1 so that the filter paper will
absorb the exhaust gas.
6) Start the engine.

7) Accelerate the engine suddenly or run it at
high idle and press the pedal of smoke
meter C2 and collect the exhaust gas into
the filter paper.
8) Place the contaminated filter paper on the
5) Remove the filter paper and compare it
clean filter paper (at least 10 sheets) in the
with the attached scale.
filter paper holder and read the indicated
6) After finishing measurement, remove the
value.
measuring instrument and return the
removed parts.
2. Measuring with smoke meter C2 removed parts.
1) Insert probe [1] of smoke meter C2 in the
outlet of exhaust pipe (1) and fix it to the
exhaust pipe with a clip.
14 D155A-6
Adjusting valve clearance 1

a Measuring instruments for valve clearance
Commercially
D Thickness gauge
available

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

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

stamped "1.6TOP" line (a) of the damper to
pointer (2) and set the No. 1 cylinder to the
compression top dead center.
a Rotate the crankshaft with the hexagonal
part at the end of the water pump drive
shaft.
a When the No. 1 cylinder is at the compres-
sion top dead center, the rocker arm of the
No. 1 cylinder can be moved by the valve
clearance with the hand. If the rocker arm 8. After adjusting the No. 1 cylinder, rotate the
cannot be moved, the No. 1 cylinder is not crankshaft forward by 120 ° to set the stamped
at the compression top dead center. In TOP line of each cylinder to pointer (2) accord-
this case, rotate the crankshaft one more ing to the firing order and adjust the valve
turn. clearance.
a Eliminate the slack of the injector wiring q Firing order: 1–5–3–6–2–4
harness and press it against the injector 9. After finishing adjustment, return the removed
body so that it will not interfere with the parts.
rocker arm. 3 Cylinder head cover mounting bolt:
Tighten the nuts alternately. 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
D155A-6 15
Measuring compression pressure1 a Disconnect the terminal of the injector wir-

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

tion.
a When measuring the compression pressure,
take care not to burn yourself on the exhaust
manifold, muffler, etc. or get caught in a rotat-
ing part.
a Measure the compression pressure under the
following conditions.
q Engine oil temperature: 40 – 60 °C
1. Remove the engine hood assembly and air 5. Install adapter E2 to the mounting hole on the
cleaner together. injector and connect compression gauge E1.
4 Engine hood assembly: 170 kg a Be sure to fit the gasket to the injector
end.
2. Remove cylinder head cover (1) of the cylinder a Fix the adapter with the injector holder.
to measure the compression pressure. 3 Holder mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a Apply a little amount of engine oil to the
connecting parts of the adapter and gauge
so that air will not leak easily.
6. Install rocker arm assembly (2) and adjust the

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

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

injector wiring harness (4) and remove injector
(5) and wiring harness.
16 D155A-6
7. Set the engine in the no-injection cranking 2) Tighten bolt (13) and washer (14) tempo-
mode with the machine monitor. rarily.
a See Testing and adjusting (Part 3), "No- 2 Spherical part of washer:
injection cranking". Engine oil
3) Tighten sleeve nut (15) of the fuel high-
pressure tube temporarily.
4) Tighten bolt (13) permanently.
3 Bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm}
5) Tighten sleeve nut (15) permanently.
3 Sleeve nut:
39.2 – 49.0 Nm {4 – 5 kgm}

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

see Adjusting valve clearance.
3 Cylinder head cover mounting bolt:
29.4 – 34.3 kgm {3.0 – 3.5 kgm}
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 pres-
sure, check that the engine speed is in the
range of the measurement condition.

parts.
a Install the injector and fuel high-pressure
tube according to the following procedure.
a Before installing the injector, replace the
copper gasket and O-ring with new ones.
1) Push in injector (11) with the hand to
assemble holder (12) temporarily.
D155A-6 17
Measuring blow-by pressure 1 value is judged abnormal, check for

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

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

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

torque converter and measure the blow-by
pressure.
a For the procedure for stalling the torque
converter, see Measuring engine speed.
a Normally, the blow-by pressure should be
measured while the engine is operated at
the rated output. In the field, however, an
approximate value can be obtained by
stalling the torque converter.
a If it is impossible to run the engine at the
rated output or stall the torque converter,
measure while the engine is running at
high idle. The value obtained in this case
is about 80% of the blow-by pressure at
the rated output.
a The blow-by pressure may vary largely
with the engine condition. If the measured
18 D155A-6
Measuring engine oil pressure 1 4. Run the engine at low idle and high idle and
measure the engine oil pressure.
a Measuring instruments for engine oil pressure
799-101-5002 Hydraulic tester
1
G 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester

tion.
a Measure the engine oil pressure under the fol-
lowing condition.
ating range 5. After finishing measurement, remove the mea-
1. Open the engine left side cover and left mud- parts.
guard. q Remove the gasket sealant sticking to the
threaded part of the removed plug with a
2. Remove engine oil pressure pickup plug (1) wire brush, apply adhesive or gasket seal-
from the cylinder block. ant to it, and install it.
2 Plug: LT-2 or LG-5
3 Plug: 16.7 – 37.2 Nm {1.7 – 3.8 kgm}
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].
D155A-6 19
Handling fuel system parts 1 Releasing residual pressure from

a Precautions for testing and maintaining fuel fuel system 1
system a Pressure is generated in the low-pressure cir-
The common rail fuel injection system (CRI) cuit and high-pressure circuit of the fuel sys-
consists of more precise parts than the con- tem while the engine is running.
ventional fuel injection pump and nozzle. If for- Low-pressure circuit:
eign matter enters this system, it can cause a Feed pump – Fuel filter – Supply pump
trouble. High-pressure circuit:
When testing and maintaining the fuel system, Supply pump – Common rail – Injector
take care more than the past. If dust, etc. a The pressure in both low-pressure circuit and
sticks to any part, wash that part thoroughly high-pressure circuit lowers to a safety level
with clean fuel. automatically 30 seconds after the engine is
a Precautions for replacing fuel filter cartridge stopped.
Be sure to use the Komatsu genuine fuel filter a Before the fuel circuit is tested and its parts are
cartridge. removed, the residual pressure in the fuel cir-
Since the common rail fuel injection system cuit must be released completely. Accordingly,
(CRI) consists of more precise parts than the observe the following.
conventional fuel injection pump and nozzle, it k Before testing the fuel system or removing
employs a high-efficiency special filter to pre- its parts, wait at for least 30 seconds after
vent foreign matter from entering it. If a filter stopping the engine until the residual pres-
other than the genuine one is used, the fuel sure in the fuel circuit is released. (Do not
system may have a trouble. Accordingly, start the work just after stopping the engine
never use such a filter. since there is residual pressure.)
a Precaution for connecting fuel spill circuit hose
The common rail fuel injection system (CRI)
consists of more precise parts than the con-
ventional fuel injection pump and nozzle. If the
engine is started while the spill circuit hose is
blocked, the spill circuit pressure increases
abnormally and the injector may be damaged.
20 D155A-6
Measuring fuel pressure 1 3. Run the engine at high idle and measure the
fuel pressure.
a Measuring instruments for fuel pressure a If the fuel pressure is in the following
Symbol Part No. Part name range, it is normal.
799-101-5002 Hydraulic tester Engine speed Fuel pressure
1
790-261-1204 Digital hydraulic tester 0.15 – 0.3 MPa
High idle
H 2 799-401-2320 Hydraulic tester {1.5 – 3 kg/cm²}
795T-471-2010 Adapter
3
07005-00812 Gasket

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

of hydraulic tester H1 and connect them to
hydraulic tester H2.
D155A-6 21
Measuring fuel return rate and fuel leakage 1
a Measuring instruments for return rate and fuel

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

fuel flowing out during the test.
tion.
22 D155A-6
1. Preparation work 5) Connect test hose J3 to the end of joint

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

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

tighten the removed joint bolt again.
a In the figure, 1 oil filter is removed
temporarily from the common rail
side.
a Be sure to fit the gaskets to both ends
of the joint.
D155A-6 23
3) Run the engine at high idle and stall the 2) Lay test hose J4 so that it will not slacken
torque converter. After the engine speed and put its end in the oil pan.
is stabilized, measure the leakage in 1
minute with measuring cylinder J5.
a For the procedure for stalling the
torque converter, see Measuring
torque converter stall speed.
a You may measure the leakage for 20
seconds and judge by multiplying the
result by 3.
a If the leakage from the pressure lim-
iter is in the following range, it is nor-
mal.
Leakage
Engine speed
(cc/min)
Torque converter
Max. 10
stall
3) Turn the starting switch ON set the

machine monitor to Adjusting function of
4) After finishing measurement, stop the the service mode.
engine. q Adjustment code: 0530 (Stall mode)
3. Testing return rate from injector cial functions of machine monitor
a Keep the hose on the pressure limiter side (EMMS)".
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.
24 D155A-6
4) Run the engine at high idle and stall the

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

engine.
4. Work after finishing measurement

After finishing all measurement, remove the
measuring instruments and return the removed
parts.
3 Common rail pressure limiter joint bolt:
17.7 – 22.6 Nm {1.8 – 2.3 kgm}
3 Supply pump overflow joint bolt:
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
D155A-6 25
Bleeding air from fuel circuit 1 a The electric priming pump stops while the
lamp is blinking. This phenomenon is not
a Bleed air from the fuel circuit in the following abnormal, however.
cases according to this procedure. a If the switch is turned "OFF" position while
q When the fuel filter is replaced the lamp is blinking, the lamp goes off and
q When fuel is used up the electric priming pump stops.
k
q When the engine is started for the first While the electric priming pump is in
time after the fuel piping or supply pump is operation, pressure is applied to the
replaced fuel circuit. Do not loosen the air
a If the fuel filter was replaced, do not fill the bleeding plug at this time, since the
main filter and prefilter with the fuel. fuel may spout out.
1. Turn the starting switch to the "OFF" position.
2. Check that the fuel valve on the fuel tank side

is open.
3. Open the left side cover of the engine and set

air bleeding piping lever (1) in the vertical posi-
tion to open the valve of the circuit.
5. After the specified time (approx. 7 minutes),

lamp (4) goes off and the electric priming pump
stops automatically.
a If only the fuel filter was replaced, the air
bleeding work is completed now.
6. If the fuel was used up or the fuel piping or

supply pump was replaced and there is not fuel
in the fuel circuit, turn switch (3) "ON" again
4. Turn "ON" switch (3) of electric priming pump after the electric priming pump stops automati-
timer (2) installed to the side of the air cleaner. cally.
a The electric priming pump operates and
lamp (4) blinks. 7. When lamp (4) goes off, the air bleeding work
is completed.
8. Set air bleeding piping lever (1) in the horizon-

tal position to stop the valve of the circuit.
a The electric priming pump has a timer in it

to start and stop itself automatically (See
the following figure).
26 D155A-6
9. Start the engine with the starting motor.

a Do not operate the starting motor continu-
ously for more than 20 seconds.
q Run the engine at low idle for about 5 min-
utes to bleed all air from the fuel circuit.
q After stopping the engine, check that the
air bleeding valve is closed.
10. If the engine does not start, start it according to

k When starting the engine, check that
there is no person around the engine.
a Perform the following procedure with the
air bleeding valve closed. (Do not open
the air bleeding valve after step 7.)
a If the engine does not start, wait for at
least 2 minutes before trying to start
again.
1) Turn the electric priming pump switch
"ON".
2) While the electric priming pump is operat-
ing, start the engine.
q If the engine does not start, repeat
the above operation.
a Do not operate the starting motor
continuously for more than 20 sec-
onds.
a If the engine does not start, wait for at
least 2 minutes before trying to start
again.
3) After the engine starts, keep it running for
at least 5 minutes to bleed all air from the
fuel circuit.
4) Stop the engine and check that the air
bleeding valve is closed.
5) From now on, start the engine as usual.
D155A-6 27
Measuring fuel circuit for leakage1 9. Check the fuel piping and devices for fuel leak-
age.
k Very high pressure is generated in the high- a Check mainly around the high-pressure
pressure circuit of the fuel system. If fuel circuit parts coated with the color checker
leaks while the engine is running, it is dan- for fuel leakage.
gerous since it can catch fire. a If any fuel leakage is detected, repair it
a After testing the fuel system or removing and and inspect again from step 1.
installing its parts, test it for fuel leakage a If no fuel leakage is detected, inspection is
according to the following procedure. completed.
a Clean and degrease the engine and the parts
around it in advance so that you can test it eas-
ily for fuel leakage.
1. Spray color checker (developer) over the joints

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

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

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

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

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

a Relieve the ripper circuit by raising the rip-
per.
28 D155A-6
Testing and adjusting alternator 6. Install belt cover (1) with the 2 mounting bolts.
belt tension 1 a Check for breakage of the pulleys, wear of
the V-grooves, contact of the belts and V-
k Stop the machine on level ground, lower grooves, and contact of the belt covers
the work equipment to the ground, stop the and rotating parts.
engine, and set the parking brake lever and a If the belt is lengthened to the adjustment
work equipment lock lever in the lock posi- limit, cut, or cracked, replace it with new
tion. one.
a If the V-belt is replaced, adjust its tension
Testing again after 1 operating hour.
1. Open the engine right side cover and remove a After tightening the bolts, check that the
the inspection plate on the right of the radiator belt tension is normal according to the
guard. above procedure.
2. Press the intermediate point of the belt

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

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

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

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

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

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

mounting bolts (3) of alternator (2).
D155A-6 29
Testing and adjusting air a After tightening the bolts, check that the
conditioner compressor belt belt tension is normal according to the
above procedure.
tension 1
tion.
Testing
1. Open the engine left side cover and left mud-
guard.
2. Press the intermediate point of the belt

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

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

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

a Check for breakage of the pulleys, wear of
the V-grooves, contact of the belts and V-
grooves, and contact of the belt covers
and rotating parts.
a If the belt is lengthened to the adjustment
limit, cut, or cracked, replace it with new
one.
a If the V-belt is replaced, adjust its tension
again after 1 operating hour.
30 D155A-6
Measuring fan speed 1 a If this adjustment code is displayed, the

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

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

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

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

parts.
4. Close the radiator mask.

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

to Adjusting function of the service mode.
a Adjustment code: 1005 (Fan 100% mode)
a For the operating method, see "Special
functions of machine monitor (EMMS)".
D155A-6 31
Measuring fan circuit oil pressure1

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

the work equipment to the ground, stop the 5. Close the radiator mask.
k
engine, and set the parking brake lever and Before starting the engine, be sure to
work equipment lock lever in the lock posi- close the radiator mask. Do not start
tion. the engine while the radiator mask is
a Measure the fan circuit oil pressure under the open.
following condition.
q Hydraulic oil temperature: Within operat- 6. Start the engine and set the machine monitor
ing range to Adjusting function of the service mode.
a Adjustment code: 1005 (Fan 100% mode)
1. Open the radiator mask and remove the fan a For the operating method, see "Special
net. functions of machine monitor (EMMS)".
a If this adjustment code is displayed, the
2. Disconnect supply hose (1) of the fan motor. fan speed is kept at 100% speed in accor-
dance with the engine speed, regardless
of the state of the machine.
3. Install adapter L2 and connect the discon-

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

gauge [2].
a When using an analog oil pressure gauge,
use one of 39.2 MPa {400 kg/cm²}.
32 D155A-6
7. While running the engine at high idle, measure Bleeding air from fan pump 1
the fan circuit oil pressure.
a If the fan pump is removed and installed or its
piping is disconnected and connected, bleed
air from the fan pump case according to the
a Before starting the following work, check that
the hydraulic oil level is normal.
1. Remove the left step cover.
2. Loosen air bleeder (1) and leave it for 15 min-

utes.

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

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

bleeder (1) and stop the engine.
3 Air bleeder:
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
D155A-6 33
Bleeding air from work equipment

pump 1
a If the work equipment pump is removed and
installed or its piping is disconnected and con-
nected, bleed air from the work equipment
pump case according to the following proce-
dure.
a Before starting the following work, check that
the hydraulic oil level is normal.
1. Remove the right step cover.
2. Loosen air bleeder (1) and leave it for 15 min-

utes.
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}
34 D155A-6
Adjusting fuel control dial and decelerator pedal 1

tion.
1. Outline of fuel control system

q The following signals are input as rotation
command signals to the engine controller.
1) Fuel control dial potentiometer signal
2) Decelerator pedal potentiometer sig-
nal
3) 3rd throttle signal (Power train con-
troller)
DIAL: Fuel control dial
q The engine controller controls the fuel
PEDAL: Decelerator pedal
control system of the engine (CRI system)
ROD: Decelerator pedal rod
according to the one of the above input
POTENTIO: Decelerator pedal potentiometer
signals which indicates the lowest engine
ENG-ECU: Engine controller
speed.
P/T-ECU: Power train controller
q Adjust the decelerator pedal speed and
ENGINE: Engine unit (CRI devices)
high idle speed with the decelerator pedal
[KOMNET]: KOMNET communication circuit (3rd
linkage.
throttle signal)
D155A-6 35
2. Preparation work 5. Work after adjustment

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

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

With the fuel control dial in the high idle posi-
tion (MAX), release decelerator pedal (1) and
check that the high idle speed is normal.
q High idle speed: 2,050 ± 50 rpm
a If the high idle speed is abnormal, adjust it
according to the following procedure.
q When the engine speed is above 1,950
rpm:
Lower the engine speed below 1,900 rpm
temporarily with stopper bolt (3) to elimi-
nate the play of the decelerator pedal, and
then adjust the engine speed to the high
idle.
q When the engine speed is below 1,950
rpm:
Adjust the engine speed to the high idle
speed with stopper bolt (3).
q Standard installed dimension (b) of stop-
per bolt: 34.8 mm
36 D155A-6
D155A-6 37
D155A-6 Bulldozer
© 2009 KOMATSU
All Rights Reserved
38 D155A-6
SEN03201-01
D155A-6

D155A-6 85001 and up

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 ...................................................................................................... 22
Measuring and adjusting work equipment oil pressure................................................................................. 23
Measuring control circuit basic pressure....................................................................................................... 26
Measuring work equipment lock solenoid valve output pressure (PPC valve basic pressure) ..................... 27
Measuring PPC valve output pressure ......................................................................................................... 28
Adjusting play of work equipment PPC valve ............................................................................................... 30
Measuring ripper pin puller solenoid valve output pressure.......................................................................... 31
Testing parts which cause hydraulic drift of blade and ripper........................................................................ 32
Measuring internal leakage of work equipment cylinder ............................................................................... 33
D155A-6 1
Releasing residual pressure from work equipment cylinder.......................................................................... 34

Bleeding air from work equipment cylinder ................................................................................................... 34
Adjusting work equipment lock lever............................................................................................................. 35
Adjusting blade.............................................................................................................................................. 36
Adjusting operator's cab................................................................................................................................ 38
2 D155A-6
Measuring power train oil

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

work equipment lock lever in the LOCK
position.
a Measure the power train oil pressure under the
following condition.
q Power train oil temperature:
Within operating range
a Since the power trail oil pressure pickup plugs
(centralized pressure pickup section) are
installed inside the right step cover, remove
that cover when measuring the power train oil
pressure.
a Pressure pickup plugs and gauges to be
used
Oil pressure
Oil pressure to be
No. Stamp gauge
measured
(MPa {kg/cm²})
Transmission main relief
1 TM 6.0 {60}
pressure
Steering right clutch
2 RC 6.0 {60}
pressure
Steering left clutch pres-
3 LC 6.0 {60}
sure
Transmission forward
4 F 6.0 {60}
clutch pressure
Transmission reverse
5 R 6.0 {60}
clutch pressure
Transmission 1st clutch
6 1ST 6.0 {60}
pressure
Transmission 2nd clutch
7 2ND 6.0 {60}
pressure
Transmission 3rd clutch
8 3RD 6.0 {60}
pressure
Steering right brake
9 RB 6.0 {60}
pressure
Steering left brake pres-
10 LB 6.0 {60}
sure
Torque converter inlet
11 IN 2.5 {25}
pressure
Torque converter outlet
12 OUT 2.5 {25}
pressure
D155A-6 3
1. Measuring transmission main relief pres- 2. Measuring right steering clutch pressure
sure (TM) (RC)
1) Connect oil pressure gauge [1] of hydrau- 1) Connect oil pressure gauge [1] of hydrau-
lic tester M to oil pressure pickup plug (1). lic tester M to oil pressure measurement
a When using an analog oil pressure nipple (2).
gauge, use one of 6.0 MPa {60 kg/ a Use a 6.0 MPa {60 kg/cm²} oil pres-
cm²}. sure gauge.
2) Start the engine and set the PCCS lever in 2) Start the engine and set the parking lever
the fully neutral position. to the FREE position.
a The parking brake lever may be set in 3) Operate the PCCS lever steering fully to
the LOCK position. the right.
3) While running the engine at low idle and a Set the direction to the neutral posi-
high idle, measure the main relief pres- tion.
sure. 4) Measure the oil pressure with the engine
at low idle and high idle.
a Check that the oil pressure becomes
0 when the PCCS lever steering is
returned to neutral.

measuring instruments and return the
removed parts.
5) After completing the measurement, remove

the measuring equipment and set to the
original condition.
4 D155A-6
3. Measuring left steering clutch pressure (LC) 4. Measuring transmission forward clutch
1) Connect oil pressure gauge [1] of hydrau- pressure (F)
lic tester M to oil pressure measurement 1) Connect oil pressure gauge [1] of hydrau-
nipple (3). lic tester M to oil pressure pickup plug (4).
a Use a 6.0 MPa {60 kg/cm²} oil pres- a When using an analog oil pressure
sure gauge. gauge, use one of 6.0 MPa {60 kg/
cm²}.
2) Start the engine and set the parking lever

to the FREE position. 2) Start the engine and set the parking brake
3) Operate the PCCS lever steering fully to lever in the FREE position.
the left. 3) Set the gearshift mode and preset range
a Set the direction to the neutral posi- as follows with the gearshift mode selector
tion. switch and shiftup or shiftdown switch.
4) Measure the oil pressure with the engine q Gearshift mode:
at low idle and high idle. Manual gearshift (Ripping)
a Check that the oil pressure becomes q Preset range: F2-R2
0 when the PCCS lever steering is 4) While pressing the brake pedal, set the
returned to neutral. direction of PCCS lever in the forward
position and shift up the gear to the 3rd
gear speed with the shiftup switch.
a Keep the steering system in neutral.
a Check that [F3] is displayed in the
gear speed display section.
5) While running the engine at high idle,
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.

the measuring equipment and set to the
original condition.
D155A-6 5

removed parts.
5. Measuring transmission reverse clutch

pressure (R)
1) Connect oil pressure gauge [1] of hydrau-
lic tester M to oil pressure pickup plug (5).
a When using an analog oil pressure
gauge, use one of 6.0 MPa {60 kg/
cm²}.

removed parts.
2) Start 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:
Manual gearshift (Ripping)
q Preset range: F2-R2
4) While pressing the brake pedal, set the
direction of PCCS lever in the reverse
position and shift up the gear to the 3rd
gear speed with the shiftup switch.
q Keep the steering system in neutral.
q Check that [R3] is displayed in the
5) While running the engine at high idle,
measure the reverse clutch pressure.
6 D155A-6
6. Measuring transmission 1st clutch pres-

sure (1ST)
lic tester M to oil pressure pickup plug (6).
cm²}.

removed parts.
7. Measuring transmission 2nd clutch pres-

sure (2ND)
2) Start the engine and set the parking brake lic tester M to oil pressure pickup plug (7).
lever in the FREE position. a When using an analog oil pressure
3) Set the gearshift mode and preset range gauge, use one of 6.0 MPa {60 kg/
as follows with the gearshift mode selector cm²}.
q Gearshift mode:
direction of PCCS lever in the forward
position.
5) While running the engine at low idle, mea-
sure the 1st clutch pressure.
pedal securely and keep your right 2) Start the engine and set the parking brake
foot on the decelerator pedal for lever in the FREE position.
safety until the work is finished. 3) Set the gearshift mode and preset range
k Do not increase the engine speed as follows with the gearshift mode selector
to high idle during measurement. switch and shiftup or shiftdown switch.
q Gearshift mode:
direction of PCCS lever in the forward
position.
D155A-6 7
5) While running the engine at low idle, mea- 4) While pressing the brake pedal, set the
sure the 2nd clutch pressure. direction of PCCS lever in the forward
k Since the torque converter is position and shift up the gear to the 3rd
stalled, keep pressing the brake gear speed with the shiftup switch.
pedal securely and keep your right a Keep the steering system in neutral.
foot on the decelerator pedal for a Check that [F3] is displayed in the
safety until the work is finished. gear speed display section.
k Do not increase the engine speed 5) While running the engine at low idle, mea-
to high idle during measurement. sure the 3rd clutch pressure.
k Do not increase the engine speed
to high idle during measurement.

removed parts.
8. Measuring transmission 3rd clutch pres-

sure (3RD)
lic tester M to oil pressure pickup plug (8). 6) After finishing measurement, remove the
a When using an analog oil pressure measuring instruments and return the
gauge, use one of 6.0 MPa {60 kg/ removed parts.
cm²}.
2) Start 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
q Gearshift mode:
8 D155A-6
9. Measuring steering right brake pressure 10. Measuring steering left brake pressure (LB)
(RB) 1) Connect oil pressure gauge [1] of hydrau-
1) Connect oil pressure gauge [1] of hydraulic tester M to oil pressure pickup plug
lic tester M to oil pressure pickup plug (9). (10).
a When using an analog oil pressure a When using an analog oil pressure
gauge, use one of 6.0 MPa {60 kg/ gauge, use one of 6.0 MPa {60 kg/
cm²}. cm²}.
2) Start the engine and set the parking brake 2) Start the engine and set the parking brake
lever in the FREE position. lever in the FREE position.
3) While running the engine at low idle and 3) While running the engine at low idle and
high idle, measure the right brake pres- high idle, measure the left brake pressure.
sure. a During measurement, check that the
a During measurement, check that the oil pressure lowers to 0 when the
oil pressure lowers to 0 when the brake pedal is pressed or the parking
brake pedal is pressed or the parking brake lever is set in the LOCK posi-
brake lever is set in the LOCK position.
tion.

4) After finishing measurement, remove the measuring instruments and return the
measuring instruments and return the removed parts.
removed parts.
D155A-6 9
11. Measuring torque converter inlet pressure 12. Measuring torque converter outlet pressure
1) Connect oil pressure gauge [1] of hydrau- 1) Connect hydraulic tester M to oil pressure
lic tester M to oil pressure measurement measurement nipple (12).
nipple (11). a Use a 2.5 MPa {25 kg/cm²} oil pres-
a Use a 2.5 MPa {25 kg/cm²} oil pressure gauge.
sure gauge.
2) Start the engine and set all the functions of

2) Start the engine and set all the functions of the PCCS lever to neutral.
the PCCS lever to neutral. 3) Measure the oil pressure with the engine
3) Measure the oil pressure with the engine at low idle and high idle.
at low idle and high idle.

4) After completing the measurement, remove the measuring equipment and set to the
the measuring equipment and set to the original condition.
original condition.
10 D155A-6
Adjusting transmission output 5. After finishing adjustment, return the removed

shaft speed sensor 1 parts.
k Stop the machine on level ground, lower 6. Start the engine, set the machine monitor to
the work equipment to the ground, stop the Monitoring function of the service mode, and
engine, and set the parking brake lever and check that the transmission speed is indicated
work equipment lock lever in the LOCK normally.
position. a Monitoring code: 31400 T/M Out Speed
1. Remove the fuel tank and transmission output functions of machine monitor (EMMS).
shaft speed sensor (1). a To rotate the transmission output shaft,
4 Fuel tank: 950 kg (when full) drive the machine actually or run the track
idle.
a Before adjusting the transmission output
shaft speed sensor, remove it and check
that its tip is free from steel chips and
flaws, and then reinstall it.
2. Screw in sensor (1) until its tip touches the

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

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

3 Nut: 49.0 – 68.6 Nm {5 – 7 kgm}
D155A-6 11
Simple test procedure for brake 6. Return the decelerator pedal slowly and check
performance 1 that the machine does not start when the
engine speed reaches the high idle speed.
k
k
Stop the machine on level ground, lower Since the torque converter is stalled,
the work equipment to the ground, stop the keep pressing the brake pedal securely
and keep your right foot on the deceler-
ator pedal for safety until the work is
position.
finished.
a Carry out the simple performance test of the
brake under the following condition.
1. Set the blade and ripper in the travel position

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

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

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

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

control dial in the high idle (MAX) position.
12 D155A-6
Adjusting brake pedal 1
a Adjusting tool for brake pedal

N 79A-264-0091 Push-pull scale

position.
a Tighten the locknut of the rod securely and
bend the cotter pin securely.
a When adjusting the brake pedal, remove the
left cover of the dashboard and left foot rest as
a unit. 2) Adjust installed dimension (b) of stopper
(2) so that dimension (a) will be 80 mm.
1. Adjusting brake potentiometer q Dimension (b) = 35.5 mm (Reference
1) Turn the starting switch ON and set the value)
machine monitor to Adjusting function of 3) Adjust installed dimension (b) of stopper
the service mode. (2) so that the brake pedal potentiometer
a Adjustment code: 0005 voltage will be the specified voltage when
(Brake pedal potentiometer initial cor- brake pedal (1) is released.
rection) q Brake pedal voltage: 2,500 ± 50 mV
a For the operating method, see "Spe- 4) Referring to "Special functions of machine
cial functions of machine monitor monitor (EMMS), Service mode 07, Adjust-
(EMMS)". ment (Adjustment ID: 0005)", perform initial
correction of the brake pedal potentiome-
ter.
D155A-6 13
2. Adjusting brake pedal pressing effort

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

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

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

After finishing adjustment, return the removed
parts.
14 D155A-6
Adjusting parking brake lever 1
k Stop the machine on level ground, lower q Brake oil pressure (At high idle)
Parking brake lever Oil pressure
work equipment lock lever in the LOCK 2.75 ± 0.29 MPa
FREE position
position. {28.0 ± 3.0 kg/cm²}
a Tighten the locknut of the rod securely and LOCK position 0 MPa {0 kg/cm²}
a Remove the lever cover in the cab.
1. Assembly and installation of lever assem-

bly
1) Assemble lever assembly (1) and adjust
the operation of limit switch (2).
q Lever raising position: OFF, lowering
position: ON
q Limit switch operation stroke: 2.8 mm
2) Install lever assembly (1).
2. Checking brake oil pressure

Run the engine and check that the brake oil
pressure is as follows when parking brake
lever (3) is set in the FREE position and LOCK
position.
a For the method of measuring the brake oil
pressure, see Measuring power train oil
pressure.
D155A-6 15
3. Checking limit switch

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

normally when parking brake lever (3) is
set in the FREE position and LOCK posi-
tion.
q FREE position:
Travel lock NC OFF, Travel lock NO
ON
q LOCK position:
Travel lock NC ON, Travel lock NO
OFF
16 D155A-6
Emergency escape method when

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

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

connect wiring harness [2] to connector
PL1 (1).
a The male housing and female hous-
ing of connector PL1 are fixed with
screws.
a Connect the wiring harness to both
male side and female side of connec-
tor PL1.
D155A-6 17
4) Start the engine and set the parking brake 2) Install volume pump [3] of pump assembly
lever in the FREE position. P2 to the outside of the operator's cab.
5) Operate switch assembly [1] and move
the machine to a safe place.
a The gear speed switch is so made
that the switch on the lower gear
speed will be operated first.
3) Remove the fuel tank under rear cover

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

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

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

parking brake lever in the FREE position.
18 D155A-6
6) Operate the volume pump to raise the

brake releasing oil pressure to the initial
pressure.
q Initial pressure: Approx. 2.74 MPa
{Approx. 28 kg/cm²}
a Since the accumulator is installed in
the circuit, the handle must be oper-
ated 30 – 50 times to raise the oil
pressure.
a If the oil pressure does not rise above
a certain level, the relief valve may be
set to low pressure. In this case,
adjust the set pressure of the relief
valve.
7) Tow the machine to a safe place.
a The brake releasing oil pressure low-
ers gradually because of internal
leakage and the brake is applied
again in about 1 minute. Accordingly,
work quickly.
a If the brake releasing pressure lowers
to about 1.57 MPa {about 16 kg/cm²},
the brake is applied. In this case,
operate the volume pump again to
raise the brake releasing pressure to
the initial pressure.
D155A-6 19
Adjusting idler clearance 1
a If the lateral guide, vertical guide, or guide

plate of the idler is worn and the idler runs out
sideways or slants, adjust the idler clearance
1. Adjusting in lateral directions

1) Travel the machine on a flat ground 1 – 2
m and measure clearance (A) (at 4 places
on the right and left sides, inside, and out
side).
2) If clearance (A) is 4 mm or wider, loosen
bolts (1) and adjust the clearance with
shim (2) to the following range.
Clearance on each side: 0.5 – 1.0 mm
a Types of shim: 0.5 mm, 1.0 mm
a Do not loosen bolts (1) more than 3
turns.
20 D155A-6
2. Adjusting in vertical directions (7) Tighten bolts (1).

1) Measure clearance (B) between support 3 Bolt:
(3) and guide plate (4) and clearance (C) 662 – 829 Nm {67.5 – 84.5 kgm}
between vertical guide (5) and wear plate a This part can be adjusted to 6 mm.
(6).
2) If the total of clearances (B) + (C) is 5 mm
or wider, pull out shim (7) and add it to
shim (8) to adjust the clearance to the fol-
lowing range.
Clearances (B) + (C): 2 mm
a When normal, clearance (C) = 0 mm.
Adjustment procedure
1] To grasp the adjustment quantity,
measure clearance (B) and let it be x.
Adjusting quantity: x – 2 mm
a Vertical guide (5) must be set free to

move shim (7) to shim (8). For this
purpose, perform following steps 2]
and 3].
2] Loosen bolts (9) (4 each on the inside
and outside).
a Loosen until the spring reaction
is lost.
3] Loosen bolts (1).
a Do not loosen the bolts more than 3
turns.
4] Pull up vertical guide (5) with a bar

etc. to reduce clearance (C) to 0 and
pull out shim (7) for the adjusting
quantity measure in step 1].
5] Add shim (7) pulled out to shim (8).
(Right, left, inside, and outside, 8
places in total)
a Check that the total number of shims
(7) and (8) in each place is the same
as the total number before the adjust-
ment.
If the number of the shims is changed,
the internal spring does not function
normally.
6] After adjusting, tighten spring holding
bolts (9).
D155A-6 21
Testing and adjusting track shoe

tension 1
position.
Testing
1. Drive the machine slowly on a level place, then
stop it.
a Do not apply the brake when stopping.
2. Place straight steel bar (1) between the idler 4. After finishing adjustment, return the removed
and front carrier roller and measure maximum parts.
clearance (a) between the bottom of the steel
bar and shoe grouser.
a For the above measurement, use an L-
shaped steel which will be deflected less.
q Standard max. clearance (a): 20 – 30 mm
Adjusting
a If the track shoe tension is abnormal, adjust it
1. Remove cover (2).
2. When the tension is too high

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

Add grease through grease fitting (4).
a If the track shoe is not tensed well, drive
the machine forward and in reverse
slowly.
22 D155A-6
Measuring and adjusting work

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

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
position.
be set in the LOCK position.
k Do not operate the work equipment
a When measuring and adjusting the work
equipment oil pressure, remove the control
or steer the machine with the oil
valve cover.
pressure gauge of 6.0 MPa {60 kg/
4 Control valve cover: 25 kg cm²} installed. If you do so, the oil
pressure gauge will be broken.
Measuring
a Measure the work equipment under the follow-
ing condition.
ing range
a The unload pressure, work equipment oil pres-
sure can be checked with the monitoring func-
tion of the service mode of the machine
monitor (See 4).
1. Measuring unload pressure

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

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

sure gauge [1] of hydraulic tester Q1.
cm²}.
D155A-6 23
2) Install nipples Q2 and connect them to oil 3. Measuring with machine monitor
pressure gauges [1] of hydraulic tester 1) Turn the starting switch ON and set the
Q1. machine monitor to Monitoring function of
a When using analog oil pressure the service mode.
gauges, use ones of 40 MPa {400 kg/ q Monitoring code:
cm²}. 70700 Hydraulic Pump Pressure 1
a For the operating method, see Spe-
(EMMS).
3) Start the engine and set the work equip-

ment lock lever in the FREE position.
4) Run the engine at high idle, operate the
2) Start the engine and measure each oil
blade control lever and ripper control lever
pressure.
to relieve each cylinder at a stroke end,
a The measuring condition of each oil
and measure the work equipment relief
pressure is the same with 1 – 3
pressure and work equipment LS relief
above.
pressure.
a Only the oil pressures on the P-stamp
a The work equipment relief pressure is
side (unload pr essure and work
measured on the P-stamp side and
equipment relief pressure) can be
the work equipment LS relief pres-
measured with the monitoring func-
sure is measured on the LS-stamp
tion. The oil pressures on the LS-
side.
k Do not steer the machine with the
stamp side (work equipment and LS
relief pressure) cannot be measured.
oil pressure gauge of 40 MPa {400
kg/cm²} installed. If you do so, the
oil pressure gauge will be broken.

removed parts.
24 D155A-6
Adjusting 3) While fixing adjustment nut (4), tighten

1. Adjusting unload pressure locknut (5).
a The unload pressure cannot be adjusted. 3 Locknut: 39 – 49 Nm {4 – 5 kgm}
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 follow-
ing procedure.
4) After finishing measurement, check the

work equipment oil pressure according to
the above measuring method.
1) While fixing adjustment nut (4), loosen

locknut (5).
2) 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/cm²}
D155A-6 25
Measuring control circuit basic

pressure 1
a Measuring instruments for control circuit basic
pressure
1
R
799-401-3200 Adapter (03)
2
02896-11009 O-ring
a The control circuit basic pressure is the pres-

sure lowered by the self-pressure reducing
4. Run the engine at high idle, set the blade con-
valve of the fan circuit. It is used commonly for
trol lever and ripper control lever in neutral,
the fan pump control and PPC valve.
k
and measure the control circuit basic pressure.
Stop the machine on level ground, lower
a The work equipment lock lever may be set
in the LOCK position.
position.
a Measure the control circuit basic pressure
under the following condition.
ing range
1. Remove the centralized pressure pickup block

top cover of the right fender of the machine.

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

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

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

nect it to oil pressure gauge [2].
a When using an analog oil pressure gauge,
use one of 6.0 MPa {60 kg/cm²}.
26 D155A-6
Measuring work equipment lock

solenoid valve output pressure
(PPC valve basic pressure) 1
a Measuring instruments for work equipment
lock solenoid valve output pressure
1
S
791T-643-1010 Elbow
2
07002-11423 O-ring
k Stop the machine on level ground, lower 4. Run the engine at high idle, set the work equip-
the work equipment to the ground, stop the ment lock lever in the LOCK position and
engine, and set the parking brake lever and FREE position, and measure the solenoid
work equipment lock lever in the LOCK valve output.
position. a If the output pressure is as follows, the
a Measure the work equipment lock solenoid operation of the work equipment lock sole-
valve output pressure under the following con- noid valve is normal.
dition.
Work equipment
q Hydraulic oil temperature: Within operat- Output pressure
lock lever
ing range
LOCK position 0 MPa {0 kg/cm²}
1. Remove the control valve cover. Same as control circuit
4
FREE position basic pressure (See stan-
Control valve cover: 25 kg dard value table)
2. Disconnect hose (1), replace elbow (2) with

adapter S2, and connect hose (1) again.
3. Install nipple [1] of hydraulic tester S1 to tool

S2 and connect oil pressure gauge [2] of 6.0
MPa {60 kg/cm2}.

suring instrument and return the removed
parts.
D155A-6 27
Measuring PPC valve output 5. Run the engine at high idle, operate the control
pressure 1 lever of the circuit to be measured, and mea-
sure the oil pressure.
a Measuring tools for PPC valve output pressure a Measure the oil pressure with the control
lever at the stroke end.
a Measure the oil pressure on the blade
799-101-5002 Hydraulic tester lowering side with the control lever at the
1
790-261-1204 Digital hydraulic tester float position.
799-401-3100 Adapter (02)
T 2
02896-11008 O-ring
799-401-3200 Adapter (03)
3
02896-11009 O-ring
k Stop the machine on a flat ground, lower

the work equipment to the ground, and set
the parking brake lever and safety lock
lever in the lock position.
a Before measuring the PPC valve output pres-
sure, check that the basic pressure of the con-
trol circuit is normal.
a Measure the PPC valve output pressure under
the following condition. 6. After finishing measurement, remove the mea-
q Hydraulic oil temperature: Within operat- suring tools and return the removed parts.
ing range
1. Remove the main control valve cover.
2. Disconnect PPC valve output pressure hose

(1) and install pressure pickup adapter (T2,
T3).
a For the circuit to be measured, see the fig-
ure on the next page.
3. Install nipple [1] of hydraulic tester T1 and con-

nect oil pressure gauge [2].
4. Start the engine and set the safety lock lever in

the free position.
28 D155A-6
1. Main valve A. Blade right tilt

2. Self-pressure reducing valve B. Blade lower
3. PPC lock valve C. Ripper lower
4. Blade PPC valve D. Ripper tilt back
5. Ripper PPC valve E. Ripper tilt in
F. Ripper tilt raise
G. Blade raise
H. Blade left tilt
D155A-6 29
Adjusting play of work equipment

PPC valve 1
a The ripper valve cannot be adjusted.
a If the play of the blade control lever end is
large, adjust the PPC valve side according to
q Standard play (a): 1 – 6 mm at position of 400
mm from lever fulcrum (in forward, backward,
right and left directions)
1. Remove boot (1).
2. Loosen locknut (2) and turn disc (3) to adjust

the play.
a Do not move the piston at this time.
3. Fix disc (3) and tighten locknut (2).

3 Locknut:
93.1 – 112.7 Nm {9.5 – 11.5 kgm}
4. Install boot (1).
30 D155A-6
Measuring ripper pin puller

solenoid valve output pressure 1
a Measuring instruments for ripper pin puller
solenoid valve output pressure
1
U
799-401-3200 Adapter (03)
2
02896-11009 O-ring

4. Run the engine at high idle, set the pin puller
switch in the pull-out position and push-in posi-
tion, and measure the solenoid valve output
position.
pressure at each position.
a Measure the ripper pin puller solenoid valve
a If the output pressure is as follows, the
output pressure under the following condition.
operation of the ripper pin puller solenoid
valve is normal.
Tested Pin puller
1. Remove the undercover of the fuel tank and Output pressure
hose switch
disconnect ripper pin puller solenoid valve Same as transmission
hose (1) or (2). Pull-out main relief pressure
q Hose (1): Pin puller cylinder head side (1) (See standard value table)
q Hose (2): Pin puller cylinder bottom side
Push-in 0 MPa {0 kg/cm²}
Pull-out 0 MPa {0 kg/cm²}
(2) Same as transmission

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

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

nect oil pressure gauge [2].
a When using an analog oil pressure gauge, 5. After finishing measurement, remove the mea-
use one of 6.0 MPa {60 kg/cm²}. suring instrument and return the removed
parts.
D155A-6 31
Testing parts which cause

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

positions and stop the engine.
1) Blade lift cylinder
Brace the blade to raise the front side of
the machine body.
a Since the blade lift cylinder is 2. Turn the starting switch ON and set the work
equipped with a piston valve, do not equipment lock lever in the FREE position.
extend it to the stroke end.
3. Extend the cylinder to be tested with the corre-
sponding lever and check its movement.
q If the lowering speed is increased, the cyl-
inder packing is defective.
q If the lowering speed does not change, the
control valve is defective.
a If the pressure in the accumulator is lost,
run the engine for about 10 seconds to
heighten the pressure in the accumulator.
[Reference]
Reason why the lowering speed is increased when
the cylinder packing is the cause of the hydraulic
drift:
2) Blade tilt cylinder 1. If the machine is set in the above position
Extract the tilt cylinder to the stroke end (where the holding pressure is applied to the
and brace the blade to push up the left bottom side), the oil leaks from the bottom side
side of the machine body. 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
3) Ripper lift cylinder unbalanced and the lowering speed is
Brace the ripper to push up the rear side increased.
of the machine body.
32 D155A-6
Measuring internal leakage of q Hose (2): Ripper lift cylinder

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

side of the tested cylinder and stop the hose
side with a plug or a flange.
a When working on the blade tilt cylinder
hoses, remove the hose cover of the frame.
k Take care not to disconnect the hoses
on the bottom side.
q Hose (1): Blade tilt cylinder
5. After finishing measurement, return the re-
Plug: 07376-70422 (Size #04)
moved parts.
O-ring: 02896-11012 (Size #04)
a Bleed air from the cylinder circuit. For de-
tails, see Bleeding air from work equip-
ment cylinder.
D155A-6 33
Releasing residual pressure from Bleeding air from work equipment

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

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

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

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

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

onds to increase the pressure in the accumula-
tor, then stop it.
5. Repeat steps 2 – 4 above 2 – 3 times.
34 D155A-6
Adjusting work equipment lock lever 1
k Stop the machine on level ground, lower a Monitoring code: 70300 Blade Sw Input
the work equipment to the ground, stop the a For the operating method, see Special
engine, and set the parking brake lever and functions of machine monitor (EMMS).
position.
a Tighten the locknut of the rod securely and
a When adjusting the work equipment lock lever,
remove the control valve cover.
4 Control valve cover: 25 kg
1. Set work equipment lock lever (1) in the LOCK

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

(a) of lever (1).
a Just set the roller of the limit switch to the
5. Check that the limit switch signal is input nor-
sliding surface. Do not move it.
mally when work equipment lock lever (1) is
set in the FREE position and LOCK position.
3. Set work equipment lock lever (1) in the FREE
q FREE position:
position and check that limit switch (2) oper-
Work equipment lock NC OFF, Work
ates normally.
equipment lock NO ON
q Stroke of limit switch: 2.5 – 3 mm
q LOCK position:
Work equipment lock NC ON, Work equip-
ment lock NO OFF
machine monitor to Monitoring function of the
service mode.
D155A-6 35
Adjusting blade 1
a If the blade is removed and installed or disas-

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

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

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

ball in the axial direction will be less
than 1 mm and the ball can rotate
smoothly.
36 D155A-6
2) Adjust the shim of center section (2) (2 2. Adjusting blade tilt distance (Single tilt
places). specification)
a After reassembling the center section, 1) Adjust installed dimension (d) of brace (4)
supply grease to it. with the handle.
2 Center section: Grease (G2-LI)
Dimen-
blade Semi-U blade Full-U blade
Adjusted Adjusted Standard Standard shim sion
point clearance clearance thickness d 1,292 mm 1,372 mm 1,372 mm
2 b See note. 4 mm
2) Measure right and left tilt distances (e1)
a Adjust the shim so that the play of the and (e2).
ball in the axial direction will be less
Dimen-
than 1 mm and the ball can rotate blade Semi-U blade Full-U blade
sion
smoothly.
e1 565 mm 570 mm 583 mm
e2 565 mm 570 mm 583 mm
3) Adjust the shim of lifting section (3) (2

places).
Adjusted Adjusted Standard Standard shim 3) If both tilt distances are not the same,
point clearance clearance thickness adjust installed dimension (d) of brace (4)
3 c Max. 1 mm 4 mm according to the following procedure.
q e1 > e2:
Increase installed dimension (d)
slightly.
q e1 < e2:
Decrease installed dimension (d)
slightly.
D155A-6 37
Adjusting operator's cab 1

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

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

water level difference (c) in hose [1].
q (a): Inside of cab (Pressurized)
q (b): Out of cab (Ambient pressure)
q (c): Measured value (Internal pres-
sure of cab)
4) Seal the clearance between the hole of a If the measured value (internal pres-
bolt (1) and hose [1] with tape (3). sure of the cab) is lower than the
5) Pour water in the hose up to about half standard value, check the seals of the
and bend the hose in a U-shape. h o l e s fo r w i r i n g h a r n e s s e s a n d
6) Secure hose [1] to the outside of the cab optional parts in the cab.
and set the water level in the vinyl hose
out of the cab to that in the cab. 2. Checking searing performance
1) Close all the openings (doors and win-
dows) of the cab.
2) Splash water around the hatched part of
the cab at the rate of about 19 l/min for 10
minutes.
a At this time, it is not necessary to
splash pressurized water.
3) Splash water horizontally from a hose over
the contact portions of seal (4) between
the cab and floor frame.
38 D155A-6
4) Check around the dashboard carefully for 4) Loosen the mounting bolts of damper rub-
water leakage. ber (6).
a If water leaks, caulk the leaking part a You can remove and install the shims
and check again. without removing the mounting bolts.
5) Increase or decrease shims (7) under
damper rubber (6) to adjust the height of
damper rubber (6) properly.
3. Testing and adjusting door lock (damper

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

temporarily. Then, open and close door
(5) 2 – 3 times to align latch (8) with striker
(9).
3) Check the engagement of latch (8) and
striker (9).
4) Tighten the mounting bolts of striker (9)
securely.
D155A-6 39
5) Open and close door (5) and check that it 2) Check that striker (10) is not leaning
is locked and unlocked smoothly. against or from center (g) of latch (11).
a If the door is not locked or unlocked 3) Check that striker (10) is aligned with cen-
smoothly (the operating effort of the ter (h) of latch (11).
knob is large), repeat adjustment q Normal: Quantity of misalignment is
from the first. 0.5 mm or less.
a Operating effort of door knob:
49 ± 19.6 N {5 ± 2 kg}
6) Apply grease to latch (8).
a If the latch dries up, the operating
e ff o r t o f t h e k n ob i s i n c r ea s e d .
Accordingly, apply sufficient grease to
the latch.
2 Latch: Grease (G2-LI)
4) Loosen the mounting bolts of striker (10).

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

striker)
a Check the relationship between the opera-
tor's cab and door (latch and striker) while
the door is locked open. If there is any
fault, adjust the open lock.
1) Check the relationship between the open
lock latch and striker from the direction of
(B).
a Move the door in the opening direc-
tion and check the engagement of the
latch and striker.
40 D155A-6
6. Testing and adjusting open lock (stopper

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

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

and (13) according to the trouble.
a If there is play, project (heighten) the
stopper rubber until the play is elimi-
nated.
a If the door is not locked easily or the
unlock lever is heavy, return (lower)
the stopper rubber in the range that
the door does not have play.
6) While fixing stopper rubbers (12) and (13),
tighten the locknuts.
D155A-6 41
D155A-6 Bulldozer
© 2009 KOMATSU
All Rights Reserved
42 D155A-6
SEN03202-03
D155A-6

D155A-6 85001 and up

Special functions of machine monitor (EMMS) ............................................................................................... 2
D155A-6 1
Special functions of machine monitor (EMMS) 1

Air conditioner specification
2 D155A-6
Heater specification Upper section of machine monitor (Display sec-

tion)
(a): Multi-display
a The figure shows an example of display of sym-
bols and gauges in the ordinary display mode
(The contents of display depend on the condi-
tion of the machine and operating method).
a When the engine is started, the battery voltage
may lower suddenly, depending on the ambi-
ent temperature and the condition of the bat-
tery. In this case, the machine monitor goes off
for a moment. This phenomenon is not a fail-
ure, however.
Upper section of machine monitor (Switch sec-
tion)
[F1]: F1 function switch
a The function of each function switch is indi-
cated by graphic mark in the multi-display (a)
above that function switch.
a If the graphic mark of a function switch is not
displayed, that function switch is not working.
Lower section of machine monitor (Switch sec-
tion)
[1]: Numeral 1 input switch/Operation mode selec-
tor switch
[2]: Numeral 2 input switch/Gearshift mode selec-
tor switch
[3]: Numeral 3 input switch/Customize switch
[4]: Numeral 4 input switch/Buzzer cancel switch
[5]: Numeral 5 input switch
[6]: Numeral 6 input switch/Customize memory
switch
[7]: Numeral 7 input switch/Air conditioner or heat-
er switch
er switch
er switch
er switch
Switch having no numerals: Air conditioner or
heater switch
a Each switch has the function indicated by
graphic mark and the function of inputting a
numeral.
a The machine monitor automatically judges
which function of each switch is currently effec-
tive, according to the display condition of multi-
display (a).
a The difference between the air conditioner
specification and heater specification is only
the functions of the switches in this section.
D155A-6 3
t Ordinary functions and special functions of machine monitor

The machine monitor has the ordinary functions and special functions and displays information of various
types on the multi-display.
Some items are displayed automatically according to the internal setting of the machine monitor and the oth-
ers are displayed according to the operation of the switches.
1. Ordinary functions: Operator mode
The items in this mode are displayed ordinarily. The operator can display and set them by operating the
switches (Display and setting of some items need special operations of the switches).
2. Special functions: Service mode
The items in this mode are not displayed ordinarily. Each serviceman can display them by operating the
switches specially. This mode is used for special setting, testing, adjusting, or troubleshooting.
Page Page
Operator mode (Outline) Service mode
5p 15 p
A Display of KOMATSU logo 5p 01 Monitoring 16 p
Mechanical system "Abnormality
A Display of screen to input password 6p 21 p
Record"
02 Abnormal- Electrical system "Abnormality
A Display of check before starting 6p 22 p
ity Record Record"
Air conditioner "Abnormality Record"/
A Display of warning after check before starting 6p 29 p
Heater "Abnormality Record"
A Display of ending of maintenance interval 6p 03 Maintenance Record 30 p
A Display of check of preset 7p 04 Maintenance Mode Change 31 p
A Display of ordinary screen 7p 05 Phone Number Entry 33 p
A Display of end screen 7p Key-on Mode 34 p
B Selection of operation mode 7p Setting of unit 35 p
B Selection of gearshift mode 8p o 06 Default Setting of maintenance password 36 p
B Customizing operation 8p Setting of camera 37 p
Special operations
B Operation of customize memory 8p Setting of ECO display 38 p

B Operation of air conditioner/heater 8p 07 Adjustment 39 p
Operation to display camera mode
B 9p 08 Pm Clinic 53 p
(if camera is installed)
B Operation to display clock and service meter 9p 09 Cylinder Cut-Out 54 p
B Check of maintenance information 10 p 10 No Injection 55 p
Setting and display of user mode
B 10 p 11 Fuel Consumption 56 p
(including KOMTRAX messages for user)
C Display of caution monitor 11 p Terminal Status 57 p
12 KOMTRAX
C Display of action code and failure code 11 p GPS & Communication Status 58 p
Settings
O (Special operations) Modem S/N 59 p
Function of checking display of LCD
D 13 p 13 Service Message 60 p
(Liquid Crystal Display)
D Function of checking service meter 13 p
D Function of changing maintenance password 14 p
a Classification of operator mode

A: Display/Function from time when starting switch is turned ON to time when screen changes to ordi-
nary screen and display after starting switch is turned OFF
B: Display/Function when switch of machine monitor is operated
C: Display/Function when certain condition is satisfied
D: Display/Function which needs special operation of switch
4 D155A-6
t Operator mode (Outline) a Display pattern of operator mode

a Only outline of the operator mode is described The contents of display from the time when
in this section. For details of contents/opera- starting switch is turned ON to the time when
tion of each function/display, see "the Struc- screen changes to ordinary screen depends on
ture, function and maintenance standard, or the setting and condition of the machine.
Operation and Maintenance Manual". a: When engine start lock is set effective
a The following are the displays or functions of b: When engine start lock is set ineffective
the operator mode explained in this section c: When there is abnormal item in check-
(including some items which need special before-starting items
operations). d: When there is maintenance item which is
not maintained after specified interval
Display pattern
a b c d Display of KOMATSU logo
When the s tar ting switch is turned ON, the
Display of KOMATSU logo 1 1 1 1
KOMATSU logo is displayed for 2 seconds.
Display of screen to input password 2 – – – After the KOMATSU logo is displayed for 2 sec-
Display of check before starting 3 2 2 2 onds, the screen changes to "Display of screen to
Display of warning after check before input password" or "Display of check before start-
– – 3 – ing".
starting
Display of ending of maintenance inter-
– – – 3
val
Display of check of preset 4 4 4 4
Display of ordinary screen 5 4 5 5
Display of end screen
Selection of operation mode
Selection of gearshift mode
Customizing operation
Operation of customize memory
Operation to cancel alarm buzzer
Operation of air conditioner/heater
a The following screen may be displayed instead
Operation to display camera mode
(if camera is installed) of the above "Display of screen to input pass-
word screen".
Operation to display clock and service meter
a If this screen is displayed, call the person
Check of maintenance information responsible to operation of KOMTRAX in your
Setting and display of user mode Komatsu distributor and ask for remedy.
(including KOMTRAX messages for user)
Display of caution monitor
Display of action code and failure code
O (Special operations)
Function of checking display of LCD (Liquid Crystal Dis-
play)
Function of checking service meter
Function of changing maintenance password
D155A-6 5
Display of screen to input password Display of warning after check before starting
After the KOMATSU logo is displayed, the screen If any abnormality is detected by the check before
to input the engine start lock password is displayed. starting, the warning monitor is displayed on the
a This screen is displayed only when the engine screen.
start lock function is set effective. a The following figure shows that the radiator
a If the password is input normally, the screen coolant level monitor (a) is warning of low radi-
changes to "Display of check before starting". ator coolant level.
a The machine monitor has some password
functions other than the engine start lock.
Those functions are independent from one
another.
Display of ending of maintenance interval

When the check before starting is carried out, if a
maintenance item is near or after the end of the set
interval, the maintenance monitor is displayed for
Display of check before starting 30 seconds to urge the operator to maintenance.
When the screen changes to the check-before- a This screen is displayed only when the mainte-
starting screen, the check before starting is carried nance function is effective. The color of the
out for 2 seconds. maintenance monitor (yellow or red) indicates
a If any abnormality is detected by the check the length of the time after the maintenance
before starting, the screen changes to "Display interval.
of warning after check before starting" or "Dis- a Set or change the maintenance function in the
play of ending of maintenance interval". service mode.
a If no abnormality is detected by the check
before starting, the screen changes to "Display
of check of preset".
a The monitors (3 pieces) displayed on the
screen are the items under the check before
starting.
6 D155A-6
Display of check of preset Display of end screen

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

Display of ordinary screen While the ordinary screen is displayed, press the
If the machine monitor starts normally, the ordinary operation mode selector switch, and the operation
screen is displayed. mode monitor (a) changes.
a Service meter (a) or a clock is displayed at the a Each time the switch is pressed, the operation
center upper section of the screen (The ser- mode changes between [P (Power)] and [E
vice meter or clock is selected with [F4]). (Economy)].
a Power train oil temperature gauge (b) is dis-
played on the multi-gauge section (It is turned
ON and OFF with the user mode function or
[F2]).
a ECO gauge (c) is displayed at the right end of
the screen (It is turned ON and OFF in the ser-
vice mode).
D155A-6 7
Selection of gearshift mode Operation of customize memory

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

While the ordinary screen is displayed, press the air
conditioner switch or heater switch, and the Air-
conditioner Adjustment screen or Heater Adjust-
ment screen is displayed.
a While the Air-conditioner Adjustment screen or
Heater Adjustment screen is displayed, if you
Customizing operation do not touch any switch for 5 seconds, the
While the ordinary screen is displayed, press the screen changes to the ordinary screen.
customize switch, and you can change the setting a Air conditioner specification
of the machine.
a If the customize memory switch is operated
while the above screen is displayed, up to 5
settings can be saved.
a Heater specification
8 D155A-6
Operation to display camera mode (if camera is Operation to display clock and service meter
installed) While the ordinary screen is displayed, press [F4],
When a camera is installed, if [F3] is pressed, the and section (a) changes to the service meter and
multi-display changes to the camera image. clock alternately.
a Set the connection of the camera in the service a When the clock is selected, adjust the time, set
mode. 12-hour or 24-hour display, and set the sum-
mer time with the user mode function.
a Display of service meter
a Up to 3 cameras can be connected. If the

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

the caution monitor is displayed at the left
upper of the screen.
a When an error that there is a user code occurs
in the camera mode, if the machine stops for
10 seconds, the screen changes to the ordi-
nary screen and displays the error information.
a When 2 or more cameras are connected, the
image of one of them or the images of 2 of
them can be displayed.
a If 2-camera image display [F4] is selected, the
image of camera 1 is displayed on the left side
of the screen and the image of camera 2 is dis-
played on the right side. The image of camera
3 is displayed only singly.
a If the images of 2 cameras are displayed
simultaneously, images are displayed at inter-
vals of 1 second on the right and left screen.
D155A-6 9
Check of maintenance information Setting and display of user mode

While the maintenance monitor or ordinary screen (including KOMTRAX messages for user)
is displayed, press [F5], and the maintenance table While the ordinary screen is displayed, press [F6],
screen is displayed. and the user menu screen is displayed.
a To reset the time left after finishing mainte- a There are following items in the user menu.
nance, more operations are necessary.
Utility Screen Select
Multi Gage Select
Screen Adjustment
Clock Adjustment
Language
Message display
Hydraulic fan reversing
[KOMTRAX message]
q There are 2 types of KOMTRAX message; one
is for the user and the other is for the service.
q For user:
A message transmitted from the KOMTRAX
base station for the user. If it is received, the
message monitor is displayed on the ordinary
screen. To see the contents of the message,
operate "Message display" in the above user
menu.
10 D155A-6
q For service: Display of action code and failure code

A message transmitted from the KOMTRAX If an abnormality which displays an action code and
base station for the service. Even if it is a failure code occurs on the ordinary screen or
received, nothing is displayed on the ordinary camera mode screen, all the information of the
screen. To see the contents of the message, abnormality is displayed.
operate "KOMTRAX message display" in the (a) : Action code (3 digits)
service menu. (b) : Failure code (5 or 6 digits)
(c) : Telephone mark
(d) : Telephone No.
Display of caution monitor a This screen is displayed only when an abnor-
If an abnormality which displays a caution monitor mality (failure code) for which an action code is
occurs on the ordinary screen or camera mode set occurs.
screen, the caution monitor is displayed large for a a The telephone mark and telephone No. are
moment and then displayed at (a) in the screen. displayed only when the telephone No. is reg-
a On the camera mode screen, the caution mon- istered in the service mode.
itor blinks at the left upper of the screen when a If multiple abnormalities occur simultaneously,
the caution is generated. all the codes are displayed repeatedly in order.
a Since the information of the displayed failure
code is recorded in the fault history in the ser-
vice mode, check the details in the service
mode.
D155A-6 11
a Remedies given by displayed action codes to operator to take (The following table is an excerpt from the
Operation and Maintenance Manual)
Action
Method of indicating trouble Examples of trouble Remedy given to operator to take
code
• Although all or a part of automatic
function stops, machine can be
• Action code and failure code are • Backup alarm does not sound.
E01 operated.
displayed. • Fan speed is kept at maximum.
• Ask your Komatsu distributor for
repair.
• If operator stops and restarts
• Gear is not shifted up or down. engine, machine can be operated
• Action code and failure code are • Engine boost pressure is abnor- without limiting any function.
E02 displayed. mal. Operator must take care, how-
• Alarm buzzer sounds. • Exhaust gas color is bad when ever.
temperature is low. • Ask your Komatsu distributor for
repair.
• Engine coolant temperature sen-
sor is abnormal.
• Action code and failure code are
• Usable gear speeds are limited.
displayed. • Move machine to safe place.
• Engine speed does not rise to
E03 • Telephone No. is displayed (if • Ask your Komatsu distributor for
maximum.
set). repair.
• Gearshift shock is increased.
• Alarm buzzer sounds.
• Steering performance lowers.
• Braking shock is increased.
• Action code and failure code are
displayed. • Engine cannot be controlled. • Stop machine immediately.
E04 • Telephone No. is displayed (if • Machine cannot travel. • Ask your Komatsu distributor for
set). • Machine stops. repair.
• Alarm buzzer sounds.
12 D155A-6
Function of checking display of LCD (Liquid Function of checking service meter

Crystal Display) To check the service meter while the starting switch
While the ordinary screen is displayed, if the follow- is turned OFF, operate the numeral input switches
ing numeral input switch and function switch are as follows. At this time, only the service meter sec-
operated as follows, all the LCD (Liquid Crystal Dis- tion displays.
play) lights up in white. q Operation of switches (simultaneous): [4] + [1]
q Operation of switches (simultaneous): [4] + a Since there is some time lag in start of the
[F2] LCD, hold down the switches until the LCD dis-
a When finishing the operation of the switches, plays normally.
release [F2] first. a After the machine monitor is used continu-
a If there is a display error in the LCD, only that ously, blue points (points which do not go off)
part is indicated in black. may be seen on this screen. This phenome-
a The LCD panel sometimes has black points non does not indicate a failure or a defect.
(points which are not lighted) and bright points
(points which do not go off) for the reason of its
characteristics. If the number of the bright
points and black points does not exceed 10,
those points are not a failure or a defect.
a To return to the former screen, press the func-
tion switch.
D155A-6 13
Function of changing maintenance password a Set a new password of 4 – 6 digits (If it

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

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

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

input a new password with the numeral input
switches and confirm it with the function
switch.
14 D155A-6
t Service mode a You may enter a 2-digit code with the

To change the operator mode to the service mode, numeral input switches to select the menu
perform the following operation. of that code and confirm it with [F6].
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 The items which can be selected in the

service menu are as follows.
01 Monitoring
Mechanical system "Abnormality
Record"
02 Abnormality Electrical system "Abnormality
Record Record"
Air conditioner "Abnormality Record"/
Heater "Abnormality Record"
03 Maintenance Record
a This operation of the switches is accepted
only while the ordinary screen is dis- 04 Maintenance Mode Change
played. 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
2. Selection of service menu 12 KOMTRAX
GPS & Communication Status
Settings
When the "Service Menu" screen is displayed, Modem S/N
the service mode is selected. Select a service
13 Service Message
menu you use with the function switches or
numeral input switches.
q [F3]: Move to lower menu a Items with 2-digit codes are the menus dis-
q [F4]: Move to upper menu played on the Service menu screen. The items
q [F5]: Return to ordinary screen (operator on their right are the menus on the next hierar-
mode) chy.
q [F6]: Confirm selection
D155A-6 15
Monitoring
The machine monitor can monitor the condition of
the machine in real time by receiving signals from
various switches, sensors, and actuators installed
to many parts of the machine and the information
from the controllers which are controlling switches,
etc.
1. Selecting menu
Select "01 Monitoring" on the "Service Menu"
screen.
3. Deciding monitoring items

After selecting monitoring items, execute moni-
toring with the function switch or numeral input
switch.
a Execution with function switch: Double-
click or hold down [F6] (about 2 seconds).
a Execution with numeral input switch: Input
[99999] and press [F6].
a When monitoring only 2 items, for exam-
ple, select them and confirm with [F6]. If
[F6] is pressed once more at this time,
monitoring is executed.
2. Selecting monitoring items
a If monitoring items are selected up to the
After the "Monitoring" screen is displayed,
limit number, monitoring is executed auto-
select items to be monitored with the function
matically.
switches or numeral input switches.
q [F1]: Move to next page (screen)
q [F2]: Move to previous page (screen)
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Delete input numeral/Return to ser-
vice menu screen
a Selection with function switches: Select an
item with [F3] or [F4] and confirm it with
[F6].
a Selection with numeral input switches:
Enter a 5-digit code, and the item of that
code is selected directly. Confirm that
item with [F6].
a If the color of the selected box changes
from yellow to red, selection of the item of
that box is confirmed.
a Up to 6 monitoring items can be selected
at a time. You may not able to set up to 6
items, however, depending on the display
form of those items.
16 D155A-6
4. Executing monitoring 6. Changing machine setting mode

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

The monitoring information can be held and
holding is reset with the function switches.
q [F3]: Reset holding
q [F4]: Hold information (displayed data)
q [F5]: Return to monitoring selection menu
screen
D155A-6 17
Monitoring items list
Code Monitoring item Unit (Initial setting: ISO) Component

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

50301 S/T Lever 2 Potentio mV mV mV P/T
50400 Brake Pedal Potentio mV mV mV P/T
31619 Brake LH ECMV(F/B) mA mA mA P/T
31618 Brake RH ECMV(F/B) mA mA mA P/T
90600 S/T Clutch LH ECMV(F/B) mA mA mA P/T
90601 S/T Clutch RH ECMV(F/B) mA mA mA P/T
31628 S.S.P Solenoid mA mA mA P/T
32900 Pitch Angle ° ° ° P/T
60100 Pitch Angle Sensor mV mV mV P/T
60500 ENG Hold Relay mV mV mV P/T
60600 BR Hold Relay mV mV mV P/T
50000 Fuel Dial Throttle % % % P/T
03000 Fuel Dial Sensor mV mV mV P/T
BL (Left brake fill sw) ON • OFF P/T
CL (Left clutch fill sw) ON • OFF P/T
31521 S/T Fill Sw Input
CR (Right clutch fill sw) ON • OFF P/T
BR (Right brake fill sw) ON • OFF P/T
50200 T/M Lever 1 Potentio mV mV mV P/T
50201 T/M Lever 2 Potentio mV mV mV P/T
31622 T/M Clutch F ECMV(F/B) mA mA mA P/T
31616 T/M Clutch R ECMV(F/B) mA mA mA P/T
31602 T/M Clutch 1st ECMV(F/B) mA mA mA P/T
31603 T/M Clutch 2nd ECMV(F/B) mA mA mA P/T
31604 T/M Clutch 3rd ECMV(F/B) mA mA mA P/T
30100 T/C Oil Temperature C C F P/T
31400 T/M Out Speed r/min rpm rpm P/T
50900 T/M Lock Relay mV mV mV P/T
40001 Vehicle Speed km/h km/h MP/h P/T
60000 Traction W W W P/T
70200 T/M Out Speed Sensor mV mV mV P/T
70400 Back Alarm Relay mV mV mV P/T
31624 Fan Pump Solenoid(F/B) mA mA mA P/T
10000 Fan Speed r/min rpm rpm P/T
SUNC (Gear shift up sw) ON • OFF P/T
SUNO (Gear shift up sw) ON • OFF P/T
40905 T/M Sw Input 1
SDNC
ON • OFF P/T
(Gear shift down sw)
18 D155A-6

Remarks
SDNO
ON • OFF P/T
(Gear shift down sw)
PNC
40905 T/M Sw Input 1 ON • OFF P/T
(Parking brake lever sw)
PNO
ON • OFF P/T
(Parking brake lever sw)
F (F clutch fill sw) ON • OFF P/T
R (R clutch fill sw) ON • OFF P/T
T/M Fill Sw
40906 1st (1st clutch fill sw) ON • OFF P/T
Input 1
2nd (2nd clutch fill sw) ON • OFF P/T
3rd (3rd clutch fill sw) ON • OFF P/T
T/M Fill Sw L/U( Lock-up clutch fill sw) ON • OFF P/T

31520
Input 2 S/C (Stator clutch fill sw) ON • OFF P/T
Brly (Back Alarm relay) ON • OFF P/T
Prly (Parking lock relay) ON • OFF P/T
40909 T/M Output 1
Fres
ON • OFF P/T
(Fan reverse solenoid)
70700 Hydraulic Pump Pressure 1 MPa kg/cm² psi P/T
70701 Hydraulic Pressure Sensor 1 mV mV mV P/T
20227 Monitor Ass’y P/N — MON
20402 Monitor Serial No — MON
20228 Monitor Prog P/N — MON
20242 P/T Con Ass’y P/N — P/T
20404 P/T Con Serial No — P/T
20243 P/T Con Prog P/N — P/T
04200 Fuel Level Sensor Volt V V V MON
04300 Battery Charge Volt V V V MON
04401 Hyd Oil Temperature C C F MON
04002 Hyd Temp Sens Volt V V V MON
18900 ECM Internal Temp C C F ENG
37200 Engine Oil Pressure kPa kg/cm² psi ENG
00201 Machine ID — ENG
20216 ECM Build Version — ENG
20217 ECM Calibration Data Ver — ENG
20400 ECM Serial No — ENG
01002 Engine Speed r/min rpm rpm ENG
36700 Engine Torque Ratio % % % ENG
31701 Throttle Position % % % ENG
03001 Throttle Pos Sens Volt mV mV mV ENG
17500 Engine Power Mode — ENG
D155A-6 19

Remarks
36400 Rail Pressure MPa kg/cm² psi ENG

36401 Rail Pressure Sens Volt V V V ENG
36200 Rail Press Command MPa kg/cm² psi ENG
36300 Injection Timing Command CA CA CA ENG
04107 Coolant Temperature C C F ENG
01405 Coolant Temp Sens Volt V V V ENG
37400 Ambient Pressure kPa kg/cm² psi ENG
37401 Ambient Press Sens Volt V V V ENG
Indication by abso-
36500 Charge Pressure-Abs kPa kg/cm² psi ENG lute value (including
ambient pressure)
36501 Charge Press Sens Volt V V V ENG
03203 Battery Power Supply V V V ENG
37300 Fuel Rate l/h l/h gal/h ENG
31706 Final Throttle Position % % % ENG
18500 Charge Temperature C C F ENG
18501 Charge Temp Sens Volt V V V ENG
18600 Inject Fueling Command mg/st mg/st mg/st ENG
17201 PCV Close Timing CA CA CA ENG
18700 Engine Output Torque Nm kgm lhft ENG
37201 Eng Oil Press Sens Volt V V V ENG
14200 Fuel Temperature C C F ENG
14201 Fuel Temp Sens Volt V V V ENG
R-sig ON • OFF P/T
Acc ON • OFF P/T
40912 P/T Sw Input Eng S ON • OFF P/T
Eng L ON • OFF P/T
Eng Sd ON • OFF P/T
WL-NO (Work equipment
ON • OFF P/T
lock Sw)
40910 P/T Sw Input 2
WL-NC (Work equipment
ON • OFF P/T
lock Sw)
W-LOK (Work equipment
40915 P/T Output ON • OFF P/T
lock SOL)
a Entry order of items in table

The items are entered in the order of display on the monitoring selection menu screen.
a Unit
The display unit can be set to ISO, meter, or inch freely (Set it with Unit in "Default" of the service menu).
"CA" in the display unit is an abbreviation for crankshaft angle.
"mg/st" in the display unit is an abbreviation for milligram/stroke.
a Components in charge
MON : The machine monitor is in charge of detection of monitoring information.
ENG : The engine controller is in charge of detection of monitoring information.
P/T : The power train controller is in charge of detection of monitoring information.
20 D155A-6
"Abnormality Record" (Mechanical system 3. Information displayed on "Abnormality Record"

"Abnormality Record") screen
The machine monitor classifies and records the On the "Mechanical Systems" screen, the fol-
abnormality which occurred in the past or which are lowing information is displayed.
occurring at present into the mechanical system (a): Occurrence order of abnormality from lat-
abnormality, electrical system abnormality, and air est one/Total number of records
conditioner abnormality or heater abnormality. (b): Failure code
To check the mechanical system "Abnormality (c): Contents of trouble
Record", perform the following procedures. (d): Number of occurrence time
(e): Service meter reading at first occurrence
1. Selecting menu (f): Service meter reach at last occurrence
Select "02 Abnormality Record" on the "Ser- q [F1]: Move to next page (screen) (if dis-
vice Menu" screen. played)
q [F2]: Move to previous page (screen) (if
displayed)
q [F5]: Return to "Abnormality Record" screen
a If no "Abnormality Record" is recorded,
"No Abnormality Record" is displayed.
a If the number of occurrence time is 1 (first
occurrence), the service meter reading at
the first occurrence and that at the last
occurrence are the same.
a If [E] is displayed on the left of a failure
code, the abnormality is still occurring or
resetting of it has not been confirmed.
a For all the failure codes that the machine
monitor can record, see the failure codes
2. Selecting sub menu table in "Abnormality Record (Electrical
After the "Abnormality Record" screen is dis- system Abnormality Record)".
played, select "01 Mechanical Systems" with
t he f u nc t i o n s wi t c h e s or nu m e r a l i np u t
switches.
q [F3]: Move to lower record
q [F4]: Move to upper record
q [F5]: Return to service menu screen
a You may enter a 2-digit code with the
numeral input switches to select the
record of that code and confirm it with
[F6].
a The following figure shows the display of
the air conditioner specification. If the
heater specification is selected, "03
Heater Abnormality Record" is displayed. 4. Deleting "Abnormality Record"
The contents of the mechanical system
"Abnormality Record" cannot be deleted.
D155A-6 21
"Abnormality Record" (Electrical system "Abnor- 3. Information displayed on "Abnormality Record"

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

1) While the "Electrical Systems" screen is
displayed, perform the following operation
with the numeral input switches.
q Operation of switches (While pressing
[4], perform the operation in order):
[4] + [1] o [2] o [3]
a Operate the switches similarly to the
procedure for changing the ordinary
display to the service mode.
22 D155A-6
a The following figure shows the screen

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

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

screen is displayed, operate the function
switches.
q [F5]: Return to "Electrical Sys. Error
Reset" screen (Delete mode)
q [F6]: Execute deletion
D155A-6 23
Failure codes table
Action Failure Component

Trouble (Displayed on screen) Category of history
code code in charge
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
E04 2201L1 Right clutch: See the list P/T Electrical system
E04 2201LH Right clutch: See the list P/T Electrical system
E04 2202L1 Left clutch: See the list P/T Electrical system
E04 2202LH Left clutch: See the list P/T Electrical system
— 2300KM Stall in 1st gear speed 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 (boost) Air Press Sensor High Error ENG Electrical system
E03 CA123 Chg (boost) 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
24 D155A-6

code code in charge
E02 CA144 Coolant Temp Sens High Error ENG Electrical system
E02 CA145 Coolant Temp Sens Low Error ENG Electrical system
E01 CA153 Chg (boost) Air Temp Sensor High Error ENG Electrical system
E01 CA154 Chg (boost) Air Temp Sensor Low Error ENG Electrical system
E03 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
— 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 Open/Short Error ENG Electrical system

E04 CA342 Calibration Code Incompatibility ENG Electrical system
E03 CA351 Injectors Drive Circuit Error ENG Electrical system
E03 CA352 Sens Supply 1 Volt Low Error ENG Electrical system
E03 CA386 Sens Supply 1 Volt High Error 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
D155A-6 25

code code in charge
E03 CA778 Eng Bkup Speed Sensor Error ENG Electrical system
E03 CA1633 KOMNET Datalink Timeout 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
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 (Monitor) MON Electrical system
E03 DB2RKR CAN Disconnection (Engine controller) ENG Electrical system
E03 DB90KR PT controller: Can communication lost P/T Electrical system
E03 DBE0KK PT controller: Source voltage reduction P/T Electrical system
E01 DBE0KT PT controller: Abnormality in controller 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
E02 DDDDKB Back up brake Sw: Short circuit P/T Electrical system
E02 DDDDKX Back up brake Sw: Signal mismatch P/T 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 P/T Electrical system
— DH21KB Weq pressure sensor: Short circuit P/T Electrical system
26 D155A-6

code code in charge
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 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
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
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
D155A-6 27

code code in charge
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
E03 DXH9KA Right clutch ECMV: Disconnection P/T Electrical system
E03 DXH9KB Right clutch ECMV: Short circuit P/T Electrical system
E04 DXH9KY Right clutch ECMV: Hot short P/T Electrical system
E03 DXHAKA Left clutch ECMV: Disconnection P/T Electrical system
E03 DXHAKB Left clutch ECMV: Short circuit P/T Electrical system
E04 DXHAKY Left clutch ECMV: Hot short 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 DXJ4KA Weq lock Sol.: Disconnection P/T Electrical system
E03 DXJ4KB Weq lock Sol.: Short circuit P/T Electrical system

The items are entered in the order of their failure codes (incremental order).
a Action code
Attached: If the failure code is detected, the action code, failure code, and telephone No. (if regis-
tered) are displayed on the ordinary screen to notify the operator of the fault.
Not attached: Even if the failure code is detected, the machine monitor does not notify the operator of
the fault.
a 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.
a Category of record
Mechanical equipment system: Fault information is recorded in the "Mechanical Systems".
Electrical equipment system: Fault information is recorded in the "Electrical Systems" .
28 D155A-6
"Abnormality Record" (Air conditioner "Abnor- 3. Information displayed on "Abnormality Record"

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

After the "Abnormality Record" screen is dis- 4. Deleting "Abnormality Record"
played, select "03 Air-conditioning System" or While the "Abnormality Record" screen is dis-
"03 Heater Abnormality Record" with the func- played, press [F2], and the number of occur-
tion switches or numeral input switches. rence time of fault is deleted. If it is confirmed
q [F3]: Move to lower record at this time that the abnormality has been
q [F4]: Move to upper record reset, the display changes to Normal.
q [F6]: Confirm selection a Heater specification
a You may enter a 2-digit code with the In the heater specification, the display of "Air
numeral input switches to select the conditioner" is replaced with "Heater" and the
record of that code and confirm it with items which are not related to the heater are
[F6]. not displayed.
D155A-6 29
Maintenance Record 01 Engine Oil Change

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

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

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

maintenance record.
30 D155A-6
Maintenance Mode Change 00 Maintenance Mode On/Off

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

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

the "Maintenance Mode On/Off" screen.
D155A-6 31
4. Contents of setting of each maintenance item 5. Function of All Default Value

After selecting each maintenance item, if the After selecting "99 Use Default Value", if the
screen is displayed, set the item with the func- screen is displayed, set with the function
tion switches. switches.
q Default: Maintenance interval set in machine a If this operation is executed, the set val-
monitor (Recommended by manufacturer ues of all the maintenance items are set to
and not changeable). default values.
q Set: Maintenance interval which can be q [F5]: Return to Maintenance Mode Change
set freely. Maintenance functions in oper- screen
ator mode operate on basis of this set time q [F6]: Execute default setting
(which is increased or decreased by 50 a A while after [F6] is pressed, the default
hours). setting completion screen is displayed.
q ON: Maintenance function of this item is Then, if the "Maintenance Mode Change"
set effective in operator mode. screen is displayed, default setting is com-
q OFF: Maintenance function of this item is pleted.
set ineffective in operator mode. a The default setting of the corrosion resis-
q [F3]: Select Reduce set value (Upper) or tor is "OFF".
OFF (Lower).
q [F4]: Select Increase set value (Upper) or
ON (Lower).
q [F5]: Cancel setting before confirmation
and return to Maintenance Mode
Change screen.
q [F6]: Confirm setting of upper or lower line.
a After the setting of the upper and lower
lines is confirmed with [F6] and the screen
changes to the Maintenance Mode
Change screen with [F5], the setting is
effective.
32 D155A-6
Phone Number Entry a If [F6] is pressed without inputting a digit,

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

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

Input nothing in the surplus positions.
a If one of the input digits is wrong, move to
that digit (and its background changes to
orange) and overwrite it with the correct
digit.
D155A-6 33
Default setting (Key-on Mode) 3. Selecting mode

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

After the "Default" screen is displayed, select
"01 Key-on Mode" with the function switches or
a Select this item similarly to an item on the
"Service Menu" screen.
a This function sets the following 4 mode
items (which are the items set with the
customize switch in the operator mode).
q Power: P/E
q Reverse slow mode: ON/OFF
q Work equipment fine control: ON/OFF
q Blade slow down: ON/OFF
34 D155A-6
Default setting (Setting of unit)

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

"02 Unit" with the function switches or numeral
input switches.
3. Selecting unit
After the "Unit" screen is displayed, select the
unit to be set with the function switches.
q [F3]: Move to lower unit
q [F4]: Move to upper unit
q [F5]: Cancel selection and return to default
screen
q [F6]: Confirm selection and return to default
screen
a When the machine is delivered, the SI unit
system is set.
D155A-6 35
Default setting (Setting of maintenance pass- q [F6]: Confirm selection and return to default
word) screen
Check or change various settings related to the
machine monitor and machine by default setting.
The function of setting maintenance password is
used to set the display of the password screen
when the functions related to the maintenance are
used in the operator mode.
1. Selecting menu
screen.
4. Displaying maintenance password screen

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

After the "Default" screen is displayed, select The password can be changed by operating
"03 Maintenance Password" with the function the switches specially in the operator mode.
switches or numeral input switches. a See "Function of changing maintenance
a Select this item similarly to an item on the password" in the operator mode.
Service menu screen. a Default password: [000000]
a If the password setting is changed from
"Enable" to "Disable", the password is
reset to the default.
a When "Enable" is set again, be sure to set
a new password.
a The maintenance password is different
from the engine start lock password.
3. Selecting Enable/Disable
After the "Maintenance Password" screen is
displayed, select the setting with the function
switches.
q Disable: Password screen is not displayed
q Enable: Password screen is displayed
q [F5]: Cancel selection and return to Initial-
ization screen
36 D155A-6
Default setting (Setting of camera) q [F3]: Move to left item

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

After the "Camera" screen is displayed, select
the setting with the function switches.
q OFF: Camera is not connected
q Original image: Image of connected cam-
era is displayed in original position (as in
mirror, used as back monitor)
q Reverse image: Image of connected cam-
era is displayed in reverse position (as
seen directly, used as front or side moni-
tor)
D155A-6 37
Default setting (Setting of ECO display) a If ECO display is turned ON, ECO is dis-
Check or change various settings related to the played when the screen changes to the
machine monitor and machine by initialization. ordinary screen.
The ECO display setting function is used to set the
display of the ECO gauge.
1. Selecting menu
screen.
a Display of ECO gauge (a)

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

After the "ECO Display" screen is displayed,
select the setting with the function switches.
q ON: Display ECO
q OFF: Do not display ECO
q [F3]: Move to left item
q [F4]: Move to right item
q [F5]: Cancel selection and return to default
screen
q [F6]: Confirm selection and return to default
screen
38 D155A-6
Adjustment
The operator can adjust various items related to the
machine with the machine monitor.
When using an adjustment item, select it according
to the following procedure.
1. Selecting menu
Select "07 Adjustment" on the "Service Menu"
screen.
3. Displaying adjustment screen

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

message of "No ready Adjustment" is dis-
played and the ID input screen does not
change (Another ID can be input again
with the numeral input switches while this
screen is displayed).
D155A-6 39
Adjustment items table

Adjustment
Adjustment item Remarks
ID
0002 Power train controller initialization
0005 Brake pedal potentiometer initial correction
0007 Engine decelerator cutting Resetting auto-decelerating function
0009 Pitch angle sensor initial correction
0010 Fan 70% mode
0530 Stall mode Recommended mode of torque converter stall
0910 Load record check mode
1005 Fan 100% mode
1012 Steering lever neutral position adjustment
1013 Steering lever leftmost position adjustment
1014 Steering lever rightmost position adjustment
1015 Right brake oil pressure offset
1016 Left brake oil pressure offset
2021 Power train controller voltage check mode
6001 R1 reverse slow set speed Fine adjustment of reverse slow mode
7842 Transmission clutch IP automatic initial correction
7843 Transmission clutch IP manual initial correction
7845 Transmission clutch IP learning display
9995 Control brake release mode Control brake: Brake ECMV (Right and left)
9996 Sudden stop prevent valve operation mode
9997 High idle cut mode
9998 Max. gear speed setting mode
40 D155A-6
Adjustment ID: 0002 (Power train controller initial- Adjustment ID: 0005 (Brake pedal potentiometer
ization) initial correction)
q This adjustment code is used to initialize the q This adjustment code is used to make the
specification code recognized by the power power train controller recognize the zero point
train controller and the set values of the mem- of the brake pedal potentiometer.
ory in the controller. a After the power train controller or brake pedal
a After the power train controller is replaced, be potentiometer is replaced or the brake pedal
sure to carry out this adjustment once. linkage is disconnected and connected, be
sure to carry out this adjustment once.
q Functions of function switches
[F3]: Unused q Functions of function switches
[F4]: Unused [F3]: Unused
[F5]: Return to adjustment item selecting [F4]: Unused
screen (ID inputting screen) [F5]: Return to adjustment item selecting
[F6]: Save setting screen (ID inputting screen)
[F6]: Save corrected value
q Operating method:
1) Press [F6] and check that the alarm q Operating method:
buzzer sounds. 1) Check that the brake pedal is in the neu-
2) Check that the displayed specification tral position (it is not pressed at all) and
code [CODE] has changed from [5x5] to keep it in that position.
[555]. 2) Press [F6] and check that the alarm buzz-
a If specification code [555] is not displayed, er sounds.
the controller wiring harness or the con- a Even if the adjustment is carried out, the
troller unit may be defective. displayed value does not change.
a Even if this adjustment code is turned off, a Even if this adjustment code is turned off,
the setting is effective. 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.
D155A-6 41
Adjustment ID: 0007 Adjustment ID: 0009 (Pitch angle sensor initial cor-
(Engine decelerator cutting) rection)
q This adjustment code is used to stop the auto- q This adjustment code is used to make the
deceleration function of the engine and check power train controller recognize the zero point
the high idle speed of the engine unit. of the pitch angle sensor and to correct the
a The engine can be driven and tested with the installation error.
auto-deceleration reset only while this adjust- a After the power train controller is replaced or
ment code is selected. the pitch angle sensor is removed and installed
a Use this adjustment code for testing, adjusting, or replaced, be sure to carry out this adjust-
or troubleshooting when necessary. ment once.
q Functions of function switches q Functions of function switches

[F5]: Return to adjustment item selecting [F5]: Return to adjustment item selecting
screen (ID inputting screen) screen (ID inputting screen)
[F6]: Unused [F6]: Save corrected value
q Operating method: q Operating method:

When this adjustment code is displayed, its 1) Check that the machine is level.
function is effective and the auto-deceleration 2) Press [F6] and check that the alarm buzz-
function is stopped. er sounds.
a After this adjustment code is turned OFF, a If adjustment is carried out, displayed item
its function is ineffective. [BODY PITCH ANGLE] changes to [0.0 °]
(The other displayed items do not
change).
a Even if this adjustment code is turned off,
the correction is effective.
42 D155A-6
Adjustment ID: 0010 Adjustment ID: 0530

(Fan 70% mode) (Stall mode)
q This adjustment code is used to set the cooling q This adjustment code is used to set the fan
fan speed to about 70% forcibly. speed in the 100% mode automatically and
a Use this adjustment code for testing, adjusting, make it possible to set the preset (gear speed
or troubleshooting when necessary. at start) to [F3-R3] to stall the torque converter.
a The preset (gear speed at start) can be
q Functions of function switches set to [F3-R3] only while this adjustment
[F3]: Increase adjustment value [FAN 70% code is selected.
SPEED MODE] a Use this adjustment code for testing,
[F4]: Decrease adjustment value [FAN 70% adjusting, or troubleshooting when neces-
SPEED MODE] sary.
[F5]: Return to adjustment item selecting
screen (ID inputting screen) q Functions of function switches
[F4]: Unused
q Operating method: [F5]: Return to adjustment item selecting
When this adjustment code is displayed, its screen (ID inputting screen)
function is effective and the cooling fan speed [F6]: Unused
is controlled to about 70% of the maximum
speed. q Mode setting information within screen
a After this adjustment code is turned OFF, [P-AUTO SFT MODE]:
its function is ineffective. 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
q Operating method:
When this adjustment code is displayed, its
function is effective and the preset (gear speed
at start) is set to [F3-R3].
k This adjustment code does not stall the
t o r q u e c o n v e r t e r a u t o m a t i c a l l y.
Accordingly, operate the levers and
pedals securely when stalling the
torque converter (For the procedure for
stalling the torque converter, see Mea-
suring engine speed).
a After this adjustment code is turned OFF,
its function is ineffective.
D155A-6 43
Adjustment ID: 0910 (Load record check mode) Adjustment ID: 1005 (Fan 100% mode)
q This adjustment code is used to check the load q This adjustment code is used to set the cooling
on the machine, odometer, and reverse odom- fan speed to about 100% forcibly. It is also
eter. used to set the adjustment value of the maxi-
a Use this adjustment code for testing, adjusting, mum speed.
or troubleshooting when necessary. a Use this adjustment code for testing, adjusting,
or troubleshooting when necessary.
[F3]: Unused q Functions of function switches
[F4]: Unused [F3]: Increase adjustment value [FAN 100%
[F5]: Return to adjustment item selecting SPEED MODE]
screen (ID inputting screen) [F4]: Decrease adjustment value [FAN 100%
[F6]: Unused SPEED MODE]
q Mode setting information within screen screen (ID inputting screen)
[1000 rpm SMR]: Time displayed by service [F6]: Save adjustment value
meter in which engine speed
was above 1,000 rpm q Operating method:
[ODO METER FORWARD]: a When this adjustment code is displayed,
Total forward travel distance its function is effective and the cooling fan
[ODO METER REVERSE]: speed is controlled to about 100% of the
Total reverse travel distance maximum speed.
1) Increase or decrease the adjustment
q Operating method: value by pressing [F3] or [F4].
When this adjustment code is displayed, its 2) When confirming the adjustment value,
function is effective and the load on the press [F6] and check that the alarm
machine, odometer, and reverse odometer are buzzer sounds.
displayed simultaneously. a After this adjustment code is turned OFF,
a The data cannot be reset. its function is ineffective but the set adjust-
a After this adjustment code is turned OFF, ment value is effective.
44 D155A-6
Adjustment ID: 1012 (Steering lever neutral posi- Adjustment ID: 1013 (Steering lever leftmost posi-
tion adjustment) tion adjustment)
q This adjustment code is used to make the q This adjustment code is used to make the
power train controller recognize the neutral power train controller recognize the leftmost
position of the steering potentiometer of the position of the steering potentiometer of the
PCCS lever. PCCS lever.
a After the power train controller or PCCS lever a After the power train controller or PCCS lever
is replaced, be sure to carry out this adjust- is replaced, be sure to carry out this adjust-
ment once. ment once.

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

1) Check that the PCCS lever is in the neu- 1) Operate the PCCS lever to the left stroke
tral position of the steering direction and end of the steering direction and keep it in
keep it in that position. that position.
2) Press [F6] and check that the alarm 2) Press [F6] and check that the alarm
buzzer sounds. buzzer sounds.
a Even if the adjustment is carried out, the a Even if the adjustment is carried out, the
displayed value does not change. displayed value does not change.
the adjustment is effective. the adjustment is effective.
a This adjustment code is used to make the a This adjustment code is used to make the
controller recognize the neutral position of controller recognize the leftmost position
the potentiometer. It is not used to adjust of the potentiometer. It is not used to
the steering force. adjust the steering force.
D155A-6 45
Adjustment ID: 1014 (Steering lever rightmost posi- Adjustment ID: 1015 (Right brake oil pressure off-
tion adjustment) set)
q This adjustment code is used to make the q This adjustment code is used to adjust the right
power train controller recognize the rightmost brake oil pressure manually.
position of the steering potentiometer of the a Use this adjustment code for work when nec-
PCCS lever. essary.
a After the power train controller or PCCS lever
is replaced, be sure to carry out this adjust- q Functions of function switches
ment once. [F3]: Increase adjustment value
[F4]: Decrease adjustment value
q Functions of function switches [F5]: Return to adjustment item selecting
[F3]: Unused screen (ID inputting screen)
[F4]: Unused [F6]: Save adjustment value
screen (ID inputting screen) q Information displayed on screen
[F6]: Save adjustment value The offset oil pressure is displayed and the
adjustment value is increased or decreased by
q Operating method: 0.1 kg/cm² (The value displayed on the screen
1) Operate the PCCS lever to the right stroke is multiplied by 100).
end of the steering direction and keep it in a The default adjustment value is 0 kg/cm².
that position. a The adjustment range is -3 – 3 kg/cm².
2) Press [F6] and check that the alarm
buzzer sounds. q Operating method:
a Even if the adjustment is carried out, the 1) Increase or decrease the adjustment val-
displayed value does not change. ue by pressing [F3] or [F4].
a Even if this adjustment code is turned off, 2) Press [F6] and check that the alarm buzz-
the adjustment is effective. er sounds.
a This adjustment code is used to make the a If the oil pressure has been adjusted, it is
controller recognize the rightmost position displayed. It can be adjusted again within
of the potentiometer. It is not used to the adjustment range, however.
adjust the steering force. a It is not necessary to operate the brake
during adjustment. After finishing adjust-
ment, however, operate the brake and
check that there is not a problem in the
actual brake performance.
the adjustment is effective.
46 D155A-6
Adjustment ID: 1016 Adjustment ID: 2021 (Power train controller voltage
(Left brake oil pressure offset) check mode)
q This adjustment code is used to adjust the left q This adjustment code is used to check the con-
brake oil pressure manually. stant power supply voltage and switch power
a Use this adjustment code for work when nec- supply voltage applied to the power train con-
essary. troller.
a Use this adjustment code for testing, adjusting,
q Functions of function switches or troubleshooting when necessary.
[F3]: Increase adjustment value
[F4]: Decrease adjustment value q Functions of function switches
screen (ID inputting screen) [F4]: Unused
[F6]: Save adjustment value [F5]: Return to adjustment item selecting
screen (ID inputting screen)
q Information displayed on screen [F6]: Unused
The offset oil pressure is displayed and the
adjustment value is increased or decreased by q Information displayed on screen
0.1 kg/cm² (The value displayed on the screen [PT CONTROLLER UNSWITCH POWER]:
is multiplied by 100). Constant power supply voltage
a The default adjustment value is 0 kg/cm². [PT CONTROLLER ACC POWER]:
a The adjustment range is -3 – 3 kg/cm². Switch power supply voltage
q Operating method q Operating method:

1) Increase or decrease the adjustment val- When this adjustment code is displayed, its
ue by pressing [F3] or [F4]. function is effective and the constant power
2) Press [F6] and check that the alarm buzz- supply voltage and switch power supply volt-
er sounds. age are displayed simultaneously.
a It is not necessary to operate the brake a After this adjustment code is turned OFF,
during adjustment. After finishing adjust- its function is ineffective.
ment, however, operate the brake and
check that there is not a problem in the
actual brake performance.
a If the oil pressure has been adjusted, it is
displayed. It can be adjusted again within
the adjustment range, however.
the adjustment is effective.
D155A-6 47
Adjustment ID: 6001 (R1 reverse slow set speed) Adjustment ID: 6002 (R2 reverse slow set speed)
q This adjustment code is used to adjust the q This adjustment code is used to adjust the
engine speed applied to travel at gear speed engine speed applied to travel at gear speed
R1 with the reverse slow mode ON. R2 with the reverse slow mode ON.
a Use this adjustment code for work when nec- a Use this adjustment code for work when nec-
essary. essary.

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

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

1) Increase or decrease the adjustment val- 1) Increase or decrease the adjustment
ue by pressing [F3] or [F4]. value by pressing [F3] or [F4].
2) Press [F6] and check that the alarm buzz- 2) Press [F6] and check that the alarm
er sounds. buzzer sounds.
a If the engine speed has been adjusted, it a If the engine speed has been adjusted, it
is displayed. It can be adjusted again is displayed. It can be adjusted again
within the adjustment range, however. within the adjustment range, however.
a It is not necessary to drive the machine a It is not necessary to drive the machine
during adjustment. After finishing adjust- during adjustment. After finishing adjust-
ment, however, drive the machine at R1 ment, however, drive the machine at R2
with the reverse slow mode ON and check with the reverse slow mode ON and check
that there is not a problem in the actual that there is not a problem in the actual
travel speed. travel speed.
48 D155A-6
Adjustment ID: 6003 (R3 reverse slow set speed) Adjustment ID: 7842 (Transmission clutch IP auto-
matic initial correction)
q This adjustment code is used to adjust the

engine speed applied to travel at gear speed q This adjustment code is used to make the
R3 with the reverse slow mode ON. power train controller recognize the mechani-
a Use this adjustment code for work when nec- cal condition of the transmission.
essary. a After the power train controller or transmission
is replaced, be sure to carry out this adjust-
q Functions of function switches ment once.
[F3]: Increase adjustment value
[F4]: Decrease adjustment value q Functions of function switches
screen (ID inputting screen) [F4]: Unused
[F6]: Save adjustment value [F5]: Return to adjustment item selecting
screen (ID inputting screen)
q Information displayed on screen [F6]: Save adjustment value
The speed reduced from the high idle speed
(2,050 rpm) is displayed and the adjustment q Conditions for correction work
value is increased or decreased by 50 rpm 1) [ENGINE SPEED]: 1,700 – 1,950 rpm
(The value displayed on the screen is multi- 2) [T/C TEMPERATURE]: 65 – 85 °C
plied by 1/10). 3) Parking brake lever: LOCK position
a The default adjustment value is 300 rpm a When using this adjustment code, keep
(Displayed value: 30). t he abo ve c ond iti ons ( In pa rti c ula r,
(Default setting: 2,050 – 300 = 1,850 rpm) increase the power train oil temperature
sufficiently before starting adjustment).
q Operating method
1) Increase or decrease the adjustment val- q Operating method:
ue by pressing [F3] or [F4]. 1) Start the engine and keep its speed in the
2) Press [F6] and check that the alarm buzz- specified range of condition with the fuel
er sounds. control dial.
a If the engine speed has been adjusted, it 2) Press [F6] and start the correction work
is displayed. It can be adjusted again and check that [1ST CLUTCH] is dis-
within the adjustment range, however. played newly on the screen.
a It is not necessary to drive the machine 3) If [END OF TEACHING] is displayed on
during adjustment. After finishing adjust- the screen, press [F6]. If the alarm buzzer
ment, however, drive the machine at R3 sounds at this time, correction work is
with the reverse slow mode ON and check completed.
that there is not a problem in the actual a The machine does not move during the
travel speed. correction work.
the adjustment is effective. the correction is effective.
D155A-6 49
Adjustment ID: 7843 (Transmission clutch IP man- Adjustment ID: 7845 (Transmission clutch IP learn-
ual initial correction) ing display)
q This adjustment code is used to carry out cor- q This adjustment code is used to check the
rection manually when the correction is not information of correction made by the opera-
carried out normally by the operation of IP tion of IP automatic correction (Adjustment ID:
automatic correction (Adjustment ID: 7842). 7842) or IP manual correction (Adjustment ID:
a Use this adjustment code after the IP correc- 7843).
tion work, if necessary. a Use this adjustment code for testing, adjusting,
or troubleshooting when necessary.
[F3]: Increase adjustment value q Functions of function switches
[F4]: Decrease adjustment value [F3]: Change display
[F5]: Return to adjustment item selecting [F4]: Change display
screen (ID inputting screen) [F5]: Return to adjustment item selecting
[F6]: Save adjustment value screen (ID inputting screen)
a If [F2] is pressed while [F1] is pressed, all [F6]: Unused
the correction values are set to 0.
q Operating method
q Functions of shift-up and shift-down switches When this adjustment code is displayed, its
You can select a clutch to be corrected manu- function is effective and the correction informa-
ally with the shift-up and shift-down switches. tion is displayed.
a After this adjustment code is turned OFF,
q Conditions for correction work its function is ineffective.
Same as the conditions for IP automatic cor-
rection (Adjustment ID: 7842).
q Operating method:
1) Start the engine and keep its speed in the
specified range of condition with the fuel
control dial.
2) Select a clutch to be corrected manually
with the shift-up or shift-down switches.
3) Increase or decrease the adjustment
value by pressing [F3] or [F4].
4) Press [F6] and check that the alarm
buzzer sounds.
a The machine does not move during the
correction work.
the correction is effective.
50 D155A-6
Adjustment ID: 9995 Adjustment ID: 9996 (Sudden stop prevent valve
(Control brake release mode) operation mode)
q This adjustment code is used to release the q This adjustment code is used to stop the sud-
control brake (right and left brake ECMV) to den stop prevent solenoid valve and right and
check the operation of the backup brake left brake ECMV to check the operation of the
(brake pedal solenoid valve). sudden stop prevent valve.
a Use this adjustment code for testing, adjusting, a Use this adjustment code for testing, adjusting,
or troubleshooting when necessary. or troubleshooting when necessary.


When this adjustment code is displayed, its When this adjustment code is displayed, its
function is effective and the control brake (right function is effective and the sudden stop pre-
and left brake ECMV) is kept released. vent solenoid valve and right and left brake
a After this adjustment code is turned OFF, ECMV are kept stopped.
its function is ineffective. a After this adjustment code is turned OFF,
D155A-6 51
Adjustment ID: 9997 Adjustment ID: 9998 (Max. gear speed setting mode)
(High idle cut mode)
q This adjustment code is used to limit the maxi-

q This adjustment code is used to limit the high mum transmission gear speed.
idle speed. q The limited gear speed is applied in both auto-
a Use this adjustment code for work when nec- matic gearshift mode and manual gearshift
essary. mode.
a Use this adjustment code for work when nec-
q Functions of function switches essary.
[F3]: Increase adjustment value [HIGH IDLE
RPM SET MODE] q Functions of function switches
[F4]: Decrease adjustment value [HIGH IDLE [F3]: Increase adjustment value [MAX SHIFT]
RPM SET MODE] [F4]: Decrease adjustment value [MAX SHIFT]

1) Increase or decrease the adjustment val- 1) Increase or decrease the adjustment val-
ue by pressing [F3] or [F4]. ue by pressing [F3] or [F4].
2) Press [F6] and check that the alarm buzz- 2) Press [F6] and check that the alarm buzz-
er sounds. er sounds.
a When resetting the limitation of the high a When resetting the limitation of the maxi-
idle speed, set the adjustment value to the mum gear speed, set the adjustment
original high idle speed (2,050 rpm). value to the maximum gear speed (3RD).
52 D155A-6
Pm Clinic q 2nd screen

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

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

2. Information displayed on Pm Clinic screen The displayed information can be held and
The Pm Clinic function displays the following released with [F3] and [F4].
information on 2 pages.
q 1st screen
D155A-6 53
Cylinder Cut-Out operation 3. Resetting disabled cylinder

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

If [F4] is pressed during the reduced cylinder
mode operation, the displayed information is
newly held (c) (The real-time information is
kept displayed on the left side).
a While the information is held, if [F3] is
2. Selecting cylinder to be disabled pressed, the holding function is reset.
After the "Cylinder Cut-Out" screen is dis- a The holding function is effective, regard-
played, select a cylinder to be disabled with the less of setting of the reduced cylinder
function switches. mode operation.
q [F1]: Move selection mark (R) to left
q [F2]: Move selection mark (R) to right
q [F4]: Hold
a This operation may be performed while
the engine is running.
a When [F6] is pressed, if background (a) of
the selected cylinder No. becomes white,
the cylinder is disabled.
a If the machine monitor disables a cylinder
but the engine controller cannot disable
that cylinder, the background of the cylin-
der No. becomes yellow.
a One or more cylinders can be disabled.
[Reference]
q If a normally operating cylinder is disabled, the
following phenomena occur.
1) Lowering of engine speed
2) Increase of final injection rate command
(quantity)
q If the engine is running near the high idle, how-
ever, the engine speed may not lower for the
reason of engine control.
q In this case, lower the engine speed with the
fuel control dial and judge by increase of the
injection rate command.
54 D155A-6
Display of No Injection a Limit the cranking time to 20 seconds to

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

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

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

If no-injection cranking (Fuel injection in no cyl-
inders) becomes effective, that is displayed on
the screen. Under this condition, crank the
engine with the starting motor.
a While the screen is changing to the follow-
ing screen, the screen of "Setting is being
prepared" is displayed.
D155A-6 55
Display of Fuel Consumption 3. Display and function during measurement

This function calculates the hourly fuel consump- Clock mark (a) flashes during measurement.
tion from the actual fuel consumption in a measur- a While the fuel consumption is being mea-
ing period and indicates it. sured, the operator can work with the
operator mode and other functions. Mea-
1. Selecting menu surement is not finished until this screen is
Select "11 Fuel Consumption" on the "Service displayed again and [F1] is pressed (Even
Menu" screen. if the starting switch is turned OFF, this
function is kept effective, although fuel
consumption is measured only while the
engine is running).
2. Starting measurement
After the screen of "Fuel Consumption" is dis-
played, start measurement with the function
switches. 4. Finishing measurement
q [F1]: Start Press [F1], and measurement is finished and
q [F2]: Clear the data are displayed on the finishing date
q [F5]: Return to Service menu screen and time side.
a When the screen of "Fuel Consumption" is
displayed, if a data is indicated, it is the 5. Displaying fuel consumption
data of the previous measurement. This If the measurement is finished, the hourly fuel
data is not an obstacle to new measure- consumption calculated from the fuel con-
ment and can be deleted by pressing [F2]. sumption calculated by the engine controller
a If [F1] is pressed, the data is displayed on and the elapsed time are displayed.
the starting date and time side and mea-
surement starts.
a The display unit of the fuel changes
according to the unit set with the initializa-
tion (unit setting) function.
SI and meter: l/h,
inch: gal/h
56 D155A-6
Display of KOMTRAX Settings (Terminal Status) q [F5]: Return to KOMTRAX Settings screen
The setting condition and operating condition of
KOMTRAX can be checked with "KOMTRAX Set-
tings".
Terminal Status is used to check the setting condi-
tion of the KOMTRAX terminal.
1. Selecting menu
Select "12 KOMTRAX Settings" on the "Ser-
vice Menu" screen.

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

On the "Terminal Status" screen, the following
items are displayed.
q Terminal Type: Model name of KOMTRAX
communication MODEM
q KOMTRAX communication: Executing con-
dition of KOMTRAX communication
q GMT time: Greenwich Meant Time (+ 9
hours in Japan)
D155A-6 57
Display of KOMTRAX Settings (GPS & Commu- 3. Contents of display of condition of positioning
nication Status) and communication
The setting condition and operating condition of On the screen of "GPS & Communication Sta-
KOMTRAX can be checked with KOMTRAX Set- tus", the following items are displayed.
tings. q Positioning: Positioning condition of GPS
Condition of positioning and communication is used q Communication: Communication environ-
to check the condition of positioning and communi- ment of communication MODEM and con-
cation of the KOMTRAX terminal. necting condi tion of c ommunication
MODEM
1. Selecting menu q Number of message not yet sent: Number
Select "12 KOMTRAX Settings" on the "Ser- of mails in machine monitor not yet sent
vice Menu" screen. q [F5]: Return to KOMTRAX Settings screen

After the Display of "KOMTRAX Settings"
screen is displayed, select "02 GPS & Commu-
nication Status" with the function switches or
58 D155A-6
Display of KOMTRAX Settings

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

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

The serial No. of KOMTRAX communication
MODEM is displayed.
q [F5]: Return to KOMTRAX Settings screen
D155A-6 59
Display of Service Message q [F6]: Confirm and return input value

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

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

If a box to enter a value with the numeral keys
is displayed under the message, enter a
proper number with the numeral input switches
and function switches and confirm it, and the
information is returned to the KOMTRAX base
station.
60 D155A-6
D155A-6 61
D155A-6 Bulldozer
© 2009 KOMATSU
All Rights Reserved
62 D155A-6
SEN03203-00
D155A-6

D155A-6 85001 and up

Handling of power supply circuit of engine controller...................................................................................... 2
Preparation work for troubleshooting of electrical system .............................................................................. 3
Pm Clinic......................................................................................................................................................... 5
D155A-6 1
Handling of power supply circuit

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

connector between the engine controller and
engine for troubleshooting, do not start the
engine.
a You may turn the starting switch to the
OFF or ON position but must not turn it to
the START position.
2 D155A-6
Preparation work for 2. Engine controller

troubleshooting of electrical 1) Open the left engine side cover and left
mudguard.
system 1 2) Remove the mounting bolts and cover (6).
a When carrying out troubleshooting of an elec-
tric circuit related to the machine monitor,
engine controller, power train controller, or work
equipment controller, expose the related con-
nectors according to the following procedure.
1. Machine monitor
1) Remove the 4 mounting bolts each from
covers (1) and (2) and remove those cov-
ers.
2) Remove the 4 mounting bolts each from
covers (3) and (4) and remove those cov-
ers together with the foot rest.
a The 2 bolts on the front window side of the
3) Insert or connect troubleshooting T-adapt-
foot rest are used as the cover mounting
ers in or to connectors EGC1, EGC2, and
bolts, too.
EGC3 of engine controller (7).
3) Remove the 4 mounting bolts of machine
a Since connectors EGC1 and EGC2
monitor (5) and pull out machine monitor
are fixed with screws, loosen those
(5) and switch cover together toward the
screws before disconnecting.
operator's seat.
a When returning connectors EGC1
and EGC2, tighten the screws to the
specified torque.
3 Screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}

ers in or to connectors CM01, CM02, and
CM03 of machine monitor (5).
a AT11 is for the GPS antenna.
a If a camera is installed, CM05 is also
wired.
D155A-6 3
3. Power train controller

1) Remove the inside lower cover of the left
console.
ers 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, tight-
en the screws to the specified torque.
3 Screw: 2.83 ± 0.28 Nm
{0.288 ± 0.028 kgm}
4 D155A-6
Pm Clinic 1
Machine model Serial No. Service meter
D155A-6 h
User's name Date of execution Inspector
/ /
Specifications
Blade Rear attachment Shoe width
T blade T Multi-shank ripper T 560 mm T
T Semi-U blade T Variable giant ripper T 610 mm
T Full-U blade T Counterweight ( kg) T 660 mm
T T T 710 mm
Working condition
Quarry/Mining Construction Type of soil (Specific gravity: ) Contents of work
T Coal T Construction/Civil engineering T Rock T Dozing %
T Gold T Road T Gravel T Side cutting %
T Limestone T Tunnel T Sand T Ripping %
T T T Clay T Travel %
Check of oil and coolant levels
T Engine coolant level When necessary
T Engine oil level T Damper case oil level T Final drive oil level
T Hydraulic oil level T Power train oil level T
Engine coolant temperature Power train oil temperature Ambient temperature Altitude
Max. range: Max. range: Max. °C/Min. °C m
Following figure (Left) Following figure (Right)
Operator's opinion Result of visual inspection
Fault history of mechanical system Fault history of electrical system

AA10NX times/1st time h/last h times/1st time h/last h
AB00MA times/1st time h/last h times/1st time h/last h
B@BAZG times/1st time h/last h times/1st time h/last h
B@BCNS times/1st time h/last h times/1st time h/last h
B@BCZK times/1st time h/last h times/1st time h/last h
B@CENS times/1st time h/last h times/1st time h/last h
B@HANS times/1st time h/last h times/1st time h/last h
CA234 times/1st time h/last h times/1st time h/last h
D155A-6 5
Check positions/Method 1
6 D155A-6
D155A-6 7
8 D155A-6
Pm Clinic check sheet
Machine model Serial No. Service meter User's name Date of execution Inspector
D155A-6
1. Engine
Accepted
Rejected
Standard
Service limit Measure-
Item Measurement condition Unit value for new
value ment result
machine
Low idling 740 – 780 740 – 780
Without deceleration
2,050 – 2,100 2,050 – 2,100
High (Adjustment: 0007)
Engine speed idle Normal (Deceleration) rpm 1,825 – 1,925 1,825 – 1,925
Decelerator pedal 850 – 900 850 – 900
F3 stall 1,615 – 1,715 1,450
F3 stall + Ripper raise relieve 1,580 – 1,680 1,395
Boost kPa Min. 85 72
Engine
F3 stall
pressure {mmHg} {Min. 640} {540}
Exhaust Ambient temperature — — — —
°C
temperature F3 stall 670 720
Blow-by pres- kPa Max. 2.94 3.92
F3 stall
sure {mmH2O} {Max. 300} {400}
Min. 034 0.21
High idle
Engine oil MPa {Min. 3.5} {2.1}
pressure {kg/cm²} Min. 010 0.08
Low idle
{Min. 1.0} {0.8}
2. Cooling fan
Accepted
Rejected
Standard
value ment result
machine
Low idle — — — —
Speed Adjust- rpm
Fan
ment: High idle 1,045 – 1,155 1,045 – 1,155

1005
Circuit MPa
High idle
pressure {kg/cm²}
D155A-6 9
3. Power train oil pressure

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

Low idle
Inlet {0.5 – 5.0} {0.5 – 5.0}
Torque converter
Monitoring: 32601
pressure Max. 1.0 Max. 1.0
High idle
MPa {Max. 10.0} {Max. 10.0}
{kg/cm²} 0.05 – 0.29 0.05 – 0.29
Low idle
Outlet {0.5 – 3.0} {0.5 – 3.0}
Monitoring: 32603
pressure 0.29 – 0.69 0.29 – 0.69
High idle
{3.0 – 7.0} {3.0 – 7.0}
Accepted
Rejected
Standard
value ment result
machine
2.81 – 3.11 Min. 2.62

Low idle
Main relief {28.7 – 31.7} {Min. 26.7}
Gear speed: P/N
pressure 3.04 – 3.33 Min. 2.84
High idle
{31.0 – 34.0} {Min. 29.0}
F clutch Gear speed: F3 2.55 – 2.94 Min. 2.35
Low idle
Transmission
pressure Brake: Applied {26.0 – 30.0} {Min. 24.0}

R clutch Gear speed: R3 MPa 2.60 – 2.99 Min. 2.40
Low idle
pressure Brake: Applied {kg/cm²} {26.5 – 30.5} {Min. 24.5}
1st clutch Gear speed: F1 2.81 – 3.11 Min. 2.62
Low idle
2nd clutch Gear speed: F2 2.60 – 2.89 Min. 2.40
Low idle
3rd clutch Gear speed: F3 2.81 – 3.11 Min. 2.62
Low idle
Accepted
Standard
Service limit Measure- Rejected
value ment result
machine
2.46 – 3.04 2.16

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

Low idle
Left brake Gear speed: N {25.0 – 31.0} {22.0}
pressure Brake: Released 2.46 – 3.04 2.16
High idle
{25.0 – 31.0} {22.0}
Brake MPa
F2 stall, high idle Machine must not move.
performance {kg/cm²}
2.3 – 2.6 2.3 – 2.6
Gear speed: N Low idle
Right clutch {23.5 – 26.5} {23.5 – 26.5}
PCCS lever: Right
pressure 2.3 – 2.6 2.3 – 2.6
{23.5 – 26.5} {23.5 – 26.5}
Clutch
2.3 – 2.6 2.3 – 2.6

Gear speed: N Low idle
Left clutch {23.5 – 26.5} {23.5 – 26.5}
PCCS lever: Left
pressure 2.3 – 2.6 2.3 – 2.6
{23.5 – 26.5} {23.5 – 26.5}
10 D155A-6
4. Work equipment oil pressure
Accepted
Rejected
Standard
value ment result
machine
Work equipment
Work equipment/HSS oil pressure
Unload 2.45 – 3.82 2.45 – 3.82

control lever: All High idle
pressure {25 – 39} {25 – 39}
levers in neutral
Work equip-
26.0 – 29.0 26.0 – 29.0
ment relief High idle
{265 – 295} {265 – 295}
pressure Cylinder stroke MPa
Work equip- end relief {kg/cm²}
24.0 – 26.0 24.0 – 26.0
ment LS relief High idle
{245 – 265} {245 – 265}
pressure
Control Work equipment
3.97 – 4.46 3.78 – 4.46
circuit basic control lever: All High idle
{40.5 – 45.5} {38.5 – 45.5}
pressure levers in neutral
5. Work equipment speed
Accepted
Rejected
Standard
value ment result
machine
Blade raise High idle 3.0 – 4.0 3.0 – 4.0

equipment
Blade left tilt High idle 1.8 – 2.8 3.1

speed
Work
sec
Ripper lower High idle 2.5 – 3.5 4.0
Ripper tilt in High idle 4.5 – 5.5 6.2
6. Hydraulic drift of work equipment
Accepted
Rejected
Standard
value ment result
machine
Hydraulic oil
°C — — — —
temperature
Hydraulic
Hydraulic drift Engine: Stopped

drift
Blade lift: 15 minutes mm Max. 150 200

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

FD Final drive Engine: Stopped —
much metal dust.
D155A-6 11
8. Repair record (Must be filled in)
Date Service meter Repair record Date Service meter Repair record
/ / h / / h
/ / h / / h
/ / h / / h
/ / h / / h
/ / h / / h
12 D155A-6
Pm Clinic undercarriage check sheet
Machine model Serial No. Service meter User's name Date of execution Inspector
D155A-6
1. Bushing temperature
Item Measurement condition Measurement result Accepted Rejected
Under- Bushing Measure just Left side of machine

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

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

H : Hot (You cannot keep touching, Very hot, Min. 50 °C)
W : Warm (Lukewarm, warmer than link, Approx. 35 °C)
C : Normal temperature: Same as link temperature
D155A-6 13
Accepted
Rejected
Clearance Measure-
Item Measurement condition Unit Pin No.
limit ment result
Left side of 1.4

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

machine (Each side)
Opening of track link (a)
14 D155A-6
D155A-6 15
D155A-6 Bulldozer
© 2007 KOMATSU
All Rights Reserved
16 D155A-6
SEN03204-02
D155A-6

D155A-6 85001 and up
40 Troubleshooting 1
Failure code table and fuse locations
Failure codes table.......................................................................................................................................... 2
Fuse locations................................................................................................................................................. 8
D155A-6 1
SEN03204-02 40 Troubleshooting
Failure codes table 1

Action Failure Component Category of Reference
code code Trouble (Displayed on screen) in charge history manual
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
Electrical
E03 15SBL1 Reverse clutch: Fill high P/T system
Electrical
E03 15SBLH Reverse clutch: Fill Low P/T system
Electrical
E03 15SEL1 Speed 1st clutch: Fill high P/T system
E03 15SELH Speed 1st clutch: Fill Low P/T Electrical
system
E03 15SFL1 Speed 2nd clutch: Fill high P/T Electrical
system
Electrical
E03 15SFLH Speed 2nd clutch: Fill Low P/T system
Electrical
E03 15SGL1 Speed 3rd clutch: Fill high P/T system
Electrical
E03 15SGLH Speed 3rd clutch: Fill Low P/T system
E04 2201L1 Right clutch: See the list P/T Electrical
system
E04 2201LH Right clutch: See the list P/T Electrical
system
E04 2202L1 Left clutch: See the list P/T Electrical
system
Electrical Troubleshooting
E04 2202LH Left clutch: See the list P/T system by failure code,
Electrical Part 1
– 2300KM Stall in 1st gear speed P/T system SEN03206-00
Electrical
E04 2301L1 Right brake: Fill high P/T 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
Electrical
– 7RFAKA ECM HOLD RELAY: Disconnection P/T system
Mechanical
– AA10NX Air Cleaner Clogging MON system
Mechanical
– AB00MA Battery Charge Abnormal MON 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
Mechanical
– B@CENS T/C Oil Overheat P/T system
Mechanical
– B@HANS Hyd Oil Overheat MON system
Electrical
E04 CA111 EMC Critical Internal Failure ENG system
E04 CA115 Eng Ne and Bkup Speed Sens Error ENG Electrical
system
2 D155A-6
Action Failure Trouble (Displayed on screen) Component Category of Reference

code code in charge history manual
E03 CA122 Chg (boost) Air Press Sensor High Error ENG Electrical
system
Electrical
E03 CA123 Chg (boost) Air Press Sensor Low Error ENG system
Electrical
E03 CA131 Throttle Sensor High Error ENG system
Electrical
E03 CA132 Throttle Sensor Low Error ENG 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 Troubleshooting
system by failure code,
Electrical Part 1
E02 CA145 Coolant Temp Sens Low Error ENG system SEN03206-00
Electrical
E01 CA153 Chg (boost) Air Temp Sensor High Error ENG system
Electrical
E01 CA154 Chg (boost) Air Temp Sensor Low Error ENG
system
E03 CA187 Sens Supply 2 Volt Low Error ENG Electrical
system
E03 CA221 Ambient Press Sens High Error ENG Electrical
system
Electrical
E03 CA222 Ambient Press Sens Low Error ENG system
Electrical
E03 CA227 Sens Supply 2 Volt High Error ENG system
Electrical
– CA234 Eng Overspeed ENG 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
Electrical
E03 CA271 PCV1 Short Error ENG system
Electrical
E03 CA272 PCV1 Open Error ENG system
Electrical
E03 CA273 PCV2 Short Error ENG system
E03 CA274 PCV2 Open Error ENG Electrical
system Troubleshooting
E03 CA322 Inj #1 Open/Short Error ENG Electrical by failure code,
system Part 2
Electrical SEN03207-00
E03 CA323 Inj #5 Open/Short Error ENG
system
Electrical
E03 CA324 Inj #3 Open/Short Error ENG system
Electrical
Electrical
E03 CA332 Inj #4 Open/Short Error ENG Electrical
system
E04 CA342 Calibration Code Incompatibility ENG Electrical
system
E03 CA351 Injectors Drive Circuit Error ENG Electrical
system
Electrical
E03 CA352 Sens Supply 1 Volt Low Error ENG system
D155A-6 3

E03 CA386 Sens Supply 1 Volt High Error ENG Electrical
system
Electrical
E04 CA441 Battery Voltage Low Error ENG system
Electrical
E04 CA442 Battery Voltage High Error ENG system
Electrical
E03 CA449 Rail Press Very High Error ENG 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
Electrical
E03 CA554 Rail Press Sensor In Range Error ENG system
Electrical
E02 CA559 Rail Press Low Error ENG system
Electrical
E03 CA689 Eng Ne Speed Sensor Error ENG
system
E03 CA731 Eng Bkup Speed Sens Phase Error ENG Electrical
system
E04 CA757 All Continuous Data Lost Error ENG Electrical
system
Electrical
E03 CA778 Eng Bkup Speed Sensor Error ENG system Troubleshooting
Electrical by failure code,
E03 CA1633 KOMNET Datalink Timeout Error ENG system Part 2
E03 CA2185 Throt Sens Sup Volt High Error ENG system
E03 CA2186 Throt Sens Sup Volt Low Error ENG Electrical
system
E03 CA2249 Rail Press Very Low Error ENG Electrical
system
E01 CA2555 Grid Htr Relay Volt Low Error ENG Electrical
system
Electrical
E01 CA2256 Grid Htr Relay Volt High Error ENG system
Electrical
– D110KA Battery relay: Disconnection P/T system
Electrical
– D110KB Battery Relay: Drive Short Circuit P/T 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
Electrical
E01 D161KB Back-up alarm relay: Short circuit P/T system
Electrical
– D190KA ACC signal relay: Disconnection P/T system
Electrical
– D190KB ACC signal relay: Short circuit P/T system
E03 D5ZKKX Throttle Dial: Out of normal range P/T Electrical
system
E03 DAFRKR CAN Disconnection (Monitor) MON Electrical Troubleshooting
Electrical Part 3
E03 DB2RKR CAN Disconnection (Engine controller) ENG SEN03208-01
system
Electrical
E03 DB90KR PT controller: Can communication lost P/T system
4 D155A-6

E03 DBE0KK PT controller: Source voltage reduction P/T Electrical
system
Electrical
E01 DBE0KT PT controller: Abnormality in controller P/T system
Electrical
E02 DBE6KK PT controller: Source voltage reduction P/T system
Electrical
E02 DBE7KK PT controller: Source voltage reduction P/T 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
Electrical
E02 DD13KA Shift down Sw: Disconnection P/T system
Electrical
E02 DD13KB Shift down Sw: Short circuit P/T system
Electrical
E03 DD14KA Parking lever Sw: Disconnection P/T
system
E03 DD14KB Parking lever Sw: Short circuit P/T Electrical
system
E02 DDDDKA Back up brake Sw: Disconnection P/T Electrical
system
Electrical
E02 DDDDKB Back up brake Sw: Short circuit P/T system
Electrical
E02 DDDDKX Back up brake Sw: Signal mismatch P/T system
Electrical
E01 DGT1KA T/C oil temp sensor: Abnormal P/T system Troubleshooting
E01 DGT1KX T/C oil temp sensor abnormal P/T Electrical by failure code,
system Part 3
– DH21KA Weq pressure sensor: Disconnection P/T
system
– DH21KB Weq pressure sensor: Short circuit P/T Electrical
system
Electrical
E03 DK10KX Fuel control Dial: Out of normal range P/T system
Electrical
E03 DK30KA ST lever 1: Disconnection P/T system
Electrical
E03 DK30KB ST lever 1: Short circuit P/T 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
Electrical
E03 DK31KA ST lever 2: Disconnection P/T system
Electrical
E03 DK31KB ST lever 2: Short circuit P/T system
Electrical
E03 DK40KA Brake potentiometer: Disconnection P/T 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
Electrical
E03 DK55L8 FR lever: Signal mismatch P/T system
D155A-6 5

E03 DK56KA FR lever 1: Disconnection P/T Electrical Troubleshooting
Electrical Part 3
E03 DK56KB FR lever 1: Short circuit P/T system SEN03208-01
Electrical
E03 DK57KA FR lever 2: Disconnection P/T system
Electrical
E03 DK57KB FR lever 2: Short circuit P/T 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
Electrical
E01 DLT3KB T/M out-speed sensor: Abnormal P/T system
Electrical
E01 DW7BKA Fan rev EPC: Disconnection P/T system
Electrical
E01 DW7BKB Fan rev EPC: Short circuit P/T
system
E04 DWN3KA Ssp solenoid: Disconnection P/T Electrical
system
E04 DWN3KB Ssp solenoid: Short circuit P/T Electrical
system
Electrical
E04 DWN3KY Ssp solenoid: Short circuit P/T system
Electrical
E01 DWN5KA Fan pump solenoid: Disconnection P/T system
Electrical
E01 DWN5KB Fan pump solenoid: Short circuit W/E system
E03 DXH4KA 1st clutch ECMV: Disconnection P/T Electrical
E03 DXH4KB 1st clutch ECMV: Short circuit P/T Electrical by failure code,
system Part 4
E03 DXH4KY 1st clutch ECMV: Short circuit P/T
system
Electrical
E03 DXH5KA 2nd clutch ECMV: Disconnection P/T system
Electrical
E03 DXH5KB 2nd clutch ECMV: Short circuit P/T system
Electrical
E03 DXH5KY 2nd clutch ECMV: Short circuit P/T 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
Electrical
E03 DXH7KA R clutch ECMV: Disconnection P/T system
Electrical
E03 DXH7KB R clutch ECMV: Short circuit P/T system
Electrical
E04 DXH7KY R clutch ECMV: Short circuit P/T 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
Electrical
E03 DXH9KA Right clutch ECMV: Disconnection P/T system
6 D155A-6

E03 DXH9KB Right clutch ECMV: Short circuit P/T Electrical
system
Electrical
E04 DXH9KY Right clutch ECMV: Hot short P/T system
Electrical
E03 DXHAKA Left clutch ECMV: Disconnection P/T system
Electrical
E03 DXHAKB Left clutch ECMV: Short circuit P/T system
E04 DXHAKY Left clutch ECMV: Hot short P/T Electrical
system
E04 DXHBKA Right brake ECMV: Disconnection P/T Electrical
E04 DXHBKB Right brake ECMV: Short circuit P/T Electrical by failure code,
system Part 4
E04 DXHBKY Right brake ECMV: Short circuit P/T system
Electrical
E04 DXHCKA Left brake ECMV: Disconnection P/T system
Electrical
E04 DXHCKB Left brake ECMV: Short circuit P/T
system
E04 DXHCKY Left brake ECMV: Short circuit P/T Electrical
system
E03 DXJ4KA Weq lock Sol.: Disconnection P/T Electrical
system
Electrical
E03 DXJ4KB Weq lock Sol.: Short circuit P/T system

The items are entered in the order of their failure codes (incremental order).
a Action code
Attached: If the failure code is detected, the action code, failure code, and telephone No. (if regis-
tered) are displayed on the ordinary screen to notify the operator of the fault.
Not attached: Even if the failure code is detected, the machine monitor does not notify the operator of
the fault.
a 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.
a Category of record
Mechanical equipment system: Fault information is recorded in the "Mechanical Systems".
Electrical equipment system: Fault information is recorded in the "Electrical Systems" .
D155A-6 7
Fuse locations 1
Connection table of circuit breakers and fuse boxes
a This connection table shows the devices to which each power supply of the fuse box supplies power (An
accessory power supply is a device which supplies power while the starting switch is in the ON position
and an unswitched power supply is a device which supplies power while the starting switch is in the OFF
and ON positions).
a When carrying out troubleshooting related to the electrical system, you should check the circuit breakers
and fuses to see if the power is supplied normally.
Circuit breakers CB1 – CB9

Circuit
Power circuit breaker Circuit
breaker Destination of power
(Type of power supply) breaker No.
capacity
CB9 20A Optional power supply
Power train controller
CB1 20A
Emergency power supply (For power train switch box)
CB105 Work equipment controller
CB2 20A
(Accessory power Emergency power supply (For work equipment switch box)
supply)
Air conditioner unit, blower motor, and compressor electromag-
CB3 20A
netic clutch
CB4 20A Headlamp, additional headlamp
CB5 20A Rear lamp, additional rear lamp, ripper point lamp
Starting switch
CB6 20A
Engine hold relay
CB30 Machine monitor
(Unswitched power
supply) CB7 20A Power train controller
Work equipment controller
CB8 30A Engine controller, Electric priming pump
CB105H
(Unswitched power — — Engine electrical intake air heater
supply)
Fuse box FS1

Power circuit breaker Fuel
Fuse No. Destination of power
(Type of power supply) capacity
CB30
(Unswitched power 1 20A Operator's cab power supply (To connection table of fuse box )
supply)
2 5A Backup alarm, backup alarm relay
CB105
(Accessory power 3 20A Operator's cab power supply (To connection table of fuse box )
supply) 4 20A Operator's cab power supply (To connection table of fuse box )
Starting switch (ACC) 5 5A Engine controller (Signal ACC)
8 D155A-6
Fuse box FS2

CB30
(Unswitched power 1 5A Pedal brake solenoid valve
supply)
2 5A Parking brake solenoid valve
CB105 Engine electrical intake air heater

(Accessory power 3 20A Ripper pin puller solenoid valve
supply) Pneumatic suspension seat
4 5A Horn
Starting switch (ACC) 5 20A Optional power supply
D155A-6 9
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)
10 D155A-6
Fuse box
Power circuit fuse Fuel
FS1-1 Radio
(Unswitched power 1 10A 12V accessory connector (Via DC converter)
supply) 12V accessory socket (Via DC converter)
Additional light relay, additional light
FS1-3 2 20A
Rotary lamp
(Accessory power
supply) 12V accessory connector (Via DC converter)
3 20A
12V accessory socket (Via DC converter)
Radio
Room lamp
FS1-4 4 20A
Cigarette lighter
(Accessory power
supply) Windshield wiper (Via intermittent relay)
5 10A Front wiper, rear wiper
6 10A Left wiper, right wiper
Location of fuse box (In operator's cab)
D155A-6 11
D155A-6 Bulldozer
© 2009 KOMATSU
All Rights Reserved
12 D155A-6
SEN03205-02
D155A-6

D155A-6 85001 and up
General information on troubleshooting
Points to remember when troubleshooting ..................................................................................................... 2
Sequence of events in troubleshooting........................................................................................................... 3
Check before troubleshooting ......................................................................................................................... 4
Classification and procedures for troubleshooting .......................................................................................... 5
Information in troubleshooting table................................................................................................................ 8
CConnection table for connector pin numbers.............................................................................................. 10
T- branch box and T- branch adapter table ................................................................................................... 46
D155A-6 1
Points to remember when troubleshooting 1

k Stop the machine in a level ground, and check that the lock pin, blocks, and parking brake are
securely fitted.
k When carrying out the operation with two or more workers, keep strictly to the agreed signals,
and do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and function.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not 4) Check the stroke of the control valve
hurry to disassemble the components. spool.
If components are disassembled immediately 5) Other maintenance items can be checked
any failure occurs: externally, so check any item that is con-
q Parts that have no connection with the fail- sidered to be necessary.
ure or other unnecessary parts will be dis-
4. Confirming failure
assembled.
q Confirm the extent of the failure yourself,
q It will become impossible to find the cause
and judge whether to handle it as a real
of the failure.
failure or as a problem with the method of
It will also cause a waste of manhours, parts,
operation, etc.
or oil or grease, and at the same time, will also
a When operating the machine to reen-
lose the confidence of the user or operator.
act the troubleshooting symptoms, do
For this reason, when carrying out trouble-
not carry out any investigation or
shooting, it is necessary to carry out thorough
measurement that may make the
prior investigation and to carry out trouble-
problem worse.
shooting in accordance with the fixed proce-
dure. 5. Troubleshooting
q Use the results of the investigation and
2. Points to ask user or operator
inspection in Items 2 – 4 to narrow down
1) Have any other problems occurred apart
the causes of failure, then use the trouble-
from the problem that has been reported?
shooting flowchart to locate the position of
2) Was there anything strange about the
the failure exactly.
machine before the failure occurred?
a The basic procedure for troubleshoot-
3) Did the failure occur suddenly, or were
ing is as follows.
there problems with the machine condition
1) Start from the simple points.
before this?
2) Start from the most likely points.
4) Under what conditions did the failure
3) Investigate other related parts or
occur?
information.
5) Had any repairs been carried out before
the failure? 6. Measures to remove root cause of failure
When were these repairs carried out? q Even if the failure is repaired, if the root
6) Has the same kind of failure occurred cause of the failure is not repaired, the
before? same failure will occur again.
To prevent this, always investigate why
3. Check before troubleshooting
the problem occurred. Then, remove the
1) Check the oil level
root cause.
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
2 D155A-6
Sequence of events in troubleshooting 1
D155A-6 3
Check before troubleshooting 1
Item Criterion Remedy

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

Mechanical 2. Check for oil leakage — Repair
equipment 3. Bleeding air — Bleed air
1. Check of battery terminals and wiring for loose-
— Retighten or replace
ness and corrosion
2. Check of alternator terminals and wiring for
looseness and corrosion
3. Check of starting motor terminals and wiring for
looseness and corrosion
4. Check of battery voltage (with engine stopped) 20 – 30 V Charge or replace
5. Check of electrolyte level Between H – L Add or replace
6. Check of wires for discoloration, burn, and
Electrical — Repair or replace
removal of cover
equipment
7. Check for released wire clamp and drooping wire — Repair
8. Check of wires for wetness (Check connectors
— Dry
and terminals for wetness, in particular)
9. Check circuit breaker for turning OFF and fuse
— Replace
for disconnection and corrosion
10. Check of alternator voltage After operating for several
Replace
(while engine speed is at middle or higher) minutes: 27.5 – 29.5 V
11. Check of battery relay for operating sound
— Replace
(when starting switch is turned ON or OFF)
4 D155A-6
Classification and procedures for troubleshooting 1

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

If a phenomenon looking like a trouble occurs in the machine, select a proper troubleshooting No. according
to the following procedure, and then go to the corresponding troubleshooting section.
1. Procedure for troubleshooting to be taken when action code and failure code are displayed on
machine monitor:
If a action code and a failure code are displayed on the machine monitor, carry out the troubleshooting
for the corresponding "Display of code" according to the displayed failure code.
2. When electrical system failure code or mechanical system failure code is recorded in fault his-
tory:
If a action code and a failure code are not displayed on the machine monitor, check for a mechanical
system failure code and an electrical system failure code with the fault history function of the machine
monitor.
If a failure code is recorded, carry out troubleshooting for the corresponding "Display of code" accord-
ing to that code.
a If an electrical system failure code is recorded, delete all the codes and reproduce them, and then
see if the trouble is still detected.
a A failure code of the mechanical system cannot be deleted.
a If a trouble is displayed in the air conditioner fault history or heater fault history by the fault history
function, carry out the corresponding troubleshooting in "E mode".
3. When action code or failure code is not displayed and no failure code is recorded in fault
history:
If a action code or a failure code is not displayed on the machine monitor and no failure code is recorded
in the fault history, a trouble that the machine cannot find out by itself may have occurred in the electrical
system or hydraulic and mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from
the table of "Phenomena looking like troubles and troubleshooting Nos.", and then carry out trouble-
shooting corresponding to that phenomenon in the "E mode", "H mode", or "S mode".
D155A-6 5
Phenomena looking like troubles and troubleshooting Nos.
Troubleshooting
No. Phenomena looking like troubles Display
E mode H mode S mode
of code
Phenomena related to action code/failure code
1 Action code and failure code are displayed on machine monitor
Accord-
When fault history is checked, failure code is displayed in mechanical
2 ing to dis-
system fault history
played
When fault history is checked, failure code is displayed in electrical code
3
system fault history
When fault history is checked, failure code is displayed in air conditioner
4
or heater fault history
Phenomena related to engine
5 Starting performance of engine 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 lack output (or lacks power) S-6
11 Exhaust gas is black (incomplete combustion) S-7
12 Oil consumption is excessive (or exhaust gas is blue) S-8
13 Oil becomes dirty quickly 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 or 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 Air cannot be bled from fuel circuit S-17
22 Preheater does not operate E-4
Phenomena related to power train
23 Power is low (Drawbar pull is low) H-1
24 Machine does not travel (at 2nd or 3rd gear speed) H-2
25 Machine does not start at any gear speed H-3
26 Machine can travel only forward or in reverse H-4
27 When gear speed or travel direction is changed, time lag is large H-5
28 Steering is not possible H-6
29 Steering is possible only on one side H-7
30 Steering overrun occurs H-8
31 Brake does not work H-9
32 Power train oil is overheated H-10
Phenomena related to work equipment
33 Speed of all work equipment is low H-11
34 No work equipment moves H-12
35 Blade lift speed or power is low H-13
6 D155A-6
Troubleshooting
No. Phenomena looking like troubles Display
E mode H mode S mode
of code
36 Blade tilt speed or power is low H-14
37 Ripper lift speed or power is low H-15
38 Ripper tilt speed or power is low H-16
39 Hydraulic drift of blade lift is large H-17
40 Hydraulic drift of blade tilt is large H-18
41 Hydraulic drift of ripper lift is large H-19
42 Ripper pin puller cylinder does not operate E-22 H-20
43 Abnormal sound comes out from around work equipment pump H-21
Fan speed is abnormal (Sound and/or vibration are abnormally large or
44 H-22
engine over heats)
Phenomena related to machine monitor
45 When starting switch turned ON, machine monitor displays nothing E-1
When starting switch turned ON (before startingengine), basic check
46 E-2
item lights up
47 Precaution item lights up while engine is running E-5
48 Emergency stop item lights up while engine is running E-6
49 Engine coolant temperature gauge does not indicate normally E-7
50 Fuel level gauge does not indicate normally E-8
Power train oil temperature gauge (multi-gauge) does not indicate
51 E-9
normally
52 Hydraulic temperature gauge (multi-gauge) does not indicate normally E-10
Contents of display by machine monitor are different from applicable
53 E-11
machine
54 Machine monitor does not display some items E-12
55 Function switch does not work E-13
56 Operation mode does not change E-14
57 Gearshift mode does not change E-15
58 Customize function does not operate normally E-16
59 Customize memory function does not normally E-17
60 Alarm buzzer cannot be stopped E-18
Air conditioner does not operate normally (including air conditioner fault
61 E-19
history)
62 When starting switch is turned OFF, service meter is not displayed E-20
63 Machine monitor cannot be set in service mode E-21
64 Ripper pin puller cylinder does not operate E-22
65 Backup alarm does not sound or does not stop E-23
66 Headlamp, rear lamp, and ripper point lamp do not light up E-24
67 Windshield wiper and window washer do not operate E-25
68 Fan does not reverse E-27
69 Gear cannot be shifted E-28
Other phenomena
70 KOMTRAX terminal does not operate normally E-26
71 Electric priming pump does not operate or does not stop automatically E-29
D155A-6 7
Information in troubleshooting table 1

a The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before carrying out troubleshooting, understand that information fully.
Action code Failure code
Display on Trouble Trouble name displayed in fault history of machine monitor
Display on machine
machine moni-
monitor
tor
Contents of
Contents of trouble detected by machine monitor or controller
trouble
Action of
Action taken by machine monitor or controller to protect system or devices when they detect
machine moni-
trouble
tor or controller
Problem that
Problem that appears on machine as result of action taken by machine monitor or controller
appears on
(shown above)
machine
Related infor-
Information related to detected trouble or troubleshooting
mation
Cause Standard value in normal state/Remarks on troubleshooting
<Contents of description>
• Standard value in normal state to judge possible causes
• Remarks on judgment
1
<Troubles in wiring harness>
• Disconnection
Connector is connected defectively or wiring harness is
broken.
• Ground fault
Wiring harness which is not connected to chassis ground
circuit is in contact with chassis ground circuit.
• Hot short
Wiring harness which is not connected to power source (24
2 V) circuit is in contact with power source (24 V) circuit.
• Short circuit
Independent wiring harnesses are in contact with each
Possible causes other abnormally.
and standard Possible causes of trouble
value in normal (Given numbers are refer-
<Precautions for troubleshooting>
state ence numbers, which do not
(1) Method of indicating connector No. and handling of T-
indicate priority)
adapter
Insert or connect T-adapter as explained below for trouble-
shooting, unless otherwise specified.
3 • If connector No. has no marks of "male" and "female",
disconnect connector and insert T-adapters in both male
side and female side.
• If connector No. has marks of "male" and "female", dis-
connect connector and connect T-adapter to only male
side or female side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (–) lead of tester as
explained below for troubleshooting, unless otherwise
specified.
4 • Connect positive (+) lead to pin No. or wiring harness
entered on front side.
• Connect negative (–) lead to pin No. or harness entered
on rear side.
8 D155A-6
Related circuit diagram
This drawing is a part of the electric circuit diagram related

to troubleshooting.
• Connector No.: Indicates (Model – Number of pins) and
(Color).
• "Connector No. and pin No." from each branching/merg-
ing point: Shows the ends of branch or source of merging
within the parts of the same wiring harness.
• Arrow (i o): Roughly shows the location on the machine.
D155A-6 9
CConnection table for connector pin numbers (Rev. 2009.04)
a 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.
10 D155A-6
D155A-6 11
12 D155A-6
D155A-6 13
14 D155A-6
D155A-6 15
16 D155A-6
D155A-6 17
18 D155A-6
D155A-6 19
20 D155A-6
D155A-6 21
22 D155A-6
D155A-6 23
24 D155A-6
D155A-6 25
26 D155A-6
D155A-6 27
28 D155A-6
D155A-6 29
30 D155A-6
D155A-6 31
32 D155A-6
D155A-6 33
34 D155A-6
D155A-6 35
36 D155A-6
D155A-6 37
38 D155A-6
D155A-6 39
40 D155A-6
D155A-6 41
42 D155A-6
D155A-6 43
44 D155A-6
D155A-6 45
T- branch box and T- branch adapter table 1

(Rev. 2009.03)
a 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.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4350 T-box (for DRC 60, ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
46 D155A-6
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol

799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 — q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 — q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT (Brown) 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for ECONO) 24 q q q
D155A-6 47
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430* 2 P q q
Socket for engine (CRI-T3) PCV
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* 2 A q q
Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 3 — q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
799-601-4140 3 FCIG q q
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
799-601-4190* 3 1,2,3L q q
Commonrail pressure
799-601-4230* 4 1,2,3,4C q q
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1,2,3,G q q
799-601-4340* 2 2,PA q q
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380* 4 1,2,3,4T q
Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 — q
799-601-4280* Box for controller (PUMP) 121 — q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
Multi-adapter for
799-601-9890 3, — q
DT2 – 4 and DTM2
4,
“*” Shows not T-adapter but socket.
48 D155A-6
D155A-6 49
D155A-6 Bulldozer
© 2009 KOMATSU
All Rights Reserved
50 D155A-6
SEN03206-00
D155A-6

D155A-6 85001 and up
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 [2201L1] When right steering clutch oil pressure command current is OFF, fill signal is ON ... 14
Failure code [2201LH] When right steering clutch oil pressure command current is ON, fill signal is OFF.. 16
Failure code [2202L1] When left steering clutch oil pressure command current is OFF, fill signal is ON ..... 18
D155A-6 1
Failure code [2202LH] When left steering clutch oil pressure command current is ON, fill signal is OFF .... 20
Failure code [2300KM] Stall in 1st gear speed.............................................................................................. 22
Failure code [2301L1] Right brake: Fill high.................................................................................................. 23
Failure code [2301LH] Right brake: Fill low .................................................................................................. 24
Failure code [2302L1] Left brake: Fill high .................................................................................................... 25
Failure code [2302LH] Left brake: Fill low..................................................................................................... 26
Failure code [7RFAKA] ECM HOLD RELAY: Disconnection......................................................................... 28
Failure code [AA10NX] Air Cleaner Clogging ............................................................................................... 30
Failure code [AB00MA] Battery Charge Abnormal........................................................................................ 32
Failure code [B@BAZG] Eng Oil Press Low ................................................................................................. 34
Failure code [B@BCNS] Eng Water Overheat.............................................................................................. 34
Failure code [B@BCZK] Eng Water Level Low............................................................................................. 35
Failure code [B@CENS] T/C Oil Overheat ................................................................................................... 35
Failure code [B@HANS] Hyd Oil Overheat................................................................................................... 36
Failure code [CA111] EMC Critical Internal Failure ....................................................................................... 38
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .......................................................................... 40
Failure code [CA122] Chg (boost) Air Press Sensor High Error ................................................................... 42
Failure code [CA123] Chg (boost) Air Press Sensor Low Error .................................................................... 44
Failure code [CA131] Throttle Sensor High Error ......................................................................................... 46
Failure code [CA132] Throttle Sensor Low Error .......................................................................................... 48
Failure code [CA135] Eng Oil Press Sensor High Error................................................................................ 50
Failure code [CA141] Eng Oil Press Sensor Low Error ................................................................................ 52
Failure code [CA144] Coolant Temp Sens High Error................................................................................... 54
Failure code [CA145] Coolant Temp Sens Low Error ................................................................................... 56
Failure code [CA153] Chg (boost) Air Temp Sensor High Error.................................................................... 58
Failure code [CA154] Chg (boost) Air Temp Sensor Low Error .................................................................... 60
Failure code [CA187] Sens Supply 2 Volt Low Error..................................................................................... 60
Failure code [CA221] Ambient Press Sens High Error ................................................................................. 62
Failure code [CA222] Ambient Press Sens Low Error .................................................................................. 64
Failure code [CA227] Sens Supply 2 Volt High Error.................................................................................... 66
2 D155A-6
Failure code [1500L0] Transmission clutch: Abnormal 1

Action code Failure code Transmission clutch: Abnormal
Trouble
E03 1500L0 (Power train controller system)
• Among failure codes related to transmission clutch, 2 or more of following failure codes occurred
similarly.
1) Either [DXH4KA] or [DXH4KB]
Contents of
• Among failure codes related to transmission clutch, following combinations of failure codes
trouble
occurred similarly.
1) [15SAL1] and [15SBL1]
2) [15SALH] and [15SBLH]
3) 2 or all of [15SEL1], [15SFL1], and [15SGL1]
4) 2 or all of [15SELH], [15SFLH], and [15SGLH]
Action of
• Limits operation of engine and transmission.
controller
Problem that • Auto-shift-down function does not operate.
appears on • Once machine is stopped, engine speed is limited to medium (half).
machine • Once machine is stopped, travel is limited to specific gear speed.
Related
• Method of reproducing failure code: Start engine + Travel.
information
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard If other failure codes are displayed, carry out troubleshooting for them.
value in normal [15SAL1], [15SALH], [15SBL1], [15SBLH], [15SEL1], [15SELH], [15SFL1], [15SFLH],
state [15SGL1], [15SGLH], [DXH4KA], [DXH4KB], [DXH5KA], [DXH5KB], [DXH6KA], [DXH6KB]
D155A-6 3
Failure code [15SAL1] Forward clutch: Fill high 1

Action code Failure code Forward clutch: Fill high
Trouble
E03 15SAL1 (Power train controller system)
Contents of • When output to transmission F clutch ECMV solenoid circuit is turned OFF, fill switch signal is
trouble turned ON.
• Sets transmission in neutral when operator sets it in reverse position (Prevention of double engage-
Action of
ment).
controller
Problem that
• Once machine is stopped, engine speed is limited to medium (half).
appears on
• Once machine is stopped, travel is limited to F1.
machine
• State of F clutch ECMV fill switch signal can be checked with monitoring function.
Related
(Code: 40906 T/M Fill Sw Input 1)
information
• Method of reproducing failure code: Start engine + Set transmission in neutral.

a Prepare with starting switch OFF, then start engine and carry
out troubleshooting.
Defective F clutch ECMV fill PCCS lever
1 FFT (male) Resistance
switch (Internal short circuit) (Travel gear speed)
Between (1) – chas- N Min. 1 Mz
sis ground F1, F2, F3 Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshoot-
Possible causes Ground fault in wiring har- ing without turning starting switch ON.
and standard 2 ness
value in normal (Contact with GND circuit) Wiring harness between STC2 (female) (35) Resis-
Min. 1 Mz
state – FFT (female) (1) and chassis ground tance
Defective power train con- PCCS lever
3 STC2 Voltage
troller (Travel gear speed)
Between (35) – chas- N 5 – 11 V
sis ground F1, F2, F3 Max. 1 V
If causes 1 – 3 are not detected in electrical system, hydraulic sys-
4 Defective hydraulic system
tem may be defective. Carry out related troubleshooting (H mode).
Circuit diagram related
4 D155A-6
Failure code [15SALH] Forward clutch: Fill low 1

Action code Failure code Forward clutch: Fill low
Trouble
E03 15SALH (Power train controller system)
Contents of • When output to transmission F clutch ECMV solenoid circuit is turned ON, fill switch signal is turned
trouble OFF.
• Sets transmission in neutral when operator sets it in forward position (Prevention of double engage-
Action of
ment).
controller
Problem that
appears on
• Once machine is stopped, travel is limited to R1.
machine
• State of F clutch ECMV fill switch signal can be checked with monitoring function.
Related
information
• Method of reproducing failure code: Start engine + Set transmission in forward position.

Defective F clutch ECMV fill PCCS lever
1 switch (Internal disconnec- FFT (male) Resistance
(Travel gear speed)
tion)
sis ground F1, F2, F3 Max. 1 z
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
Possible causes ing without turning starting switch ON.
ness (Disconnection in wiring
and standard 2
or defective contact in con- Wiring harness between STC2 (female) (35) Resis-
value in normal Max. 1 z
nector) – FFT (female) (1) tance
state
3 STC2 Voltage
sis ground F1, F2, F3 Max. 1 V
D155A-6 5
Failure code [15SBL1] Reverse clutch: Fill high 1

Action code Failure code Reverse clutch: Fill high
Trouble
E03 15SBL1 (Power train controller system)
Contents of • When output to transmission R clutch ECMV solenoid circuit is turned OFF, fill switch signal is
trouble turned ON.
• Sets transmission in neutral when operator sets it in forward position (Prevention of double engage-
Action of
ment).
controller
Problem that
appears on
machine
• State of R clutch ECMV fill switch signal can be checked with monitoring function.
Related
information

Defective R clutch ECMV fill PCCS lever
1 FRT (male) Resistance
switch (Internal short circuit) (Travel gear speed)
sis ground R1, R2, R3 Max. 1 z
and standard 2 ness (Contact with GND cir-
value in normal cuit) Wiring harness between STC2 (female) (25) Resis-
Min. 1 Mz
state – FRT (female) (1) and chassis ground tance
3 STC2 Voltage
sis ground R1, R2, R3 Max. 1 V
6 D155A-6
Failure code [15SBLH] Reverse clutch: Fill low 1

Action code Failure code Reverse clutch: Fill low
Trouble
E03 15SBLH (Power train controller system)
Contents of • When output to transmission R clutch ECMV solenoid circuit is turned ON, fill switch signal is turned
trouble OFF.
• Sets transmission in neutral when operator sets it in reverse position (Prevention of double engage-
Action of
ment).
controller
Problem that
appears on
machine
• State of R clutch ECMV fill switch signal can be checked with monitoring function.
Related
information
• Method of reproducing failure code: Start engine + Set transmission in reverse position.

Defective R clutch ECMV fill PCCS lever
1 switch (Internal disconnec- FRT (male) Resistance
(Travel gear speed)
tion)
sis ground R1, R2, R3 Max. 1 z
and standard 2
nector) – FRT (female) (1) tance
state
3 STC2 Voltage
sis ground R1, R2, R3 Max. 1 V
D155A-6 7
Failure code [15SEL1] Speed 1st clutch: Fill high 1

Action code Failure code Speed 1st clutch: Fill high
Trouble
E03 15SEL1 (Power train controller system)
Contents of • When output to transmission 1st clutch ECMV solenoid circuit is turned OFF, fill switch signal is
trouble turned ON.
Action of
controller
Problem that
appears on
• Once machine is stopped, travel is limited to F1 and R1.
machine
• State of 1st clutch ECMV fill switch signal can be checked with monitoring function.
Related
information

a Prepare with starting switch OFF, then start engine, select
manual gearshift mode, and carry out troubleshooting.
Defective 1st clutch ECMV PCCS lever
F1T (male) Resistance
1 fill switch (Internal short cir- (Travel gear speed)
cuit) Other than F1, N, or
Between (1) – chas- Min. 1 Mz
R1
sis ground
F1, R1 Max. 1 z
Min. 1 Mz
state – F1T (female) (1) and chassis ground tance
PCCS lever
Defective power train con- STC3 Voltage
3 (Travel gear speed)
troller
Other than F1, N, or
Between (19) – chas- 5 – 11 V
R1
sis ground
F1, R1 Max. 1 V
8 D155A-6
Failure code [15SELH] Speed 1st clutch: Fill low 1

Action code Failure code Speed 1st clutch: Fill low
Trouble
E03 15SELH (Power train controller system)
Contents of • When output to transmission 1st clutch ECMV solenoid circuit is turned ON, fill switch signal is
trouble turned OFF.
Action of
controller
machine • Once machine is stopped, travel is limited to F2 and R2.
• State of 1st clutch ECMV fill switch signal can be checked with monitoring function.
Related (Code: 40906 T/M Fill Sw Input 1)
information • Method of reproducing failure code: Start engine + Set transmission in F1 or R1 position (in manual
gearshift mode).

Defective 1st clutch ECMV PCCS lever
1 fill switch (Internal discon- (Travel gear speed)
nection) Other than F1, N, or
R1
sis ground
F1, R1 Max. 1 z
and standard 2
nector) – F1T (female) (1) tance
state
PCCS lever
troller
R1
sis ground
F1, R1 Max. 1 V
D155A-6 9
Failure code [15SFL1] Speed 2nd clutch: Fill high 1

Action code Failure code Speed 2nd clutch: Fill high
Trouble
E03 15SFL1 (Power train controller system)
Contents of • When output to transmission 2nd clutch ECMV solenoid circuit is turned OFF, fill switch signal is
trouble turned ON.
Action of
controller
• State of 2nd clutch ECMV fill switch signal can be checked with monitoring function.
Related
information

Defective 2nd clutch ECMV PCCS lever
R2
sis ground
F2, R2 Max. 1 z
Min. 1 Mz
PCCS lever
troller
R2
sis ground
F2, R2 Max. 1 V
10 D155A-6
Failure code [15SFLH] Speed 2nd clutch: Fill low 1

Action code Failure code Speed 2nd clutch: Fill low
Trouble
E03 15SFLH (Power train controller system)
Contents of • When output to transmission 2nd clutch ECMV solenoid circuit is turned ON, fill switch signal is
trouble turned OFF.
Action of
controller
Problem that
appears on
machine
• State of 2nd clutch ECMV fill switch signal can be checked with monitoring function.
gearshift mode).

Defective 2nd clutch ECMV PCCS lever
R2
sis ground
F2, R2 Max. 1 z
and standard 2
state
PCCS lever
troller
R2
sis ground
F2, R2 Max. 1 V
D155A-6 11
Failure code [15SGL1] Speed 3rd clutch: Fill high 1

Action code Failure code Speed 3rd clutch: Fill high
Trouble
E03 15SGL1 (Power train controller system)
Contents of • When output to transmission 3rd clutch ECMV solenoid circuit is turned OFF, fill switch signal is
trouble turned ON.
Action of
controller
• State of 3rd clutch ECMV fill switch signal can be checked with monitoring function.
Related
information

Defective 3rd clutch ECMV PCCS lever
R3
sis ground
F3, R3 Max. 1 z
Min. 1 Mz
PCCS lever
troller
R3
sis ground
F3, R3 Max. 1 V
12 D155A-6
Failure code [15SGLH] Speed 3rd clutch: Fill low 1

Action code Failure code Speed 3rd clutch: Fill low
Trouble
E03 15SGLH (Power train controller system)
Contents of • When output to transmission 3rd clutch ECMV solenoid circuit is turned ON, fill switch signal is
trouble turned OFF.
Action of
controller
Problem that
appears on
machine
• State of 3rd clutch ECMV fill switch signal can be checked with monitoring function.
gearshift mode).

Defective 3rd clutch ECMV PCCS lever
R3
sis ground
F3, R3 Max. 1 z
and standard 2
state
PCCS lever
troller
R3
sis ground
F3, R3 Max. 1 V
If causes 1 - 3 are not detected in electrical system, hydraulic sys-
D155A-6 13
Failure code [2201L1] When right steering clutch oil pressure command
current is OFF, fill signal is ON 1
Action code Failure code When right steering clutch oil pressure command current is OFF, fill
Trouble signal is ON
Contents of
• The fill switch signal is not set off at output stop of the right steering clutch solenoid circuit.
trouble
Action of • Flashes caution lamp and turns on caution buzzer.
controller • Limits operation of engine, transmission, and brake.
Problem that • Once machine is stopped, engine speed is limited to medium (half).
appears on • Once machine is stopped, it never runs.
machine • Auto-shift down function does not work.
• The input state (ON/OFF) from the right steering clutch fill switch can be checked in real-time moni-
Related
toring mode. (Code 31521: Steering fill switch input state)
information
• Method of reproducing failure code: Engine start

a Prepare with starting switch OFF. Engine start for troubleshoot-
ing.
Defective right steering
1 clutch fill switch FCLR (male) PCCS lever Resistance
(Internal short) Between (1) – N (Neutral) Min. 1 Mz
chassis ground Right max. steering Max. 1 z
Possible causes Defective harness grounding ing without turning starting switch ON.
2
and standard (Contact with ground circuit) Wiring harness between STC2 (female) (3) – Resis-
value in normal Min. 1Mz
FCLR (female) (1) with chassis ground tance
state
ing.
Defective power train control- STC2 PCCS lever Voltage
3
ler
Between (3) – N (Neutral) 5 – 11 V
chassis ground Right max. steering Max. 1 V
When no fault is detected in the electric system, the hydraulic pres-
Defective hydraulic pressure
4 sure system is assumed to be abnormal. Carry out the related trou-
system
bleshooting (H mode).
14 D155A-6
D155A-6 15
Failure code [2201LH] When right steering clutch oil pressure command
current is ON, fill signal is OFF 1
Action code Failure code When right steering clutch oil pressure command current is ON, fill
Trouble signal is OFF
E04 2201LH (Power train controller system)
Contents of
• The fill switch signal is not set off at output to the right steering clutch solenoid circuit.
trouble
• The input state (ON/OFF) from the right steering clutch fill switch can be checked in real-time moni-
Related toring mode. (Code 31521: Steering fill switch input state)
information • Method of reproducing failure code: Engine start + Parking brake lever release + PCCS lever oper-
ate (right steering)

ing.
1 clutch fill switch FCLR (male) PCCS lever Resistance
chassis ground Right max. steering Max. 1 z
Possible causes ness (Disconnection in wiring ing without turning starting switch ON.
2
and standard or defective contact in con- Wiring harness between STC2 (female) (3) – Resis-
value in normal nector) Max. 1 z
FCLR (female) (1) tance
state
ing.
3
ler
chassis ground Right max. steering Max. 1 V
system
16 D155A-6
D155A-6 17
Failure code [2202L1] When left steering clutch oil pressure command
current is OFF, fill signal is ON 1
Action code Failure code When left steering clutch oil pressure command current is OFF, fill
Trouble signal is ON
Contents of
• The fill switch signal is not set off at output stop of the left steering clutch solenoid circuit.
trouble
• The input state (ON/OFF) from the left steering clutch fill switch can be checked in real-time moni-
Related
toring mode. (Code 31521: Steering fill switch input state)
information
• Method of reproducing failure code: Engine start

ing.
Defective left steering clutch
1 fill switch FCLL (male) PCCS lever Resistance
chassis ground Left max. steering Max. 1 z
Possible causes Defective harness grounding ing without turning starting switch ON.
2
and standard (Contact with ground circuit) Wiring harness between STC2 (female) (13) Resis-
value in normal Min. 1 Mz
– FCLL (female) (1) with chassis ground tance
state
ing.
3
ler
chassis ground Left max. steering Max. 1 V
system
18 D155A-6
D155A-6 19
Failure code [2202LH] When left steering clutch oil pressure command
current is ON, fill signal is OFF 1
Action code Failure code When left steering clutch oil pressure command current is ON, fill
Trouble signal is OFF
Contents of
• The fill switch signal is not set off at output to the left steering clutch solenoid circuit.
trouble
• The input state (ON/OFF) from the left steering clutch fill switch can be checked in real-time moni-
Related toring mode. (Code 31521: Steering fill switch input state)
information • Method of reproducing failure code: Engine start + Parking brake lever release + PCCS lever oper-
ate (left steering)

ing.
1 fill switch FCLL (male) PCCS lever Resistance
chassis ground Left max. steering Max. 1 z
Possible causes ness (Disconnection in wiring ing without turning starting switch ON.
2
and standard or defective contact in con- Wiring harness between STC2 (female) (13) Resis-
– FCLL (female) (1) tance
state
ing.
3
ler
chassis ground Left max. steering Max. 1 V
system
20 D155A-6
D155A-6 21
Failure code [2300KM] Stall in 1st gear speed 1

Action code Failure code Stall in 1st gear speed
Trouble
— 2300KM (Engine controller system)
Contents of
—
trouble
Action of
• Saves only history.
controller
Problem that
appears on —
machine
Related
—
information

and standard
value in normal 1 Work prohibited by operator —
state
22 D155A-6
Failure code [2301L1] Right brake: Fill high 1

Action code Failure code Right brake: Fill high
Trouble
Contents of • When output to steering case right brake ECMV solenoid circuit is turned OFF, fill switch signal is
trouble turned ON.
Action of
• Limits operation of engine, transmission, and brake.
controller
Problem that • Applies brake lightly during travel.
machine • Once machine is stopped, machine cannot travel at all.
• State of right brake ECMV fill switch signal can be checked with monitoring function.
Related (Code: 31521 S/T Fill Sw Input)
information • Method of reproducing failure code: Start engine + Operate parking brake lever (Free) + Operate
brake pedal (Press).

a Prepare with starting switch OFF, then start engine, set parking
brake lever in Free position, and carry out troubleshooting.
Defective right brake ECMV
1 fill switch (Internal short cir- FBRR (male) Brake pedal Resistance
cuit) Between (1) – chas- Released Max. 1 z
sis ground Pressed Min. 1 Mz
Min. 1 Mz
state – FBRR (female) (1) and chassis ground tance
Defective power train con- STC2 Brake pedal Voltage
3
troller
Between (38) – chas- Released Max. 1 V
sis ground Pressed 5 – 11V
D155A-6 23
Failure code [2301LH] Right brake: Fill low 1

Action code Failure code Right brake: Fill low
Trouble
Contents of • When output to steering case right brake ECMV solenoid circuit is turned ON, fill switch signal is
trouble turned OFF.
Action of
controller
• State of right brake ECMV fill switch signal can be checked with monitoring function.

1 fill switch (Internal short cir- FBRR (male) Brake pedal Resistance
cuit) Between (1) – chas- Released Max. 1 z
and standard 2
nector) – FBRR (female) (1) tance
state
3
troller
sis ground Pressed 5 – 11 V
24 D155A-6
Failure code [2302L1] Left brake: Fill high 1

Action code Failure code Left brake: Fill high
Trouble
Contents of • When output to steering case left brake ECMV solenoid circuit is turned OFF, fill switch signal is
trouble turned ON.
Action of
controller
• State of left brake ECMV fill switch signal can be checked with monitoring function.

Defective left brake ECMV fill FBRL (male) Brake pedal Resistance
1
switch (Internal short circuit)
Between (1) – chas- Released Max. 1 z
Min. 1 Mz
state – FBRL (female) (1) and chassis ground tance
3
troller
D155A-6 25
Failure code [2302LH] Left brake: Fill low 1

Action code Failure code Left brake: Fill low
Trouble
Contents of • When output to steering case left brake ECMV solenoid circuit is turned ON, fill switch signal is
trouble turned OFF.
Action of
controller
• State of left brake ECMV fill switch signal can be checked with monitoring function.

Defective left brake ECMV fill FBRL (male) Brake pedal Resistance
1
switch (Internal short circuit)
Between (1) – chas- Released Max. 1 z
and standard 2
nector) – FBRL (female) (1) tance
state
3
troller
26 D155A-6
D155A-6 27
Failure code [7RFAKA] ECM HOLD RELAY: Disconnection 1

Action code Failure code ECM HOLD RELAY: Disconnection
Trouble
— 7RFAKA (Power train controller system)
Contents of
• When ground circuit of engine cut relay circuit is disconnected to turn output ON, no current flows.
trouble
Action of
• None in particular.
controller
Problem that
appears on • When engine cut mechanism is installed, engine cannot be cut (stopped).
machine
• State of engine cut relay circuit signal can be checked with monitoring function.
(Code: 40912 P/T Sw Input)
Related
• Method of reproducing failure code: Start engine.
information
• This failure code detects abnormality on primary side (coil side) of engine cut relay but does not
detect abnormality on secondary side (contact side).

Defective engine cut relay ing without turning starting switch ON.
1
(Internal disconnection) ACT (male) Resistance
Between (1) – (2) 200 – 400 z
Disconnection in wiring har- ing without turning starting switch ON.
ness (Disconnection in wiring Wiring harness between STC2 (female) (19) Resis-
2 Max. 1 z
or defective contact in con- – ACT (female) (2) tance
Possible causes nector) Wiring harness between ACT (female) (1) – Resis-
Max. 1 z
and standard terminal 270. tance
value in normal a Prepare with starting switch OFF, then carry out troubleshoot-
state ing without turning starting switch ON.
Short circuit in wiring har- Wiring harness between STC2 (female) (19) Resis-
Min. 1 Mz
3 ness (Contact with GND cir- – ACT (female) (2) and chassis ground tance
cuit) Wiring harness between ACT (female) (1),
Resis-
(3) – terminal 270, circuit branch end and Min. 1 Mz
tance
chassis ground.
a Prepare with starting switch OFF, then turn starting switch ON
Defective power train con- and carry out troubleshooting.
4
troller STC2 Voltage
Between (19) – chassis ground 20 – 30 V
28 D155A-6
D155A-6 29
Failure code [AA10NX] Air Cleaner Clogging 1

Action code Failure code Air Cleaner Clogging
Trouble
— AA10NX (Machine monitor system)
Contents of • While engine was running, air cleaner clogging switch signal circuit detected clogging of air cleaner
trouble (opening of sensor contact).
Action of
machine monitor
Problem that
appears on • If machine is used as it is, engine may be damaged.
machine
Related
information

Clogged air cleaner
1 a Air cleaner may be clogged. Check and clean or replace it.
(When system is normal)
Defective air cleaner clog- AF1 (male) Air cleaner Resistance
2 ging switch (Internal discon- Normal (Intake air
nection) Max. 1 z
resistance: *1)
Between (1) – (2)
Clogged (Intake air
Min. 1 Mz
resistance: *2)
Possible causes
and standard
value in normal
state ness (Disconnection in wiring Wiring harness between CM02 (female) (4) Resis-
3 Max. 1 z
or defective contact in con- – AF1 (female) (1) tance
nector) Wiring harness between CM01 (female) (7), Resis-
Max. 1 z
CM02 (female) (7) – AF1 (female) (2) tance
CM02 Air cleaner Voltage
Defective power train con-
4 Normal (Intake air
troller Max. 1 V
resistance: *1)
Between (4) – (7)
Clogged (Intake air
20 – 30 V
resistance: *2)
*1: Max. -3,430 Pa {-350 mmH2O}

*2: -7,470 ± 490Pa {-762 ± 50 mmH2O}
30 D155A-6
D155A-6 31
Failure code [AB00MA] Battery Charge Abnormal 1

Action code Failure code Battery Charge Abnormal
Trouble
— AB00MA (Machine monitor system)
Contents of
• While engine was running, alternator signal circuit detected that battery charge voltage was low.
trouble
Action of
• Displays charge level monitor red on machine monitor.
machine monitor
Problem that
appears on • If machine is used as it is, battery may not be charged.
machine
• Battery voltage can be checked with monitoring function.
Related
(Code: 03203 Battery Power Supply)
information

Possible causes Defective charge by alterna-
1 CM01 Engine Voltage
and standard tor (When system is normal)
value in normal Between (11) – chas- Above medium
27.5 – 29.5 V
state sis ground speed
If cause 1 is not detected, charge level monitor system may be
Defective charge level moni-
2 defective. Carry out "E-5 Caution item lights up while engine is
tor system
running" in E mode.
32 D155A-6
D155A-6 33
Failure code [B@BAZG] Eng Oil Press Low 1

Action code Failure code Eng Oil Press Low
Trouble
— B@BAZG (Engine controller system)
Contents of • While engine was running, engine oil pressure sensor signal circuit detected that engine oil pres-
trouble sure was abnormally low.
Action of • Displays engine oil pressure monitor red on machine monitor.
controller • Continues operation with limited output (Limits injection rate and engine speed).
Problem that
appears on • If machine is used as it is, engine may be seized.
machine
• Engine oil pressure sensor signal is input to engine controller and then transmitted to machine mon-
itor through communication system.
Related
• Engine oil pressure can be checked with monitoring function.
information
(Code: 37200 Engine Oil Pressure)

Possible causes Low engine oil pressure
1 Check engine oil pressure. If it is low, remove cause.
and standard (When system is normal)
value in normal If cause 1 is not detected, engine oil pressure sensor may be
state Defective engine oil pressure
2 defective. Carry out troubleshooting for failure codes [CA135] and
sensor system
[CA141].
Failure code [B@BCNS] Eng Water Overheat 1

Action code Failure code Eng Water Overheat
Trouble
— B@BCNS (Engine controller system)
Contents of • While engine was running, engine coolant temperature sensor signal circuit detected that engine
trouble coolant was overheated.
Action of
• Displays engine coolant temperature monitor red on machine monitor.
controller
Problem that
appears on • If machine is used as it is, engine may be seized.
machine
• Engine coolant temperature sensor signal is input to engine controller and then transmitted to
machine monitor through communication system.
Related
• Engine coolant temperature can be checked with monitoring function.
information
(Code: 04107 Coolant Temperature)

Possible causes Overheated engine coolant Check engine coolant for overheating. If it is overheated, remove
1
and standard (When system is normal) cause.
value in normal If cause 1 is not detected, engine coolant temperature sensor may
state Defective engine coolant
2 be defective. Carry out troubleshooting for failure codes [CA144]
temperature sensor system
and [CA145].
34 D155A-6
Failure code [B@BCZK] Eng Water Level Low 1

Action code Failure code Eng Water Level Low
Trouble
— B@BCZK (Machine controller system)
Contents of • While starting switch was ON (and engine was stopped) or engine was running, radiator coolant
trouble level switch signal circuit detected that radiator coolant level was low (sensor contact was open).
Action of • Displays radiator coolant level monitor red on machine monitor.
machine monitor • Continues operation with limited output (Limits injection rate and engine speed).
Problem that
appears on • If machine is used as it is, engine may be overheated.
machine
Related
information

Possible causes Low coolant level Check radiator sub tank for lowering of coolant level. If coolant
1
and standard (When system is normal) level is low, add coolant.
value in normal If cause 1 is not detected, radiator coolant level monitor may be
state Defective radiator coolant
2 defective. Carry out "E-2 Caution item lights up while starting
level monitor system
switch is ON (and engine is stopped)" in E mode.
Failure code [B@CENS] T/C Oil Overheat 1

Action code Failure code T/C Oil Overheat
Trouble
— B@CENS (Power train controller system)
Contents of • While engine was running, torque converter oil temperature sensor signal circuit detected that
trouble power train oil was overheated.
Action of
• Displays torque converter oil temperature monitor red on machine monitor.
controller
Problem that
appears on • If machine is used as it is, power train components may be damaged.
machine
• Torque converter oil temperature sensor signal is input to power train controller and then transmit-
ted to machine monitor through communication system.
Related
• Power train oil temperature can be checked with monitoring function.
information
(Code: 30100 T/C Oil Temperature)

Possible causes Overheated power train oil Check power train oil for overheating. If it is overheated, remove
1
and standard (When system is normal) cause.
value in normal Defective torque converter If cause 1 is not detected, torque converter oil temperature sensor
state 2 oil temperature sensor sys- system may be defective. Carry out troubleshooting for failure
tem code [DGT1KA] or [DGT1KX].
D155A-6 35
Failure code [B@HANS] Hyd Oil Overheat 1

Action code Failure code Hyd Oil Overheat
Trouble
— B@HANS (Machine monitor system)
Contents of • While engine was running, hydraulic oil temperature sensor signal circuit detected that hydraulic oil
trouble was overheated.
Action of
• Displays hydraulic oil temperature monitor red on machine monitor.
controller
Problem that
appears on • If machine is used as it is, work equipment and HSS circuit components may be damaged.
machine
• Hydraulic oil temperature can be checked with monitoring function.
Related
(Code: 04401 Hyd Oil Temperature)
information

Overheated hydraulic oil Check hydraulic oil for overheating. If it is overheated, remove
Possible causes 1
(When system is normal) cause.
and standard
value in normal If cause 1 is not detected, hydraulic oil temperature gauge system
state Defective hydraulic oil tem- may be defective. Carry out troubleshooting for "E-10 Hydraulic oil
2
perature gauge system temperature gauge (Multi-gauge) does not indicated normally" in E
mode.
36 D155A-6
D155A-6 37
Failure code [CA111] EMC Critical Internal Failure 1

Action code Failure code EMC Critical Internal Failure
Trouble
E04 CA111 (Engine controller system)
Contents of
• Trouble occurred in engine controller.
trouble
Action of
controller
Problem that
appears on • Engine runs normally but may stop during operation or may not be able to start.
machine
Related • Source voltage of engine controller can be checked with monitoring function.
information (Code: 03203 Battery Power Supply)

Defective circuit breaker If circuit breaker is turned OFF, circuit probably has ground fault.
1
(CB30 or CB8) (See cause 3.)
ing without turning starting switch ON.
Wiring harness between EGC3 (female) (3), Resis-
Max. 1 z
Disconnection in wiring har- (4) – CB8 (2) tance
ness (Disconnection in wiring Wiring harness between CB8 (1) – CB30 Resis-
2 Max. 1 z
or defective contact in con- (B30S) tance
nector) Wiring harness between CB30 (B30L) – ter- Resis-
Max. 1 z
minal BRB tance
Max. 1 z
(2) – chassis ground (GND20) tance
Possible causes a Prepare with starting switch OFF, then carry out troubleshoot-
and standard ing without turning starting switch ON.
value in normal Wiring harness between EGC3 (female) (3), Resis-
state Min. 1 Mz
(4) – CB8 (2) and chassis ground tance
Wiring harness between CB8 (1) – CB30
Ground fault in wiring har- Resis-
(B30S), circuit branch end and chassis Min. 1 Mz
3 ness (Contact with GND cir- tance
ground
cuit)
Wiring harness between CB30 (B30L) – ter- Resis-
Min. 1 Mz
minal BRB and chassis ground tance
Wiring harness between EGC3 (female) (1),
Resis-
(2) – chassis ground (GND20) and chassis Min. 1 Mz
tance
ground
and carry out troubleshooting.
4 Defective engine controller EGC3 Starting switch Voltage
Between (3), (4) –
ON 20 – 30 V
(1), (2)
38 D155A-6
D155A-6 39
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 1

Action code Failure code Eng Ne and Bkup Speed Sens Error
Trouble
Contents of
• Trouble occurred in Ne speed sensor circuit and Bkup speed sensor circuit simultaneously.
trouble
Action of
controller
Problem that
• Engine cannot be started (if engine has been stopped).
appears on
• Engine stops (if engine has been running).
machine
Related
information

Defective Ne speed sensor Ne speed sensor system may be defective. Carry out trouble-
1
system shooting for code [CA689].
Defective Bkup speed sen- Bkup speed sensor system may be defective. Carry out trouble-
2
sor system shooting for code [CA778].
Possible causes Defective mount of Ne speed Check mount of Ne speed sensor directly for defect (defective
3
and standard sensor installation of sensor, internal trouble of flywheel, etc.)
value in normal Defective mount of Bkup Check mount of Bkup speed sensor directly for defect (defective
state 4
speed sensor installation of sensor, internal trouble of supply pump, etc.)
Defective connection (Wrong Check Ne speed sensor and Bkup speed sensor directly for defec-
5
connection) of sensor tive connection (wrong connection).
If causes 1 – 5 are not detected, engine controller may be defec-
6 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
40 D155A-6
D155A-6 41
Failure code [CA122] Chg (boost) Air Press Sensor High Error 1
Action code Failure code Chg (boost) Air Press Sensor High Error
Trouble
Contents of
• Signal voltage in charge pressure sensor circuit is abnormally high.
trouble
Action of
• Fixes charge pressure (400 kPa {4.08 kg/cm2}) and continues operation.
controller
Problem that
appears on • Acceleration performance of engine lowers or black smoke is produced more during acceleration.
machine
Related • State of charge pressure sensor can be checked with monitoring function.
information (Code: 36500 Charge Pressure-Abs)

Defective sensor power sup- If code [CA187] or [CA227] is indicated, carry out troubleshooting
1
ply system for it first.
or start engine and carry out troubleshooting.
PIM Voltage
Defective charge pressure
2 Between (1) – (3) Power supply 4.75 – 5.25 V
sensor (Internal trouble)
Pressure sensor voltage is measured with wiring harness con-
nected. Accordingly, if voltage is abnormal, check wiring harness
and controller, too, for another cause of trouble, and then judge.
Disconnection in wiring har- Wiring harness between EGC1 (female) Resis-
Max. 1 z
ness (Disconnection in wiring (37) – PIM (female) (1) tance
3
or defective contact in con- Wiring harness between EGC1 (female) Resis-
nector) Max. 1 z
(47) – PIM (female) (3) tance
Wiring harness between EGC1 (female) Resis-
Max. 1 z
(44) – PIM (female) (2) tance
value in normal Wiring harness between EGC1 (female) Resis-
Ground fault in wiring har- Min. 1 Mz
state (37) – PIM (female) (1) and chassis ground tance
4 ness (Contact with GND cir-
cuit) Wiring harness between EGC1 (female) Resis-
Min. 1 Mz
(47) – PIM (female) (3) and chassis ground tance
Min. 1 Mz
(44) – PIM (female) (2) and chassis ground tance
Wiring harness between EGC1 (female)
Resis-
(37) – PIM (female) (1) and between EGC1 Min. 1 Mz
tance
Short circuit in wiring har- (female) (47) – PIM (female) (3)
5 ness (with another wiring Wiring harness between EGC1 (female)
harness) Resis-
tance
(female) (44) – PIM (female) (2)
Chassis ground between EGC1 (female)
Resis-
tance
(female) (44) – PIM (female) (2)
6 Defective engine controller
EGC1 Voltage
Between (37) – (47) Power supply 4.75 – 5.25 V
42 D155A-6
D155A-6 43
Failure code [CA123] Chg (boost) Air Press Sensor Low Error 1
Action code Failure code Chg (boost) Air Press Sensor Low Error
Trouble
Contents of
• Signal voltage in charge pressure sensor circuit is abnormally low.
trouble
Action of • Fixes charge pressure (400 kPa {4.08 kg/cm2}) and continues
controller • operation.
Problem that
appears on • Acceleration performance of engine lowers or black smoke is produced more during acceleration.
machine
Related • State of charge pressure sensor can be checked with monitoring function.
information (Code: 36500 Charge Pressure-Abs)

and standard
value in normal Carry out troubleshooting for failure code [CA122].
state
44 D155A-6
D155A-6 45
Failure code [CA131] Throttle Sensor High Error 1

Action code Failure code Throttle Sensor High Error
Trouble
Contents of
• Signal voltage in decelerator pedal potentiometer circuit is abnormally high.
trouble
Action of
• Sets throttle position with fuel control dial signal and continues operation.
controller
Problem that
appears on
machine
Related • State of decelerator pedal optimum operation range signal can be checked with monitoring function.
information (Code: 03001 Throttle Pos Sens Volt)

Defective sensor power sup- If code [CA2185] or [CA2186] is indicated, carry out troubleshoot-
1
ply system ing for it first.
Defective fuel control dial DCL (male) Resistance

2
(Internal trouble) Between (B) – (C) 1.5 – 2.5 kz
Between (A) – (B) 0 – 3 kz
Between (A) – (C) 0 – 3 kz
Disconnection in wiring har- Wiring harness between EGC2 (female) (9) Resis-
Max. 1 z
ness (Disconnection in wiring – DCL (female) (A) tance
3
Possible causes or defective contact in con- Wiring harness between EGC2 (female) Resis-
nector) Max. 1 z
and standard (22) – DCL (female) (B) tance
state Max. 1 z
(23) – DCL (female) (C) tance
Wiring harness between EGC2 (female) (9) Resis-
– DCL (female) (A) and chassis ground tance
Min. 1 Mz
(22) – DCL (female) (B) and chassis ground tance
Min. 1 Mz
(23) – DCL (female) (C) and chassis ground tance
5 Defective engine controller EGC2 Voltage
Between (9) – (23) Signal 0.5 – 4.5 V
46 D155A-6
D155A-6 47
Failure code [CA132] Throttle Sensor Low Error 1

Action code Failure code Throttle Sensor Low Error
Trouble
Contents of
• Signal voltage in decelerator pedal potentiometer circuit is abnormally low.
trouble
Action of
• Sets throttle position with fuel control dial signal and continues operation.
controller
Problem that
appears on
machine

and standard
state
48 D155A-6
D155A-6 49
Failure code [CA135] Eng Oil Press Sensor High Error 1

Action code Failure code Eng Oil Press Sensor High Error
Trouble
Contents of
• Signal voltage in engine oil pressure sensor circuit is abnormally high.
trouble
Action of
• Sets engine oil pressure to default value (250 kPa {2.55 kg/cm2}) and continues operation.
controller
Problem that
appears on
machine
Related • State of engine oil pressure sensor can be checked with monitoring function.
information (Code: 37201 Eng Oil Press Sens Volt)

1
POIL Voltage
Defective engine oil pressure
2 Between (1) – (2) Power supply 4.75 –5.25 V
sensor (Internal trouble)
Sensor voltage is measured with wiring harness connected.
Accordingly, if voltage is abnormal, check wiring harness and con-
troller, too, for another cause of trouble, and then judge.
Max. 1 z
ness (Disconnection in wiring (37) – POIL (female) (1) tance
3
nector) Max. 1 z
(47) – POIL (female) (2) tance
Max. 1 z
(13) – POIL (female) (3) tance
and standard
state (37) – POIL (female) (1) and chassis ground tance
Min. 1 Mz
(47) – POIL (female) (2) and chassis ground tance
Min. 1 Mz
(13) – POIL (female) (3) and chassis ground tance
Resis-
(37) – POIL (female) (1) and between EGC1 Min. 1 Mz
tance
Short circuit in wiring har- (female) (47) – POIL (female) (2)
harness) Resis-
tance
(female) (13) – POIL (female) (3)
Resis-
tance
(female) (13) – POIL (female) (3)
EGC1 Voltage
50 D155A-6
D155A-6 51
Failure code [CA141] Eng Oil Press Sensor Low Error 1

Action code Failure code Eng Oil Press Sensor Low Error
Trouble
Contents of
• Signal voltage in engine oil pressure sensor circuit is abnormally low.
trouble
Action of
• Sets engine oil pressure to default value (250 kPa {2.55 kg/cm2}) and continues operation.
controller
Problem that
appears on
machine
Related • State of engine oil pressure sensor can be checked with monitoring function.
information (Code: 37201 Eng Oil Press Sens Volt)

and standard
state
52 D155A-6
D155A-6 53
Failure code [CA144] Coolant Temp Sens High Error 1

Action code Failure code Coolant Temp Sens High Error
Trouble
Contents of
• Signal voltage in engine coolant temperature sensor circuit is abnormally high.
trouble
Action of
• Fixes engine coolant temperature (90°C) and continues operation.
controller
Problem that
appears on • Startability of engine lowers at low temperature.
machine
Related • State of engine coolant temperature sensor can be checked with monitoring function.
information (Code: 04105 Coolant Temp Sens Volt)

TWTR (male) Coolant temperature Resistance
Defective engine coolant 0°C 30 – 37 kz
1 temperature sensor (Internal
25°C 9.3 – 10.7 kz
trouble)
Between (A) – (B) 50°C 3.2 – 3.8 kz
80°C 1.0 – 1.3 kz
95°C 700 – 800 z
ness (Disconnection in wiring Wiring harness between EGC1 (female) Resis-
2 Max. 1 z
Possible causes or defective contact in con- (15) – TWTR (female) (A) tance
and standard nector) Wiring harness between EGC1 (female) Resis-
(38) – TWTR (female) (B) tance
state
Ground fault in wiring har- ing without turning starting switch ON.
3 ness (Contact with GND cir- Wiring harness between EGC1 (female)
cuit) Resis-
(15) – TWTR (female) (A) and chassis Min. 1 Mz
tance
ground
EGC1 (female) Coolant temperature Resistance
0°C 30 – 37 kz
25°C 9.3 – 10.7 kz
Between (15) – (38) 50°C 3.2 – 3.8 kz
80°C 1.0 – 1.3 kz
95°C 700 – 800 z
54 D155A-6
D155A-6 55
Failure code [CA145] Coolant Temp Sens Low Error 1

Action code Failure code Coolant Temp Sens Low Error
Trouble
Contents of
• Signal voltage in engine coolant temperature sensor circuit is abnormally low.
trouble
Action of
• Fixes engine coolant temperature (90°C) and continues operation.
controller
Problem that
machine
Related • State of engine coolant temperature sensor can be checked with monitoring function.
information (Code: 04105 Coolant Temp Sens Volt)

and standard
state
56 D155A-6
D155A-6 57
Failure code [CA153] Chg (boost) Air Temp Sensor High Error 1
Action code Failure code Chg (boost) Air Temp Sensor High Error
Trouble
Contents of
• Signal voltage in charge temperature sensor circuit is abnormally high.
trouble
Action of
• Fixes charge temperature (intake air temperature) (70°C) and continues operation.
controller
Problem that
machine
Related • State of charge temperature sensor signal can be checked with monitoring function.
information (Code: 18501 Charge Temp Sens Volt)

Intake air
TIM (male) Resistance
temperature
Defective charge tempera- 0°C 29 – 36 kz

1
ture sensor (Internal trouble) 25°C 9 – 11 kz
Between (A) – (B)
40°C 4.9 – 5.8 kz
100°C 600 – 700 kz
Between (A) – chas-
All range Min. 1 Mz
sis ground
Possible causes
and standard 2 Max. 1 z
or defective contact in con- (23) – TIM (female) (A) tance
value in normal
nector) Wiring harness between EGC1 (female) Resis-
state Max. 1 z
(47) – TIM (female) (B) tance
Min. 1 Mz
(23) – TIM (female) (A) and chassis ground tance
Intake air
EGC1 (female) Resistance
temperature
4 Defective engine controller 0°C 29 – 36 kz
25°C 9 – 11 kz
Between (23) – (47)
40°C 4.9 – 5.8 kz
100°C 600 – 700 kz
58 D155A-6
D155A-6 59
Failure code [CA154] Chg (boost) Air Temp Sensor Low Error 1
Action code Failure code Chg (boost) Air Temp Sensor Low Error
Trouble
Contents of
• Signal voltage in charge temperature sensor circuit is abnormally low.
trouble
Action of
• Fixes charge temperature (intake air temperature) (70°C) and continues operation.
controller
Problem that
machine
Related • State of charge temperature sensor signal can be checked with monitoring function.
information (Code: 18501 Charge Temp Sens Volt)

and standard
state
Failure code [CA187] Sens Supply 2 Volt Low Error 1

Action code Failure code Sens Supply 2 Volt Low Error
Trouble
Contents of
• Signal voltage in sensor power supply 2 (5 V) circuit is abnormally low.
trouble
• Operates Bkup speed sensor with signals of Ne speed sensor.
Action of • Sets oil pressure sensor to default value (250 kPa {2.55 kg/cm2}) and continues operation.
controller • Sets ambient pressure sensor to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.
• Fixes charge pressure sensor value (400 kPa {4.1 kg/cm2}) and continues operation.
Problem that
appears on • Engine output drops.
machine
Related
information

and standard
state
60 D155A-6
D155A-6 61
Failure code [CA221] Ambient Press Sens High Error 1

Action code Failure code Ambient Press Sens High Error
Trouble
Contents of
• Signal voltage in ambient pressure sensor circuit is abnormally high.
trouble
Action of
• Sets ambient pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.
controller
Problem that
machine
Related • State of ambient pressure sensor signal can be checked with monitoring function.
information (Code: 37401 Ambient Press Sens Volt)

1
PAMB Voltage
Defective ambient pressure Between (1) – (3) Power supply 4.75 – 5.25 V
2
sensor (Internal trouble) Between (2) – (3) Signal 0.3 – 4.7 V
Max. 1 z
ness (Disconnection in wiring (37) – PAMB (female) (1) tance
3
nector) Max. 1 z
(38) – PAMB (female) (3) tance
Max. 1 z
– PAMB (female) (2) tance
Possible causes
and standard
value in normal Wiring harness between EGC1 (female) (37) Resis-
state – PAMB (female) (1) and chassis ground tance
cuit) Wiring harness between EGC1 (female) (38) Resis-
Min. 1 Mz
– PAMB (female) (3) and chassis ground tance
Min. 1 Mz
– PAMB (female) (2) and chassis ground tance
Resis-
(37) – PAMB (female) (1) and between Min. 1 Mz
tance
Short circuit in wiring har- EGC1 (female) (38) - PAMB (female) (3)
harness) Resis-
tance
EGC1 (female) (3) – PAMB (female) (2)
Resis-
tance
EGC1 (female) (3) – PAMB (female) (2)
a repare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
6 Defective engine controller EGC1 Voltage
Between (37) – (38) 4.75 – 5.25 V
Between (3) – (38) 0.3 – 4.7 V
62 D155A-6
D155A-6 63
Failure code [CA222] Ambient Press Sens Low Error 1

Action code Failure code Ambient Press Sens Low Error
Trouble
Contents of
• Signal voltage in ambient pressure sensor circuit is abnormally low.
trouble
Action of
• Sets ambient pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.
controller
Problem that
machine
Related • State of ambient pressure sensor signal can be checked with monitoring function.
information (Code: 37401 Ambient Press Sens Volt)

and standard
state
64 D155A-6
D155A-6 65
Failure code [CA227] Sens Supply 2 Volt High Error 1

Action code Failure code Sens Supply 2 Volt High Error
Trouble
Contents of
• Signal voltage in sensor power supply 2 (5 V) circuit is abnormally high.
trouble
• Operates Bkup speed sensor with signals of Ne speed sensor.
Action of • Sets oil pressure sensor to default value (250 kPa [2.55 kg/cm2}) and continues operation.
controller • Sets ambient pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.
• Fixes charge (boost) pressure sensor value (400 kPa [4.1 kg/cm2}) and continues operation.
Problem that
machine
Related
information

1 Defective related system If another failure code is indicated, carry out troubleshooting for it.
Disconnect devices Bkup speed sensor G connector
Defective sensor (Internal at right in order. If Oil pressure sensor POIL connector
2 "E" of failure code
trouble) Ambient pressure
disappears when a PAMB connector
sensor
device is discon-
nected, that device Charge pressure
PIM connector
has trouble in it. sensor
3 Max. 1 z
or defective contact in con- (37) – each sensor (female) tance
Possible causes Max. 1 z
and standard (47) – each sensor (female) tance
(37) – each sensor (female) and chassis Min. 1 Mz
ground
cuit)
Resis-
(47) – each sensor (female) and chassis Min. 1 Mz
tance
ground
Short circuit in wiring har- ing without turning starting switch ON.
harness) Resis-
(37) – each sensor (female) and between Min. 1 Mz
tance
EGC1 (female) (47) – each sensor (female)
EGC1 Voltage
Between (37) – (47) 4.75 – 5.25 V
66 D155A-6
D155A-6 67
D155A-6 Bulldozer
© 2007 KOMATSU
All Rights Reserved
68 D155A-6
SEN03207-01
D155A-6

D155A-6 85001 and up
codes, Part 2
Failure code [CA234] Eng Overspeed ............................................................................................................ 3
Failure code [CA238] Ne Speed Sens Supply Volt Error ................................................................................ 4
Failure code [CA263] Fuel Temp Sensor High Error....................................................................................... 6
Failure code [CA265] Fuel Temp Sensor Low Error ....................................................................................... 8
Failure code [CA271] PCV1 Short Error ......................................................................................................... 9
Failure code [CA272] PCV1 Open Error ....................................................................................................... 10
Failure code [CA273] PCV2 Short Error ........................................................................................................11
Failure code [CA274] PCV2 Open Error ....................................................................................................... 12
Failure code [CA322] Inj #1 Open/Short Error .............................................................................................. 14
D155A-6 1
Failure code [CA342] Calibration Code Incompatibility ................................................................................. 26

Failure code [CA351] Injectors Drive Circuit Error ........................................................................................ 28
Failure code [CA352] Sense Supply 1 Volt Low Error................................................................................... 30
Failure code [CA386] Sense Supply 1 Volt High Error.................................................................................. 32
Failure code [CA441] Battery Voltage Low Error .......................................................................................... 34
Failure code [CA442] Battery Voltage High Error.......................................................................................... 34
Failure code [CA449] Rail Press Very High Error ......................................................................................... 35
Failure code [CA451] Rail Press Sensor High Error ..................................................................................... 36
Failure code [CA452] Rail Press Sensor Low Error ...................................................................................... 38
Failure code [CA553] Rail Press High Error.................................................................................................. 38
Failure code [CA554] Rail Press Sensor In Range Error .............................................................................. 39
Failure code [CA559] Rail Press Low Error .................................................................................................. 40
Failure code [CA689] Eng Ne Speed Sensor Error....................................................................................... 44
Failure code [CA731] Eng Bkup Speed Sens Phase Error ........................................................................... 46
Failure code [CA757] All Continuous Data Lost Error................................................................................... 46
Failure code [CA778] Eng Bkup Speed Sensor Error ................................................................................... 48
Failure code [CA1633] KOMNET Datalink Timeout Error ............................................................................. 50
Failure code [CA2185] Throt Sens Sup Volt High Error ................................................................................ 52
Failure code [CA2186] Throt Sens Sup Volt Low Error................................................................................. 54
Failure code [CA2249] Rail Press Very Low Error ........................................................................................ 54
Failure code [CA2555] Grid Htr Relay Volt Low Error ................................................................................... 55
Failure code [CA2556] Grid Htr Relay Volt High Error .................................................................................. 56
Failure code [D110KA] Battery relay: Disconnection .................................................................................... 58
Failure code [D110KB] Battery Relay: Drive Short Circuit ............................................................................ 60
Failure code [D130KA] Neutral relay: Disconnection .................................................................................... 62
Failure code [D130KB] Neutral relay: Short circuit........................................................................................ 64
Failure code [D161KA] Back-up alarm relay: Disconnection ........................................................................ 66
Failure code [D161KB] Back-up alarm relay: Short circuit ............................................................................ 68
Failure code [D190KA] ACC signal relay: Disconnection.............................................................................. 70
Failure code [D190KB] ACC signal relay: Short circuit ................................................................................. 72
2 D155A-6
Failure code [CA234] Eng Overspeed 1

Action code Failure code Eng Overspeed
Trouble
— CA234 (Engine controller system)
Contents of
• Engine speed is above operating range.
trouble
Action of
• Limits fuel injection rate until engine speed lowers to operating range.
controller
Problem that
appears on • Engine speed fluctuates.
machine
Related • Engine speed can be checked with monitoring function.
information (Code: 01002 Engine Speed)

Possible causes
and standard Way of use of machine may be improper. Teach proper way of use
2 Improper way of use
value in normal to operator.
state If causes 1 – 2 are not detected, engine controller may be defec-
out.)
D155A-6 3
Failure code [CA238] Ne Speed Sens Supply Volt Error 1

Action code Failure code Ne Speed Sens Supply Volt Error
Trouble
Contents of
• Trouble occurred in Ne speed sensor power supply (5 V) circuit.
trouble
Action of
• Controls Ne speed sensor with signals of Bkup speed sensor.
controller
Problem that
• Running engine stops (when Bkup speed sensor is also abnormal).
appears on
• Stopped engine cannot be started (when Bkup speed sensor is also abnormal).
machine
Related
information

Disconnect devices
Defective Ne speed sensor at right in order. If
(Internal trouble) Engine Ne speed
disappears when a NE connector
sensor
device is discon-
nected, that device
has trouble in it.
2 Max. 1 z
or defective contact in con- (16) – NE (female) (1) tance
Possible causes
Max. 1 z
and standard (48) – NE (female) (2) tance
Ground fault in wiring har-
3 ness (Contact with GND cir- Min. 1 Mz
(16) – NE (female) (1) and chassis ground tance
cuit)
Min. 1 Mz
harness) Resis-
(16) – NE (female) (1) and between EGC1 Min. 1 Mz
tance
(female) (48) – NE (female) (2)
EGC1 Voltage
Between (16) – (48) 4.75 – 5.25 V
4 D155A-6
D155A-6 5
Failure code [CA263] Fuel Temp Sensor High Error 1

Action code Failure code Fuel Temp Sensor High Error
Trouble
Contents of
• Signal voltage in fuel temperature sensor circuit is abnormally high.
trouble
Action of
• Fixes fuel temperature (90 °C) and continues operation.
controller
Problem that
appears on
machine
Related • State of fuel temperature sensor signal can be checked with monitoring function.
information (Code: 14201 Fuel Temp Sens Volt)

TFUEL (male) Fuel temperature Resistance
Defective fuel temperature 0°C 30 – 37 kz

1
sensor (Internal trouble) 25°C 9.3 – 10.7 kz
Between (A) – (B) 50°C 3.2 – 3.8 kz
80°C 1.0 – 1.3 kz
95°C 700 – 800 z
Possible causes 2 Max. 1 z
or defective contact in con- (30) – TFUEL (female) (A) tance
and standard nector)
Max. 1 z
state (47) – TFUEL (female) (B) tance
Min. 1 Mz
– TFUEL (female) (A) and chassis ground tance
EGC1 (female) Fuel temperature Resistance
0°C 30 – 37 kz
25°C 9.3 – 10.7 kz
Between (30) – (47) 50°C 3.2 – 3.8 kz
80°C 1.0 – 1.3 kz
95°C 700 – 800 z
6 D155A-6
D155A-6 7
Failure code [CA265] Fuel Temp Sensor Low Error 1

Action code Failure code Fuel Temp Sensor Low Error
Trouble
Contents of
• Signal voltage in fuel temperature sensor circuit is abnormally low.
trouble
Action of
• Fixes fuel temperature (90°C) and continues operation.
controller
Problem that
appears on
machine
Related
information

and standard
state
8 D155A-6
Failure code [CA271] PCV1 Short Error 1

Action code Failure code PCV1 Short Error
Trouble
Contents of
• There is short circuit in PCV1 circuit of supply pump.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Defective supply pump PCV1 (male) Resistance
1
PCV1 (Internal short circuit) Between (1) – (2) 2.3 – 5.3 z
Between (1), (2) – chassis
Min. 1 Mz
ground
– PCV1 (female) (1) and chassis ground tance
Possible causes cuit)
and standard Min. 1 Mz
value in normal
state a Prepare with starting switch OFF, then turn starting switch ON
Hot short (Short circuit with Wiring harness between EGC1 (female) (4)
3 Voltage Max. 1 V
24V circuit) in wiring harness – PCV1 (female) (1) and chassis ground
Wiring harness between EGC1 (female) (5)
Voltage Max. 1 V
– PCV1 (female) (2) and chassis ground
Between (4) – (5) 2.3 – 5.3 z
Min. 1 Mz
ground
D155A-6 9
Failure code [CA272] PCV1 Open Error 1

Action code Failure code PCV1 Open Error
Trouble
Contents of
• There is disconnection in PCV1 circuit of supply pump.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1 PCV1 (Internal disconnec-
tion) Between (1) – (2) 2.3 – 5.3 z
Min. 1 Mz
ground
ness (Disconnection in wiring Wiring harness between EGC1 (female) (4) Resis-
2 Max. 1 z
or defective contact in con- – PCV1 (female) (1) tance
Possible causes nector) Wiring harness between EGC1 (female) (5) Resis-
and standard Max. 1 z
– PCV1 (female) (2) tance
value in normal
state a Prepare with starting switch OFF, then carry out troubleshoot-
cuit)
Min. 1 Mz
Between (4) – (5) 2.3 – 5.3 z
Min. 1 Mz
ground
10 D155A-6
Failure code [CA273] PCV2 Short Error 1

Action code Failure code PCV2 Short Error
Trouble
Contents of
• There is short circuit in PCV2 circuit of supply pump.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1
PCV2 (Internal short circuit) Between (1) – (2) 2.3 – 5.3 z
Min. 1 Mz
ground
value in normal
Hot short (Short circuit with Wiring harness between EGC1 (female) (9)
3 Voltage Max. 1 V
24V circuit) in wiring harness – PCV2 (female) (1) and chassis ground
Wiring harness between EGC1 (female) (10)
Voltage Max. 1 V
– PCV2 (female) (2) and chassis ground
Between (9) – (10) 2.3 – 5.3 z
Min. 1 Mz
ground
D155A-6 11
Failure code [CA274] PCV2 Open Error 1

Action code Failure code PCV2 Open Error
Trouble
Contents of
• There is disconnection in PCV2 circuit of supply pump.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1 PCV2 (Internal disconnec-
tion) Between (1) – (2) 2.3 – 5.3 z
Min. 1 Mz
ground
ness (Disconnection in wiring Wiring harness between EGC1 (female) (9) Resis-
2 Max. 1 z
or defective contact in con- – PCV2 (female) (1) tance
Possible causes nector) Wiring harness between EGC1 (female) Resis-
(10) – PCV2 (female) (2) tance
value in normal
cuit)
Min. 1 Mz
Between (9) – (10) 2.3 – 5.3 z
Min. 1 Mz
ground
12 D155A-6
D155A-6 13
Failure code [CA322] Inj #1 Open/Short Error 1

Action code Failure code Inj #1 Open/Short Error
Trouble
Contents of
• There is disconnection or short circuit in injector #1 circuit.
trouble
Action of
controller
Problem that
• Output drops.
appears on
• Rotation is unstable.
machine
Related
information

Defective injector #1 (Inter- CN1 (male) Resistance
1
nal trouble) Between (1) – (2) 0.4 – 1.1 z
Min. 1 Mz
ground
2 Max. 1 z
or defective contact in con- (45) – CN1 (female) (1) tance
Max. 1 z
Possible causes (53) – CN1 (female) (2) tance
and standard a Prepare with starting switch OFF, then carry out troubleshoot-
value in normal ing without turning starting switch ON.
state Ground fault in wiring har-
(45) – CN1 (female) (1) and chassis ground tance
cuit)
Min. 1 Mz
If a failure code of troubles in multiple injectors is displayed, carry
Defective another cylinder
4 out troubleshooting for it. Carry out troubleshooting for a short cir-
injector or wiring harness
cuit in circuit #2 or #3.
Between (45) – (53) 0.4 – 1.1 z
Min. 1 Mz
ground
14 D155A-6
D155A-6 15

Trouble
Contents of
trouble
Action of
controller
Problem that
• Output drops.
appears on
machine
Related
information

1
Min. 1 Mz
ground
2 Max. 1 z
Max. 1 z
cuit)
Min. 1 Mz
Between (46) – (60) 0.4 – 1.1 z
Min. 1 Mz
ground
16 D155A-6
D155A-6 17

Trouble
Contents of
trouble
Action of
controller
Problem that
• Output drops.
appears on
machine
Related
information

1
Min. 1 Mz
ground
2 Max. 1 z
Max. 1 z
cuit)
Min. 1 Mz
Between (55) – (52) 0.4 – 1.1 z
Min. 1 Mz
ground
18 D155A-6
D155A-6 19

Trouble
Contents of
trouble
Action of
controller
Problem that
• Output drops.
appears on
machine
Related
information

1
Min. 1 Mz
ground
2 Max. 1 z
Max. 1 z
cuit)
Min. 1 Mz
Between (57) – (59) 0.4 – 1.1 z
Min. 1 Mz
ground
20 D155A-6
D155A-6 21

Trouble
Contents of
trouble
Action of
controller
Problem that
• Output drops.
appears on
machine
Related
information

1
Min. 1 Mz
ground
2 Max. 1 z
Max. 1 z
cuit)
Min. 1 Mz
Between (54) – (51) 0.4 – 1.1 z
Min. 1 Mz
ground
22 D155A-6
D155A-6 23

Trouble
Contents of
trouble
Action of
controller
Problem that
• Output drops.
appears on
machine
Related
information

1
Min. 1 Mz
ground
2 Max. 1 z
Max. 1 z
cuit)
Min. 1 Mz
Between (56) – (58) 0.4 – 1.1 z
Min. 1 Mz
ground
24 D155A-6
D155A-6 25
Failure code [CA342] Calibration Code Incompatibility 1

Action code Failure code Calibration Code Incompatibility
Trouble
Contents of
• Incompatibility occurred in engine controller data.
trouble
Action of
controller
Problem that
appears on • Engine continues operation normally, but it may stop during operation or may not be able to start.
machine
Related
information

and standard
state
26 D155A-6
D155A-6 27
Failure code [CA351] Injectors Drive Circuit Error 1

Action code Failure code Injectors Drive Circuit Error
Trouble
Contents of
• Trouble occurred in injector drive circuit.
trouble
Action of
• Limits engine output and continues operation (Limits common rail pressure).
controller
Problem that
machine

If another failure code (failure code of trouble in injector system) is
1 Defective related system
indicated, carry out troubleshooting for it.
Defective circuit breaker If circuit breaker is turned OFF, circuit probably has ground fault
2
(CB30 or CB8) (See cause 4).
Max. 1 z
Disconnection in wiring har- (4) – CB8 (2) tance
ness (Disconnection in wiring Wiring harness between CB8 (1) – CB30 Resis-
3 Max. 1 z
or defective contact in con- (B30S) tance
nector) Wiring harness between CB30 (B30L) – ter- Resis-
Max. 1 z
minal BRB tance
and standard
Min. 1 Me
(4) – CB8 (2) and chassis ground tance
(B30S) or circuit branch end and chassis Min. 1 Me
ground
cuit)
Min. 1 Me
Wiring harness between EGC3 (female) (1),
Resis-
(2) – chassis ground (GND20) and chassis Min. 1 Me
tance
ground
EGC3 Voltage
Between (3), (4) – (1), (2) 20 – 30 V
28 D155A-6
D155A-6 29
Failure code [CA352] Sense Supply 1 Volt Low Error 1

Action code Failure code Sense Supply 1 Volt Low Error
Trouble
Contents of
• Signal voltage in sensor power supply 1 (5 V) circuit of engine controller is abnormally low.
trouble
Action of
• Limits common rail pressure sensor output and continues operation (Limits common rail pressure).
controller
Problem that
machine
Related
information

and standard
state
30 D155A-6
D155A-6 31
Failure code [CA386] Sense Supply 1 Volt High Error 1

Action code Failure code Sense Supply 1 Volt High Error
Trouble
Contents of
• Signal voltage in sensor power supply (5 V) circuit is abnormally high.
trouble
Action of
• Limits common rail pressure sensor output and continues operation (Limits common rail pressure).
controller
Problem that
machine
Related
information

Disconnect devices
Defective sensor (Internal at right in order. If “E”
2 of failure code disap-
trouble) Common rail pres-
pears when a device PFUEL connector
sure sensor
is disconnected, that
device has trouble in
it.
3 Max. 1 z
or defective contact in con- (33) – PFUEL (female) (1) tance
and standard (47) – PFUEL (female) (3) tance
(33) – PFUEL (female) (1) and chassis Min. 1 Mz
ground
cuit)
Resis-
(47) – PFUEL (female) (3) and chassis Min. 1 Mz
tance
ground
harness) Resis-
(33) – PFUEL (female) (1) and between Min. 1 Mz
tance
EGC1 (female) (47) – PFUEL (female) (3)
EGC1 Voltage
Between (33) – (47) 4.75 – 5.25 z
32 D155A-6
D155A-6 33
Failure code [CA441] Battery Voltage Low Error 1

Action code Failure code Battery Voltage Low Error
Trouble
Contents of
• Power supply circuit voltage of engine controller is abnormally low.
trouble
Action of
controller
Problem that
machine

and standard
state
Failure code [CA442] Battery Voltage High Error 1

Action code Failure code Battery Voltage High Error
Trouble
Contents of
• Power supply circuit voltage of engine controller is abnormally low.
trouble
Action of
controller
Problem that
machine

and standard
state
34 D155A-6
Failure code [CA449] Rail Press Very High Error 1

Action code Failure code Rail Press Very High Error
Trouble
Contents of
• Common rail pressure sensor circuit detected abnormally high pressure (level 2).
trouble
Action of
controller
Problem that
machine
Related • Common rail pressure can be checked with monitoring function.
information (Code: 36400 Rail Pressure)

and standard
state
D155A-6 35
Failure code [CA451] Rail Press Sensor High Error 1

Action code Failure code Rail Press Sensor High Error
Trouble
Contents of
• Signal voltage in common rail pressure sensor circuit is abnormally high.
trouble
Action of
controller
Problem that
machine
Related • State of common rail pressure sensor signal can be checked with monitoring function.
information (Code: 36401 Rail Pressure Sense Volt)

1
PFUEL Voltage
Defective common rail pres- Between (1) – (3) Power supply 4.75 – 5.25 V
2
sure sensor (Internal trouble) Between (2) – (3) Signal 0.26 – 4.6 V
Max. 1 z
ness (Disconnection in wiring (33) – PFUEL (female) (1) tance
3
nector) Max. 1 z
(25) – PFUEL (female) (2) tance
Possible causes Wiring harness between EGC1 (female) Resis-
(47) – PFUEL (female) (3) tance
value in normal
– PFUEL (female) (1) and chassis ground tance
Min. 1 Mz
Min. 1 Mz
Resis-
tance
Short circuit in wiring har- EGC1 (female) (25) – PFUEL (female) (2)
harness) Resis-
tance
Resis-
tance
36 D155A-6
Possible causes a Prepare with starting switch OFF, then turn starting switch ON
and standard or start engine and carry out troubleshooting.
value in normal 6 Defective engine controller EGC1 Voltage
state Between (33) – (47) 4.75 – 5.25 V
Between (25) – (47) 0.26 – 4.6 V
D155A-6 37
Failure code [CA452] Rail Press Sensor Low Error 1

Action code Failure code Rail Press Sensor Low Error
Trouble
Contents of
• Signal voltage in common rail pressure sensor circuit is abnormally low.
trouble
Action of
controller
Problem that
machine

and standard
state
Failure code [CA553] Rail Press High Error 1

Action code Failure code Rail Press High Error
Trouble
Contents of
• Common rail pressure sensor circuit detected abnormally high pressure (level 1).
trouble
Action of
controller
Problem that
machine

2 Use of improper fuel Check fuel used directly (for high viscosity).
Defective electrical system of Common rail pressure sensor may have electric trouble. Carry out
3
Possible causes common rail pressure sensor troubleshooting for failure code [CA451].
and standard Defective mechanical system
value in normal 4 of common rail pressure sen- Check mechanical system of common rail pressure sensor directly.
state sor
Check overflow valve directly for broken spring, worn seat, and
5 Defective overflow valve
stuck ball.
6 Clogging of overflow piping Check overflow piping directly for clogging.
7 Defective pressure limiter Check pressure limiter directly for mechanical defect.
38 D155A-6
Failure code [CA554] Rail Press Sensor In Range Error 1

Action code Failure code Rail Press Sensor In Range Error
Trouble
Contents of
• In-range error occurred in common rail pressure sensor circuit.
trouble
Action of
controller
Problem that
machine

and standard
value in normal Carry out troubleshooting for Failure code [CA451].
state
D155A-6 39
Failure code [CA559] Rail Press Low Error 1

Action code Failure code Rail Press Low Error
Trouble
Contents of
• Supply pump does not feed fuel (level 1).
trouble
Action of
• Limits common rail pressure.
controller
Problem that
machine

2 Use of improper fuel Check fuel used directly for improper quality.
a For contents of troubleshooting, see Note 1. For check of pres-
sure in fuel low-pressure circuit, see Testing and adjusting,
Defective low-pressure cir- Testing fuel pressure.
3
cuit device
Pressure in fuel low-pressure 0.15 – 0.3 M.P.O.
circuit (high idle) {1.5 – 3.0 kg/am2}
4 Clogging of filter/strainer a For contents of troubleshooting, see Note 2.
Defective electrical system of Supply pump PCV may have electric trouble. Carry out trouble-
5
supply pump PCV shooting for following codes; [CA271], [CA272], [CA273], [CA274].
Defective common rail pres- Common rail pressure sensor may be defective. Check wiring har-
6
sure sensor ness for damage.
Possible causes
and standard a For testing of leakage from pressure limiter, see Testing and
value in normal adjusting, Measuring fuel return rate and fuel leakage.
state 7 Defective pressure limiter Leakage from pressure limiter
(Operation equivalent to rated Max. 10 CD/min.
operation (under stall load))
a For measuring of return (spill) limit from injector, see Testing
and adjusting, Measuring fuel return rate and fuel leakage.
Speed in rated operation
Return (Spill) limit from injector
(stall load)
8 Defective injector 1,600 wpm 960 CD/min.

1,700 wpm 1,020 cc/min
1,800 rpm 1,080 cc/min
1,900 rpm 1,140 cc/min
2,000 rpm 1,200 cc/min
9 Defective supply pump If causes 1 – 8 are not detected, supply pump may be defective.
<How to use check sheet>

Carry out the above troubleshooting and take a record of the contents of the attached "Check sheet for rail
pressure low error".
40 D155A-6
Note 1: When low-pressure circuit is defective, check the following:

q Fuel level
q Clogged fuel tank breather
q Water separator/Prefilter filled with water
q Clogged fuel filter
q Clogged screen in water separator
q Stuck or worn feed pump, clogged filter
q Leaked or clogged low-pressure fuel pipe
q Bypass valve malfunction, defective assembly of other parts (See Fig.1.)
q Clogged fuel filter
q Fuel in oil pan (fuel leakage in head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q Overflow valve (1): Spring is seen through both holes.
q Bypass valve (2): Spring is seen through hole on nut side.
q 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.
q Fuel filter: Replace. (Replace both prefilter and main filter.)
q Water separator: Disassemble and check. If screen (4) is clogged, clean it. (See Fig. 2.)
q Gauze filter: Disassemble and check. Clean, if clogged.
q Upstream strainer of gauze filter: Disassemble and check. Clean, if clogged.
D155A-6 41
Check sheet for rail pressure low error
Model D155A-6 Work No.

Machine serial No. # Date of check / /
Engine SAA6D140E-5 Service meter h
Engine serial No. # Worker's name
A. Visual check Good NG

1 Fuel leakage to outside
2 Clogging of fuel tank breather
B. Check with machine monitor (02 Fault history, 01 monitoring, and 09 reduced cylinder mode operation) Good NG
3 Check of failure code / / / /
Check of monitoring information
Standard value Measured
Code Displayed item Checking condition ISO unit Good NG
(Reference value) value
Low idle r/min 715 – 765
01002 Engine speed High idle r/min 1,825 – 1,925
Torque converter stall r/min 1,560 – 1,660
Final accelerator Low idle % 0
31706
position High idle % 100
Final fuel injection
18600 rate command Torque converter stall mg/st — — —
(by weight)
4 Final common rail
36200 Torque converter stall MPa — — —
pressure command
Common rail pres-
36400 Torque converter stall MPa — — —
sure
Low idle CA — — —
Final injection tim-
36300 High idle CA — — —
ing command
Torque converter stall CA — — —
Chg (boost) pres-
36500 Torque converter stall kPa — — —
sure
Engine coolant tem-
04107 Low idle °C — — —
perature
14200 Fuel temperature Low idle °C — — —
Check of reduced cylinder mode operation (Engine speed)
Setting Reduced cylinder Checking condition ISO unit Good NG
No. 1 cylinder r/min — — —
5 No. 2 cylinder r/min — — —
Reduce No. 3 cylinder r/min — — —
each
cylinder No. 4 cylinder r/min — — —
42 D155A-6

C. Check of fuel circuit pressure Checking condition Unit Good NG
Fuel low-pressure circuit MPa 0.15 – 0.3
6 High idle
pressure {kg/cm2} {1.5 – 3.0}
D. Check of strainers and filters Good NG

7 Visual check of strainers
8 Visual check of gauze filter
9 Visual check of fuel filter
10 Visual check of bypass valve
E. Check of leakage and Standard value Measured

Checking condition Unit Good NG
return rate (Reference value) value
Leakage through pressure
11 Torque converter stal cc/min Max. 10
limiter
Torque converter stall
cc/min 960
1,600 rpm
cc/min 1,020
1,700 rpm
Torque converter stall Speed:
12 Return rate from injector cc/min 1,080
1,800 rpm Leakage
cc/min 1,140
1,900 rpm
cc/min 1,200
2,000 rpm
D155A-6 43
Failure code [CA689] Eng Ne Speed Sensor Error 1

Action code Failure code Eng Ne Speed Sensor Error
Trouble
Contents of
• Trouble occurred in engine Ne speed sensor circuit.
trouble
Action of
• Operates with signals of Bkup speed sensor.
controller
Problem that
• Running engine stops (when Bkup speed sensor is also abnormal).
appears on
• Stopped engine cannot be started (when Bkup speed sensor is also abnormal).
machine
Related
information

Defective sensor power sup-
1 If code [CA238] is indicated, carry out troubleshooting for it first.
ply system
Max. 1 z
ness (Disconnection in wiring (16) – NE (female) (1) tance
2
nector) Max. 1 z
(48) – NE (female) (2) tance
Max. 1 z
(27) – NE (female) (3) tance
Min. 1 Mz
Min. 1 Mz
and standard (27) – NE (female) (3) and chassis ground tance
Resis-
tance
Short circuit in wiring har- (female) (48) – NE (female) (2)
harness) Resis-
tance
Resis-
tance
Defective mount of sensor or Check Ne speed sensor directly for defective mount (defective
5 defective rotation sensing clearance) or check rotation sensing part (flywheel) directly for
part defect.
If causes 1 – 5 are not detected, engine Ne speed sensor may be
Defective engine Ne speed
6 defective. (Since trouble is in system, troubleshooting cannot be
sensor
carried out.)
out.)
44 D155A-6
D155A-6 45
Failure code [CA731] Eng Bkup Speed Sens Phase Error 1

Action code Failure code Eng Bkup Speed Sens Phase Error
Trouble
Contents of
• Engine Bkup sensor circuit detected phase error.
trouble
Action of
• Controls with signals of engine Ne speed sensor.
controller
Problem that
• Running engine stops (when Ne speed sensor is also abnormal).
appears on
• Stopped engine cannot be started (when Ne speed sensor is also abnormal).
machine
Related
information

Possible causes
Defective engine Ne speed Engine Ne speed sensor may be defective. Carry out trouble-
and standard 1
sensor system shooting for failure code [CA689].
value in normal
state Defective engine Bkup Engine Bkup speed sensor may be defective. Carry out trouble-
2
speed sensor system shooting for failure code [CA778].
Failure code [CA757] All Continuous Data Lost Error 1

Action code Failure code All Continuous Data Lost Error
Trouble
Contents of
• All data in engine controller are lost.
trouble
Action of
controller
Problem that
machine
Related
information

and standard
state
46 D155A-6
D155A-6 47
Failure code [CA778] Eng Bkup Speed Sensor Error 1

Action code Failure code Eng Bkup Speed Sensor Error
Trouble
Contents of
• Trouble occurred in engine Bkup speed sensor circuit.
trouble
Action of
• Operates with signals of Ne speed sensor.
controller
Problem that
• Running engine stops (when Ne speed sensor is also abnormal).
appears on
• Stopped engine cannot be started (when Ne speed sensor is also abnormal).
machine
Related
information

1
Max. 1 z
ness (Disconnection in wiring (37) – G (female) (1) tance
2
nector) Max. 1 z
(47) – G (female) (2) tance
Max. 1 z
(26) – G (female) (3) tance
(37) – G (female) (1) and chassis ground tance
Min. 1 Mz
(47) – G (female) (2) and chassis ground tance
Min. 1 Mz
and standard (26) – G (female) (3) and chassis ground tance
Resis-
(37) – G (female) (1) and between EGC1 Min. 1 Mz
tance
Short circuit in wiring har- (female) (47) – G (female) (2)
harness) Resis-
tance
(female) (26) – G (female) (3)
Resis-
tance
(female) (26) – G (female) (3)
Defective mount of sensor or Check Bkup speed sensor directly for defective mount (defective
5 defective rotation sensing clearance) or check rotation sensing part (in supply pump) directly
part for defect.
If causes 1 – 5 are not detected, engine Bkup speed sensor may
Defective engine Bkup
6 be defective. (Since trouble is in system, troubleshooting cannot
speed sensor
be carried out.)
out.)
48 D155A-6
D155A-6 49
Failure code [CA1633] KOMNET Datalink Timeout Error 1

Action code Failure code KOMNET Datalink Timeout Error
Trouble
Contents of • Trouble occurred in KOMNET (CAN) communication circuit between engine controller and machine
trouble monitor, power train controller, and work equipment controller.
Action of
• Operates in default mode or maintains condition when abnormality occurs.
controller
Problem that
appears on
machine
Related
information

Disconnection in wiring har- Wiring harness between CM02 (female) (8),
Resis-
ness (Disconnection in wiring (9) – EGC2 (female) (46), STC2 (female) Max. 1 z
1 tance
or defective contact in con- (32)
nector) Wiring harness between CM02 (female)
Resis-
(10) – EGC2 (female) (47), STC2 (female) Max. 1 z
tance
(22)
Wiring harness between CM02 (female) (8),
(9) – EGC2 (female) (46), STC2 (female) Resis-
(32), ACCN (female) (17), SRV (male) (3) or tance
CA1 (female) (A) and chassis ground
cuit)
Wiring harness between CM02 (female)
Possible causes (10) – EGC2 (female) (47), STC2 (female) Resis-
Min. 1 Mz
and standard (22), ACCN (female) (18), SRV (male) (10) tance
value in normal or CA1 (female) (B) and chassis ground
(9) – EGC2 (female) (46), STC2 (female)
Voltage Max. 1 V
Hot short (Contact with GND (32), ACCN (female) (17), SRV (male) (3)
3
circuit) in wiring harness or CA1 (female) (A) and chassis ground
Voltage Max. 1 V
(22), ACCN (female) (18), SRV (male) (10)
or CA1 (female) (B) and chassis ground
Prepare with starting switch OFF, then carry out troubleshooting
Defective CAN terminal without turning starting switch ON.
4 resistance (Internal discon-
CA1 (male) Resistance
nection or short circuit)
Between (A) – (B) Approx. 120 z
out.)
50 D155A-6
D155A-6 51
Failure code [CA2185] Throt Sens Sup Volt High Error 1

Action code Failure code Throt Sens Sup Volt High Error
Trouble
Contents of
• Signal voltage in throttle sensor power supply (5 V) circuit is abnormally high.
trouble
Action of
• Sets throttle position with signal of fuel control dial and continues operation.
controller
Problem that
appears on
machine

Disconnect devices
Defective fuel control dial at right in order. If
(Internal trouble) Decelerator pedal
disappears when a DCL connector
potentiometer
device is discon-
nected, that device
has trouble in it.
2 Max. 1 z
or defective contact in con- (22) – DCL (female) (B) tance
Possible causes
Max. 1 z
and standard (23) – DCL (female) (C) tance
(22) – DCL (female) (B) and chassis ground tance
cuit)
Min. 1 Mz
(23) – DCL (female) (C) and chassis ground tance
harness) Resis-
(22) – DCL (female) (B) and between EGC2 Min. 1 Mz
tance
(female) (23) – DCL (female) (C)
EGC2 Voltage
Between (22) – (23) 4.75 – 5.25 V
52 D155A-6
D155A-6 53
Failure code [CA2186] Throt Sens Sup Volt Low Error 1

Action code Failure code Throt Sens Sup Volt Low Error
Trouble
Contents of
• Signal voltage in throttle sensor power supply (5 V) circuit of engine controller is abnormally low.
trouble
Action of
• Sets throttle position with signal of fuel control dial and continues operation.
controller
Problem that
appears on
machine

and standard
state
Failure code [CA2249] Rail Press Very Low Error 1

Action code Failure code Rail Press Very Low Error
Trouble
Contents of
• Very low pressure error (level 2) occurred in supply pump.
trouble
Action of
• Limits common rail pressure.
controller
Problem that
machine
Related
information

and standard
state
54 D155A-6
Failure code [CA2555] Grid Htr Relay Volt Low Error 1

Action code Failure code Grid Htr Relay Volt Low Error
Trouble
Contents of
• There is disconnection in intake air heater relay circuit.
trouble
Action of
controller
Problem that
appears on • Engine does not start easily at low temperature.
machine
Related • Engine coolant temperature can be checked with monitoring function.
information (Code: 04107 Coolant Temperature)

and standard
value in normal Carry out troubleshooting failure code [CA2556].
state
D155A-6 55
Failure code [CA2556] Grid Htr Relay Volt High Error 1

Action code Failure code Grid Htr Relay Volt High Error
Trouble
Contents of
• There is short circuit in intake air heater relay.
trouble
Action of
controller
Problem that
appears on • Engine does not start easily at low temperature.
machine
• Engine controller has automatic preheating function, which is turned ON when engine coolant tem-
Related perature is below -5 °C (for up to 30 seconds).
information • Engine coolant temperature can be checked with monitoring function.

Defective intake air heater ing without turning starting switch ON.
1
relay (Internal trouble) PHR (male) Resistance
Between (1) – (2) 200 – 400 z
2 Max. 1 z
Possible causes or defective contact in con- (40) – PHR (female) (1) tance
and standard nector) Wiring harness between PHR (female) (2) – Resis-
Max. 1 z
value in normal chassis ground (GND03) tance
Min. 1 Mz
(40) – PHR (female) (1) and chassis ground tance
4 Defective engine controller EGC2 Coolant temperature Voltage
Between (40) – chas- -5 °C or higher Max. 1 V
sis ground Below -5 °C 20 – 30 V
56 D155A-6
D155A-6 57
Failure code [D110KA] Battery relay: Disconnection 1

Action code Failure code Battery relay: Disconnection
Trouble
– D110KA (Power train controller system)
Contents of
• Turns signal to battery relay holding circuit, no current flows.
trouble
Action of
• Turns signal to battery relay holding circuit OFF.
controller
Problem that
appears on • Problem may occur in writing data into ROM (non-volatile memory) of each controller.
machine
• tate of battery relay holding circuit signal can be checked with monitoring function.
Related
(Code: 60600 BR Hold Relay)
information
• Method of reproducing failure code: Turn starting switch ON o OFF.

Defective battery relay (Inter- ing without turning starting switch ON.
1
nal disconnection) Battery relay Continuity
Between terminals SW – BRE There is continuity
2 Max. 1 z
or defective contact in con- – terminal SW tance
Possible causes nector)
and standard Wiring harness between terminal BRE and Resis-
Max. 1 z
value in normal chassis ground tance
Hot short (Short circuit with
3
24V circuit) in wiring harness Wiring harness between STC3 (female) (4)
– terminal SW, terminal 260, terminal AL/R Voltage Max. 1 V
or circuit branch end and chassis ground
4 STC3 Starting switch Voltage
troller
Between (4) – chas-
OFF Max. 1 V
sis ground
58 D155A-6
D155A-6 59
Failure code [D110KB] Battery Relay: Drive Short Circuit 1

Action code Failure code Battery Relay: Drive Short Circuit
Trouble
– D110KB (Power train controller system)
Contents of
• When signal was output to battery relay circuit, abnormal current flowed.
trouble
Action of
• Turns signal to battery relay holding circuit OFF.
controller
Problem that
appears on • Problem may occur in writing data into ROM (non-volatile memory) of each controller.
machine
• State of battery relay holding circuit signal can be checked with monitoring function.
Related
(Code: 60600 BR Hold Relay)
information
• Method of reproducing failure code: Turn starting switch ON o OFF.

Defective battery relay (Inter- Battery relay Continuity/Resistance
1
nal short circuit) Between terminals SW – BRE There is continuity
Between terminal SW – chassis
Min. 1 Mz
ground
Possible causes
value in normal Ground fault in wiring har- ing without turning starting switch ON.
state 2 ness (Contact with GND cir- Wiring harness between STC3 (female) (4)
cuit) Resis-
– terminal SW, terminal 260 or RSD Min. 1 Mz
tance
(female) (1) and chassis ground
3 STC3 Starting switch Voltage
troller
Between (4) – chas-
ON 20 – 30 V
sis ground
60 D155A-6
D155A-6 61
Failure code [D130KA] Neutral relay: Disconnection 1

Action code Failure code Neutral relay: Disconnection
Trouble
E02 D130KA (Power train controller system)
Contents of
• When ground circuit of neutral safety relay circuit is disconnected, no current flows.
trouble
Action of
• Turns output of neutral safety relay circuit OFF.
controller
Problem that
appears on • Engine cannot be started.
machine
• State of neutral safety relay circuit signal can be checked with monitoring function.
(Code: 59099 T/M Lock Relay)
Related
• Method of reproducing failure code: Turn starting switch ON + Operate parking brake lever (Free).
information
• This failure code detects abnormality on primary side (coil side) of neutral safety relay but does not

1 Defective fuse (FS2-5) If fuse is broken, circuit probably has ground fault (See cause 4).
Defective neutral safety relay ing without turning starting switch ON.
2
(Internal disconnection) NSF (male) Resistance
Between (1) – (2) 300 – 600 z
3 Max. 1 z
or defective contact in con- – NSF (female) (2) tance
Possible causes nector) Wiring harness between NSF (female) (1) – Resis-
Max. 1 z
and standard FS21 (5) tance
Ground fault in wiring har- Wiring harness between STC2 (female) (8) Resis-
Min. 1 Mz
4 ness (Contact with GND cir- – NSF (female) (2) and chassis ground tance
cuit) Wiring harness between NSF (female) (1) –
Resis-
FS21 (5) or circuit branch end and chassis Min. 1 Mz
tance
ground
Defective power train con- STC2 Parking brake lever Voltage
5
troller
Between (8) – chas- Lock Max. 1 V
sis ground Free 20 – 30 V
62 D155A-6
D155A-6 63
Failure code [D130KB] Neutral relay: Short circuit 1

Action code Failure code Neutral relay: Short circuit
Trouble
E02 D130KB (Power train controller system)
Contents of
• When ground circuit of neutral safety relay was disconnected, abnormal current flowed.
trouble
Action of
• Turns output of neutral safety relay circuit OFF.
controller
Problem that
appears on • Engine cannot be started.
machine
• State of neutral safety relay circuit signal can be checked with monitoring function.
(Code: 59099 T/M Lock Relay)
Related
information
• This failure code detects abnormality on primary side (coil side) of neutral safety relay but does not

Defective neutral safety relay ing without turning starting switch ON.
1
(Internal short circuit) NSF (male) Resistance
Between (1) – (2) 300 – 600 z
and standard Hot short (Short circuit with and carry out troubleshooting.
2
value in normal 24V circuit) in wiring harness Wiring harness between STC2 (female) (8)
state Voltage Max. 1 V
– NSF (female) (2) and chassis ground
Defective power train con- STC2 Parking brake lever Voltage
3
troller
Between (8) – chas- Lock Max. 1 V
sis ground Free 20 – 30 V
64 D155A-6
D155A-6 65
Failure code [D161KA] Back-up alarm relay: Disconnection 1

Action code Failure code Back-up alarm relay: Disconnection
Trouble
E01 D161KA (Power train controller system)
Contents of
• When ground circuit of back-up alarm relay circuit is disconnected, no current flows.
trouble
Action of
• Turns output of back-up alarm relay circuit OFF.
controller
Problem that
appears on • Back-up alarm does not sound
machine
• State of back-up alarm relay circuit signal can be checked with monitoring function.
(Code: 70400 Back Alarm Relay)
Related
• Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (R: Reverse).
information
• This failure code detects abnormality on primary side (coil side) of back-up alarm relay but does not

Defective back-up alarm ing without turning starting switch ON.
2
relay (Internal disconnection) BKA (male) Resistance
Between (1) – (2) 300 – 600 z
3 Max. 1 z
or defective contact in con- – BKA (female) (2) tance
nector) Wiring harness between BKA (female) (1) – Resis-
FS12 (2) tance
and standard
Ground fault in wiring har- Wiring harness between STC2 (female) (18)
Resis-
4 ness (Contact with GND cir- – BKA (female) (2) or circuit branch end and Min. 1 Mz
tance
cuit) chassis ground
Wiring harness between BKA (female) (1), Resis-
Min. 1 Mz
(3) – FS12 (2) and chassis ground tance
5 STC2 Voltage
troller (Directional)
sis ground R (Reverse) Max. 1 V
66 D155A-6
D155A-6 67
Failure code [D161KB] Back-up alarm relay: Short circuit 1

Action code Failure code Back-up alarm relay: Short circuit
Trouble
E01 D161KB (Power train controller system)
Contents of
• When ground circuit of back-up alarm relay was disconnected, abnormal current flowed.
trouble
Action of
• Turns output of back-up alarm relay circuit OFF.
controller
Problem that
appears on • Back-up alarm does not sound.
machine
• State of back-up alarm relay circuit signal can be checked with monitoring function.
(Code: 70400 Back Alarm Relay)
Related
• Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (R: Reverse)
information
• This failure code detects abnormality on primary side (coil side) of back-up alarm relay but does not

Defective back-up alarm ing without turning starting switch ON.
1
relay (Internal short circuit) BKA (male) Resistance
Between (1) – (2) 300 – 600 z
Possible causes and carry out troubleshooting.
and standard 2
value in normal – BKA (female) (2) or circuit branch end and Voltage Max. 1 V
state chassis ground
3 STC2 Voltage
troller (Directional)
sis ground R (Reverse) Max. 1 V
68 D155A-6
D155A-6 69
Failure code [D190KA] ACC signal relay: Disconnection 1

Action code Failure code ACC signal relay: Disconnection
Trouble
– D190KA (Power train controller system)
Contents of
• When ground circuit of ACC signal drive relay circuit is disconnected, no current flows.
trouble
Action of
• Turns signal to ACC signal drive relay circuit OFF.
controller
Problem that
• Turbo-timer function does not operate (if turbo-timer is installed).
appears on
• Machine is not affected particularly (if turbo-timer is not installed).
machine
• State of ACC signal drive relay circuit signal can be checked with monitoring function.
(Code: 60500 ENG Hold Relay)
Related
• Method of reproducing failure code: Turn starting switch ON o OFF (if turbo-timer is installed).
information
• This failure code detects abnormality on primary side (coil side) of ACC signal drive relay but does
not detect abnormality on secondary side (contact side).

Defective ACC signal drive ing without turning starting switch ON.
1
relay (Internal disconnection) EHL (male) Resistance
Between (1) – (2) 200 – 400 z
or defective contact in con- – EHL (female) (2) tance
value in normal Wiring harness between EHL (female) (1) – Resis-
Max. 1 z
state branch point (J) tance
Hot short (Short circuit with and carry out troubleshooting.
3
Voltage Max. 1 V
– EHL (female) (2) and chassis ground
Defective power train con- ing without turning starting switch ON.
4
troller STC2 (female) Resistance
Between (9) – chassis ground 200 – 400 z
70 D155A-6
D155A-6 71
Failure code [D190KB] ACC signal relay: Short circuit 1

Action code Failure code ACC signal relay: Short circuit
Trouble
– D190KB (Power train controller system)
Contents of
• When ground circuit of ACC signal drive relay was disconnected, abnormal current flowed.
trouble
Action of
• Turns output of ACC signal drive relay circuit OFF.
controller
Problem that
• Turbo-timer function does not operate (if turbo-timer is installed).
appears on
• Machine is not affected particularly (if turbo-timer is not installed).
machine
• State of ACC signal drive relay circuit signal can be checked with monitoring function.
(Code: 60500 ENG Hold Relay)
Related
• Method of reproducing failure code: Turn starting switch ON o OFF (if turbo-timer is installed).
information
• This failure code detects abnormality on primary side (coil side) of ACC signal drive relay but does
not detect abnormality on secondary side (contact side).

Defective ACC signal drive ing without turning starting switch ON.
1
relay (Short circuit) EHL (male) Resistance
Between (1) – (2) 200 – 400 z
Possible causes
and standard Ground fault in wiring har- ing without turning starting switch ON.
value in normal 2 ness (Contact with GND cir-
state cuit) Wiring harness between STC2 (female) (9) Resis-
1 Mz
– EHL (female) (2) and chassis ground tance
3
Between (9) – chassis ground 200 – 400 z
72 D155A-6
D155A-6 73
D155A-6 Bulldozer
© 2008 KOMATSU
All Rights Reserved
74 D155A-6
SEN03208-01
D155A-6

D155A-6 85001 and up
codes, Part 3
Failure code [D5ZKKX] Throttle Dial: Out of normal range............................................................................. 4
Failure code [DAFRKR] CAN Disconnection (Monitor) ................................................................................... 6
Failure code [DB2RKR] CAN Disconnection (Engine controller) .................................................................... 8
Failure code [DB90KR] PT 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
D155A-6 1
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 [DGT1KA] T/C oil temp sensor: Abnormal................................................................................ 40
Failure code [DGT1KX] T/C oil temp sensor: Abnormal................................................................................ 42
Failure code [DH21KA] Weq pressure sensor: Disconnection...................................................................... 44
Failure code [DH21KB] Weq pressure sensor: Short circuit ......................................................................... 46
Failure code [DK10KX] Fuel control Dial: Out of normal range..................................................................... 48
Failure code [DK30KA] ST lever 1: Disconnection........................................................................................ 50
Failure code [DK30KB] ST lever 1: Short circuit ........................................................................................... 52
Failure code [DK30KX] ST lever 1: Out of normal range .............................................................................. 54
Failure code [DK30KZ] RL lever: Disconnection or short circuit ................................................................... 54
Failure code [DK30L8] ST lever: Signal mismatch........................................................................................ 55
Failure code [DK31KA] ST lever 2: Disconnection........................................................................................ 56
Failure code [DK31KB] ST lever 2: Short circuit ........................................................................................... 58
Failure code [DK40KA] Brake potentiometer: Disconnection........................................................................ 60
Failure code [DK40KB] Brake potentiometer: Short circuit ........................................................................... 62
Failure code [DK55KX] FR lever: Out of normal range ................................................................................. 64
Failure code [DK55KZ] FR lever: Disconnection or short circuit ................................................................... 64
Failure code [DK55L8] FR lever: Signal mismatch ....................................................................................... 65
Failure code [DK56KA] FR lever 1: Disconnection ....................................................................................... 66
Failure code [DK56KB] FR lever 1: Short circuit ........................................................................................... 68
2 D155A-6
D155A-6 3
Failure code [D5ZKKX] Throttle Dial: Out of normal range 1

Action code Failure code Throttle Dial: Out of normal range
Trouble
E03 D5ZKKX (Power train controller system)
Contents of
• Signal voltage of fuel control dial is below 0.30 V or above 4.55 V.
trouble
Action of • Continues control with decelerator pedal potentiometer signal.
controller • Limits operation of engine and transmission.
Problem that
appears on
machine
• State of fuel control dial can be checked with monitoring function.
Related
(Code: 03000 Fuel Dial Sensor)
information
• Method of reproducing failure code: Turn starting switch ON.

Defective sensor 5V power If failure code [DBE7KK] is also displayed, carry out troubleshoot-
1
supply system ing for it first.
Defective fuel control dial DIAL (male) Resistance
2 (Internal disconnection or
Between (1) – (3) 4.0 – 6.0 kz
short circuit)
Between (1) – (2) 0.25 – 7.0 kz
Between (2) – (3) 0.25 – 7.0 kz
or defective contact in con- – DIAL (female) (1) tance
and standard
nector) Wiring harness between STC1 (female) (1) Resis-
state –DIAL (female) (2) tance
cuit) Wiring harness between STC1 (female) (1) Resis-
Min. 1 Mz
– DIAL (female) (2) and chassis ground tance
5 24 V circuit) in wiring har-
ness Wiring harness between STC1 (female) (1)
Voltage Max. 1 V
– DIAL (female) (2) and chassis ground
6
Between (1) – (21) 0.30 – 4.33 V
4 D155A-6
D155A-6 5
Failure code [DAFRKR] CAN Disconnection (Monitor) 1

Action code Failure code CAN Disconnection (Monitor)
Trouble
E03 DAFRKR (Machine monitor system)
Contents of • Machine monitor cannot recognize engine controller, power train controller, or work equipment con-
trouble troller in CAN communication circuit.
Action of
controller
Problem that • System may not operate normally.
Related
information

Resis-
1 tance
Resis-
tance
(22)
cuit)
Min. 1 Mz
Voltage Max. 1 V
Hot short (Short circuit with (32), ACCN (female) (17), SRV (male) (3) or
3
24V circuit) in wiring harness CA1 (female) (A) and chassis ground
Voltage Max. 1 V
Defective CAN terminal ing without turning starting switch ON.
If causes 1 – 4 are not detected, machine monitor, engine control-
Defective machine monitor
5 ler, or power train controller may be defective. (Since trouble is in
or controller
system, troubleshooting cannot be carried out.)
6 D155A-6
D155A-6 7
Failure code [DB2RKR] CAN Disconnection (Engine controller) 1

Action code Failure code CAN Disconnection (Engine controller)
Trouble
E03 DB2RKR (Power train controller system)
Contents of
• Power train controller cannot recognize engine controller in CAN communication circuit.
trouble
Action of
controller
Related
information

Resis-
1 tance
Resis-
tance
(22)
cuit)
Min. 1 Mz
Possible causes (22), ACCN (female) (18), SRV (male) (10) tance
and standard or CA1 (female) (B) and chassis ground
value in normal a Prepare with starting switch OFF, then turn starting switch ON
state and carry out troubleshooting.
Hot short (Short circuit with Voltage Max. 1 V
(32), ACCN (female) (17), SRV (male) (3) or
ness
Voltage Max. 1 V
If causes 1 – 4 are not detected, engine controller or power train
Defective engine controller
5 controller may be defective. (Since trouble is in system, trouble-
or power train controller
shooting cannot be carried out.)
Defective engine controller As the engine controller power supply can be detective, carry out
6
power supply troubleshooting for "Failure code CA111".
8 D155A-6
D155A-6 9
Failure code [DB90KR] PT controller: Can communication lost 1

Action code Failure code PT controller: Can communication lost
Trouble
E03 DB90KR (Power train controller system)
Contents of • Power train controller cannot recognize machine monitor, engine controller or work equipment con-
trouble troller in CAN communication circuit.
Action of
controller
Related
information

Resis-
1 tance
Resis-
tance
(22)
cuit)
Min. 1 Mz
(32), ACCN (female) (17), SRV (male) (3) or
ness
Voltage Max. 1 V
If causes 1 – 4 are not detected, machine monitor, engine control-
Defective machine monitor
5 ler, or power train controller may be defective. (Since trouble is in
or controller
system, troubleshooting cannot be carried out.)
10 D155A-6
D155A-6 11
Failure code [DBE0KK] PT controller: Source voltage reduction 1

Action code Failure code PT controller: Source voltage reduction
Trouble
E03 DBE0KK (Power train controller system)
Contents of
• Source voltage of work equipment controller is below 17 V.
trouble
Action of
controller
• Machine monitor may not display normally.
Problem that
• Relays and solenoids may not be driven and system may not operate normally.
appears on
machine • Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, it cannot travel at all.
Related • Source voltage of power train controller can be checked with adjusting function. (Code: 2121)
information • Method of reproducing failure code: Turn starting switch ON.

1
(CB1, CB7, CB30 or CB105) (See cause 3).
Wiring harness between STC3 (female) (1), Resis-
Max. 1 z
(11) – CB7 (2) tance
Wiring harness between CB7 (1) – CB30 Resis-
Max. 1 z
(B30S) tance
Disconnection in wiring har- minal BRB Max. 1 z
tance
2
or defective contact in con- Wiring harness between STC3 (female) (2), Resis-
Max. 1 z
nector) (12), (22) – CB1 (2) tance
Wiring harness between CB1 (1) – CB105 Resis-
Max. 1 z
(B105S) tance
Wiring harness between CB105 (B105L) – Resis-
Max. 1 z
terminal BRC tance
Possible causes Wiring harness between STC3 (female)
and standard Resis-
(21), (31), (32), (33) – chassis ground Max. 1 z
value in normal tance
(GND11)
state
Wiring harness between STC3 (female) (1),
Resis-
(11) – CB7 (2) or circuit branch end and Min. 1 Mz
tance
chassis ground
Resis-
(B30S) or circuit branch end and chassis Min. 1 Mz
tance
ground
cuit)
Wiring harness between STC3 (female) (2),
Resis-
(12), (22) – CB1 (2) or PL1 (female) (68) Min. 1 Mz
tance
and chassis ground
Resis-
(B105S) or circuit branch end and chassis Min. 1 Mz
tance
ground
Wiring harness between CB105 (B105L) – Resis-
Min. 1 Mz
terminal BRC and chassis ground tance
12 D155A-6

Possible causes
STC3 Starting switch Voltage
and standard
value in normal Defective power train con- Between (1), (11) –
4 OFF 20 – 30 V
state troller (21), (31), (32), (33)
Between (2), (12),
(22) – (21), (31), (32), ON 20 – 30 V
(33)
D155A-6 13
Failure code [DBE0KT] PT controller: Abnormality in controller 1

Action code Failure code PT controller: Abnormality in controller
Trouble
E01 DBE0KT (Power train controller system)
Contents of
• Information in ROM (non-volatile memory) of power train controller is abnormal.
trouble
Action of
• Sets internal adjustment values to default values.
controller
Problem that
• Shifting feel of transmission may become bad.
appears on
machine • Adjusting function may not operate normally.
Related
information

Turn Adjustment function in service mode ON and perform opera-
Possible causes Defective adjustment of tion of reproducing trouble. If "E" of failure code disappears at this
1
and standard power train controller time, system is normal.
value in normal • Adjustment code: 0002 (Initialization of power train controller)
state
Troubleshooting cannot be carried out since defect is in power train
2 controller. (If there is not any visible trouble in machine, controller
troller
may be used as it is.)
14 D155A-6
D155A-6 15

Trouble
Contents of • Voltage of 24V power supply circuit for power train controller sensors is below 17 V or above 30 V.
trouble • Abnormal current flowed in 24V power supply circuit for power train controller sensors.
Action of • Turns output of 24V power supply circuit OFF, if abnormal current flows.
Related
information

Defective pitch angle sensor
1 or torque converter pressure
sensor (Internal trouble) Disconnect devices at right in order. If "E" of failure code disap-
pears when a device is disconnected, that device has trouble in it.
Possible causes
and standard
state
Min. 1 Mz
– PT1 (female) (C) tance
3
Between (16) – (21) 20 – 30 V
16 D155A-6
D155A-6 17

Trouble
Contents of • Voltage of 5V power supply circuit for power train controller sensors is below 4.5 V or above 5.5 V.
trouble • Abnormal current flowed in 5V power supply circuit for power train controller sensors.
Action of • Turns output of 5V power supply circuit OFF, if abnormal current flows.
Related
information

Disconnect devices Brake pedal
Defective brake pedal poten- at right in order. If Connector BRK
potentiometer
1 tiometer, fuel control dial or "E" of failure code
PCCS lever (Internal trouble) disappears when a
Fuel control dial Connector DIAL
device is discon-
nected, that device
PCCS lever Connector TLV1
has trouble in it.
Wiring harness between STC1 (female) (22)
Resis-
– BRK (female) (C) and chassis ground Min. 1 Mz
tance
Ground fault in wiring har- [Brake pedal potentiometer system]
2 ness (Contact with GND cir- Wiring harness between STC1 (female) (22)
cuit) Resis-
– DIAL (female) (1) and chassis ground Min. 1 Mz
Possible causes tance
[Fuel control dial system]
and standard
value in normal Wiring harness between STC1 (female) (22)
Resis-
state – TLV1 (female) (4), (5) and chassis ground Min. 1 Mz
tance
[PCCS lever system]
– BRK (female) (C) and chassis ground Voltage Max. 1 V
[Brake pedal potentiometer system]
3
– DIAL (female) (1) and chassis ground Voltage Max. 1 V
[Fuel control dial system]
– TLV1 (female) (4), (5) and chassis ground Voltage Max. 1 V
[PCCS lever system]
4
Between (22) – (21) 4.5 – 5.5 V
18 D155A-6
D155A-6 19
Failure code [DBE9KQ] PT controller: Type select signal 1

Action code Failure code PT controller: Type select signal
Trouble
E04 DBE9KQ (Power train controller system)
Contents of • Specification setting in power train controller does not match to specification setting signal
trouble (Power train controller cannot be recognized).
Action of • Turns all outputs of power train controller OFF.
Problem that • Machine does not move at all.
machine • Once machine is stopped, it cannot travel at all.
Related
information

Turn Adjustment function in service mode ON and perform opera-
Defective adjustment of tion of reproducing trouble. If "E" of failure code disappears at this
1
power train controller time, system is normal.
• Adjustment code: 0002 (Initialization of power train controller)
Possible causes Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
and standard ness (Disconnection in wiring ing without turning starting switch ON.
2
value in normal or defective contact in con- Wiring harness between STC3 (female) (40) Resis-
nector) Max. 1 z
state – chassis ground (GND11) tance
3 STC3 Voltage
troller
Wiring harness between (40) –
Max. 1 V
chassis ground
20 D155A-6
D155A-6 21
Failure code [DD12KA] Shift up Sw: Disconnection 1

Action code Failure code Shift up Sw: Disconnection
Trouble
E02 DD12KA (Power train controller system)
Contents of
• Signals of 2 systems of shift-up switch circuit are turned OFF (opened) simultaneously.
trouble
Action of
• Recognizes that shift-up switch is not pressed.
controller
Problem that
• Transmission gear cannot be shifted up.
appears on
machine • Auto shift-down function does not operate.
• "NO" signal of 2 systems of switch is for sensing operation and "NC" signal is for detecting error.
Related • State of shift-up switch signal can be checked with monitoring function.
information (Code: 40905 T/M Sw Input 1)
• Method of reproducing failure code: Turn starting switch ON + Operate shift-up switch.

Shift-up switch
SFTU (male)
Defective shift-up switch OFF (Released) ON (Pressed)
1
(Internal disconnection) Resistance between
Max. 1 z Min. 1 Mz
(3) – (2)
Resistance between
Min. 1 Mz Max. 1 z
(1) – (2)
Disconnection in wiring har- Wiring harness between STC3 (female) (9) Resis-
Max. 1 z
ness (Disconnection in wiring – SFTU (female) (1) tance
2
nector) Max. 1 z
Possible causes – SFTU (female) (2) tance
and standard Wiring harness between STC1 (female) (12) Resis-
– SFTU (female) (3) tance
state
Hot short (Short circuit with Wiring harness between STC3 (female) (9)
3 Voltage Max. 1 V
24V circuit) in wiring harness – SFTU (female) (1) and chassis ground
Voltage Max. 1 V
– SFTU (female) (3) and chassis ground
Shift-up switch
STC1 ,STC3
OFF (Released) ON (Pressed)
4 Voltage between
troller
STC1 (12) – STC1 Max. 1 V 5 – 11 V
(4)
Voltage between
5 – 11 V Max. 1 V
STC3 (9) – STC1 (4)
22 D155A-6
D155A-6 23
Failure code [DD12KB] Shift up Sw: Short circuit 1

Action code Failure code Shift up Sw: Short circuit
Trouble
E02 DD12KB (Power train controller system)
Contents of
• Signals of 2 systems of shift-up switch circuit are turned ON (closed) simultaneously.
trouble
Action of
• Recognizes that shift-up switch is not pressed.
controller
Problem that
• Transmission gear cannot be shifted up.
appears on
Related • State of shift-up switch signal can be checked with monitoring function.
• Method of reproducing failure code: Turn starting switch ON + Operate shift-up switch.

Shift-up switch
SFTU (male)
Defective shift-up switch OFF (Released) ON (Pressed)
1
(Internal short circuit) Resistance between
Max. 1 z Min. 1 Mz
(3) – (2)
Resistance between
Min. 1 Mz Max. 1 z
(1) – (2)
and standard Ground fault in wiring har-
value in normal Wiring harness between STC3 (female) (9) Resis-
state – SFTU (female) (1) and chassis ground tance
cuit)
Wiring harness between STC1 (female) (12) Resis-
Min. 1 Mz
– SFTU (female) (3) and chassis ground tance
Shift-up switch
STC1 ,STC3
Defective power train con- OFF (Released) ON (Pressed)
3
troller Voltage between
Max. 1 V 5 – 11 V
STC1 (12) – STC1 (4)
Voltage between
5 – 11 V Max. 1 V
STC3 (9) – STC1 (4)
24 D155A-6
D155A-6 25
Failure code [DD13KA] Shift down Sw: Disconnection 1

Action code Failure code Shift down Sw: Disconnection
Trouble
Contents of
• Signals of 2 systems of shift-down switch circuit are turned OFF (opened) simultaneously.
trouble
Action of
• Recognizes that shift-down switch is not pressed.
controller
Problem that
• Transmission gear cannot be shifted down.
appears on
Related • State of shift-down switch signal can be checked with monitoring function.
• Method of reproducing failure code: Turn starting switch ON + Operate shift-down switch.

Shift-down switch
SFTD (female)
Defective shift-down switch OFF (Released) ON (Pressed)
1
Max. 1 z Min. 1 Mz
(3) – (2)
Resistance between
Min. 1 Mz Max. 1 z
(1) – (2)
Max. 1 z
ness (Disconnection in wiring – SFTD (female) (1) tance
2
Possible causes nector) Max. 1 z
– SFTD (female) (2) tance
and standard
Max. 1 z
state – SFTD (female) (3) tance
Hot short (Short circuit with Wiring harness between STC1 (female) (18)
3 Voltage Max. 1 V
24V circuit) in wiring harness – SFTD (female) (1) and chassis ground
Voltage Max. 1 V
– SFTD (female) (3) and chassis ground
Shift-down switch
STC1
4
Max. 1 V 5 – 11 V
(24) –- (4)
Voltage between
5 – 11 V Max. 1 V
(18) – (4)
26 D155A-6
D155A-6 27
Failure code [DD13KB] Shift down Sw: Short circuit 1

Action code Failure code Shift down Sw: Short circuit
Trouble
Contents of
• Signals of 2 systems of shift-down switch circuit are turned ON (closed) simultaneously.
trouble
Action of
• Recognizes that shift-down switch is not pressed.
controller
Problem that
• Transmission gear cannot be shifted down.
appears on
Related • State of shift-down switch signal can be checked with monitoring function.
• Method of reproducing failure code: Turn starting switch ON + Operate shift-down switch.

Shift-down switch
SFTD (female)
Defective shift-down switch OFF (Released) ON (Pressed)
1
Max. 1 z Min. 1 Mz
(3) – (2)
Resistance between
Min. 1 Mz Max. 1 z
(1) – (2)
state – SFTD (female) (1) and chassis ground tance
cuit)
Min. 1 Mz
– SFTD (female) (3) and chassis ground tance
Shift-down switch
STC1
3
Max. 1 V 5 – 11 V
(24) – (4)
Voltage between
5 – 11 V Max. 1 V
(18) – (4)
28 D155A-6
D155A-6 29
Failure code [DD14KA] Parking lever Sw: Disconnection 1

Action code Failure code Parking lever Sw: Disconnection
Trouble
Contents of
• Signals of 2 systems of parking brake lever switch circuit are turned OFF (opened) simultaneously.
trouble
Action of • Recognizes that parking brake lever is in FREE position.
Problem that
appears on
Related • State of parking brake lever switch signal can be checked with monitoring function.
• Method of reproducing failure code: Turn starting switch ON + Operate parking brake lever.

Parking brake lever
Defective parking brake lever PKSW (male)
FREE position LOCK position
2 switch (Internal disconnec-
tion) Resistance between
Max. 1 z Min. 1 Mz
(A) – (B)
Resistance between
Min. 1 Mz Max. 1 z
(A) – (C)
Disconnection in wiring har- Wiring harness between FS22 (2) – PKSW Resis-
Max. 1 z
ness (Disconnection in wiring (female) (A) tance
3
nector) Max. 1 z
– PKSW (female) (B) tance
Possible causes
Max. 1 z
value in normal – PKSW (female) (C) tance
Wiring harness between FS22 (2) – PKSW Resis-
Min. 1 Mz
Ground fault in wiring har- (female) (A) and chassis ground tance
4 ness (Contact with GND cir- Wiring harness between STC1 (female) (23) Resis-
cuit) Min. 1 Mz
– PKSW (female) (B) and chassis ground tance
Resis-
– PKSW (female) (C), PKS (female) (1) or Min. 1 Mz
tance
PKD (female) (1) and chassis ground
Parking brake lever
STC1
Defective power train con- FREE position LOCK position
5
troller Voltage between (23)
20 – 30 V Max. 1 V
– chassis ground
Voltage between (17)
Max. 1 V 20 – 30 V
– chassis ground
30 D155A-6
D155A-6 31
Failure code [DD14KB] Parking lever Sw: Short circuit 1

Action code Failure code Parking lever Sw: Short circuit
Trouble
Contents of
• Signals of 2 systems of parking brake lever switch circuit are turned ON (closed) simultaneously.
trouble
Action of • Recognizes that parking brake lever is in FREE position.
Problem that
appears on
Related • State of parking brake lever switch signal can be checked with monitoring function.
• Method of reproducing failure code: Turn starting switch ON + Operate parking brake lever.

Parking brake lever
PKSW (male)
Defective parking brake lever FREE position LOCK position
1
switch (Internal short circuit) Resistance between
Max. 1 z Min. 1 Mz
(A) – (B)
Resistance between
Min. 1 Mz Max. 1 z
(A) – (C)
and standard Wiring harness between STC1 (female) (23)
value in normal Hot short (Short circuit with Voltage Max. 1 V
2 – PKSW (female) (B) and chassis ground
state 24V circuit) in wiring harness
– PKSW (female) (C), PKS (female) (1) or Voltage Max. 1 V
PKD (female) (1) and chassis ground
Parking brake lever
STC1
Defective power train con- FREE position LOCK position
3
20 – 30 V Max. 1 V
– chassis ground
Voltage between (17)
Max. 1 V 20 – 30 V
– chassis ground
32 D155A-6
D155A-6 33
Failure code [DDDDKA] Back up brake Sw: Disconnection 1

Action code Failure code Back up brake Sw: Disconnection
Trouble
E02 DDDDKA (Power train controller system)
Contents of
• Signals of 2 systems of brake pedal switch circuit are turned OFF (opened) simultaneously.
trouble
Action of • Recognizes that brake pedal is not pressed.
Problem that
appears on
Related • State of brake pedal switch signal can be checked with monitoring function.
information (Code: 40905 T/M Sw Input1)
• Method of reproducing failure code: Turn starting switch ON + Operate brake pedal.

Brake pedal
BKSW (male)
Defective brake pedal switch Released Pressed
2
Max. 1 z Min. 1 Mz
(A) – (B)
Resistance between
Min. 1 Mz Max. 1 z
(A) – (C)
Disconnection in wiring har- Wiring harness between FS22 (1) – BKSW Resis-
Max. 1 z
ness (Disconnection in wiring (female) (A) tance
3
nector) Max. 1 z
– BKSW (female) (B) tance
Possible causes
Max. 1 z
value in normal – BKSW (female) (C) tance
Wiring harness between FS22 (1) – BKSW Resis-
Min. 1 Mz
Ground fault in wiring har- (female) (A) and chassis ground tance
4 ness (Contact with GND cir- Wiring harness between STC1 (female) (11) Resis-
cuit) Min. 1 Mz
– BKSW (female) (B) and chassis ground tance
Resis-
– BKSW (female) (C), PBS (female) (1) or Min. 1 Mz
tance
PBD (female) (1) and chassis ground
Brake pedal
STC1
Defective power train con- Released Pressed
5
20 – 30 V Max. 1 V
– chassis ground
Voltage between (5)
Max. 1 V 20 – 30 V
– chassis ground
34 D155A-6
D155A-6 35
Failure code [DDDDKB] Back up brake Sw: Short circuit 1

Action code Failure code Back up brake Sw: Short circuit
Trouble
E02 DDDDKB (Power train controller system)
Contents of
• Signals of 2 systems of brake pedal switch circuit are turned ON (closed) simultaneously.
trouble
Action of • Recognizes that brake pedal is not pressed.
Problem that
appears on
Related • State of brake pedal switch signal can be checked with monitoring function.

Brake pedal
BKSW (male)
Defective brake pedal switch Released Pressed
1
Max. 1 z Min. 1 Mz
(A) – (B)
Resistance between
Min. 1 Mz Max. 1 z
(A) – (C)
and standard Wiring harness between STC1 (female) (11)
value in normal Hot short (Short circuit with Voltage Max. 1 V
2 – BKSW (female) (B) and chassis ground
state 24V circuit) in wiring harness
– BKSW (female) (C), PBS (female) (1), or Voltage Max. 1 V
PBD (female) (1) and chassis ground
Brake pedal
STC1
Defective power train con- Released Pressed
3
20 – 30 V Max. 1 V
– chassis ground
Voltage between (5)
Max. 1 V 20 – 30 V
– chassis ground
36 D155A-6
D155A-6 37
Failure code [DDDDKX] Back up brake Sw: Signal mismatch 1

Action code Failure code Back up brake Sw: Signal mismatch
Trouble
E02 DDDDKX (Power train controller system)
Contents of
• Brake pedal potentiometer signal does not match to brake pedal switch signal.
trouble
Action of
controller
Problem that
appears on • Backup brake may not operate.
machine
• State of brake pedal potentiometer signal can be checked with monitoring function.
Related
(Code: 50400 Brake Pedal Potentio)
information

Defective brake pedal switch If failure code [DDDDKA] or [DDDDKB] is also displayed, carry out
1
system troubleshooting for it first.
Possible causes
and standard Adjust brake pedal and perform operation of reproducing trouble.
value in normal 2 Defective brake pedal switch If "E" of failure code disappears at this time, system is normal.
state • Testing and adjusting item: Adjusting brake pedal
If causes 1 – 2 are not detected, power train controller may be
troller
carried out.)
38 D155A-6
D155A-6 39
Failure code [DGT1KA] T/C oil temp sensor: Abnormal 1

Action code Failure code T/C oil temp sensor: Abnormal
Trouble
E01 DGT1KA (Power train controller system)
Contents of
• Torque converter oil temperature sensor signal is out of normal range.
trouble
Action of
controller
Problem that
appears on • Power train oil temperature gauge may not indicate normally.
machine
• Torque converter oil temperature can be checked with monitoring function.
Related
information
• Method of reproducing failure code: Turn starting switch ON or start engine.

Defective torque converter ing without turning starting switch ON.
oil temperature sensor (Inter- TCT (male) Resistance
1
nal short circuit or disconnec-
tion) Between (1) – (2) 1 – 50 kz
Between (1) – chassis ground Min. 1 Mz
2 Max. 1 z
or defective contact in con- – TCT (female) (1) tance
– TCT (female) (2) tance
and standard
state 3 ness (Contact with GND cir-
Min. 1 Mz
– TCT (female) (1) and chassis ground tance
4
Voltage Max. 1 V
– TCT (female) (1) and chassis ground
Defective power train con- STC1 (female) Resistance
5
troller
Between (9) – (21) 1 – 50 kz
40 D155A-6
D155A-6 41
Failure code [DGT1KX] T/C oil temp sensor: Abnormal 1

Action code Failure code T/C oil temp sensor: Abnormal
Trouble
E01 DGT1KX (Power train controller system)
Contents of
• Torque converter oil temperature sensor signal is out of normal range.
trouble
Action of
controller
Problem that
appears on • Power train oil temperature gauge may not indicate normally.
machine
• Torque converter oil temperature can be checked with monitoring function.
Related
information
• Method of reproducing failure code: Turn starting switch ON or start engine.

Defective torque converter ing without turning starting switch ON.
oil temperature sensor (Inter- TCT (male) Resistance
1
nal short circuit or disconnec-
tion) Between (1) – (2) 1 – 50 kz
2 Max. 1 z
or defective contact in con- – TCT (female) (1) tance
– TCT (female) (2) tance
and standard
state 3 ness (Contact with GND cir-
Min. 1 Mz
– TCT (female) (1) and chassis ground tance
4
Voltage Max. 1 V
– TCT (female) (1) and chassis ground
5
troller
Between (9) – (21) 1 – 50 kz
42 D155A-6
D155A-6 43
Failure code [DH21KA] Weq pressure sensor: Disconnection 1

Action code Failure code Weq pressure sensor: Disconnection
Trouble
– DH21KA (Power train controller system)
Contents of
• Signal voltage of work equipment pump oil pressure sensor is below 0.5 V.
trouble
Action of
controller
Problem that
appears on • Oil pressure of work equipment pump cannot be monitored.
machine
• State of work equipment pump oil pressure sensor can be checked with monitoring function.
Related
(Code: 70701 Hydraulic Pressure Sensor 1)
information

Defective sensor 5V power If failure code [DB95KK] is also displayed, carry out troubleshoot-
1
or start engine and carry out troubleshooting in each case.
HHP Voltage
Defective work equipment oil
Between (B) – (A) Power supply 4.5 – 5.5 V
2 pressure sensor (Internal
trouble) Between (C) – (A) Signal 0.5 – 6.0 V
value in normal
state Max. 1 z
ness (Disconnection in wiring – HHP (female) (A) tance
3
nector) Max. 1 z
– HHP (female) (B) tance
Max. 1 z
– HHP (female) (C) tance
Min. 1 Mz
– HHP (female) (C) and chassis ground tance
troller
carried out.)
44 D155A-6
D155A-6 45
Failure code [DH21KB] Weq pressure sensor: Short circuit 1

Action code Failure code Weq pressure sensor: Short circuit
Trouble
– DH21KB (Power train controller system)
Contents of
• Signal voltage of work equipment pump oil pressure sensor is below 6.0 V.
trouble
Action of
controller
Problem that
appears on • Oil pressure of work equipment pump cannot be monitored.
machine
• State of work equipment pump oil pressure sensor can be checked with monitoring function.
Related
(Code: 70701 Hydraulic Pressure Sensor 1)
information

Defective sensor 5V power If failure code [DB95KK] is also displayed, carry out troubleshoot-
1
or start engine and carry out troubleshooting in each case.
HHP Voltage
Defective work equipment oil
Between (B) – (A) Power supply 4.5 – 5.5 V
2 pressure sensor (Internal
Possible causes trouble) Between (C) – (A) Signal 0.5 – 6.0 V
and standard
value in normal
state
3
Voltage Max. 1 V
– HHP (female) (C) and chassis ground
troller
carried out.)
46 D155A-6
D155A-6 47
Failure code [DK10KX] Fuel control Dial: Out of normal range 1

Action code Failure code Fuel control Dial: Out of normal range
Trouble
E03 DK10KX (Power train controller system)
Contents of
• Signal voltage of fuel control dial is out of normal range.
trouble
Action of • Continues control with signal of decelerator pedal potentiometer.
Problem that
appears on
machine
• State of fuel control dial signal can be checked with monitoring function.
Related
(Code: 03000 Fuel Dial Sensor)
information

1
Defective fuel control dial DIAL (male) Resistance
Between (1) – (3) 4.0 – 6.0 kz
short circuit)
Between (1) – (2) 0.25 – 7.0 kz
Between (2) – (3) 0.25 – 7.0 kz
Max. 1 z
ness (Disconnection in wiring – DIAL (female) (1) tance
3
nector) Max. 1 z
– DIAL (female) (2) tance
Max. 1 z
– DIAL (female) (3) tance
value in normal Ground fault in wiring har- Wiring harness between STC1 (female) (22)
Resis-
state 4 ness (Contact with GND cir- – DIAL (female) (1) or circuit branch end Min. 1 Mz
tance
cuit) and chassis ground
Min. 1 Mz
– DIAL (female) (2) and chassis ground tance
– DIAL (female) (1) or circuit branch end Voltage Max. 1 V
Hot short (Short circuit with and chassis ground
5
Voltage Max. 1 V
– DIAL (female) (2) and chassis ground
– DIAL (female) (3) or circuit branch end Voltage Max. 1 V
and chassis ground
6
troller
Between (22) – (21) 4.6 – 5.4 V
Between (1) – (21) 0.5 – 4.5 V
48 D155A-6
D155A-6 49
Failure code [DK30KA] ST lever 1: Disconnection 1

Action code Failure code ST lever1: Disconnection
Trouble
E03 DK30KA (Power train controller system)
Contents of
• Signal voltage of PCCS lever steering potentiometer 1 system is below 0.5 V.
trouble
Action of • Continues control with signal of PCCS lever steering potentiometer 2 system.
Problem that
appears on
machine
• State of PCCS lever steering potentiometer 1 signal can be checked with monitoring function.
Related (Code: 50300 S/T Lever 1 Potentio)
information • Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (in steering
direction).

1
Defective PCCS lever steer- TLV1 (male) PCCS lever Resistance
2 ing potentiometer 1 (Internal
Between (5) – (8) 3.2 kz ± 20%
disconnection)
Between (5) – (7) Neutral 3.2 kz ± 20%
Between (7) – (8) 3.2 kz ± 20%
Possible causes
and standard
value in normal ness (Disconnection in wiring Wiring harness between STC1 (female) (22) Resis-
3 Max. 1 z
state or defective contact in con- – TLV1 (female) (5) tance
Max. 1 z
– TLV1 (female) (7) tance
Min. 1 Mz
– TLV1 (female) (7) and chassis ground tance
5
Between (2) – (21) 0.5 – 4.5 V
50 D155A-6
D155A-6 51
Failure code [DK30KB] ST lever 1: Short circuit 1

Action code Failure code ST lever1: Short circuit
Trouble
E03 DK30KB (Power train controller system)
Contents of
• Signal voltage of PCCS lever steering potentiometer 1 system is above 4.5 V.
trouble
Problem that
appears on
machine
direction).

1
Between (5) – (8) 3.2 kz ± 20%
short circuit)
Possible causes Between (5) – (7) Neutral 3.2 kz ± 20%
and standard
value in normal Between (7) – (8) 3.2 kz ± 20%
3
Voltage Max. 1 V
– TLV1 (female) (7) and chassis ground
4
Between (2) – (21) 0.5 – 4.5 V
52 D155A-6
D155A-6 53
Failure code [DK30KX] ST lever 1: Out of normal range 1

Action code Failure code ST lever 1: Out of normal range
Trouble
Contents of • In PCCS lever steering potentiometer 1 and 2 systems, either of failure codes [DK30KA] and
trouble [DK30KB] and either of failure codes [DK31KA] and [DK31KB] occurred simultaneously.
Action of
controller
Problem that
appears on
machine
• State of PCCS lever steering potentiometer signal can be checked with monitoring function.
(Code: 50300 S/T Lever 1 Potentio)
Related
information
• Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (in steering
direction).

and standard
value in normal Carry out troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
state
Failure code [DK30KZ] RL lever: Disconnection or short circuit 1

Action code Failure code ST lever: Disconnection or short circuit
Trouble
E04 DK30KZ (Power train controller system)
• In PCCS lever steering potentiometer 1 and 2 systems, when starting switch is turned ON, only
Contents of
either side is abnormal and then either of failure codes [DK30KA] and [DK30KB] and either of fail-
trouble
ure codes [DK31KA] and [DK31KB] occurred simultaneously.
Action of
controller
Problem that
appears on
machine
Related
information
direction).

and standard
state
54 D155A-6
Failure code [DK30L8] ST lever: Signal mismatch 1

Action code Failure code ST lever: Signal mismatch
Trouble
E03 DK30L8 (Power train controller system)
Contents of • In PCCS lever steering potentiometer 1 and 2 systems, total of both signal voltages is below 4.41 V
trouble or above 5.59 V.
Action of • Continues control with signal of normal one of PCCS lever steering potentiometer 1 and 2 systems.
Problem that
appears on
machine
Related
information
direction).

and standard
state
D155A-6 55
Failure code [DK31KA] ST lever 2: Disconnection 1

Action code Failure code ST lever 2: Disconnection
Trouble
Contents of
• Signal voltage of PCCS lever steering potentiometer 2 system is below 0.5 V.
trouble
Problem that
appears on
machine
direction).

1
Between (5) – (8) 3.2 kz ± 20%
disconnection)
Between (6) – (8) 3.2 kz ± 20%
Possible causes
and standard
3 Max. 1 z
Max. 1 z
Min. 1 Mz
5
Between (19) – (21) 0.5 – 4.5 V
56 D155A-6
D155A-6 57
Failure code [DK31KB] ST lever 2: Short circuit 1

Action code Failure code ST lever 2: Short circuit
Trouble
Contents of
• Signal voltage of PCCS lever steering potentiometer 2 system is above 4.5 V.
trouble
Problem that
appears on
machine
direction).

1
Between (5) – (8) 3.2 kz ± 20%
short circuit)
and standard
3
Voltage Max. 1 V
4
Between (19) – (21) 0.5 – 4.5 V
58 D155A-6
D155A-6 59
Failure code [DK40KA] Brake potentiometer: Disconnection 1

Action code Failure code Brake potentiometer: Disconnection
Trouble
Contents of
• Signal voltage of brake pedal potentiometer is below 0.5 V.
trouble
Action of
• Cannot recognize brake pedal position.
controller
Problem that
appears on • Auto shift-down function may not operate normally.
machine
Related
information

1
Defective brake pedal poten- BRK (male) Resistance
2 tiometer (Internal disconnec-
Between (C) – (A) 4.0 – 6.0 kz
tion)
Between (B) – (A) 0.25 – 7.0 kz
Between (B) – (C) 0.25 – 7.0 kz
Max. 1 z
Possible causes ness (Disconnection in wiring – BRK (female) (A) tance
and standard 3
– BRK (female) (B) tance
state
Max. 1 z
– BRK (female) (C) tance
Ground fault in wiring har- Wiring harness between STC1 (female) (3) Resis-
Min. 1 Mz
4 ness (Contact with GND cir- – BRK (female) (B) and chassis ground tance
cuit) Wiring harness between STC1 (female) (22)
Resis-
– BRK (female) (C) or circuit branch end Min. 1 Mz
tance
and chassis ground
5
Between (3) – (21) 0.5 – 4.5 V
60 D155A-6
D155A-6 61
Failure code [DK40KB] Brake potentiometer: Short circuit 1

Action code Failure code Brake potentiometer: Short circuit
Trouble
Contents of
• Signal voltage of brake pedal potentiometer is above 4.5 V.
trouble
Action of
• Cannot recognize brake pedal position.
controller
Problem that
appears on • Auto shift-down function may not operate normally.
machine
Related
information

1
Defective brake pedal poten- BRK (male) Resistance
2 tiometer (Internal short cir-
Between (C) – (A) 4.0 – 6.0 kz
cuit)
Between (B) – (A) 0.25 – 7.0 kz
Possible causes Between (B) – (C) 0.25 – 7.0 kz
and standard a Prepare with starting switch OFF, then turn starting switch ON
value in normal and carry out troubleshooting.
state
3 – BRK (female) (B) and chassis ground
24V circuit) in wiring harness
– BRK (female) (C) or circuit branch end Voltage Max. 1 V
and chassis ground
4
Between (3) – (21) 0.5 – 4.5 V
62 D155A-6
D155A-6 63
Failure code [DK55KX] FR lever: Out of normal range 1

Action code Failure code FR lever 1: Out of normal range
Trouble
Contents of • In PCCS lever F-R potentiometer 1 and 2 systems, either of failure codes [DK56KA] and [DK56KB]
trouble and either of failure codes [DK57KA] and [DK57KB] occurred simultaneously.
Action of
controller
Problem that
appears on
machine
• State of PCCS lever F-R potentiometer signal can be checked with monitoring function.
(Code: 50200 T/M Lever 1 Potentio)
Related
information
• Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (in F-R direc-
tion).

and standard
state
Failure code [DK55KZ] FR lever: Disconnection or short circuit 1

Action code Failure code FR lever: Disconnection or short circuit
Trouble
E04 DK55KZ (Power train controller system)
• In PCCS lever F-R potentiometer 1 and 2 systems, when starting switch is turned ON, only either
Contents of
side is abnormal and then either of failure codes [DK56KA] and [DK56KB] and either of failure
trouble
codes [DK57KA] and [DK57KB] occurred simultaneously.
Action of
controller
Problem that
appears on
machine
Related
information
tion).

and standard
state
64 D155A-6
Failure code [DK55L8] FR lever: Signal mismatch 1

Action code Failure code FR lever: Signal mismatch
Trouble
E03 DK55L8 (Power train controller system)
Contents of • In PCCS lever F-R potentiometer 1 and 2 systems, total of both signal voltages is below 4.41 V or
trouble above 5.59 V.
Action of • Continues control with signal of normal one of PCCS lever F-R potentiometer 1 and 2 systems.
Problem that
appears on
machine
Related
information
tion).

and standard
state
D155A-6 65
Failure code [DK56KA] FR lever 1: Disconnection 1

Action code Failure code FR lever 1: Disconnection
Trouble
Contents of
• Signal voltage of PCCS lever F-R potentiometer 1 system is below 0.5 V.
trouble
Action of • Continues control with signal of PCCS lever F-R potentiometer 2 system.
Problem that
appears on
machine
• State of PCCS lever F-R potentiometer 1 signal can be checked with monitoring function.
Related (Code: 50200 T/M Lever 1 Potentio)
information • Method of reproducing failure code: Turn starting switch ON + Operate PCCS lever (in F-R direc-
tion).

1
Defective PCCS lever F-R TLV1 (male) PCCS lever Resistance
2 potentiometer 1 (Internal dis-
Between (4) – (1) 3.2 kz ± 20%
connection)
Between (3) – (1) 3.2 kz ± 20%
Possible causes
and standard
3 Max. 1 z
Max. 1 z
Min. 1 Mz
5
Between (13) – (21) 0.5 – 4.5 V
66 D155A-6
D155A-6 67
Failure code [DK56KB] FR lever 1: Short circuit 1

Action code Failure code FR lever 1: Short circuit
Trouble
Contents of
• Signal voltage of PCCS lever F-R potentiometer 1 system is above 4.5 V.
trouble
Problem that
appears on
machine
tion).

1
2 potentiometer 1 (Internal
Between (4) – (1) 3.2 kz ± 20%
short circuit)
and standard
3
Voltage Max. 1 V
4
Between (13) – (21) 0.5 – 4.5 V
68 D155A-6
D155A-6 69
D155A-6 Bulldozer
© 2009 KOMATSU
All Rights Reserved
70 D155A-6
SEN03209-00
D155A-6

D155A-6 85001 and up
codes, Part 4
Failure code [DK57KA] FR lever 2: Disconnection ......................................................................................... 4
Failure code [DK57KB] FR lever 2: Short circuit............................................................................................. 6
Failure code [DKH1KA] Pitch angle sensor: Disconnection............................................................................ 8
Failure code [DKH1KB] Pitch angle sensor: Short circuit ............................................................................. 10
Failure code [DLT3KA] T/M out-speed sensor: Disconnection ..................................................................... 12
Failure code [DLT3KB] T/M out-speed sensor: Abnormal ............................................................................ 13
Failure code [DW7BKA] Fan rev EPC: Disconnection.................................................................................. 14
Failure code [DW7BKB] Fan rev EPC: Short circuit ..................................................................................... 15
Failure code [DWN3KA] Ssp solenoid: Disconnection.................................................................................. 16
Failure code [DWN3KB] Ssp solenoid: Short circuit ..................................................................................... 18
Failure code [DWN3KY] Ssp solenoid: Short circuit ..................................................................................... 20
Failure code [DWN5KA] Fan pump solenoid: Disconnection........................................................................ 22
Failure code [DWN5KB] Fan pump solenoid: Short circuit ........................................................................... 23
Failure code [DXH4KA] 1st clutch ECMV: Disconnection............................................................................. 24
D155A-6 1
Failure code [DXH4KB] 1st clutch ECMV: Short circuit................................................................................. 25

Failure code [DXH4KY] 1st clutch ECMV: Short circuit................................................................................. 26
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection............................................................................ 27
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit ............................................................................... 28
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit ............................................................................... 29
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection............................................................................. 30
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit ................................................................................ 31
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit ................................................................................ 32
Failure code [DXH7KA] R clutch ECMV: Disconnection ............................................................................... 33
Failure code [DXH7KB] R clutch ECMV: Short circuit................................................................................... 34
Failure code [DXH7KY] R clutch ECMV: Short circuit................................................................................... 35
Failure code [DXH8KA] F clutch ECMV: Disconnection................................................................................ 36
Failure code [DXH8KB] F clutch ECMV: Short circuit ................................................................................... 37
Failure code [DXH8KY] F clutch ECMV: Short circuit ................................................................................... 38
Failure code [DXH9KA] Right steering clutch ECMV disconnection ............................................................. 40
Failure code [DXH9KB] Right steering clutch ECMV short circuit................................................................. 42
Failure code [DXH9KY] Right steering clutch ECMV hot short ..................................................................... 44
Failure code [DXHAKA] Left steering clutch ECMV disconnection ............................................................... 46
Failure code [DXHAKB] Left steering clutch ECMV short circuit................................................................... 48
Failure code [DXHAKY] Left steering clutch ECMV hot short ....................................................................... 50
Failure code [DXHBKA] Right brake ECMV: Disconnection ......................................................................... 52
Failure code [DXHBKB] Right brake ECMV: Short circuit ............................................................................. 54
Failure code [DXHBKY] Right brake ECMV: Short circuit ............................................................................. 56
Failure code [DXHCKA] Left brake ECMV: Disconnection............................................................................ 58
Failure code [DXHCKB] Left brake ECMV: Short circuit ............................................................................... 60
Failure code [DXHCKY] Left brake ECMV: Short circuit ............................................................................... 62
Failure code [DXJ4KA] Weq lock Sol.: Disconnection .................................................................................. 64
Failure code [DXJ4KB] Weq lock Sol.: Short circuit ...................................................................................... 65
2 D155A-6
D155A-6 3
Failure code [DK57KA] FR lever 2: Disconnection 1

Action code Failure code FR lever 2: Disconnection
Trouble
Contents of
• Signal voltage of PCCS lever F-R potentiometer 2 system is below 0.5 V.
trouble
Problem that
appears on
machine
tion).

1
2 potentiometer 2 (Internal dis-
Between (4) – (1) 3.2 kz ± 20%
connection)
Between (2) – (1) 3.2 kz ± 20%
Possible causes
and standard
3 Max. 1 z
Max. 1 z
Min. 1 Mz
5
Between (7) – (21) 0.5 – 4.5 V
4 D155A-6
D155A-6 5
Failure code [DK57KB] FR lever 2: Short circuit 1

Action code Failure code FR lever 2: Short circuit
Trouble
Contents of
• Signal voltage of PCCS lever F-R potentiometer 2 system is above 4.5 V.
trouble
Problem that
appears on
machine
tion).

1
2 potentiometer 2 (Internal
Between (4) – (1) 3.2 kz ± 20%
short circuit)
and standard
3
Voltage Max. 1 V
4
Between (7) – (21) 0.5 – 4.5 V
6 D155A-6
D155A-6 7
Failure code [DKH1KA] Pitch angle sensor: Disconnection 1

Action code Failure code Pitch angle sensor: Disconnection
Trouble
E03 DKH1KA (Power train controller system)
Contents of
• Signal voltage of pitch angle sensor is below 0.5 V.
trouble
Action of • Cannot sense pitch angle of machine.
Problem that • Gearshift shock is made on slope or steering shock is made on level ground.
• State of pitch angle sensor signal can be checked with monitoring function.
Related
(Code: 60100 Pitch Angle Sensor)
information

1
PT1 Voltage
Defective pitch angle sensor Between (C) – (A) Power supply 20 – 30 V
2
(Internal trouble) Between (B) – (A) Signal 0.15 – 4.85 V
value in normal
state Max. 1 z
ness (Disconnection in wiring – PT1 (female) (A) tance
3
nector) Max. 1 z
– PT1 (female) (B) tance
Max. 1 z
– PT1 (female) (C) tance
Min. 1 Mz
– PT1 (female) (B) and chassis ground tance
troller
carried out.)
8 D155A-6
D155A-6 9
Failure code [DKH1KB] Pitch angle sensor: Short circuit 1

Action code Failure code Pitch angle sensor: Short circuit
Trouble
E03 DKH1KB (Power train controller system)
Contents of
• Signal voltage of pitch angle sensor is above 4.85 V.
trouble
Action of • Cannot sense pitch angle of machine.
Problem that • Gearshift shock is made on slope or steering shock is made on level ground.
• State of pitch angle sensor signal can be checked with monitoring function.
Related
(Code: 60100 Pitch Angle Sensor)
information

1
PT1 Voltage
Defective pitch angle sensor Between (C) – (A) Power supply 20 – 30 V
2
Possible causes (Internal trouble) Between (B) – (A) Signal 0.15 – 4.85 V
and standard
value in normal
state
3
Voltage Max. 1 V
– PT1 (female) (B) and chassis ground
troller
carried out.)
10 D155A-6
D155A-6 11
Failure code [DLT3KA] T/M out-speed sensor: Disconnection 1

Action code Failure code T/M out-speed sensor: Disconnection
Trouble
E01 DLT3KA (Power train controller system)
Contents of
• No signal is input from transmission bevel speed sensor.
trouble
Action of
• Recognizes that transmission bevel speed is 0 rpm.
controller
Problem that
• Transmission bevel speed cannot be monitored.
appears on
• Traction force cannot be calculated.
machine
• Transmission bevel speed can be checked with monitoring function.
Related (Code: 31400 T/M Out Speed)
information • Method of reproducing failure code: Turn starting switch ON + Drive machine (actually or with no
load).

Defective transmission bevel
1 speed sensor (Internal dis- BVRV (male) Resistance
connection or short circuit) Between (1) – (2) 500 – 1,000 z
Possible causes
and standard ness (Disconnection in wiring Wiring harness between STC2 (female) (30) Resis-
2 Max. 1 z
value in normal or defective contact in con- – BVRV (female) (1) tance
state nector) Wiring harness between STC2 (female) (29) Resis-
Max. 1 z
– BVRV (female) (2) tance
Min. 1 Mz
– BVRV (female) (1) and chassis ground tance
troller
carried out.)
12 D155A-6
Failure code [DLT3KB] T/M out-speed sensor: Abnormal 1

Action code Failure code T/M out-speed sensor: Abnormal
Trouble
E01 DLT3KB (Power train controller system)
Contents of
• No signal is input from transmission bevel speed sensor.
trouble
Action of
• Recognizes that transmission bevel speed is 0 rpm.
controller
Problem that
• Transmission bevel speed cannot be monitored.
appears on
• Traction force cannot be calculated.
machine
• Transmission bevel speed can be checked with monitoring function.
Related (Code: 31400 T/M Out Speed)
information • Method of reproducing failure code: Turn starting switch ON + Drive machine (actually or with no
load).

Defective transmission bevel
1 speed sensor (Internal dis- BVRV (male) Resistance
connection or short circuit) Between (1) – (2) 500 – 1,000 z
Possible causes
and standard ness (Disconnection in wiring Wiring harness between STC2 (female) (30) Resis-
2 Max. 1 z
value in normal or defective contact in con- – BVRV (female) (1) tance
state nector) Wiring harness between STC2 (female) (29) Resis-
Max. 1 z
– BVRV (female) (2) tance
Min. 1 Mz
– BVRV (female) (1) and chassis ground tance
troller
carried out.)
D155A-6 13
Failure code [DW7BKA] Fan rev EPC: Disconnection 1

Action code Failure code Fan rev EPC: Disconnection
Trouble
E01 DW7BKA (Power train controller system)
Contents of
• When signal is output to fan reverse solenoid circuit, no current flows.
trouble
Action of
• Turns signal to fan reverse solenoid circuit OFF.
controller
Problem that
appears on • Fan reverse function cannot be used.
machine
• Operating condition of fan reverse solenoid can be checked with monitoring function.
Related
(Code: 40909 T/M Output 1)
information
• Method of reproducing failure code: Turn starting switch ON + Select fan reverse mode.

Defective fan reverse sole- ing without turning starting switch ON.
1
noid (Internal disconnection) FAR (male) Resistance
Between (1) – (2) 34 – 44 z
Possible causes ness (Disconnection in wiring Wiring harness between STC3 (female) (18) Resis-
or defective contact in con- – FAR (female) (1) tance
value in normal nector) Wiring harness between STC3 (female) (13) Resis-
state Max. 1 z
– FAR (female) (2) tance
3
Voltage Max. 1 V
– FAR (female) (1) and chassis ground
troller
carried out.)
14 D155A-6
Failure code [DW7BKB] Fan rev EPC: Short circuit 1

Action code Failure code Fan rev EPC: Short circuit
Trouble
E01 DW7BKB (Power train controller system)
Contents of
• When signal was output to fan reverse solenoid circuit, abnormal current flowed.
trouble
Action of
• Turns signal to fan reverse solenoid circuit OFF.
controller
Problem that
appears on • Fan reverse function cannot be used.
machine
• Operating condition of fan reverse solenoid can be checked with monitoring function.
Related
(Code: 40909 T/M Output 1)
information
• Method of reproducing failure code: Turn starting switch ON + Select fan reverse mode.

Defective fan reverse sole- FAR (male) Resistance
1
noid (Internal short circuit)
Between (1) – (2) 34 – 44 z
– FAR (female) (1) and chassis ground tance
state
3 ness (with another wiring Wiring harness between STC3 (female) (18)
harness) Resis-
– FAR (female) (1) and between STC3 Min. 1 Mz
tance
(female) (13) – FAR (female) (2)
troller
carried out.)
D155A-6 15
Failure code [DWN3KA] Ssp solenoid: Disconnection 1

Action code Failure code Ssp solenoid: Disconnection
Trouble
E04 DWN3KA (Power train controller system)
Contents of
• When signal is output to sudden stop prevent solenoid circuit, no current flows.
trouble
Action of
controller
Problem that • Brake is applied lightly during travel.
• Output to sudden stop prevent solenoid can be checked with monitoring function.
Related
(Code: 31628 SSP Solenoid)
information

Defective sudden stop pre- ing without turning starting switch ON.
1 vent solenoid (Internal dis-
SSP (male) Resistance
connection)
Between (1) – (2) 3.5 – 12.5 z
or defective contact in con- – SSP (female) (1) tance
Max. 1 z
state – SSP (female) (2) tance
3
Voltage Max. 1 V
– SSP (female) (1) and chassis ground
4
Between (7) – (23) 3.5 – 12.5 z
16 D155A-6
D155A-6 17
Failure code [DWN3KB] Ssp solenoid: Short circuit 1

Action code Failure code Ssp solenoid: Short circuit
Trouble
E04 DWN3KB (Power train controller system)
Contents of
• When signal was output to sudden stop prevent solenoid circuit, abnormal current flowed.
trouble
Action of
controller
Related
information

Defective sudden stop pre-
1 vent solenoid (Internal short SSP (male) Resistance
circuit) Between (1) – (2) 3.5 – 12.5 z
Possible causes cuit) Wiring harness between STC3 (female) (7) Resis-
Min. 1 Mz
and standard – SSP (female) (1) and chassis ground tance
Short circuit in wiring har-
harness) Resis-
– SSP (female) (1) and between STC3 Min. 1 Mz
tance
(female) (23) – SSP (female) (2)
4
troller
Between (7) – (23) 3.5 – 12.5 z
18 D155A-6
D155A-6 19
Failure code [DWN3KY] Ssp solenoid: Short circuit 1

Action code Failure code Ssp solenoid: Short circuit
Trouble
E04 DWN3KY (Power train controller system)
Contents of
• When signal was output to sudden stop prevent solenoid circuit, abnormal current flowed.
trouble
Action of
controller
Related
information

Defective sudden stop pre-
1 vent solenoid (Internal short SSP (male) Resistance
circuit) Between (1) – (2) 3.5 – 12.5 z
2
Possible causes 24V circuit) in wiring harness Wiring harness between STC3 (female) (7)
Voltage Max. 1 V
and standard – SSP (female) (1) and chassis ground
harness) Resis-
– SSP (female) (1) and between STC3 Min. 1 Mz
tance
(female) (23) – SSP (female) (2)
4
troller
Between (7) – (23) 3.5 – 12.5 z
20 D155A-6
D155A-6 21
Failure code [DWN5KA] Fan pump solenoid: Disconnection 1

Action code Failure code Fan pump solenoid: Disconnection
Trouble
E01 DWN5KA (Power train controller system)
Contents of
• When signal is output to fan pump EPC solenoid circuit, no current flows.
trouble
Action of
• Turns signal to fan pump EPC solenoid circuit OFF.
controller
Problem that
appears on • Fan speed is kept at maximum.
machine
• If fan EPC solenoid system has disconnection or short circuit, fan cannot be reversed.
Related • Output to fan pump EPC solenoid can be checked with monitoring function.
information (Code: 31624 Fan pump Solenoid (F/B))

Defective fan pump EPC ing without turning starting switch ON.
1 solenoid (Internal disconnec-
FAC (male) Resistance
tion)
Between (1) – (2) 2 – 12 z
or defective contact in con- – FAC (female) (1) tance
state Max. 1 z
– FAC (female) (2) tance
3
Voltage Max. 1 V
– FAC (female) (1) end and chassis ground
troller
carried out.)
22 D155A-6
Failure code [DWN5KB] Fan pump solenoid: Short circuit 1

Action code Failure code Fan pump solenoid: Short circuit
Trouble
E01 DWN5KB (Power train controller system)
Contents of
• When signal was output to fan pump EPC solenoid circuit, abnormal current flowed.
trouble
Action of
• Turns signal to fan pump EPC solenoid circuit OFF.
controller
Problem that
appears on • Fan speed is kept at maximum.
machine
• If fan EPC solenoid system has disconnection or short circuit, fan cannot be reversed.
Related • Output to fan pump EPC solenoid can be checked with monitoring function.
information (Code: 31624 Fan pump Solenoid (F/B))

Defective fan pump EPC
1 solenoid (Internal short cir- FAC (male) Resistance
cuit) Between (1) – (2) 2 – 12 z
– FAC (female) (1) and chassis ground tance
state
harness) Resis-
– FAC (female) (1) and between STC3 Min. 1 Mz
tance
(female) (23) – FAC (female) (2)
troller
carried out.)
D155A-6 23
Failure code [DXH4KA] 1st clutch ECMV: Disconnection 1

Action code Failure code 1st clutch ECMV: Disconnection
Trouble
E03 DXH4KA (Power train controller system)
Contents of
• When signal is output to transmission 1st clutch ECMV solenoid circuit, no current flows.
trouble
Action of • Turns signal to transmission 1st clutch ECMV solenoid circuit OFF.
Problem that • Auto shift-down function does not operate.
• Output to 1st clutch ECMV solenoid can be checked with monitoring function.
Related
(Code: 31602 T/M Clutch 1st ECMV (F/B))
information
• Method of reproducing failure code: Start engine + Set gear to F1 or R1.

Defective 1st clutch ECMV ing without turning starting switch ON.
1
solenoid S1T (male) Resistance
Between (1) – (2) 3.5 – 12.5 z
2 Max. 1 z
and standard or defective contact in con- – S1T (female) (1) tance
Max. 1 z
state – S1T (female) (2) tance
3
– S1T (female) (2) or circuit branch end and Voltage Max. 1 V
chassis ground
troller
carried out.)
24 D155A-6
Failure code [DXH4KB] 1st clutch ECMV: Short circuit 1

Action code Failure code 1st clutch ECMV: Short circuit
Trouble
E03 DXH4KB (Power train controller system)
Contents of
• When signal was output to transmission 1st clutch ECMV solenoid circuit, abnormal current flowed.
trouble
Related
information

Defective 1st clutch ECMV
1 solenoid (Internal short cir- S1T (male) Resistance
cuit) Between (1) – (2) 3.5 – 12.5 z
– S1T (female) (1) and chassis ground tance
state
harness) Resis-
– S1T (female) (1) and between STC3 Min. 1 Mz
tance
(female) (23) – S1T (female) (2)
troller
carried out.)
D155A-6 25
Failure code [DXH4KY] 1st clutch ECMV: Short circuit 1

Action code Failure code 1st clutch ECMV: Short circuit
Trouble
E03 DXH4KY (Power train controller system)
Contents of
• When signal was output to transmission 1st clutch ECMV solenoid circuit, abnormal current flowed.
trouble
Related
information

Defective 1st clutch ECMV
cuit) Between (1) – (2) 3.5 – 12.5 z
Possible causes Hot short (Short circuit with and carry out troubleshooting.
and standard 2
value in normal Voltage Max. 1 V
– S1T (female) (1) and chassis ground
state
harness) Resis-
tance
troller
carried out.)
26 D155A-6
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection 1

Action code Failure code 2nd clutch ECMV: Disconnection
Trouble
Contents of
• When signal is output to transmission 2nd clutch ECMV solenoid circuit, no current flows.
trouble
Action of • Turns signal to transmission 2nd clutch ECMV solenoid circuit OFF.
• Output to 2nd clutch ECMV solenoid can be checked with monitoring function.
Related
(Code: 31603 T/M Clutch 2nd ECMV (F/B))
information

Defective 2nd clutch ECMV ing without turning starting switch ON.
S2T (male) Resistance
tion)
Between (1) – (2) 3.5 – 12.5 z
2 Max. 1 z
and standard or defective contact in con- – S2T (female) (1) tance
Max. 1 z
state – S2T (female) (2) tance
3
chassis ground
troller
carried out.)
D155A-6 27
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit 1

Action code Failure code 2nd clutch ECMV: Short circuit
Trouble
Contents of
• When signal was output to transmission 2nd clutch ECMV solenoid circuit, abnormal current flowed.
trouble
Related
information

Defective 2nd clutch ECMV
cuit) Between (1) – (2) 3.5 – 12.5 z
state
harness) Resis-
tance
troller
carried out.)
28 D155A-6
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit 1

Action code Failure code 2nd clutch ECMV: Short circuit
Trouble
Contents of
• When signal was output to transmission 2nd clutch ECMV solenoid circuit, abnormal current flowed.
trouble
Related
information

Defective 2nd clutch ECMV
cuit) Between (1) – (2) 3.5 – 12.5 z
and standard 2
state
harness) Resis-
tance
troller
carried out.)
D155A-6 29
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection 1

Action code Failure code 3rd clutch ECMV: Disconnection
Trouble
Contents of
• When signal is output to transmission 3rd clutch ECMV solenoid circuit, no current flows.
trouble
Action of • Turns signal to transmission 3rd clutch ECMV solenoid circuit OFF.
Problem that
appears on
machine
• Output to 3rd clutch ECMV solenoid can be checked with monitoring function.
Related
(Code: 31604 T/M Clutch 3rd ECMV (F/B))
information

Defective 3rd clutch ECMV
1 solenoid (Internal disconnec- S3T (male) Resistance
tion) Between (1) – (2) 3.5 – 12.5 z
or defective contact in con- – S3T (female) (1) tance
value in normal nector)
state Wiring harness between STC3 (female) (23) Resis-
Max. 1 z
– S3T (female) (2) tance
3
chassis ground
troller
carried out.)
30 D155A-6
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit 1

Action code Failure code 3rd clutch ECMV: Short circuit
Trouble
Contents of
• When signal was output to transmission 3rd clutch ECMV solenoid circuit, abnormal current flowed.
trouble
Problem that
appears on
machine
Related
information

cuit) Between (1) – (2) 3.5 – 12.5 z
state
harness) Resis-
tance
troller
carried out.)
D155A-6 31
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit 1

Action code Failure code 3rd clutch ECMV: Short circuit
Trouble
Contents of
• When signal was output to transmission 3rd clutch ECMV solenoid circuit, abnormal current flowed.
trouble
Problem that
appears on
machine
Related
information

cuit) Between (1) – (2) 3.5 – 12.5 z
and standard 2
state
harness) Resis-
tance
troller
carried out.)
32 D155A-6
Failure code [DXH7KA] R clutch ECMV: Disconnection 1

Action code Failure code R clutch ECMV: Disconnection
Trouble
Contents of
• When signal is output to transmission R clutch ECMV solenoid circuit, no current flows.
trouble
Action of • Turns signal to transmission R clutch ECMV solenoid circuit OFF.
Problem that
appears on
machine
• Output to R clutch ECMV solenoid can be checked with monitoring function.
Related
(Code: 31616 T/M Clutch R ECMV (F/B))
information
• Method of reproducing failure code: Start engine + Set gear to R (Reverse).

Defective R clutch ECMV ing without turning starting switch ON.
SRT (male) Resistance
tion)
Between (1) – (2) 3.5 – 12.5 z
2 Max. 1 z
and standard or defective contact in con- – SRT (female) (1) tance
Max. 1 z
state – SRT (female) (2) tance
3
– SRT (female) (2) or circuit branch end and Voltage Max. 1 V
chassis ground
troller
carried out.)
D155A-6 33
Failure code [DXH7KB] R clutch ECMV: Short circuit 1

Action code Failure code R clutch ECMV: Short circuit
Trouble
Contents of
• When signal was output to transmission R clutch ECMV solenoid circuit, abnormal current flowed.
trouble
Problem that
appears on
machine
Related
information

Defective R clutch ECMV
1 solenoid (Internal short cir- SRT (male) Resistance
cuit) Between (1) – (2) 3.5 – 12.5 z
– SRT (female) (1) and chassis ground tance
state
harness) Resis-
– SRT (female) (1) and between STC3 Min. 1 Mz
tance
(female) (13) – SRT (female) (2)
If causes 1 - 3 are not detected, power train controller may be
troller
carried out.)
34 D155A-6
Failure code [DXH7KY] R clutch ECMV: Short circuit 1

Action code Failure code R clutch ECMV: Short circuit
Trouble
Contents of
• When signal was output to transmission R clutch ECMV solenoid circuit, abnormal current flowed.
trouble
Problem that
appears on
machine
Related
information

Defective R clutch ECMV
1 solenoid (Internal short cir- SRT (male) Resistance
cuit) Between (1) – (2) 3.5 – 12.5 z
and standard 2
– SRT (female) (1) and chassis ground
state
harness) Resis-
– SRT (female) (1) and between STC3 Min. 1 Mz
tance
(female) (13) – SRT (female) (2)
troller
carried out.)
D155A-6 35
Failure code [DXH8KA] F clutch ECMV: Disconnection 1

Action code Failure code F clutch ECMV: Disconnection
Trouble
Contents of
• When signal is output to transmission F clutch ECMV solenoid circuit, no current flows.
trouble
Action of • Turns signal to transmission F clutch ECMV solenoid circuit OFF.
Problem that
appears on
machine
• Output to F clutch ECMV solenoid can be checked with monitoring function.
Related
(Code: 31622 T/M Clutch F ECMV (F/B))
information
• Method of reproducing failure code: Start engine + Set gear to F (Forward).

Defective F clutch ECMV ing without turning starting switch ON.
SFT (male) Resistance
tion)
Between (1) – (2) 3.5 – 12.5 z
2 Max. 1 z
and standard or defective contact in con- – SFT (female) (1) tance
Max. 1 z
state – SFT (female) (2) tance
3
– SFT (female) (2) or circuit branch end and Voltage Max. 1 V
chassis ground
troller
carried out.)
36 D155A-6
Failure code [DXH8KB] F clutch ECMV: Short circuit 1

Action code Failure code F clutch ECMV: Short circuit
Trouble
Contents of
• When signal was output to transmission F clutch ECMV solenoid circuit, abnormal current flowed.
trouble
Problem that
appears on
machine
Related
information

Defective F clutch ECMV
1 solenoid (Internal short cir- SFT (male) Resistance
cuit) Between (1) – (2) 3.5 – 12.5 z
– SFT (female) (1) and chassis ground tance
state
harness) Resis-
– SFT (female) (1) and between STC3 Min. 1 Mz
tance
(female) (13) – SFT (female) (2)
troller
carried out.)
D155A-6 37
Failure code [DXH8KY] F clutch ECMV: Short circuit 1

Action code Failure code F clutch ECMV: Short circuit
Trouble
Contents of
• When signal was output to transmission F clutch ECMV solenoid circuit, abnormal current flowed.
trouble
Problem that
appears on
machine
Related
information

Defective F clutch ECMV
1 solenoid (Internal short cir- SFT (male) Resistance
cuit) Between (1) – (2) 3.5 – 12.5 z
and standard 2
– SFT (female) (1) and chassis ground
state
harness) Resis-
– SFT (female) (1) and between STC3 Min. 1 Mz
tance
(female) (13) – SFT (female) (2)
troller
carried out.)
38 D155A-6
D155A-6 39
Failure code [DXH9KA] Right steering clutch ECMV disconnection 1

Action code Failure code Right steering clutch ECMV disconnection
Trouble
Contents of
• When signal is output to right steering clutch solenoid circuit, current does not flow.
trouble
• Flashes caution lamp and turns on caution buzzer.
Action of
• Stops outputting to right steering clutch solenoid circuit.
controller
Problem that • Machine cannot be steered to right.
• Outputting to right steering clutch solenoid (Current) can be checked in real-time moniitoring mode.
Related (Code 90601: Right steering clutch ECMV (E-POCV) command current, output current)
information • Method of reproducing failure code:
Turn starting switch ON + Release parking brake lever, + Operate PCCS lever (to steer to right).

a Prepare with starting switch OFF, then carry out troubleshooting
Defective right steering without turning starting switch ON.
1 clutch solenoid
SCLR (male) Resistance
(Internal short circuit)
Between (1) – (2) 5 – 15 z
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
and standard without turning starting switch ON.
Disconnection in wiring
value in normal
harness (Disconnection in Wiring harness between STC3 (female) (35) Resis-
state 2 Max. 1 z
wiring or defective contact in – SCLR (female) (1) tance
connector) Wiring harness between STC3 (female) (3) – Resis-
Max. 1 z
SCLR (female) (2) tance
If causes 1 and 2 are not detected, power train controller may be
Defective power train control-
ler
carried out.)
40 D155A-6
D155A-6 41
Failure code [DXH9KB] Right steering clutch ECMV short circuit 1

Action code Failure code Right steering clutch ECMV short circuit
Trouble
Contents of
• When signal was output to right steering clutch solenoid circuit, abnormal current flowed.
trouble
Action of
controller
Problem that • Machine cannot be steered to right.

without turning starting switch ON.
1 clutch solenoid SCLR (male) Resistance
(Internal short circuit) Between (1) – (2) 5 – 15 z
Short circuit with chassis without turning starting switch ON.
Possible causes 2 ground in wiring harness Short circuit of wiring harness between
and standard (Contact with ground circuit) STC3 (female) (35) – SCLR (female) (1) with Resis-
Min. 1 Mz
chassis ground
state
Short circuit in wiring
3 harness (with another wiring Short circuit of wiring harness between
harness) STC3 (female) (35) – SCLR (female) (1) with Resis-
Min. 1 Mz
wiring harness between STC3 (female) (3) – tance
SCLR (female) (2)
ler
carried out.)
42 D155A-6
D155A-6 43
Failure code [DXH9KY] Right steering clutch ECMV hot short 1

Action code Failure code Right steering clutch ECMV hot short
Trouble
Contents of
• Some current always flows into right steering clutch solenoid circuit.
trouble
Action of
controller
Problem that • Machine cannot be steered to right. (R clutch cannot be disengaged.)
machine • Once machine is stopped, it cannot travel any more.

1 clutch solenoid SCLR (male) Resistance
and standard and carry out troubleshooting.
value in normal Short circuit of wiring harness between
state Hot short in wiring harness STC3 (female) (35) – SCLR (female) (1) with Voltage Max. 1 V
2
(Contact with 24 V circuit) chassis ground
Short circuit of wiring harness between
STC3 (female) (3) – SCLR (female) (2) with Voltage Max. 1 V
chassis ground
ler
carried out.)
44 D155A-6
D155A-6 45
Failure code [DXHAKA] Left steering clutch ECMV disconnection 1

Action code Failure code Left steering clutch ECMV disconnection
Trouble
E03 DXHAKA (Power train controller system)
Contents of
• When signal is output to left steering clutch solenoid circuit, current does not flow.
trouble
Action of
• Stops outputting to left steering clutch solenoid circuit.
controller
Problem that • Machine cannot be steered to left.
• Outputting to left steering clutch solenoid (Current) can be checked in real-time moniitoring mode.
Related (Code 90600: Left steering clutch ECMV (E-POCV) command current, output current)
Turn starting switch ON + Release parking brake lever, + Operate PCCS lever (to steer to left).

Defective left steering clutch without turning starting switch ON.
1 solenoid
SCLL (male) Resistance
(Internal short circuit)
Between (1) – (2) 5 – 15 z
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
and standard without turning starting switch ON.
value in normal
harness (Disconnection in Wiring harness between STC3 (female) (25) Resis-
state 2 Max. 1 z
wiring or defective contact in – SCLL (female) (1) tance
connector) Wiring harness between STC3 (female) (3) – Resis-
Max. 1 z
SCLL (female) (2) tance
ler
carried out.)
46 D155A-6
D155A-6 47
Failure code [DXHAKB] Left steering clutch ECMV short circuit 1

Action code Failure code Left steering clutch ECMV short circuit
Trouble
E03 DXHAKB (Power train controller system)
Contents of
• When signal was output to left steering clutch solenoid circuit, abnormal current flowed.
trouble
Action of
controller
Problem that • Machine cannot be steered to left.
information • Method of reproducing error code:

1 solenoid SCLL (male) Resistance
Short circuit with chassis without turning starting switch ON.
Possible causes 2 ground in wiring harness Short circuit of wiring harness between
and standard (Contact with ground circuit) STC3 (female) (25) – SCLL (female) (1) with Resis-
Min. 1 Mz
chassis ground
state
Short circuit in wiring
3 harness (with another wiring Short circuit of wiring harness between
harness) STC3 (female) (25) – SCLL (female) (1) with Resis-
Min. 1 Mz
wiring harness between STC3 (female) (3) – tance
SCLL (female) (2)
ler
carried out.)
48 D155A-6
D155A-6 49
Failure code [DXHAKY] Left steering clutch ECMV hot short 1

Action code Failure code Left steering clutch ECMV hot short
Trouble
E04 DXHAKY (Power train controller system)
Contents of
• Some current always flows into left steering clutch solenoid circuit, current does not flow.
trouble
Action of
controller
Problem that • Machine cannot be steered to left. (L clutch cannot be disengaged.)
machine • Once machine is stopped, it cannot travel any more.

1 solenoid SCLL (male) Resistance
and standard and carry out troubleshooting.
value in normal Short circuit of wiring harness between
state Hot short in wiring harness STC3 (female) (25) – SCLL (female) (1) with Voltage Max. 1 V
2
(Contact with 24 V circuit) chassis ground
Short circuit of wiring harness between
STC3 (female) (3) – SCLL (female) (2) with Voltage Max. 1 V
chassis ground
ler
carried out.)
50 D155A-6
D155A-6 51
Failure code [DXHBKA] Right brake ECMV: Disconnection 1

Action code Failure code Right brake ECMV: Disconnection
Trouble
E04 DXHBKA (Power train controller system)
Contents of
• When signal is output to steering case right brake ECMV solenoid circuit, no current flows.
trouble
Action of • Turns signal to steering case right brake ECMV solenoid circuit OFF.
• Output to right brake ECMV solenoid can be checked with monitoring function.
Related
(Code: 31618 Brake RH ECMV (F/B))
information

Defective right brake ECMV ing without turning starting switch ON.
SBRR (male) Resistance
tion)
Between (1) – (2) 3.5 – 12.5 z
or defective contact in con- – SBRR (female) (1) tance
Max. 1 z
state – SBRR (female) (2) tance
3
Voltage Max. 1 V
– SBRR (female) (1) and chassis ground
4
Between (15) – (3) 3.5 – 12.5 z
52 D155A-6
D155A-6 53
Failure code [DXHBKB] Right brake ECMV: Short circuit 1

Action code Failure code Right brake ECMV: Short circuit
Trouble
E04 DXHBKB (Power train controller system)
Contents of • When signal was output to steering case right brake ECMV solenoid circuit, abnormal current
trouble flowed.
Related
information

1 solenoid (Internal short cir- SBRR (male) Resistance
cuit) Between (1) – (2) 3.5 – 12.5 z
Min. 1 Mz
and standard – SBRR (female) (1) and chassis ground tance
harness) Resis-
– SBRR (female) (1) and between STC3 Min. 1 Mz
tance
(female) (3) – SBRR (female) (2)
4
troller
Between (15) – (3) 3.5 – 12.5 z
54 D155A-6
D155A-6 55
Failure code [DXHBKY] Right brake ECMV: Short circuit 1

Action code Failure code Right brake ECMV: Short circuit
Trouble
E04 DXHBKY (Power train controller system)
Contents of • When signal was output to steering case right brake ECMV solenoid circuit, abnormal current
trouble flowed.
Related
information

1 solenoid (Internal short cir- SBRR (male) Resistance
cuit) Between (1) – (2) 3.5 – 12.5 z
2
Voltage Max. 1 V
and standard – SBRR (female) (1) and chassis ground
harness) Resis-
– SBRR (female) (1) and between STC3 Min. 1 Mz
tance
(female) (3) – SBRR (female) (2)
4
troller
Between (15) – (3) 3.5 – 12.5 z
56 D155A-6
D155A-6 57
Failure code [DXHCKA] Left brake ECMV: Disconnection 1

Action code Failure code Left brake ECMV: Disconnection
Trouble
E04 DXHCKA (Power train controller system)
Contents of
• When signal is output to steering case left brake ECMV solenoid circuit, no current flows.
trouble
Action of • Turns signal to steering case left brake ECMV solenoid circuit OFF.
• Output to left brake ECMV solenoid can be checked with monitoring function.
Related
(Code: 31619 Brake LH ECMV (F/B))
information

Defective left brake ECMV ing without turning starting switch ON.
SBRL (male) Resistance
tion)
Between (1) – (2) 3.5 – 12.5 z
or defective contact in con- – SBRL (female) (1) tance
Max. 1 z
state – SBRL (female) (2) tance
3
Voltage Max. 1 V
– SBRL (female) (1) and chassis ground
4
Between (5) – (3) 3.5 – 12.5 z
58 D155A-6
D155A-6 59
Failure code [DXHCKB] Left brake ECMV: Short circuit 1

Action code Failure code Left brake ECMV: Short circuit
Trouble
E04 DXHCKB (Power train controller system)
Contents of
• When signal was output to steering case left brake ECMV solenoid circuit, abnormal current flowed.
trouble
Related
information

Defective left brake ECMV
1 solenoid (Internal short cir- SBRL (male) Resistance
cuit) Between (1) – (2) 3.5 – 12.5 z
Min. 1 Mz
and standard – SBRL (female) (1) and chassis ground tance
harness) Resis-
– SBRL (female) (1) and between STC3 Min. 1 Mz
tance
(female) (3) – SBRL (female) (2)
4
troller
Between (5) – (3) 3.5 – 12.5 z
60 D155A-6
D155A-6 61
Failure code [DXHCKY] Left brake ECMV: Short circuit 1

Action code Failure code Left brake ECMV: Short circuit
Trouble
E04 DXHCKY (Power train controller system)
Contents of
• When signal was output to steering case left brake ECMV solenoid circuit, abnormal current flowed.
trouble
Related
information

Defective left brake ECMV
1 solenoid (Internal short cir- SBRL (male) Resistance
cuit) Between (1) – (2) 3.5 – 12.5 z
2
Voltage Max. 1 V
and standard – SBRL (female) (1) and chassis ground
harness) Resis-
– SBRL (female) (1) and between STC3 Min. 1 Mz
tance
(female) (3) – SBRL (female) (2)
4
troller
Between (5) – (3) 3.5 – 12.5 z
62 D155A-6
D155A-6 63
Failure code [DXJ4KA] Weq lock Sol.: Disconnection 1

Action code Failure code Weq lock Sol.: Disconnection
Trouble
E03 DXJ4KA (Power train controller system)
Contents of
• When signal is output to work equipment lock solenoid circuit, no current flows.
trouble
Action of
• Turns signal to work equipment lock solenoid circuit OFF.
controller
Problem that
appears on • Blade and ripper cannot be operated.
machine
Related • Method of reproducing failure code: Turn starting switch ON + Operate work equipment lock lever
information (Free).

Defective work equipment ing without turning starting switch ON.
1 lock solenoid (Internal dis-
WLK (male) Resistance
connection)
Between (1) – (2) 20 – 60 z
and standard Disconnection in wiring har-
2 Max. 1 z
state or defective contact in con- – WLK (female) (1) tance
Max. 1 z
– WLK (female) (2) tance
3
Between (8) – (3) 20 – 60 z
64 D155A-6
Failure code [DXJ4KB] Weq lock Sol.: Short circuit 1

Action code Failure code Weq lock Sol.: Short circuit
Trouble
E03 DXJ4KB (Power train controller system)
Contents of
• When signal was output to work equipment lock solenoid circuit, abnormal current flowed.
trouble
Action of
• Turns signal to work equipment lock solenoid circuit OFF.
controller
Problem that
appears on • Blade and ripper cannot be operated.
machine
Related • Method of reproducing failure code: Turn starting switch ON + Operate work equipment lock lever
information (Free).

Defective work equipment
1 lock solenoid (Internal short WLK (male) Resistance
circuit) Between (1) – (2) 20 – 60 z
Possible causes 2 ness (Contact with GND cir-
– WLK (female) (1) and chassis ground tance
value in normal
3
Voltage Max. 1 V
– WLK (female) (1) and chassis ground
4
troller
Between (8) – (3) 20 – 60 z
D155A-6 65
D155A-6 Bulldozer
© 2007 KOMATSU
All Rights Reserved
66 D155A-6
SEN03210-01
D155A-6

D155A-6 85001 and up
Troubleshooting of electrical system
(E-mode)
Before carrying out troubleshooting for electrical system ............................................................................... 3
E-1 When starting switch turned ON, machine monitor displays nothing ....................................................... 8
E-2 When starting switch turned ON (before starting engine), basic check item lights up............................ 10
E-3 Engine does not start (Engine does not turn) ......................................................................................... 12
E-4 Preheater does not operate.................................................................................................................... 15
E-5 Precaution item lights up while engine is running .................................................................................. 18
E-6 Emergency stop item lights up while engine is running.......................................................................... 20
E-7 Engine coolant temperature gauge does not indicate normally ............................................................. 22
E-8 Fuel level gauge does not indicate normally .......................................................................................... 23
E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally ........................................ 25
E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally .............................................. 26
E-11 Contents of display by machine monitor are different from applicable machine................................... 28
E-12 Machine monitor does not display some items .................................................................................... 28
D155A-6 1
E-13 Function switch does not work ............................................................................................................. 28

E-14 Operation mode does not change ........................................................................................................ 29
E-15 Gearshift mode does not change ......................................................................................................... 29
E-16 Customize function does not operate normally .................................................................................... 30
E-17 Customize memory function does not normally.................................................................................... 30
E-18 Alarm buzzer cannot be stopped.......................................................................................................... 31
E-19 Air conditioner does not operate normally (including air conditioner fault history) ............................... 32
E-20 When starting switch is turned OFF, service meter is not displayed .................................................... 46
E-21 Machine monitor cannot be set in service mode .................................................................................. 46
E-22 Ripper pin puller cylinder does not operate .......................................................................................... 48
E-23 Backup alarm does not sound or does not stop ................................................................................... 50
E-24 Headlamp, rear lamp, and ripper point lamp do not light up................................................................. 52
E-25 Windshield wiper and window washer do not operate.......................................................................... 57
E-26 KOMTRAX terminal does not operate normally ................................................................................... 73
E-27 Fan does not reverse............................................................................................................................ 74
E-28 Gear cannot be shifted ......................................................................................................................... 76
E-29 Electric priming pump does not operate or does not stop automatically .............................................. 78
2 D155A-6
Before carrying out troubleshooting for electrical system 1

Connection table of circuit breakers and fuse boxes
a This connection table shows the devices to which each power supply of the fuse box supplies power (An
accessory power supply is a device which supplies power while the starting switch is in the ON position
and an unswitched power supply is a device which supplies power while the starting switch is in the OFF
and ON positions).
a When carrying out troubleshooting related to the electrical system, you should check the circuit breakers
and fuses to see if the power is supplied normally.
Circuit breakers CB1 – CB9

Circuit
Power circuit breaker Circuit
breaker Destination of power
(Type of power supply) breaker No.
capacity
CB9 20A Optional power supply
Power train controller
CB1 20A
Emergency power supply (For power train switch box)
CB105 Work equipment controller
CB2 20A
(Accessory power Emergency power supply (For work equipment switch box)
supply)
Air conditioner unit, blower motor, and compressor electromag-
CB3 20A
netic clutch
CB4 20A Headlamp, additional headlamp
CB5 20A Rear lamp, additional rear lamp, ripper point lamp
Starting switch
CB6 20A
Engine hold relay
CB30 Machine monitor
(Unswitched power
supply) CB7 20A Power train controller
Work equipment controller
CB8 30A Engine controller, electric priming pump
CB105H
(Unswitched power — — Engine electrical intake air heater
supply)
Fuse box FS1

CB30
(Unswitched power 1 20A Operator's cab power supply (To connection table of fuse box )
supply)
2 5A Backup alarm, backup alarm relay
CB105
(Accessory power 3 20A Operator's cab power supply (To connection table of fuse box )
supply)
4 20A Operator's cab power supply (To connection table of fuse box )
Starting switch (ACC) 5 5A Engine controller (Signal ACC)
D155A-6 3
Fuse box FS2

CB30
(Unswitched power 1 5A Pedal brake solenoid valve
supply)
2 5A Parking brake solenoid valve
CB105 Engine electrical intake air heater

(Accessory power 3 20A Ripper pin puller solenoid valve
supply) Pneumatic suspension seat
4 5A Horn
Starting switch (ACC) 5 20A Optional power supply
4 D155A-6
Locations of circuit breakers CB30, CB105, and CB105H (In battery room)
Locations of circuit breakers CB1 – CB9 and fuse boxes FS1 and FS2 (In battery room)
D155A-6 5
Fuse box
Power circuit fuse Fuel
FS1-1 Radio
(Unswitched power 1 10A 12V accessory connector (Via DC converter)
supply) 12V accessory socket (Via DC converter)
Additional light relay, additional light
FS1-3 2 20A
Rotary lamp
(Accessory power
supply) 12V accessory connector (Via DC converter)
3 20A
12V accessory socket (Via DC converter)
Radio
Room lamp
FS1-4 4 20A
Cigarette lighter
(Accessory power
supply) Windshield wiper (Via intermittent relay)
5 10A Front wiper, rear wiper
6 10A Left wiper, right wiper
Location of fuse box (In operator's cab)
6 D155A-6

a The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before carrying out troubleshooting, understand that information fully.
Trouble Trouble which occurred in the machine

Related
information
1
<Troubles in wiring harness>
• Disconnection
Connector is connected defectively or wiring harness is
broken.
• Ground fault
Wiring harness which is not connected to chassis ground
circuit is in contact with chassis ground circuit.
• Hot short
Wiring harness which is not connected to power source (24
2 V) circuit is in contact with power source (24 V) circuit.
• Short circuit
Independent wiring harnesses are in contact with each
Possible causes other abnormally.
<Precautions for troubleshooting>
state ence numbers, which do
(1) Method of indicating connector No. and handling of T-
not indicate priority)
adapter
Insert or connect T-adapter as explained below for trouble-
shooting, unless otherwise specified.
3 • If connector No. has no marks of "male" and "female",
disconnect connector and insert T-adapters in both male
side and female side.
• If connector No. has marks of "male" and "female", dis-
connect connector and connect T-adapter to only male
side or female side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (–) lead of tester as
explained below for troubleshooting, unless otherwise
specified.
4 • Connect positive (+) lead to pin No. or wiring harness
entered on front side.
• Connect negative (–) lead to pin No. or harness entered
on rear side.
This drawing is a part of the electric circuit diagram related to troubleshooting.

• Connector No.: Indicates (Model – Number of pins) and (Color).
• "Connector No. and pin No." from each branching/merging point:
Shows the ends of branch or source of merging within the parts of the
same wiring harness.
• Arrow (io): Roughly shows the location on the machine.
D155A-6 7
E-1 When starting switch turned ON, machine monitor displays nothing 1
Trouble • When starting switch turned ON, machine monitor displays nothing.
• When starting switch is turned ON, machine monitor displays KOMATSU logo, screen to input pass-
word (if set), screen of check before starting, screen to check setting of preset, and ordinary screen
Related in order.
information • When the engine is started, the battery voltage may lower suddenly, depending on the ambient tem-
perature and the condition of the battery. In this case, the machine monitor goes off for a moment.
This phenomenon is not a failure, however.

1 Low charge level of battery Electrolyte specific gravity
Battery voltage (2 pieces)
(1 piece)
Min. 24 V Min. 1.26
Defective circuit breaker If circuit breaker is turned OFF, circuit probably has ground fault.
2
(CB30, CB6, or CB7) (See cause 6.)
Machine monitor connector may be connected wrongly. Check it
Wrong connection of connec-
3 directly (Connection between connectors CM01 and CM02 and
tor
between connectors CM03 and CM04).
Defective starting switch and carry out troubleshooting.
4
(Internal disconnection) Starting switch Resistance
Between 250 – 270 ON Max. 1 z
Possible causes
state Wiring harness between battery (–) – chas- Resis-
Max. 1 z
sis ground tance
Wiring harness between battery (+) – termi- Resis-
Max. 1 z
nal BRB – CB30 (B30L) tance
Wiring harness between CB30 (B30S) – Resis-
Max. 1 z
Disconnection in wiring har- CB7 (1) tance
ness (Disconnection in wiring Wiring harness between CB7 (2) – CM01 Resis-
5 Max. 1 z
or defective contact in con- (female) (1), (2) tance
Max. 1 z
Wiring harness between CB30 (B30S) – Resis-
Max. 1 z
CB6 (1) tance
Wiring harness between CB6 (2) – terminal Resis-
Max. 1 z
250 tance
Wiring harness between terminal 270 – Resis-
Max. 1 z
CM01 (female) (14) tance
8 D155A-6

Wiring harness between battery (+) – termi- Resis-
Min. 1 Mz
nal BRB – CB30 (B30L) and chassis ground tance
Wiring harness between CB30 (B30S) –
Resis-
CB7 (1) or circuit branch end and chassis Min. 1 Mz
tance
ground
Wiring harness between CB7 (2) – CM01
Resis-
Ground fault in wiring har- (female) (1), (2) or circuit branch end and Min. 1 Mz
tance
6 ness (Contact with GND cir- chassis ground
cuit) Wiring harness between CB30 (B30S) –
Possible causes Resis-
CB6 (1) or circuit branch end and chassis Min. 1 Mz
and standard tance
ground
value in normal
state Wiring harness between CB6 (2) – terminal
Resis-
250 or circuit branch end and chassis Min. 1 Mz
tance
ground
Wiring harness between terminal 270 –
Resis-
CM01 (female) (14) or circuit branch end Min. 1 Mz
tance
and chassis ground
a Prepare with starting switch OFF, then hold starting switch OFF
and ON and carry out troubleshooting in each case.
CM01 Starting switch Voltage
7 Defective machine monitor Between (1), (2) –
OFF 20 – 30 V
(3) , (4)
Between (14) –
ON 20 – 30 V
(3), (4)
D155A-6 9
E-2 When starting switch turned ON (before starting engine), basic

check item lights up 1
Trouble • When starting switch turned ON (before starting engine), basic check item lights up.
Related
• Basic check item is only lowering of radiator coolant level.
information

Lowering of radiator coolant
Coolant level in radiator sub tank may be low. Check it and add
1 level (When system is nor-
coolant if necessary.
mal)
Defective radiator coolant Sub tank coolant
WLV (male) Resistance
2 level switch (Internal discon- level
nection) Between FULL –
Max. 1 z
Between (1) – (2) LOW
Possible causes Below LOW Min. 1 Mz

value in normal Disconnection in wiring har- ing without turning starting switch ON.
state ness (Disconnection in wiring Wiring harness between CM02 (female) (3) Resis-
3 Max. 1 z
or defective contact in con- – WLV (female) (1) tance
Max. 1 z
CM02 (female) (7) – WLV (female) (2) tance
Sub tank coolant
CM02 Voltage
4 Defective machine monitor level
Between FULL –
Between (3) – Max. 1 V
LOW
chassis ground
Below LOW 20 – 30 V
10 D155A-6
D155A-6 11
E-3 Engine does not start (Engine does not turn) 1

Trouble • Engine does not start (Engine does not turn).
Related • Engine starting circuit has following 2 start lock mechanisms.

1) Start lock with password of machine monitor
information 2) Start lock with parking brake lever and work equipment lock lever

1 Low charge level of battery Electrolyte specific gravity
Battery voltage (2 pieces)
(1 piece)
Min. 24 V Min. 1.26
a Prepare with starting switch OFF, then keep starting switch
OFF and turn it to START and carry out troubleshooting in each
case.
Defective starting switch
2 Starting switch Resistance
(Internal disconnection)
OFF Min. 1 Mz
Between 250 – 280
START Max. 1 z
a Prepare with starting switch OFF, then turn starting switch to
START and carry out troubleshooting.
Defective neutral safety relay
3 Replace neutral safety relay (Right No.) with another
(Internal trouble)
relay. If engine starts at this time, neutral safety relay is NSF
defective.
a Prepare with starting switch OFF, then turn starting switch to
START and carry out troubleshooting.
Starting motor Voltage
Between B –
Battery power supply 20 –30 V
chassis ground
Defective starting motor
4 Between ST (2) –
(Internal defect) Starting signal 20 –30 V
chassis ground
Possible causes
and standard Between ST (2) –
Generation signal Max. 13 V
value in normal chassis ground
state
If battery power supply, starting signal, and generation signal are
normal but starting motor does not turn, starting motor is defective.
Defective alternator (Internal
5 Alternator Voltage
short circuit)
Between R –
Generation signal Max. 13 V
chassis ground
Disconnection in wiring har-
ness (Disconnection in wiring Wiring harness between terminal 280 – NSF Resis-
6 Max. 1 z
or defective contact in con- (female) (3) tance
nector)
Wiring harness between NSF (female) (5) – Resis-
Max. 1 z
EG2 (8) – ST (female) (1) tance
Ground fault in wiring har- Wiring harness between terminal 280 – NSF
Resis-
7 ness (Contact with GND cir- (female) (3) or circuit branch end and chas- Min. 1 Mz
tance
cuit) sis ground
Wiring harness between NSF (female) (5) – Resis-
EG2 (8) – ST (female) (1) and chassis ground Min. 1 Mz
tance
8
24V circuit) in wiring harness Wiring harness between terminal R – ST
(female) (2) or circuit branch end and chas- Voltage Max. 1 V
sis ground
12 D155A-6

and standard
value in normal Detective engine controller As the engine controller power supply can be detective, carry out
9
state power supply troubleshooting for "Failure code CA111".
D155A-6 13
14 D155A-6
E-4 Preheater does not operate 1

Trouble (1) When starting switch is turned to HEAT position, preheating monitor does not light up.
• Preheater monitor lights up when starting switch is turned to HEAT.
Related
• If engine coolant temperature is below -5 °C, automatic warm-up system operates and preheating
information
monitor lights up for up to 40 seconds.

OFF and turn it to HEAT and carry out troubleshooting in each
case.
1 Starting switch Resistance
OFF Min. 1 Mz
Between 250 – 255
HEAT Max. 1 z
Possible causes
and standard Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
ness (Disconnection in wiring ing without turning starting switch ON.
value in normal 2
state or defective contact in con- Wiring harness between CM01 (female) Resis-
nector) Max. 1 z
(16) – terminal 255 tance
OFF and turn it to HEAT and carry out troubleshooting in each
case.
3 Defective machine monitor CM01 Starting switch Voltage
Between (16) – OFF Max. 1 V
chassis ground HEAT 20 – 30 V
D155A-6 15
(2) When starting switch is turned to HEAT position, intake air heater mounting part does not become
Trouble
warm.
Related • Check that engine can be turned with starting motor (If engine cannot be turned, carry out trouble-
information shooting for E-3 Engine does not start (Engine does not turn)).

1
(CB105H) (See cause 5).
a Prepare with starting switch OFF (with wiring harness con-
nected), then turn starting switch to HEAT and carry out trou-
bleshooting.
Defective heater relay (Inter- Heater relay Starting switch Voltage
2
nal disconnection) Between HT –
20 – 30 V
chassis ground
HEAT
Between HT/B –
20 – 30 V
chassis ground
a Prepare with starting switch OFF (with wiring harness con-
nected), then turn starting switch to HEAT and carry out trou-
bleshooting in each case.
Defective intake air heater RHT Starting switc Voltage
3
(Internal disconnection) Between terminal –
HEAT 20 – 30 V
chassis ground
If voltage is normal but heater mounting part does not become
Possible causes warm, intake air heater is defective.
state
Wiring harness between terminal 255 – ter- Resis-
Max. 1 z
Disconnection in wiring har- minal HT tance
ness (Disconnection in wiring Wiring harness between terminal BRC – Resis-
4 Max. 1 z
or defective contact in con- CB105H (B105HS) tance
nector) Wiring harness between CB105H (B105HL) Resis-
Max. 1 z
– terminal HT/A tance
Wiring harness between terminal HT/B – Resis-
Max. 1 z
terminal RHT tance
Wiring harness between terminal 255 – ter-
Resis-
minal HT or CM01 (female) (16) or circuit Min. 1 Mz
tance
Ground fault in wiring har- branch end and chassis ground
5 ness (Contact with GND cir- Wiring harness between terminal BRC – Resis-
Min. 1 Mz
cuit) CB105H (B105HS) and chassis ground tance
Wiring harness between CB105H (B105HL) Resis-
Min. 1 Mz
– terminal HT/A and chassis ground tance
Wiring harness between terminal HT/B Resis-
Min. 1 Mz
– terminal RHT and chassis ground tance
16 D155A-6
D155A-6 17
E-5 Precaution item lights up while engine is running 1

Trouble • Precaution item lights up while engine is running.
• Check item is only charge level monitor.
Related
• State of generation signal of alternator can be checked with monitoring function.
information
(Code: 04300 Battery Charge Volt)

Defective generation by out troubleshooting.
1 alternator (when system is Alternator Engine speed Voltage
normal) Between R –
Medium or higher 20 – 30 V
chassis ground
ness (Disconnection in wiring ing without turning starting switch ON.
2
Possible causes or defective contact in con- Wiring harness between CM01 (female) (11) Resis-
nector) Max. 1 z
and standard – terminal R tance
3 ness (Contact with GND cir- Wiring harness between CM01 (female) (11)
cuit) Resis-
– terminal R or circuit branch end and chas- Min. 1 Mz
tance
sis ground
4 Defective machine monitor CM01 Engine Voltage
Between (11) –
Medium or higher 20 – 30 V
chassis ground
18 D155A-6
D155A-6 19
E-6 Emergency stop item lights up while engine is running 1

Trouble (1) Engine coolant temperature monitor lights up.
• Signals of engine coolant temperature sensor are input to engine controller and then transmitted to
Related machine monitor through communication system.

Overheating of engine cool- Engine coolant may be overheated. If it is overheated, remove
1
ant (when system is normal) cause.
Possible causes
and standard If cause 1 is not detected, engine coolant temperature sensor sys-
Defective engine coolant
value in normal 2 tem may be defective. Carry out troubleshooting for failure codes
temperature sensor system
state [CA144] and [CA145].
If causes 1 and 2 are not detected, machine monitor may be defec-
3 Defective machine monitor tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
Trouble (2) Engine oil pressure monitor lights up.

• Signals of engine oil pressure sensor are input to engine controller and then transmitted to machine
Related monitor through communication system.
information • Engine oil pressure can be checked with monitoring function.
(Code: 37200 Engine Oil Pressure)

Lowering of engine oil pres-
1 sure (when system is nor- Engine oil pressure may be low. If it is low, remove cause.
Possible causes mal)
and standard If cause 1 is not detected, engine oil pressure sensor system may
value in normal Defective engine oil pressure
2 be defective. Carry out troubleshooting for failure codes [CA135]
state sensor system
and [CA141].
out.)
Trouble (3) Power train oil temperature monitor lights up.

• Signals of torque converter oil temperature sensor are input to power train controller and then trans-
Related mitted to machine monitor through communication system.
information • Power train oil temperature can be checked with monitoring function.

Overheating of power train Power train oil may be overheated. If it is overheated, remove
1
oil (when system is normal) cause.
Possible causes
and standard If cause 1 is not detected, power train oil temperature sensor sys-
Defective power train oil tem-
value in normal 2 tem may be defective. Carry out troubleshooting for failure codes
perature sensor system
state [DGT1KA] and [DGT1KX].
out.)
20 D155A-6
Trouble (4) Hydraulic oil temperature monitor lights up.

Related • Hydraulic oil temperature can be checked with monitoring function.
information (Code: 04401 Hyd Oil Temperature)

Possible causes Overheating of hydraulic oil Hydraulic oil may be overheated. If it is overheated, remove
1
and standard (when system is normal) cause.
value in normal If cause 1 is not detected, hydraulic oil temperature gauge system
state Defective hydraulic oil tem-
2 may be defective. Carry out troubleshooting for E-10 Hydraulic oil
perature gauge system
temperature gauge (Multi-gauge) does not display normally.
D155A-6 21
E-7 Engine coolant temperature gauge does not indicate normally 1

(1) While engine coolant temperature is rising normally, temperature gauge does not rise from white
Trouble range (C).
(2) While engine coolant temperature is stabilized normally, temperature gauge rises to red range (H).

Possible causes
Defective engine coolant Engine coolant temperature sensor system may be defective.
and standard 1
temperature sensor system Carry out troubleshooting for failure codes [CA144] and [CA145].
value in normal
state If cause 1 is not detected, machine monitor may be defective.
2 Defective machine monitor
(Since trouble is in system, troubleshooting cannot be carried out.)
(3) Display of coolant temperature gauge is different from actual engine coolant temperature.
Trouble (4) Display of engine coolant temperature gauge is different from display of engine coolant tempera-
ture monitor.

a Turn starting switch ON or start engine and carry out trouble-
shooting.
Engine coolant temperature Coolant temperature gauge level
Possible causes
and standard 105 °C 6
value in normal 1 Defective machine monitor 102 °C 5
state 100 °C 4
85 °C 3
60 °C 2
30 °C 1
Engine coolant temperature gauge and coolant temperature monitor
22 D155A-6
E-8 Fuel level gauge does not indicate normally 1

(1) While fuel is added, fuel level gauge does not rise from red range (E).
Trouble
(2) While fuel level is low, fuel level gauge does not lower from green range top (F)
Related • Signal voltage of fuel level sensor can be checked with monitoring function.
nformation (Code: 04200 Fuel Level Sensor Volt)

Defective fuel level sensor
1 (Internal disconnection or FLV (male) Fuel level Resistance
short circuit) FULL Approx. 4 z
Between (1) – (2)
EMPTY Approx. 85 z
ness (Disconnection in wiring Wiring harness between CM01 (female) (9) Resis-
2 Max. 1 z
or defective contact in con- – FLV (female) (1) tance
Possible causes
nector) Wiring harness between CM01 (female) Resis-
value in normal (12) – FLV (female) (2) tance
cuit) Wiring harness between CM01 (female) (9) Resis-
Min. 1 Mz
– FLV (female) (1) and chassis ground tance
4
24V circuit) in wiring harness Wiring harness between CM01 (female) (9)
Voltage Max. 1 V
– FLV (female) (1) and chassis ground
If causes 1 – 4 are not detected, machine monitor may be defec-
out.)
D155A-6 23
(3) Display of fuel level gauge is different from actual fuel level.
Trouble
(4) Display of fuel level gauge is different from display of fuel level monitor.
Related • Signal voltage of fuel level sensor can be checked with monitoring function.
information (Code: 04200 Fuel Level Sensor Volt)

shooting.
Quantity of fuel Reading of fuel level gauge
Possible causes
and standard 565 l 6
value in normal 1 Defective machine monitor 425 l 5
state 310 l 4
220 l 3
150 l 2
75 l 1
Fuel level gauge and fuel level monitor
24 D155A-6
E-9 Power train oil temperature gauge (multi-gauge) does not indicate
normally 1
(1) While power train oil temperature is rising normally, temperature gauge does not rise from white
Trouble range (C).
(2) While power train oil temperature is stabilized normally, temperature gauge rises to red range (H).
• Signals of power train oil temperature sensor are input to power train controller and then transmitted
Related to machine monitor through communication system.

Possible causes Power train oil temperature sensor system may be defective.
Defective power train oil tem-
and standard 1 Carry out troubleshooting for failure codes [DGT1KA] and
perature sensor system
value in normal [DGT1KX].
state If cause 1 is not detected, machine monitor may be defective.
(3) Display of power train temperature gauge is different from actual power train oil temperature.
Trouble (4) Display of power train oil temperature gauge is different from display of power train oil temperature
monitor.
• Signals of power train oil temperature sensor are input to power train controller and then transmitted
Related to machine monitor through communication system.

shooting.
Power train oil temperature
Power train oil temperature
Possible causes gauge level
state
118 °C 4
80 °C 3
50 °C 2
0 °C 1
Power train oil temperature gauge and power train oil temperature monitor
D155A-6 25
E-10 Hydraulic temperature gauge (multi-gauge) does not indicate

normally 1
(1) While hydraulic oil temperature is rising normally, temperature gauge does not rise from white
Trouble range (C).
(2) While hydraulic oil temperature is stabilized normally, temperature gauge rises to red range (H).
Related • Hydraulic temperature can be checked with monitoring function.

Defective hydraulic oil tem- ing without turning starting switch ON.
perature sensor system HDT (male) Resistance
1
(Internal disconnection or
short circuit) Between (1) – (2) 3.5 – 90 kz
ness (Disconnection in wiring Wiring harness between CM01 (female) (8) Resis-
2 Max. 1 z
or defective contact in con- – HDT (female) (1) tance
Possible causes
nector) Wiring harness between CM01 (female) Resis-
value in normal (12) – HDT (female) (2) tance
cuit) Wiring harness between CM01 (female) (8) Resis-
Min. 1 Mz
– HDT (female) (1) and chassis ground tance
4
24V circuit) in wiring harness Wiring harness between CM01 (female) (8)
Voltage Max. 1 V
– HDT (female) (1) and chassis ground
out.)
26 D155A-6
(3) Display of hydraulic oil temperature gauge is different from actual hydraulic oil temperature.
Trouble (4) Display of hydraulic oil temperature gauge is different from display of hydraulic oil temperature
monitor.
Related • Hydraulic oil temperature can be checked with monitoring function.

shooting.
Reading of hydraulic oil temper-
Possible causes ature gauge
state
98 °C 4
70 °C 3
20 °C 2
0 °C 1
Hydraulic oil temperature gauge and hydraulic oil temperature monitor
D155A-6 27
E-11 Contents of display by machine monitor are different from

applicable machine 1
Trouble • Contents of display by machine monitor are different from applicable machine.
Related
information

and standard
value in normal Machine monitor may be defective. (Since trouble is in system,
state troubleshooting cannot be carried out.)
E-12 Machine monitor does not display some items 1

Trouble • Machine monitor does not display some items.
• The LCD panel sometimes has black points (points which are not lighted) and bright points (points
Related
which do not go off) for the reason of its characteristics. If the number of the bright points and black
information
points does not exceed 10, those points are not a failure or a defect.

a Turn starting switch ON and carry out troubleshooting.
Possible causes
Defective machine monitor When following switches are operated, if all LCD panel is lighted
and standard 1
(LCD panel) up (all surface becomes white), LCD panel is normal.
value in normal
state • Operation of switches: [4] + [F2] (Press simultaneously)
Defective machine monitor If cause 1 is not detected, machine monitor may be defective.
2
(body) (Since trouble is in system, troubleshooting cannot be carried out.)
E-13 Function switch does not work 1

Trouble • Function switch does not work.
Related
information

and standard
28 D155A-6
E-14 Operation mode does not change 1

Trouble (1) When operation mode switch is operated, display of operation mode monitor does not change.
Related
information

and standard
Trouble (2) When operation mode is changed, engine output is not changed.
Related • Engine output mode recognized by engine controller can be checked with monitoring function.
information (Code: 17500 Engine Power Mode)

Possible causes
Machine monitor may be defective. (Since trouble is in system,
and standard 1 Defective machine monitor
troubleshooting cannot be carried out.)
value in normal
state Engine controller may be defective. (Since trouble is in system,
E-15 Gearshift mode does not change 1

Trouble (1) When gearshift mode switch is operated, display of speed mode section does not change.
Related
information

and standard
Trouble (2) When gearshift mode is changed, gearshift setting of power train is not changed.
Related
information

Possible causes
Machine monitor may be defective. (Since trouble is in system,
and standard 1 Defective machine monitor
value in normal
state Defective power train con- Power train controller may be defective. (Since trouble is in sys-
2
troller tem, troubleshooting cannot be carried out.)
D155A-6 29
E-16 Customize function does not operate normally 1

Trouble (1) When customize switch is operated, customize screen is not displayed.
Related
information

and standard
Trouble (2) When setting is changed on customize screen, setting of machine is not changed.
Related
information

Possible causes Machine monitor may be defective. (Since trouble is in system,
and standard troubleshooting cannot be carried out.)
value in normal Defective engine controller,
state Engine controller, power train controller may be defective. (Since
2 defective power train control-
trouble is in system, troubleshooting cannot be carried out.)
ler
E-17 Customize memory function does not normally 1

Trouble (1) When customize memory switch is operated, customize memory screen is not displayed.
Related
information

and standard
Trouble (2) When selection is changed on customize memory screen, setting of machine is not changed.
Related
information

Possible causes Machine monitor may be defective. (Since trouble is in system,
and standard troubleshooting cannot be carried out.)
value in normal Defective engine controller,
state Engine controller, power train controller may be defective. (Since
2 defective power train control-
trouble is in system, troubleshooting cannot be carried out.)
ler
30 D155A-6
E-18 Alarm buzzer cannot be stopped 1

Trouble • Alarm buzzer cannot be stopped.
Related
information

and standard
D155A-6 31
E-19 Air conditioner does not operate normally

(including air conditioner fault history) 1
Trouble (1) When air conditioner switch is operated, air conditioner control screen is not displayed.
Related
information

and standard
Trouble (2) When air conditioner switch is operated, air conditioner does not operate at all.
Related
information

1
(CB3) (See cause 4).
If fuse in unit is broken, circuit in unit probably has ground fault
2 Defective fuse in unit
(See cause 4).
ness (Disconnection in wiring Wiring harness between CB3 (2) – fuse in Resis-
3 Max. 1 z
or defective contact in con- unit - ACCN (wiring side) (6) tance
nector)
Wiring harness between ACCN (wiring side) Resis-
Max. 1 z
Possible causes
value in normal Ground fault in wiring har- ing without turning starting switch ON.
state 4 ness (Contact with GND cir- Wiring harness between CB3 (2) – fuse in
cuit) Resis-
unit – ACCN (wiring side) (6) or circuit Min. 1 Mz
tance
branch end and chassis ground
Defective air conditioner con- ACCN (wiring side) Voltage
5
troller Between (6) – (16) 20 – 30 V
If above voltage is normal, air conditioner controller may be defec-
tive.
out.)
32 D155A-6
Trouble (3) Air does not come out (Air flow is insufficient).
Related
information

ing without turning starting switch ON (coil side).
AC03 (male) Resistance
Between (1) – (3) 140 – 340 z
Defective blower relay
1 a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting (contact side).
AC03 Air conditioner switch Voltage
Between (4) –
Air blow position 20 – 30 V
chassis ground
Defective power transistor
2 Fan switch If air flow changes according to
(Internal defect)
Operate between Low and operation of fan switch, power
Medium and High. transistor (ACPT) is normal.
3 Defective blower motor ACBM (wiring side) Air conditioner switch Voltage
Possible causes
and standard (Internal defect) Between (1) – (2) Air blow position 20 – 30 V
value in normal If above voltage is normal and blower motor does not revolve,
state blower motor (ACBM) is defective.
Wiring harness between CB3 (2) – fuse in Resis-
Max. 1 z
unit - AC03 (female) (1) tance
Wiring harness between AC03 (female) (3) Resis-
Max. 1 z
– ACCN (wiring side) (36) tance
Wiring harness between CB3 (2) – AC03 Resis-
Max. 1 z
Disconnection in wiring har- (female) (4) tance
ness (Disconnection in wiring Wiring harness between AC03 (female) (5) Resis-
4 Max. 1 z
or defective contact in con- – ACBM (wiring side) (1) tance
nector) Wiring harness between ACBM (wiring side) Resis-
Max. 1 z
(2) – ACPT (wiring side) (3) tance
Wiring harness between ACPT (wiring side) Resis-
Max. 1 z
Max. 1 z
(2) – ACCN (wiring side) (8) tance
Max. 1 z
D155A-6 33

Wiring harness between AC03 (female) (3)
Resis-
– ACCN (wiring side) (36) and chassis Min. 1 Mz
tance
ground
– ACBM (wiring side) (1) and chassis Min. 1 Mz
ground
and standard Wiring harness between ACBM (wiring side)
Resis-
value in normal (2) – ACPT (wiring side) (3) and chassis Min. 1 Mz
tance
state ground
Wiring harness between ACPT (wiring side)
Resis-
(2) – ACCN (wiring side) (8) and chassis Min. 1 Mz
tance
ground
If causes 1 – 5 are not detected, air conditioner controller may be
Defective air conditioner con-
troller
carried out.)
If causes 1 – 5 are not detected, air conditioner system may be
Defective air conditioner sys-
7 defective. See Machine Component Volume, Shop Manual, Trou-
tem
bleshooting, Air conditioner, Troubleshooting.
34 D155A-6
Trouble (4) Air is not cooled (Cooling performance is insufficient).

Related
information

ing without turning starting switch ON (coil side).
Between (1) – (3) 140 – 340 z
Defective compressor relay
1 a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting (contact side).
AC04 Air conditioner switch Voltage
Between (2) –
Cooling position 20 – 30 V
chassis ground
Internal air sensor may be defective. Carry out troubleshooting for
2 Defective internal air sensor
"Abnormality in internal air sensor".
Defective high and low pres- High and low pressure switches may be defective. Carry out trou-
3
sure switches bleshooting for "Abnormality in refrigerant".
Defective compressor clutch
4 Compressor clutch may be defective. Check it directly.
(Internal defect)
Defective compressor (Inter-
5 Compressor may be defective. Check it directly.
nal defect)
value in normal Wiring harness between CB3 (2) – fuse in Resis-
state Max. 1 z
Disconnection in wiring har- unit – AC04 (female) (1) tance
6 Max. 1 z
or defective contact in con- – ACCN (wiring side) (35) tance
nector) Wiring harness between CB3 (2) – AC04 Resis-
Max. 1 z
(female) (4) tance
Max. 1 z
– A/C (female) (1) tance
Ground fault in wiring har- Wiring harness between AC04 (female) (3)
Resis-
7 ness (Contact with GND cir- – ACCN (wiring side) (35) and chassis Min. 1 Mz
tance
cuit) ground
Min. 1 Mz
– A/C (female) (1) and chassis ground tance
troller
carried out.)
If causes 1 – 7 are not detected, air conditioner system may be
Defective air conditioner sys-
9 defective. See Machine Component Volume, Shop Manual, Trou-
tem
bleshooting, "Air conditioner", Troubleshooting.
D155A-6 35
(5) Air conditioner fault history: Communication condition "CAN disconnection", Communication condi-
Trouble
tion "Abnormal"
• While abnormality in communication is being detected, "CAN disconnection" is displayed.
• If abnormality in communication has been detected and reset, "Abnormality" is displayed.
Related
• If "CAN disconnection" is displayed as communication condition, communication cannot be carried
information
out normally. Accordingly, condition of other items is not displayed.
• Method of reproducing fault history: Turn starting switch ON.

1 Max. 1 z
or defective contact in con- – CM02 (female) (8), (9) tance
nector) Wiring harness between AC02 (female) (2) Resis-
Max. 1 z
– CM02 (female) (10) tance
– CM02 (female) (8), (9), EGC2 (female) Resis-
Ground fault in wiring har- Max. 1 z
(46), STC2 (female) (32), CA1 (female) (A), tance
or SRV (female) (3) and chassis ground
cuit)
– CM02 (female) (10), EGC2 (female) (47), Resis-
Max. 1 z
STC2 (female) (22), CA1 (female) (B), or tance
SRV (female) (10) and chassis ground
Possible causes
and standard
value in normal
state Wiring harness between AC02 (female) (1)
– CM02 (female) (8), (9), EGC2 (female) Resis-
Min. 1 Mz
Hot short (Short circuit with (46), STC2 (female) (32), CA1 (female) (A), tance
3
24V circuit) in wiring harness or SRV (female) (3) and chassis ground
– CM02 (female) (10), EGC2 (female) (47), Resis-
Min. 1 Mz
STC2 (female) (22), CA1 (female) (B), or tance
SRV (female) (10) and chassis ground
4 resistance (Internal short cir-
cuit or disconnection)
troller
carried out.)
out.)
36 D155A-6
Trouble (6) Air conditioner fault history: Setting condition "Abnormality"

• If setting of air conditioner controller model is different from setting of machine monitor model,
"Abnormality" is displayed.
Related
information
out normally. Accordingly, this condition is not displayed.
• Method of reproducing fault history: Turn starting switch ON.

Possible causes
Defective air conditioner con- Air conditioner controller may be defective. (Since trouble is in
and standard 1
troller system, troubleshooting cannot be carried out.)
value in normal
state Machine monitor may be defective. (Since trouble is in system,
Trouble (7) Air conditioner fault history: Internal air sensor "Abnormality"
Related
information
• Method of reproducing fault history: Turn starting switch ON + Turn air conditioner (A/C) switch ON.

Defective internal air sensor ing without turning starting switch ON.
ACPS (device side) Resistance
short circuit)
Between (1) – (2) 300 z – 430 kz
ness (Disconnection in wiring Wiring harness between ACCN (wiring side) Resis-
2 Max. 1 z
or defective contact in con- (11) – ACPS (wiring side) (2) tance
nector) Wiring harness between ACCN (wiring side) Resis-
(27) – ACPS (wiring side) (1) tance
and standard
value in normal
state Short circuit in wiring har-
3 Wiring harness between ACCN (wiring side)
ness (with GND circuit) Resis-
(11) – ACPS (wiring side) (2) and chassis Min. 1 Mz
tance
ground
4
24V circuit) in wiring harness Wiring harness between ACCN (wiring side)
(11) – ACPS (wiring side) (2) and chassis Voltage Max. 1 V
ground
troller
carried out.)
D155A-6 37
Trouble (8) Air conditioner fault history: External air sensor "Unused"
• External air sensor is not used in air conditioner system of this machine.
Related
information

and standard
value in normal Since external air sensor is not used in air conditioner system of
1 Normal display
state this machine, above display is normal.
Trouble (9) Air conditioner fault history: Air flow sensor "Abnormality"
Related
information

Defective air flow sensor ing without turning starting switch ON.
ACFS (device side) Resistance
short circuit)
Between (1) – (2) 100 z – 115 kz
2 Max. 1 z
or defective contact in con- (12) – ACFS (wiring side) (2) tance
(27) – ACFS (wiring side) (1) tance
and standard
value in normal
state Short circuit in wiring har-
3 Wiring harness between ACCN (wiring side)
ness (with GND circuit) Resis-
(12) – ACFS (wiring side) (2) and chassis Min. 1 Mz
tance
ground
4
24V circuit) in wiring harness Wiring harness between ACCN (wiring side)
(12) – ACFS (wiring side) (2) and chassis Voltage Max. 1 V
ground
troller
carried out.)
38 D155A-6
Trouble (10) Air conditioner fault history: Daylight sensor "Abnormality"

Related
information

Defective daylight sensor
1 Daylight sensor may be defective.
(Internal defect)
2 Max. 1 z
or defective contact in con- (3) – SLS (female) (1) tance
Max. 1 z
(15) – SLS (female) (2) tance
Possible causes Ground fault in wiring har- Wiring harness between ACCN (wiring side)
and standard Resis-
3 ness (Contact with GND cir- (3) – SLS (female) (1) or circuit branch end Min. 1 Mz
state
Wiring harness between ACCN (wiring side) Resis-
Min. 1 Mz
(15) – SLS (female) (2) and chassis ground tance
Wiring harness between ACCN (wiring side)
4 (3) – SLS (female) (1) or circuit branch end Voltage Max. 1 V
and chassis ground
Wiring harness between ACCN (wiring side)
Voltage Max. 1 V
(15) – SLS (female) (2) and chassis ground
troller
carried out.)
D155A-6 39
Trouble (11) Air conditioner fault history: Air outlet damper 1 "Abnormality"
Related
information

Defective air outlet servomo-
1 Air outlet servomotor may be defective.
tor 1 (Internal defect)
Wiring harness between ACB1 (wiring side) Resis-
Max. 1 z
Disconnection in wiring har- Wiring harness between ACB1 (wiring side) Resis-
Max. 1 z
ness (Disconnection in wiring (3) – ACCN (wiring side) (27) tance
2
or defective contact in con- Wiring harness between ACB1 (wiring side) Resis-
nector) Max. 1 z
Max. 1 z
Max. 1 z
Wiring harness between ACB1 (wiring side)
Resis-
(1) – ACCN (wiring side) (3) or circuit Min. 1 Mz
tance
Possible causes Ground fault in wiring har- Resis-
and standard 3 ness (Contact with GND cir- tance
ground
value in normal cuit)
state Wiring harness between ACB1 (wiring side)
Resis-
(6) - ACCN (wiring side) (24) and chassis Min. 1 Mz
tance
ground
Resis-
tance
ground
(1) – ACCN (wiring side) (3) or circuit Voltage Max. 1 V
Hot short (Short circuit with (5) – ACCN (wiring side) (9) and chassis Voltage Max. 1 V
4
24V circuit) in wiring harness ground
(6) – ACCN (wiring side) (24) and chassis Voltage Max. 1 V
ground
ground
troller
carried out.)
40 D155A-6
Trouble (12) Air conditioner fault history: Air outlet damper 2 "Abnormality"
Related
information

Defective air outlet servomo-
1 Air outlet servomotor may be defective.
tor 2 (Internal defect)
Max. 1 z
Disconnection in wiring har- Wiring harness between ACB2 (wiring side) Resis-
Max. 1 z
2
or defective contact in con- Wiring harness between ACB2 (wiring side) Resis-
nector) Max. 1 z
Max. 1 z
Max. 1 z
Resis-
tance
ground
state Wiring harness between ACB2 (wiring side)
Resis-
(6) - ACCN (wiring side) (24) and chassis Min. 1 Mz
tance
ground
Resis-
tance
ground
4
ground
ground
troller
carried out.)
D155A-6 41
Trouble (13) Air conditioner fault history: A/M damper "Abnormality"

Related
information

Defective air mix servomotor
1 Air mix servomotor may be defective.
(Internal defect)
Wiring harness between ACSM (wiring side) Resis-
Max. 1 z
Disconnection in wiring har- Wiring harness between ACSM (wiring side) Resis-
Max. 1 z
2
or defective contact in con- Wiring harness between ACSM (wiring side) Resis-
nector) Max. 1 z
(5) – ACCN(wiring side) (2) tance
Max. 1 z
Max. 1 z
Wiring harness between ACSM (wiring side)
Resis-
tance
ground
state Wiring harness between ACSM (wiring side)
Resis-
tance
ground
Resis-
tance
ground
4
ground
ground
troller
carried out.)
42 D155A-6
Trouble (14) Air conditioner fault history: Refrigerant "Abnormality"

Related
information

Insufficient refrigerant (gas)
1 Refrigerant (gas) may be insufficient. Check it directly.
(when system is normal)
Defective high and low pres- ing without turning starting switch ON.
2 sure switches (Internal dis-
connection)
Possible causes Between (1) – (2) Max. 1 z
state Disconnection in wiring har-
3 Max. 1 z
or defective contact in con- (4) – AC05 (female) (1) tance
nector) Wiring harness between AC05 (female) (2) Resis-
Max. 1 z
– chassis ground (GND12) tance
troller
carried out.)
D155A-6 43
44 D155A-6
D155A-6 45
E-20 When starting switch is turned OFF, service meter is not

displayed 1
Trouble • When starting switch is turned OFF, service meter is not displayed.
• While starting switch is at OFF position, if following switches are operated, service meter is dis-
Related
played at top center of screen.
information
Operation of switches: [4] + [1] (Press simultaneously)

When starting switch is turned ON, if machine monitor displays
Possible causes
Defective backup power sup- nothing, backup power supply system may be defective. In this
and standard 1
ply system case, carry out troubleshooting for "E-1 When starting switch
value in normal
turned ON, machine monitor displays nothing".
state
If cause 1 is not detected, machine monitor may be defective.
E-21 Machine monitor cannot be set in service mode 1

Trouble • Machine monitor cannot be set in service mode.
Related • If following switches are operated, machine monitor is set in service mode.
information Operation of switches: [4] + [1] o [2] o [3] (While pressing [4], press other switches in order)

and standard
46 D155A-6
D155A-6 47
E-22 Ripper pin puller cylinder does not operate 1

(1) When pin puller switch is pulled out, cylinder is not retracted.
Trouble
(2) When pin puller switch is pushed in, cylinder is not extended.
Related
information

1 Defective fuse(FS2-3) If fuse is broken, circuit probably has ground fault (See cause 5).
2 Defective pin puller switch PLSW (male) Pin puller switch Resistance
Pulled out Max. 1 z
Between (1) – (2)
Pushed in Min. 1 Mz
3 Defective pin puller solenoid PPL (male) Resistance
Between (1) – (2) 10 – 80 z
Disconnection in wiring har- Wiring harness between FS22 (3) – PLSW Resis-
ness (Disconnection in wiring (female) (1) tance
and standard 4
value in normal or defective contact in con- Wiring harness between PLSW (female) (2) Resis-
nector) Max. 1 z
state – PPL (female) (1) tance
Wiring harness between PLSW (female) (2) Resis-
Max. 1 z
Ground fault in wiring har- Wiring harness between FS22 (3) – PLSW
Resis-
5 ness (Contact with GND cir- (female) (1) or circuit branch end and chas- Min. 1 Mz
tance
cuit) sis ground
Wiring harness between PLSW (female) (2) Resis-
Min. 1 Mz
– PPL (female) (1) and chassis ground tance
Wiring harness between FS22 (3) – PLSW
6 (female) (1) or circuit branch end and chas- Voltage Max. 1 V
sis ground
Wiring harness between PLSW (female) (2)
Voltage Max. 1 V
– PPL (female) (1) and chassis ground
48 D155A-6
D155A-6 49
E-23 Backup alarm does not sound or does not stop 1

Trouble • Backup alarm does not sound or does not stop.
Related
information

Defective backup alarm relay
1 (Internal disconnection or Replace backup alarm relay (Right No.) with
short circuit) another relay. If backup alarm operates nor-
BKA
mally at this time, backup alarm relay is
defective.
Disconnection in wiring har- Wiring harness between BKA (female) (3) – Resis-
Max. 1 z
ness (Disconnection in wiring branch point (F) tance
2
or defective contact in con- Wiring harness between BKA (female) (5) – Resis-
Possible causes nector) Max. 1 z
BKAL (female) (1) tance
and standard
value in normal Wiring harness between BKAL (female) (2) Resis-
Max. 1 z
state – chassis ground (GND03) tance
3 ness (Contact with GND cir- Wiring harness between BKA (female) (5) –
cuit) Resis-
BKAL (female) (1) or circuit branch end and Min. 1 Mz
tance
chassis ground
4
24V circuit) in wiring harness Wiring harness between BKA (female) (5) –
BKAL (female) (1) or circuit branch end and Voltage Max. 1 V
chassis ground
Defective backup alarm
5 If causes 1 – 4 are not detected, backup alarm may be defective.
(Internal trouble)
50 D155A-6
D155A-6 51
E-24 Headlamp, rear lamp, and ripper point lamp do not light up 1
Trouble (1) Headlamp does not light up.
Related • Only when headlamp switch is set in "Moon" mark position, screen brightness of machine monitor is
information changed for night.

1
Defective headlamp (Broken Headlamp bulb and ground wire may be defective. Check them
2
bulb, default grounding) directly.
FLSW (male) Headlamp switch Resistance
Defective headlamp switch
3 Between (5) – (4) Moon mark Max. 1 z
Between (5) – (4)
Neutral Min. 1 Mz
Between (5) – (6)
Between (5) – (6) Sun mark Max. 1 z
Defective left headlamp relay
4 (Internal disconnection or Replace left headlamp relay (Right No.) with
short circuit) another relay. If left headlamp becomes
LMFL
normal at this time, left headlamp relay is
defective.
Defective right headlamp
5 relay (Internal disconnection Replace right headlamp relay (Right No.)
Possible causes or short circuit) with another relay. If right headlamp
LMFR
and standard becomes normal at this time, right head-
value in normal lamp relay is defective.
Defective diode LMD1 or ing without turning starting switch ON.
6 LMD2 (Internal disconnec-
LMD1 (male), LMD2 (male) Continuity
tion)
Between (2) – (1) There is continuity
Max. 1 z
FLSW (female) (5) tance
Wiring harness between FLSW (female) (4) Resis-
Max. 1 z
– LMD1 (female) (2) tance
Wiring harness between LMD1 (female) (1),
Resis-
Disconnection in wiring har- LMD2 (female) (1) – LMFL (female) (1), Max. 1 z
tance
ness (Disconnection in wiring LMFR (female) (1)
7
or defective contact in con- Wiring harness between LMFL (female) (2),
nector) Resis-
LMFR (female) (2) – chassis ground Max. 1 z
tance
(GND03)
Wiring harness between CB4 (2) – LMFL Resis-
Max. 1 z
(female) (3), LMFR (female) (3) tance
Wiring harness between LMFL (female) (5) Resis-
Max. 1 z
– LHDL (female) (1) tance
Wiring harness between LMFR (female) (5) Resis-
Max. 1 z
– LHDR (female) (1) tance
52 D155A-6

Resis-
FLSW (female) (5) or circuit branch end and Min. 1 Mz
tance
chassis ground
Wiring harness between FLSW (female) (4),
Resis-
(3) – LMD1 (female) (2) or CM01 (female) Min. 1 Mz
Possible causes tance
(13) and chassis ground
value in normal Wiring harness between LMD1 (female) (1),
8 ness (Contact with GND cir- Resis-
state LMD2 (female) (1) – LMFL (female) (1), Min. 1 Mz
cuit) tance
LMFR (female) (1) and chassis ground
Wiring harness between CB4 (2) – LMFL
Resis-
(female) (3), LMFR (female) (3) and chassis Min. 1 Mz
tance
ground
Wiring harness between LMFL (female) (5) Resis-
Min. 1 Mz
– LHDL (female) (1) and chassis ground tance
Wiring harness between LMFR (female) (5) Resis-
Min. 1 Mz
– LHDR (female) (1) and chassis ground tance
D155A-6 53
Trouble (2) Rear lamp and ripper point lamp do not light up.
Related
information

1
Defective rear lamp (Broken Rear lamp bulb and ground wire may be defective. Check them
2
bulb, default grounding) directly.
Defective ripper point lamp
(Broken bulb, default ground- Ripper point lamp bulb and ground wire may be defective. Check
3
ing) them directly.

Defective rear lamp switch RLSW (male) Rear lamp switch Resistance
4
OFF Min. 1 Mz
Between (5) – (6)
ON Max. 1 z
Defective rear lamp relay and carry out troubleshooting.
5 (Internal disconnection or Replace rear lamp relay (Right No.) with
short circuit) another relay. If rear lamp becomes normal LMRE
at this time, rear lamp relay is defective.
Possible causes and carry out troubleshooting.
and standard Defective ripper point lamp
value in normal 6 relay (Internal disconnection Replace ripper point lamp relay (Right No.)
or short circuit) with another relay. If ripper point lamp
state LMRP
becomes normal at this time, ripper point
lamp relay is defective.
Max. 1 z
RLSW (female) (5) tance
Wiring harness between RLSW (female) (6) Resis-
Max. 1 z
– LMRE (female) (1), LMRP (female) (1) tance
Wiring harness between LMRE (female) (2),
Resis-
LMRP (female) (2) – chassis ground Max. 1 z
Disconnection in wiring har- tance
(GND03)
7 Wiring harness between CB5 (2) – LMRE Resis-
or defective contact in con- Max. 1 z
(female) (3), LMRP (female) (3) tance
nector)
Wiring harness between LMRE (female) (5) Resis-
Max. 1 z
– LREL (female) (1), LRER (female) (1) tance
Wiring harness between LREL (female) (2) Resis-
Max. 1 z
Wiring harness between LRER (female) (2) Resis-
Max. 1 z
Wiring harness between LMRP (female) (5) Resis-
Max. 1 z
– LRP1 (female) (1) tance
54 D155A-6

Resis-
RLSW (female) (5) or circuit branch end and Min. 1 Mz
tance
chassis ground
Wiring harness between RLSW (female) (6),
Possible causes Resis-
(1) – LMRE (female) (1), LMRP (female) (1) Min. 1 Mz
and standard Ground fault in wiring har- tance
and chassis ground
state cuit) Wiring harness between CB5 (2) – LMRE
Resis-
(female) (3), LMRP (female) (3) and chassis Min. 1 Mz
tance
ground
Wiring harness between LMRE (female) (5)
Resis-
– LREL (female) (1), LRER (female) (1) and Min. 1 Mz
tance
chassis ground
Wiring harness between LMRP (female) (5) Resis-
Min. 1 Mz
– LRP1 (female) (1) and chassis ground tance
D155A-6 55
56 D155A-6
E-25 Windshield wiper and window washer do not operate 1

Trouble (1) No windshield wipers and window washers do not operate.
Related
information

Defective fuse
1 If fuse is broken, circuit probably has ground fault (See cause 3).
(FS12 – 4 or -4)
ness (Disconnection in wiring Wiring harness between FS12 (4) – fuse Resis-
2 Max. 1 z
Possible causes or defective contact in con- (B3) tance
value in normal Wiring harness between fuse (4) – CN11 Resis-
Max. 1 z
state (female) (5) tance
Wiring harness between FS12 (4) – fuse Min. 1 Mz
(B3) and chassis ground
cuit)
Wiring harness between fuse (4) – CN11 Resis-
Min. 1 Mz
(female) (5) and chassis ground tance
D155A-6 57
Trouble (2) Front windshield wiper does not operate (Continuous operation is defective).
• If fuse ( -5) is broken, operations of both front windshield wiper and rear windshield wiper become
Related defective.
information • If fuse ( -4) is broken, intermittent operation of all windshield wipers becomes defective.
• Carry out troubleshooting with front wiper switch ON and intermittent switch OFF.

1 Defective fuse ( -5) If fuse is broken, circuit probably has ground fault (See cause 7).
Defective front wiper motor CN23 Front wiper switch Voltage
2
(Internal trouble)
Between (6) – (1) ON 20 – 30 V
If voltage is normal but wiper does not operate, motor is defective.
Defective front wiper switch CN14 (male) Front wiper switch Resistance
3
OFF Min. 1 Mz
Between (2) – (3)
ON Max. 1 z
Defective front wiper inter-
4 mittent selector relay (Inter- Replace front wiper intermittent selector
nal trouble) relay (Right No.) with another relay. If front
CN29
Possible causes wiper becomes normal at this time, intermit-
and standard tent selector relay is defective.
state and carry out troubleshooting.
5 mittent relay (Internal trou- Replace front wiper intermittent relay (Right
ble) No.) with another relay. If front wiper
CN28
becomes normal at this time, intermittent
relay is defective.
(female) (3), (5), CN28 (female) (3), or Max. 1 z
tance
CN23 (female) (3)
Wiring harness between CN14 (female) (2) Resis-
ness (Disconnection in wiring Max. 1 z
6 – CN29 (female) (3) tance
or defective contact in con-
nector) Wiring harness between CN29 (female) (4) Resis-
Max. 1 z
– CN28 (female) (4) tance
Max. 1 z
Max. 1 z
58 D155A-6

Wiring harness between fuse (5) – CN14
(female) (3), (5), CN28 (female) (3), CN23 Resis-
Possible causes Min. 1 Mz
(female) (3), or circuit branch end and chas- tance
and standard Ground fault in wiring har- sis ground
state cuit) Wiring harness between CN14 (female) (2) Resis-
Min. 1 Mz
– CN29 (female) (3) and chassis ground tance
Min. 1 Mz
Min. 1 Mz
Trouble (3) Front windshield wiper does not operate intermittently.

• Before carrying out troubleshooting, check that continuous operation is normal.
Related • If fuse ( -4) is broken, intermittent operation of all windshield wipers becomes defective.
information • Carry out troubleshooting with front wiper switch and intermittent switch ON.
• During intermittent operation, wiper stops for 5 seconds after each cycle of operation.

Defective intermittent switch CN11 (male) Intermittent switch Resistance
1
OFF Min. 1 Mz
Between (5) – (6)
ON Max. 1 z
2 mittent selector relay (Inter- Replace front wiper intermittent selector
nal trouble) relay (Right No.) with another relay. If front
CN29
wiper becomes normal at this time, intermit-
tent selector relay is defective.
Possible causes 3 mittent relay (Internal trou- Replace front wiper intermittent relay (Right
and standard ble) No.) with another relay. If front wiper
CN28
value in normal becomes normal at this time, intermittent
state relay is defective.
Disconnection in wiring har- Wiring harness between CN11 (female) (6) Resis-
Max. 1 z
ness (Disconnection in wiring – CN29 (female) (1) tance
4
or defective contact in con- Wiring harness between CN29 (female) (5) Resis-
nector) Max. 1 z
Max. 1 z
Ground fault in wiring har- Wiring harness between CN11 (female) (6)
Resis-
5 ness (Contact with GND cir- – CN29 (female) (1) or circuit branch end Min. 1 Mz
tance
Min. 1 Mz
D155A-6 59
Trouble (4) Rear windshield wiper does not operate (Continuous operation is defective).
• If fuse ( -5) is broken, operations of both front windshield wiper and rear windshield wiper become
Related infor- defective.
mation • If fuse ( -4) is broken, intermittent operation of all windshield wipers becomes defective.
• Carry out troubleshooting with rear wiper switch ON and intermittent switch OFF.

Defective rear wiper motor CN37 Rear wiper switch Voltage
2
(Internal trouble)
Between (6) – (1) ON 20 – 30 V
Defective rear wiper switch CN12 (male) Rear wiper switch Resistance
3
OFF Min. 1 Mz
Between (2) – (3)
ON Max. 1 z
Defective rear wiper intermit-
4 tent selector relay (Internal Replace rear wiper intermittent selector
trouble) relay (Right No.) with another relay. If rear
CN33
Possible causes wiper becomes normal at this time, intermit-
and standard tent selector relay is defective.
state
Defective rear wiper intermit- Replace rear wiper intermittent relay (Right
5
tent relay (Internal trouble) No.) with another relay. If rear wiper
CN32
becomes normal at this time, intermittent
relay is defective.
(female) (3), (5), CN32 (female) (3), or Max. 1 z
tance
CN37 (female) (6)
ness (Disconnection in wiring Max. 1 z
6 – CN33 (female) (3) tance
nector) Wiring harness between CN33 (female) (4) Resis-
Max. 1 z
Max. 1 z
Max. 1 z
60 D155A-6

Wiring harness between fuse (5) – CN12

(female) (3), (5), CN32 (female) (3), CN37 Resis-
Possible causes Min. 1 Mz
(female) (6), or circuit branch end and chas- tance
and standard Ground fault in wiring har- sis ground
state cuit) Wiring harness between CN12 (female) (2) Resis-
Min. 1 Mz
Min. 1 Mz
–- CN32 (female) (4) and chassis ground tance
Min. 1 Mz
Trouble (5) Rear windshield wiper does not operate intermittently.

information • Carry out troubleshooting with rear wiper switch and intermittent switch ON.

1
OFF Min. 1 Mz
Between (5) – (6)
ON Max. 1 z
Defective rear wiper intermit-
2 tent selector relay (Internal Replace rear wiper intermittent selector
trouble) relay (Right No.) with another relay. If rear
CN33
tent selector relay is defective.
Defective rear wiper intermit- Replace rear wiper intermittent relay (Right
Possible causes 3
tent relay (Internal trouble) No.) with another relay. If rear wiper
and standard CN32
value in normal becomes normal at this time, intermittent
state relay is defective.
Max. 1 z
4
nector) Max. 1 z
Max. 1 z
Resis-
tance
Min. 1 Mz
D155A-6 61
Trouble (6) Right door wiper does not operate (Continuous operation is defective).
• If fuse ( -6) is broken, operations of both right door wiper and left door wiper become defective.
Related
• Carry out troubleshooting with right door wiper switch ON and intermittent switch OFF.

Defective right door wiper Right door wiper
2 CN17 Voltage
motor (Internal trouble) switch
Between (3) – (1) ON 20 – 30 V
3 switch (Internal disconnec- CN13 (male) Resistance
switch
tion)
OFF Min. 1 Mz
Between (2) – (3)
ON Max. 1 z
Defective right door wiper
4 intermittent selector relay Replace right door wiper intermittent selec-
(Internal trouble) tor relay (Right No.) with another relay. If
CN31
right door wiper becomes normal at this
Possible causes time, intermittent selector relay is defective.
state Defective right door wiper
5 intermittent relay (Internal Replace right door wiper intermittent relay
trouble) (Right No.) with another relay. If right door
CN30
tent relay is defective.

Max. 1 z
(female) (3), (5) or CN17 (female) (4) tance

Max. 1 z
(female) (3) tance
ness (Disconnection in wiring – CN31 (female) (3) Max. 1 z
6 tance
nector) Max. 1 z
Max. 1 z
Max. 1 z
Max. 1 z
62 D155A-6


(female) (3), (5), CN17 (female) (4), or cir- Min. 1 Mz
tance
cuit branch end and chassis ground
Possible causes
and standard Wiring harness between fuse (6) – CN30 Resis-
value in normal (female) (3) or circuit branch end and chas- Min. 1 Mz
state cuit) sis ground
Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
D155A-6 63
Trouble (7) Right door wiper does not operate intermittently.

information • Carry out troubleshooting with right door wiper switch and intermittent switch ON.

1
OFF Min. 1 Mz
Between (5) – (6)
ON Max. 1 z
2 intermittent selector relay Replace right door wiper intermittent selec-
(Internal trouble) tor relay (Right No.) with another relay. If
CN31
right door wiper becomes normal at this
time, intermittent selector relay is defective.
Possible causes 3 intermittent relay (Internal Replace right door wiper intermittent relay
and standard trouble) (Right No.) with another relay. If right door
CN30
value in normal wiper becomes normal at this time, intermit-
state tent relay is defective.
Max. 1 z
4
nector) Max. 1 z
Max. 1 z
Resis-
tance
Min. 1 Mz
64 D155A-6
Trouble (8) Left door wiper does not operate (Continuous operation is defective).
• If fuse ( -6) is broken, operations of both right door wiper and left door wiper become defective.
Related
• Carry out troubleshooting with left door wiper switch ON and intermittent switch OFF.

Defective left door wiper Left door wiper
2 CN24 Voltage
motor (Internal trouble) switch
Between (3) – (1) ON 20 – 30 V
3 switch (Internal disconnec- CN15 (male) Resistance
switch
tion)
OFF Min. 1 Mz
Between (2) – (3)
ON Max. 1 z
Defective left door wiper
4 intermittent selector relay Replace left door wiper intermittent selector
(Internal trouble) relay (Right No.) with another relay. If left
CN27
door wiper becomes normal at this time,
Possible causes intermittent selector relay is defective.
state Defective left door wiper
5 intermittent relay (Internal Replace left door wiper intermittent relay
trouble) (Right No.) with another relay. If left door
CN26
tent relay is defective.
Max. 1 z
(female) (3), (5) tance

Max. 1 z
(female) (3) or CN24 (female) (4) tance
ness (Disconnection in wiring – CN27 (female) (3) Max. 1 z
6 tance
nector) Max. 1 z
Max. 1 z
Max. 1 z
Max. 1 z
D155A-6 65


(female) (3), (5) or circuit branch end and Min. 1 Mz
tance
chassis ground
Possible causes
and standard Ground fault in wiring har- Wiring harness between fuse (6) – CN26 Resis-
value in normal (female) (3), CN24 (female) (4) or circuit Min. 1 Mz
state branch end and chassis ground
cuit)
Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
66 D155A-6
Trouble (9) Left door wiper does not operate intermittently.

information • Carry out troubleshooting with left door wiper switch and intermittent switch ON.

1
OFF Min. 1 Mz
Between (5) – (6)
ON Max. 1 z
2 intermittent selector relay Replace left door wiper intermittent selector
(Internal trouble) relay (Right No.) with another relay. If left
CN27
door wiper becomes normal at this time,
intermittent selector relay is defective.
Possible causes 3 intermittent relay (Internal Replace left door wiper intermittent relay
and standard trouble) (Right No.) with another relay. If left door
CN26
value in normal wiper becomes normal at this time, intermit-
state tent relay is defective.
Max. 1 z
4
nector) Max. 1 z
Max. 1 z
Resis-
tance
Min. 1 Mz
D155A-6 67
Trouble (10) Water does not come out from front window washer.
• Before carrying out troubleshooting, check that windshield wiper operates normally.
Related
information • If fuse ( -5) is broken, operations of both front window washer and rear window washer become
defective.

Defective front window WSH1 Front wiper switch Voltage
2 washer motor (Internal trou- ON
ble) Between (3) – (4) 20 – 30 V
(Wash position)
If voltage is normal but washer does not operate, motor is defec-
tive.
Defective front wiper switch CN14 (male) Front wiper switch Resistance
3
(Internal disconnection) OFF Min. 1 Mz
Possible causes Between (5) – (6) ON
(Wash position)
value in normal
state
Disconnection in wiring har- Wiring harness between fuse (5) – CN14 Resis-
Max. 1 z
ness (Disconnection in wiring (female) (3), (5) tance
4
nector) Max. 1 z
– WSH1 (female) (3) tance
Wiring harness between WSH1 (female) (4) Resis-
Max. 1 z
Ground fault in wiring har- Wiring harness between fuse (5) – CN14 Resis-
5 ness (Contact with GND cir- (female) (3), (5) or circuit branch end and Min. 1 Mz
tance
Min. 1 Mz
– WSH1 (female) (3) and chassis ground tance
68 D155A-6
Trouble (11) Water does not come out from rear window washer.
Related
information • If fuse ( -5) is broken, operations of both front window washer and rear window washer become
defective.

Defective rear window WSH2 Rear wiper switch Voltage
2 washer motor (Internal trou- ON
ble) Between (3) – (4) 20 – 30 V
(Wash position)
tive.
Defective rear wiper switch CN12 (male) Rear wiper switch Resistance
3
(Internal disconnection) OFF Min. 1 Mz
Possible causes Between (5) – (6) ON
(Wash position)
value in normal
Max. 1 z
4
nector) Max. 1 z
Max. 1 z
tance
Min. 1 Mz
D155A-6 69
Trouble (12) Water does not come out from right door washer.
Related
information • If fuse ( -6) is broken, operations of both right door washer and left door washer become defec-
tive.

and carry out troubleshooting
Right door wiper
WSH2 Voltage
Defective right door washer switch
2
motor (Internal trouble) ON
Between (1) – (2) 20 – 30 V
(Wash position)
tive.
CN13 (male) Resistance
3 switch (Internal disconnec- switch
Possible causes tion) OFF Min. 1 Mz
and standard Between (5) – (6) ON
(Wash position)
state
Max. 1 z
4
nector) Max. 1 z
Max. 1 z
Ground fault in wiring har- Wiring harness between fuse (6) – CN13
Resis-
tance
Min. 1 Mz
70 D155A-6
Trouble (13) Water does not come out from left door washer.
Related
• If fuse ( -6) is broken, operations of both right door washer and left door washer become defec-
information
tive.

Left door wiper
WSH1 Voltage
Defective left door washer switch
2
motor (Internal trouble) ON
Between (1) – (2) 20 – 30 V
(Wash position)
tive.
CN15 (male) Resistance
3 switch (Internal disconnec- switch
Possible causes tion) OFF Min. 1 Mz
and standard Between (5) – (6) ON
(Wash position)
state
Max. 1 z
4
nector) Max. 1 z
Max. 1 z
tance
Min. 1 Mz
D155A-6 71
72 D155A-6
E-26 KOMTRAX terminal does not operate normally 1

Trouble • KOMTRAX terminal does not operate normally.
• If KOMTRAX terminal administrator makes request for checking system on machine side for trou-
Related ble, carry out following troubleshooting.
information • Even if KOMTRAX terminal has trouble, it does not particularly appear on machine.
• Carry out all troubleshooting on service menu screen of machine monitor.

a Turn starting switch ON and check "Setting condition of termi-
nal" screen.
1 Defective transmission 1
Check item Normal display
Communication start check Completion
a Turn starting switch ON and check "Condition of positioning
and communication" screen.
N ###,##,##(Latitude)
2 Defective GPS
Positioning E ###,##,##(Longitude)
Possible causes
In positioning
and standard
value in normal If latitude and longitude are not displayed in 5 minutes on open
state ground, notify KOMTRAX service hot line.
Defective communication Check item Normal display
3
environment Communication Zone level 1 – Zone level 3
If zone level 1 – 3 is not displayed within communication zone of
ORBCOMM, notify KOMTRAX service hot line.
4 Defective transmission 2
Number of items not transmitted 0 – 9 (Normally 0)
a Select "Setting condition of terminal" from "12 Display a Select "Condition of positioning and communication"
of KOMTRAX setting" in the service menu of the from "12 Display of KOMTRAX setting" in the service
machine monitor. menu of the machine monitor.
D155A-6 73
E-27 Fan does not reverse 1

Trouble • When fan is set in fan cleaning mode or fan reverse mode (if equipped), fan does not reverse.
Related • If any switched is operated during reverse prohibition period, orange lamp blinks.
information • Orange lamp lights up in cleaning mode and reverse mode.

Abnormality in fan reverse If failure code [DW7BKA], [DW7BKB] or [DW7BKY] is displayed,
1
solenoid carry out troubleshooting for it first.
Operation of fan cleaning
2 switch in reverse prohibition If switch is operated after engine is started, fan does not reverse
period and orange lamp blinks. At this time, orange lamp indicated that
switch operation is ineffective but does not indicate trouble.
Operation of fan reverse Turn key switch OFF to stop engine and turn battery relay OFF, and
3 switch (if equipped) in then set fan in fan cleaning or fan reverse mode again.
reverse prohibition period
Defective fan cleaning switch FAN1 (male) Switch Resistance
OFF Min. 1 Mz
Between (2) and (1)
CLN position Max. 1 z
4 FAN2 (male) Switch Resistance
OFF Min. 1 Mz
Defective fan cleaning switch
Possible causes (if equipped) Between (1) and (3) CLN position Min. 1 Mz
and standard (Internal disconnection) REV position Max. 1 z
value in normal OFF Min. 1 Mz
state
Between (4) and (3) CLN position Max. 1 z
REV position Min. 1 Mz
[When standard cleaning ing without turning starting switch ON.
switch is employed]
Wiring harness between FAN1 (female) (1) Resis-
Disconnection in wiring Max. 1 z
and GND7 tance
harness
(Internal disconnection) Wiring harness between FAN1 (female) (2) Resis-
Max. 1 z
and STCN2 (female) (38) tance
5
[When optional reverse Wiring harness between FAN2 (female) (3) Resis-
switch is employed] Max. 1 z
and GND7 tance
harness Wiring harness between FAN2 (female) (4) Resis-
Max. 1 z
(Internal disconnection) and STCN2 (female) (38) tance
Wiring harness between FAN2 (female) (1) Resis-
Max. 1 z
and STCN2 (female) (2) tance
If causes 1 – 5 are not detected, steering controller may be defec-
6 Defective steering controller tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
74 D155A-6
D155A-6 75
E-28 Gear cannot be shifted 1

Trouble • Gear cannot be shifted.
Related
information

a When failure code related to gear shift operation switch is not
displayed
Gear shift operation switch Hold down shift operation switch for 10 seconds. If any of following
trouble failure codes is displayed at this time, carry out troubleshooting for
Possible causes • Shift-up switch it.
1
and standard • Shift-down switch [DD12KA], [DD12KB], [DD13KA], [DD13KB]
value in normal • Shift switch
(Optional type lever) a When failure code related to gear shift operation switch is dis-
state
played
Carry out troubleshooting for displayed failure code.
If action code displays failure code [E03] or [E04], gear speed is
2 Gear speed limit
limited. Carry out troubleshooting gear speed limit first.
3 Defect in transmission clutch Transmission clutch may have defect in it. Check it directly.
76 D155A-6
D155A-6 77
E-29 Electric priming pump does not operate or does not stop
automatically 1
Trouble • Electric priming pump does not operate or does not stop automatically
Relative
information

1 Low battery charge level Battery charge level may be low. Check battery directly.
Defective circuit breaker If circuit breaker No. 10 is turned OFF, circuit probably has ground
2
No. 10 fault. (Check cause No. 5)
Disconnection in wiring a Prepare with battery ground cable disconnected, then connect it
harness (Power supply and carry out troubleshooting (since power supply is unswitched).
system)
3
(Disconnection in wiring or
defective contact in con- Between EPP (1) – (2) Voltage 20 – 30 V
nector)
a Prepare with battery ground cable disconnected, then connect
battery and turn electric priming pump ON and carry out trouble-
shooting.
harness • Lamp blinks but stops in about 5 seconds.
(Drive power supply sys- Between EFP (1) – (2) Voltage 20 – 30 V
4
tem) (Disconnection in wir- a Prepare with battery ground cable disconnected, then carry out
ing or defective contact in troubleshooting without reconnecting (since power supply is
connector) unswitched).
Resis-
Between EPP (female) (2) – ground Max. 1 z
tance
Possible causes a Prepare with battery ground cable disconnected, then carry out
and standard troubleshooting without reconnecting (since power supply is
value in normal unswitched).
state Wiring harness between EPP (female) (1) – Resis-
Min. 1 Mz
Ground fault in wiring har- circuit breaker B30S and ground tance
5 ness (Contact with GND Wiring harness between EPP (female) (3) – Resis-
Min. 1 Mz
circuit) EFP (female) (1) and ground tance
Wiring harness between EPP (female) (4) – Resis-
Min. 1 Mz
EFP (female) (2) and ground tance
Resis-
Between EFP (female) (1) – (2) 1–3z
tance
a Prepare with battery ground cable disconnected, then connect
battery and turn electric priming pump ON and carry out trouble-
shooting.
Between EPP (3) – (4) Voltage 20 – 30 V
Defective electric priming
6 pump switch (Malfunction • Lamp blinks but output voltage is improper.
or automatic stop failure) • Results of troubleshooting steps 1 – 4 are normal and lamp does
not blink.
a When electric priming pump does not stop automatically, electric
priming pump switch may be defective. (Turn toggle switch OFF to
stop pump and then replace switch.)
• Lamp blinks but stops in about 5 seconds.
Overload on electric prim-
7 a If pump is overloaded, power supply is turned OFF automatically
ing pump
to protect circuit (Priming switch is reset automatically).
1
1
1
78 D155A-6

a Prepare with battery ground cable disconnected, then carry out
troubleshooting without reconnecting (since power supply is
Possible causes unswitched).
and standard Resis-
Between EFP (male) (1) – (2) 1–3z
value in normal 8 Trouble in electric priming tance
state pump
Resis-
Between EFP (male) (1) – pump body Min. 1 Mz
tance
Resis-
Between EFP (male) (2) – pump body Min. 1 Mz
tance
D155A-6 79
D155A-6 Bulldozer
© 2008 KOMATSU
All Rights Reserved
80 D155A-6
SEN03211-00
D155A-6

D155A-6 85001 and up
Troubleshooting of hydraulic and
mechanical system (H-mode)
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 Steering is not possible ............................................................................................................................ 9
H-7 Steering is possible only on one side ..................................................................................................... 10
H-8 Steering overrun occurs ..........................................................................................................................11
H-9 Brake does not work .............................................................................................................................. 12
H-10 Power train oil is overheated................................................................................................................ 13
H-11 Speed of all work equipment is low ...................................................................................................... 14
H-12 No work equipment moves................................................................................................................... 15
H-13 Blade lift speed or power is low............................................................................................................ 16
D155A-6 1
H-14 Blade tilt speed or power is low............................................................................................................ 17

H-15 Ripper lift speed or power is low .......................................................................................................... 18
H-16 Ripper tilt speed or power is low .......................................................................................................... 19
H-17 Hydraulic drift of blade lift is large ........................................................................................................ 19
H-18 Hydraulic drift of blade tilt is large ........................................................................................................ 20
H-19 Hydraulic drift of ripper lift is large ........................................................................................................ 20
H-20 Ripper pin puller cylinder does not operate.......................................................................................... 21
H-21 Abnormal sound comes out from around work equipment pump......................................................... 22
H-22 Fan speed is abnormal (Sound and/or vibration are abnormally large or engine over heats).............. 23
2 D155A-6

a The following information is summarized in the troubleshooting table. Before carrying out troubleshoot-
ing, understand that information fully.
Trouble Trouble which occurred in the machine

Related
information
Possible causes 2
state ence numbers, which do
not indicate priority)
3
D155A-6 3
H-1 Power is low (Drawbar pull is low) 1

Trouble • Power is low (Drawbar pull is low).
Related
• Before carrying out troubleshooting, check that power train oil level is normal.
information

a Prepare with engine stopped, then run engine at high idle and
carry out troubleshooting.
1 Defective engine
PCCS lever Engine speed
F3 stall 1,450 rpm
2 Defective power train pump Power train pump may be defective. Check it directly.
Prepare with starting switch ON, then run engine at high idle and
Torque converter Torque converter
3 Trouble in torque converter PCCS lever
inlet pressure outlet pressure
Max. 1.0 MPa 0.29 – 0.69 MPa
Neutral
{Max. 10.0 kg/cm2} {3.0 – 7.0 kg/cm2}
PCCS lever Transmission main relief pressure
Min. 2.84 MPa
Neutral TM
{Min. 29.0 kg/cm2}
Improper set pressure or
4 internal trouble of transmis- a Prepare with engine stopped, then keep engine stopped and
sion main relief valve carry out troubleshooting.
Check directly that free length of spring and number of shims are
normal and spool moves smoothly.
Possible causes • Free length of spring (large): 122 mm
and standard • Free length of spring (small): 108 mm
value in normal • Number of shims: 6
state a Prepare with engine stopped, then run engine at low idle and
PCCS lever Transmission clutch Clutch pressure
Min. 2.35 MPa
F3 stall F
{Min. 24.0 kg/cm2}
Min. 2.40 MPa
Malfunction of transmission R3 stall R
5 {Min. 24.5 kg/cm2}
clutch valve (ECMV)
Min. 2.62 MPa
F1 stall 1ST
{Min. 26.7 kg/cm2}
Min. 2.35 MPa
F2 stall 2ND
{Min. 24.0 kg/cm2}
Min. 2.62 MPa
F3 stall 3RD
{Min. 26.7 kg/cm2}
Prepare with engine stopped, then run engine at high idle and
6 Defective brake valve Parking brake lever Steering brake Brake oil pressure
RB 2.16 MPa
Free
LB {22.0 kg/cm2}
Defective adjustment of
If check result of cause 6 is abnormal, parking brake lever or brake
7 parking brake lever or brake
pedal linkage is adjusted defectively. Check them directly.
pedal linkage
8 Trouble in transmission Transmission may have trouble in it. Check it directly.
4 D155A-6
H-2 Machine does not travel (at 2nd or 3rd gear speed) 1
Trouble • Machine does not travel (at 2nd or 3rd gear speed).
Related • Before carrying out troubleshooting, check that power train oil level is normal.
information • Before carrying out troubleshooting, check that transmission main relief pressure is normal (See H-1).

a Prepare with starting switch ON, then run engine at high idle
Max. 1.0 MPa 0.29 – 0.69 MPa
Neutral
{Max. 10.0 kg/cm2} {3.0 – 7.0 kg/cm2}
a Prepare with engine stopped, then run engine at low idle and
Possible causes Malfunction of transmission
2 Min. 2.35 MPa
and standard clutch valve (ECMV) F2 stall 2ND
{Min. 24.0 kg/cm2}
value in normal
state Min. 2.62 MPa
F3 stall 3RD
{Min. 26.7 kg/cm2}
Trouble in transmission Transmission clutch (2nd or 3rd gear speed) may have trouble in it.
3
clutch Check it directly.
Malfunction of parking brake Parking brake may be malfunctioning (Dragging). Check linkage
4
(Dragging) and valves.
a Move to level place, start engine, and check.
Malfunction of brake (Drag- Run engine at low idle and set transmission in F2. If machine does
5
ging) not move at this time, brake is dragging. Carry out troubleshooting
for "H-8 Brake does not work".
6 Trouble in transmission Transmission may have trouble in it. Check it directly.
D155A-6 5
H-3 Machine does not start at any gear speed 1

Trouble • Machine does not start at any gear speed.
Related
information

Min. 2.84 MPa
Neutral TM
{Min. 29.0 kg/cm2}
• Free length of spring (large): 122 mm
• Free length of spring (small): 108 mm
• Number of shims: 6
carry out troubleshooting (after checking transmission main
relief pressure is normal).
Possible causes Min. 2.35 MPa
F3 stall F
and standard {Min. 24.0 kg/cm2}
value in normal Malfunction of transmission Min. 2.40 MPa
state 3 R3 stall R
clutch valve (ECMV) {Min. 24.5 kg/cm2}
Min. 2.62 MPa
F1 stall 1ST
{Min. 26.7 kg/cm2}
Min. 2.35 MPa
F2 stall 2ND
{Min. 24.0 kg/cm2}
Min. 2.62 MPa
F3 stall 3RD
{Min. 26.7 kg/cm2}
Trouble in transmission Transmission clutch (F or R) may have trouble in it. Check it
4
clutch directly.
Brake pedal Steering brake Brake pressure
2.16 MPa
5 Malfunction of brake Released
RB {22.0 kg/cm2}
LB 0 MPa
Pressed
{0 kg/cm2}
If brake pressure is abnormal, carry out troubleshooting for "H-8
Brake does not work".
6 D155A-6
H-4 Machine can travel only forward or in reverse 1

Trouble • Machine can travel only forward or in reverse.
Related
information

Min. 2.84 MPa
Neutral TM
{Min. 29.0 kg/cm2}
Possible causes • Free length of spring (large): 122 mm
and standard • Free length of spring (small): 108 mm
value in normal • Number of shims: 6
state a Prepare with engine stopped, then run engine at low idle and
Malfunction of transmission PCCS lever Transmission clutch Clutch pressure
3
clutch valve (ECMV) Min. 2.35 MPa
F3 stall F
{Min. 24.0 kg/cm2}
Min. 2.40 MPa
R3 stall R
{Min. 24.5 kg/cm2}
Defective transmission clutch If check result of cause 3 is abnormal, seal of transmission clutch
4
seal (F or R) may be defective. Check it directly.
Trouble in transmission Transmission clutch (F or R) may have trouble in it. Check it
5
clutch directly.
D155A-6 7
H-5 When gear speed or travel direction is changed, time lag is large 1
Trouble • When gear speed or travel direction is changed, time lag is large.
Related
information

Min. 2.84 MPa
Neutral TM
{Min. 29.0 kg/cm2}
• Free length of spring (large): 122 mm
• Free length of spring (small): 108 mm
• Number of shims: 6
Possible causes
and standard PCCS lever Transmission clutch Clutch pressure
value in normal Min. 2.35 MPa
state F3 stall F
{Min. 24.0 kg/cm2}
Malfunction of transmission Min. 2.40 MPa
3 R3 stall R
clutch valve (ECMV) {Min. 24.5 kg/cm2}
Min. 2.62 MPa
F1 stall 1ST
{Min. 26.7 kg/cm2}
Min. 2.35 MPa
F2 stall 2ND
{Min. 24.0 kg/cm2}
Min. 2.62 MPa
F3 stall 3RD
{Min. 26.7 kg/cm2}
Defective transmission clutch If check result of cause 3 is abnormal, seal of transmission clutch
4
seal (F or R) may be defective. Check it directly.
Trouble in transmission
5 Transmission clutch may have trouble in it. Check it directly.
clutch
a Move to level place, start engine, and check.
Malfunction of brake (Drag- Run engine at low idle and set transmission in F2. If machine does
6
ging) not move at this time, brake is dragging. Carry out troubleshooting
for "H-8 Brake does not work".
8 D155A-6
H-6 Steering is not possible 1

Trouble • Steering is not possible.
Related • Before troubleshooting, check that the power train oil level is normal.
information • Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.)

a Prepare with starting the engine, then drive the engine in low
idle mode for troubleshooting.
1 Defective operation of brake Raise machine with blade and ripper, drive it in F3 (or R3), and steer
it in direction in which machine cannot turn. If track shoe stops at
this time, brake is defective. (Carry out troubleshooting for "H-9
Brake does not work".)
a Prepare with starting switch OFF, then drive the engine in high
PCCS lever Left stroke end Right stroke end
Possible causes 2.3 – 2.6 MPa 0 MPa

Left clutch pressure
and standard {23.5 – 26.5 kg/cm2} {0 kg/cm2}
Defective operation of steer-
value in normal 2 0 MPa 2.3 – 2.6 MPa
ing clutch valve (ECMV) Right clutch pressure
state {0 kg/cm2} {23.5 – 26.5 kg/cm2}
0 MPa 3.04 – 3.33 MPa
Left brake pressure
{0 kg/cm2} {31.0 – 34.0 kg/cm2}
3.04 – 3.33 MPa 0 MPa
Right brake pressure
{31.0 – 34.0 kg/cm2} {0 kg/cm2}
Defective seal of steering When the cause 2 is not applicable, the clutch seal is supposed to
3
clutch be defective. Check it directly.
Internal defect of steering The inside of the steering clutch is supposed to be defective, check
4
clutch it directly.
Malfunction of steering
5 Carry out troubleshooting related to steering potentiometer.
potentiometer of travel lever
D155A-6 9
H-7 Steering is possible only on one side 1

Trouble • Steering is possible only on one side.

1 Defective operation of brake Raise machine with blade and ripper, drive it in F3 (or R3), and steer
it in direction in which machine cannot turn. If track shoe stops at
this time, brake is defective. (Carry out troubleshooting for "H-9
Brake does not work".)
Possible causes 2.3 – 2.6 MPa 0 MPa

Left clutch pressure
and standard {23.5 – 26.5 kg/cm2} {0 kg/cm2}
value in normal 2 0 MPa 2.3 – 2.6 MPa
ing clutch valve (ECMV) Right clutch pressure
state {0 kg/cm2} {23.5 – 26.5 kg/cm2}
0 MPa 3.04 – 3.33 MPa
Left brake pressure
{0 kg/cm2} {31.0 – 34.0 kg/cm2}
3.04 – 3.33 MPa 0 MPa
{31.0 – 34.0 kg/cm2} {0 kg/cm2}
Defective seal of steering When the cause 1 is not applicable, the clutch seal is supposed to
3
clutch be defective. Check it directly.
Internal defect of steering The inside of the steering clutch is supposed to be defective, check
4
clutch it directly.
Malfunction of steering
5 Carry out troubleshooting related to steering potentiometer.
potentiometer of travel lever
10 D155A-6
H-8 Steering overrun occurs 1

Trouble • Steering overrun occurs.

Possible causes
1 Defective operation of brake Lift the machine with the blade and the ripper and steer the wheel
and standard
value in normal for F3 travel (or R3 travel). If the track shoe stops, the brake is
state defective. (Execute the troubleshooting of “Brake does not work.”)
When the track shoe does not stop in the troubleshooting of the
2 cause 1, the steering clutch is defective. (Execute the troubleshoot-
ing clutch
ing of “Steering is not possible.”)
D155A-6 11
H-9 Brake does not work 1

Trouble • Brake does not work.

a Start the engine for troubleshooting.
1 Degradation of brake Step on the brake pedal, shift the gear to F2 and drive the engine in
high idle mode. When the machine moves, the brake performance
is degraded.
Defective operation of brake The brake pedal and the brake valve are supposed not to work nor-
2
pedal mally. Check them directly.
Possible causes
2.3 – 2.6 MPa 0 MPa
and standard Left clutch pressure
{23.5 – 26.5 kg/cm2} {0 kg/cm2}
value in normal Defective operation of steer-
state 3 0 MPa 2.3 – 2.6 MPa
ing brake valve (ECMV) Right clutch pressure
{0 kg/cm2} {23.5 – 26.5 kg/cm2}
0 MPa 3.04 – 3.33 MPa
Left brake pressure
{0 kg/cm2} {31.0 – 34.0 kg/cm2}
3.04 – 3.33 MPa 0 MPa
{31.0 – 34.0 kg/cm2} {0 kg/cm2}
When the brake seal is not normal in the troubleshooting of the
4 Defective brake seal cause 3, the brake seal is supposed to be defective. Check it
directly.
The inside of the brake is supposed to be defective. Check it
5 Internal defect of brake
directly.
12 D155A-6
H-10 Power train oil is overheated 1

Trouble • Power train oil is overheated.
• Before carrying out troubleshooting, check that power train oil temperature gauge indicates actual
Related
oil temperature (If it does not, carry out troubleshooting for "E-9 Power train oil temperature gauge
information
(Multi-gauge) does not indicate normally".
• Before carrying out troubleshooting, check that transmission main relief pressure is normal (See H-1).

Engine cooling system may be defective or engine output may be
1 Defective engine
increased. Carry out troubleshooting for engine unit (S mode).
Defective power train pump Power train pump may be defective or air is in suction circuit.
2
or air in suction circuit Check them directly.
Possible causes
Max. 1.0 MPa 0.29 – 0.69 MPa
and standard Neutral
{Max. 10.0 kg/cm2} {3.0 – 7.0 kg/cm2}
value in normal
state Malfunction of transmission Transmission clutch may be malfunctioning (slipping). Check it
4
clutch (Slip) directly.
a Start engine and check.
Malfunction of brake (Drag- 1. Float machine above ground with blade and ripper.
5 2. Run engine at low idle and set transmission gear in F3 or R3.
ging)
3. If track shoe does not turn, brake is dragging.
(Carry out troubleshooting for "H-9 Brake does not work".)
a Start engine and check.
6 Malfunction of brake (Slip) Stall machine at F3. If machine does not stop perfectly, brake is
slipping.
D155A-6 13
H-11 Speed of all work equipment is low 1

Trouble • Speed of all work equipment is low.
Related
• Before carrying out troubleshooting, check that oil level in hydraulic tank is normal.
information

Defective PTO (work equip- Work equipment pump drive section of PTO may be defective.
1
ment pump drive section) Check them directly.
2 Work equipment pump may be defective. Check them directly.
pump
PCCS lever
3 Malfunction of unload valve Blade control lever Unload pressure
2.45 (+1.37/0) MPa
Neutral {25 (+14/0) kg/cm2}
Possible causes a Prepare with starting switch ON, then run engine at high idle
and standard Improper set pressure or and carry out troubleshooting.
value in normal 4 malfunction of main relief Blade control lever Main relief pressure
state valve 27.5 ± 1.5 MPa
Raise relief
{280 ± 15 kg/cm2}
Improper set pressure or PCCS lever
5 malfunction of self-acting Blade control lever Control circuit basic pressure
pressure reducing valve Ripper control lever
3.78 – 4.46 MPa
Neutral
{38.5 – 45.5 kg/cm2}
If check result of cause 5 is abnormal, fan pump may have trouble
6 Trouble in fan pump
in it. Check it directly.
If cause 5 is detected, oil may be leaking in PPC valve. Check
7 Internal leak of PPC valve
PPC valve directly.
14 D155A-6
H-12 No work equipment moves 1

Trouble • No work equipment moves.
Related
information

Defective PTO (work equip- Work equipment pump drive section of PTO may be defective.
1
ment pump drive section) Check them directly.
2 Work equipment pump may be defective. Check them directly.
pump
PCCS lever
3 Malfunction of unload valve Blade control lever Unload pressure
2.45 (+1.37/0) MPa
Neutral {25 (+14/0) kg/cm2}
Improper set pressure or and carry out troubleshooting.
Possible causes 4 malfunction of main relief Blade control lever Main relief pressure
and standard valve 27.5 ± 1.5 MPa
value in normal Raise relief
{280 ± 15 kg/cm2}
state
5 malfunction of self-acting Blade control lever Control circuit basic pressure
3.78 – 4.46 MPa
Neutral
{38.5 – 45.5 kg/cm2}
Work equipment lock lever Solenoid valve output pressure
Malfunction of work equip-
6 0 MPa
ment lock solenoid valve Lock
{0 kg/cm2}
3.78 – 4.46 MPa
Free
{38.5 – 45.5 kg/cm2}
D155A-6 15
H-13 Blade lift speed or power is low 1

Trouble • Blade lift speed or power is low.
Related • Check that blade has not been modified.
information • If hydraulic drift of blade lift is large, carry out troubleshooting for "H-17 Hydraulic drift of blade lift is
large" first.

1 malfunction of main relief Blade control lever Main relief pressure
valve 27.5 ± 1.5 MPa
Raise relief {280 ± 15 kg/cm2}
Possible causes 2 malfunction of self-acting Blade control lever Control circuit basic pressure
and standard pressure reducing valve Ripper control lever
value in normal 3.78 – 4.46 MPa
state Neutral
{38.5 – 45.5 kg/cm2}
Malfunction of blade lift con- Spool of blade lift control valve may be malfunctioning. Check it
3
trol valve (spool) directly.
Suction valve of blade lift control valve may be malfunctioning.
Check it directly.
Malfunction of blade lift con-
4
trol valve (suction valve)
* This suction valve can be checked by replacing it with suction
valve of ripper lift or ripper tilt control valve and observing
change of phenomenon.
Air may be in blade lift cylinder. Bleed air and then judge from
5 Air in blade lift cylinder
16 D155A-6
H-14 Blade tilt speed or power is low 1

Trouble • Blade tilt speed or power is low.
information • If hydraulic drift of blade tilt is large, carry out troubleshooting for "H-18 Hydraulic drift of blade tilt is
large" first.

1 malfunction of main relief Blade control lever Main relief pressure
Left tilt relief {280 ± 15 kg/cm2}
Possible causes carry out troubleshooting.
and standard
value in normal Improper set pressure or PCCS lever
state 2 malfunction of self-acting Blade control lever Control circuit basic pressure
3.78 – 4.46 MPa
Neutral
{38.5 – 45.5 kg/cm2}
Malfunction of blade tilt con- Spool of blade tilt control valve may be malfunctioning. Check it
3
Air may be in blade tilt cylinder. Bleed air and then judge from
4 Air in blade tilt cylinder
D155A-6 17
H-15 Ripper lift speed or power is low 1

Trouble • Ripper lift speed or power is low.
Related • Check that ripper has not been modified.
information • If hydraulic drift of ripper lift is large, carry out troubleshooting for "H-19 Hydraulic drift of ripper lift is
large" first.

1 malfunction of main relief Ripper control lever Main relief pressure
Raise relief {280 ± 15 kg/cm2}
state Neutral
{38.5 – 45.5 kg/cm2}
Malfunction of ripper lift con- Spool of ripper lift control valve may be malfunctioning. Check it
3
Suction valve of ripper lift control valve may be malfunctioning.
Check it directly.
Malfunction of ripper lift con-
4
* This suction valve can be checked by replacing suction valves
on head side and bottom side with each other and observing
Air may be in ripper lift cylinder. Bleed air and then judge from
5 Air in ripper lift cylinder
18 D155A-6
H-16 Ripper tilt speed or power is low 1

Trouble • Ripper tilt speed or power is low.
Related • Before carrying out troubleshooting, check that oil level in hydraulic tank is normal.
information • Check that ripper has not been modified.

1 malfunction of main relief Ripper control lever Main relief pressure
Tilt-in relief {280 ± 15 kg/cm2}
state Neutral
{38.5 – 45.5 kg/cm2}
Malfunction of ripper tilt con- Spool of ripper tilt control valve may be malfunctioning. Check it
3
Suction valve of ripper tilt control valve may be malfunctioning.
Check it directly.
Malfunction of ripper tilt con-
4
* This suction valve can be checked by replacing suction valves
on head side and bottom side with each other and observing
Air may be in ripper tilt cylinder. Bleed air and then judge from
5 Air in ripper tilt cylinder
H-17 Hydraulic drift of blade lift is large 1

Trouble • Hydraulic drift of blade lift is large.
information • Before carrying out troubleshooting, check that oil is not leaking from work equipment circuit.

a Start engine and prepare, then stop engine and carry out trou-
bleshooting.
Perform following procedure. If hydraulic drift is increased at this
Possible causes time, seal of blade lift control valve spool is defective.
Defective seal of blade lift
and standard 1 1. Brace blade against ground by lifting operation to push up front
control valve (spool)
value in normal part of machine.
state 2. Stop engine and then turn starting switch ON.
3. Set blade control lever in "Lower" position and check phenom-
enon.
Defective seal of blade lift
2 Seal of blade lift cylinder may be defective. Check it directly.
cylinder
D155A-6 19
H-18 Hydraulic drift of blade tilt is large 1

Trouble • Hydraulic drift of blade tilt is large.

bleshooting.
Defective seal of blade tilt time, seal of blade tilt control valve spool is defective.
Possible causes 1 1. Brace blade against ground by tilting operation to push up front
and standard part of machine.
value in normal 2. Stop engine and then turn starting switch ON.
state 3. Set blade control lever in "Tilt left" position and check phenom-
enon.
Defective seal of blade tilt carry out troubleshooting.
2
cylinder Blade tilt cylinder Leakage from cylinder
Left tilt relief 12 cc/min
H-19 Hydraulic drift of ripper lift is large 1

Trouble • Hydraulic drift of ripper lift is large.
Related • Check that ripper has not been modified.

bleshooting.
Defective seal of ripper lift time, seal of ripper lift control valve spool is defective.
Possible causes 1 1. Brace ripper against ground by lifting operation to push up rear
and standard part of machine.
value in normal 2. Stop engine and then turn starting switch ON.
state 3. Set ripper control lever in "Lower" position and check phenom-
enon.
Defective seal of ripper lift carry out troubleshooting.
2
cylinder Ripper lift cylinder Leakage from cylinder
Lower relief 11 cc/min
20 D155A-6
H-20 Ripper pin puller cylinder does not operate 1

Giant ripper specification
Trouble • Ripper pin puller cylinder does not operate.
Related
• Before carrying out troubleshooting, check that transmission main relief pressure is normal (See H-1).
information

Possible causes
and standard Malfunction of pin puller sole- Solenoid output
1 Pin puller switch Check point
value in normal noid pressure
state Pushed in Cylinder bottom side Min. 2.84 MPa
Pulled out Cylinder head side {Min. 29.0 kg/cm2}
2 Trouble in pin puller cylinder Pin puller cylinder has trouble in it. Check it directly.
D155A-6 21
H-21 Abnormal sound comes out from around work equipment pump 1
Trouble • Abnormal sound comes out from around work equipment pump.
Related
information

1 Use of improper oil Oil used may be improper. Check it directly.
Possible causes Clogged hydraulic tank
2 Hydraulic tank strainer may be clogged. Check it directly.
and standard strainer
value in normal Suction circuit of work equipment pump may have sucked in air.
state 3 Air in suction circuit
Check it directly.
Trouble in work equipment
4 Work equipment pump may have trouble in it.
pump
22 D155A-6
H-22 Fan speed is abnormal (Sound and/or vibration are abnormally

large or engine over heats) 1
Trouble • Fan speed is abnormal (Sound and/or vibration are abnormally large or engine over heats).
Related
• Before starting troubleshooting, check that oil level in hydraulic tank is normal.
information

a Start engine and carry out troubleshooting.
Measurement conditions Engine speed
Engine at low idle 740 + 40
0 rpm
1 Defective engine speed
0
Engine at high idle 2,100 - 50 rpm
If engine speed is not increased to specification, carry out trouble-
shooting for "S-5 Engine hunts".
Defective PTO (fan pump
2 Fan pump drive of PTO may be defective. Check it directly.
drive)
a Prepare with starting switch OFF, then run engine at high idle
Possible causes Fan pump EPC circuit basic
Measurement conditions
and standard pressure
state —
{38.5 – 45.5 kg/cm2}
Defect in fan pump or fan and carry out troubleshooting.
3
motor
Measurement conditions Fan drive circuit pressure
15.7 ± 2.5 MPa
Fan 100% mode
{160 ± 25 kg/cm2}
Measurement conditions Fan speed
Fan 100% mode 1,100 + 5%
0 rpm
Fan may be broken or may be installed defectively. Check it

4 Defective fan
directly.
D155A-6 23
D155A-6 Bulldozer
© 2007 KOMATSU
All Rights Reserved
24 D155A-6
SEN03212-01
D155A-6

D155A-6 85001 and up
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart............................................................................................................ 3
S-1 Starting performance of engine is poor .................................................................................................... 6
S-2 Engine does not start ............................................................................................................................... 7
S-3 Engine does not pick up smoothly.......................................................................................................... 10
S-4 Engine stops during operation.................................................................................................................11
S-5 Engine does not rotate smoothly ............................................................................................................ 12
S-6 Engine lack output (or lacks power) ....................................................................................................... 13
S-7 Exhaust gas is black (incomplete combustion) ...................................................................................... 14
S-8 Oil consumption is excessive (or exhaust gas is blue) ........................................................................... 15
S-9 Oil becomes dirty quickly........................................................................................................................ 16
S-10 Fuel consumption is excessive............................................................................................................. 17
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 18
S-12 Oil pressure drops ................................................................................................................................ 19
S-13 Oil level rises (Entry of coolant or fuel)................................................................................................. 20
S-14 Coolant temperature becomes too high (Overheating) ........................................................................ 21
S-15 Abnormal noise is made....................................................................................................................... 22
D155A-6 1
S-16 Vibration is excessive ........................................................................................................................... 23

S-17 Air cannot be bled from fuel circuit ....................................................................................................... 24
2 D155A-6
Method of using troubleshooting chart 1

The troubleshooting chart consists of the "ques-
Causes
tions", "check items", "causes", and "troubleshoot-
ing" blocks.
The questions and check items are used to pinpoint
high probability causes by simple inspection or
from phenomena without using troubleshooting
1 2 3 4
tools.
Next, troubleshooting tools or direct inspection are
applied to check the narrowed causes in order from
the most probable one to make final confirmation
according to the troubleshooting procedure.
[Questions] 1
Questions
Items to be drawn from the user or operator. 2
They correspond to A and B in the chart on the A
3
right. The items in A are basic ones. The
4
items in B can be drawn from the user or oper-
ator, depending on their level. 5
[Check items] B 6
Simple check items used by the serviceman to 7
narrow the causes. They correspond to C in C 8
the chart on the right.
Check items
9
[Causes]
10
Items to be narrowed from the questions and
check items. The serviceman narrows down 11
the probable causes from A, B, and C. Troubleshooting a
[Troubleshooting]
b
Items used to find out the true cause by verify-
ing the narrowed causes finally in order from c
the most probable one by applying trouble- d
shooting tools or direct inspection.
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, and w.
E: Causes to be referred to for questions and check items
Q : Causes related to questions and check items
w : Causes highly probable among ones marked with Q
a When narrowing the "causes", apply the items marked with w before those marked with Q.
When narrowing the "causes", do not apply the items marked with E. (If no items have other marks and
the causes cannot be narrowed, however, you may apply them.)
D155A-6 3
<Example of troubleshooting> Exhaust gas color is black (incomplete combustion)

Let us assume that a trouble of “Exhaust gas color is black” occurred and we checked the [Questions] and
[Check items] and found the following 3 items to be the causal symptoms; [Exhaust gas color slowly became
black], [Power slowly became weaker], and [Dust indicator is lighting red].
4 D155A-6
There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 6 items in
the [Causes] sections.
The method of pinpointing the [cause] from the causal relationship and approaching the [troubleshooting] is
explained according to Step 1 — Step 3 shown below.
D155A-6 5
S-1 Starting performance of engine is poor 1

General causes why starting performance is poor Causes
Defective electrical system
Leaking or clogged fuel piping or entry of air

q
Clogged air breather hole of fuel tank cap

q Insufficient supply of fuel
Defective contact of valve and vale seat
Defective alternator (generator section)

Defective alternator (regulator section)
Insufficient intake of air
Stuck or seized supply pump plunger

q
Defective intake air heater system

q Improper selection of fuel
Defective or deteriorated battery

Clogged feed pump gauze filter
q Coolant in exhaust pipe
Clogged air cleaner element

a The common rail fuel injection system (CRI) recog-
Worn piston ring, cylinder

nizes the fuel injection timing electrically. Accordingly,
even if the starting operation is carried out, the engine
Clogged fuel filter
Defective injector
may not start until the crankshaft revolves 2 turns at
maximum. This phenomenon does not indicate a trou-
ble, however
Confirm recent repair history

Degree of use of
machine
Operated for long period E E E E
Became worse gradually Q w w Q Q

Starting performance
Engine starts easily when warm w w
Questions
Non-specified fuel is used Q Q Q Q

Filters have not been replaced according to Operation and Maintenance Manual w w w Q Q
Engine oil must be added more frequently w
When engine is preheated or when temperature is low, preheating monitor does not indi-
cate normally (if monitor is installed) w
During operation, charge level monitor indicates abnormal charge
(if monitor is installed) w w
Dust indicator is red (if it is installed) w

Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w Q
Priming pump is too light or too heavy to operate w Q Q
Starting motor cranks engine slowly w
While engine is When air bleeding plug of fuel filter is removed, fuel does not flow
out w w
rotated with starting
motor w
Check items
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
Engine does not pick up smoothly and combustion is irregular Q Q w
Engine hunts (rotation is irregular) Q w Q Q
Blow-by gas is excessive w
Inspect air cleaner directly q

Compression pressure is low q q
When air is bled from fuel system, air comes out q
Inspect fuel filter directly q
Troubleshooting
Inspect feed pump gauze filter directly q

Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by
code q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
change q
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Is voltage of 20 – 30 V generated between alternator terminals B and E Yes q
while engine is running at low idle? No q
Specific gravity of electrolyte and battery voltage are low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
*1: Displayed failure codes: [CA559] and [CA2249]
6 D155A-6
S-2 Engine does not start 1

a) Engine does not rotate Causes
General causes why engine does not rotate
Defective starting motor (safety relay section)

q Seized internal parts of engine
Defective connection of battery terminal
Defective starting motor (motor section)

o See "S-4 Engine stops during operation"
q Water hammer caused by coolant which entered cylinder

q Defective electrical system
Defective starting circuit wiring

q Trouble in drive devices on applicable machine side
Broken flywheel ring gear

o Carry out troubleshooting for devices on applicable machine

Defective battery relay
Questions
Degree of use of
Operated for long period E E
machine
When starting switch is Horn does not sound Q Q w
turned ON Horn volume is low w
Battery electrolyte level is low w
Battery terminal is loose w
When starting switch is turned ON, no operating sound comes out from battery relay Q w
When starting switch is turned to START, starting pinion does not move out Q Q w
Check items
Speed of rotation is low w

When starting switch is
turned to START, start- Makes grating noise w w
ing pinion moves out, Soon disengages again w
but
Makes rattling noise and does not turn Q Q w
Inspect flywheel ring gear directly q
on applicable machine side

Carry out troubleshooting
Troubleshooting
There is not voltage (20 – 30 V) between battery relay terminals B and E q

Turn starting switch When terminals B and C of starting switch are connected, engine starts q
OFF, connect cables, When terminals B and C at safety relay outlet are connected, engine
turn starting switch ON, starts q
and carry out trouble-
shooting Even if terminals B and C at safety relay outlet are connected, engine
q
does not start
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
—
D155A-6 7
b) Engine rotates but no exhaust gas comes out Causes

General causes why engine rotates but no exhaust gas
Malfunction of overflow valve (Does not close)

comes out

Fuel is not supplied
Wrong connection of supply pump PCV

q
Seized or abnormally worn feed pump

q Supply of fuel is extremely small
Broken supply pump shaft or key

q Improper selection of fuel (particularly in winter)
Defective supply pump PCV
Malfunction flow damper

Insufficient fuel in tank
Defective fuel injector

Use of improper fuel
Clogged fuel filter

Questions
Degree of use of
Operated for long period E E E
machine
Exhaust gas suddenly stopped coming out (when starting again) w Q w w w E E
Filters have not been replaced according to Operation and Maintenance Manual w w E Q
Fuel tank is empty w
Air breather hole of fuel tank cap is clogged Q w
There are rust and water in fuel drained from fuel tank Q Q Q Q Q
There is not fuel in removed fuel filter w w
Fuel is leaking from fuel piping w
Check items

When air bleeding plug of fuel filter is removed, fuel does Q Q w Q
While engine is not flow out
rotated with starting
motor When spill hose from injector is disconnected, little fuel
spills Q w w w w Q

Troubleshooting
Inspect feed pump directly q

Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indi- q q q q
cated by code
Carry out troubleshooting according to "PCV1 Short/Open Error (*2) or PCV2
Short/Open Error (*3)" indicated by code q
Inspect overflow valve directly q

Engine can be started in reduced cylinder mode q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Remedy
Add
*1: Displayed failure codes [CA559] and [CA2249]

8 D155A-6
c) Exhaust gas comes but engine does not start Causes
Defective coolant temperature sensor or wiring harness

(fuel is injected)
Worn dynamic valve system (Valve, rocker lever, etc.)

General causes why exhaust smoke comes out but engine
does not start
Leaking or clogged fuel system or entry of air

q Lack of rotating force due to defective electrical system


q Insufficient intake of air
Clogged injector or defective spray
Defective intake air heater system

Worn piston ring or cylinder liner

Use of improper fuel
Clogged fuel filter

Degree of use of machine Operated for long period E E E E
Suddenly failed to start w w Q
Questions
Non-specified fuel is used Q Q

Filters have not been replaced according to Operation and Maintenance Manual w w w
Engine oil must be added more frequently w
When engine is preheated or when temperature is low, preheating monitor does not indi-
cate normally (if monitor is installed) w
Dust indicator is red (if it is installed) w

Air breather hole of fuel tank cap is clogged Q
There are rust and water in fuel drained from fuel tank w w
There is not fuel in removed fuel filter w
Starting motor rotates engine slowly w
When engine is rotated, abnormal sound comes out from around cylinder head w
Check items
When air bleeding plug of fuel filter is removed, fuel does not
While engine is rotated flow out Q w w
with starting motor,
When spill hose from injector is disconnected, little fuel spills w

Inspect dynamic valve system directly q
Compression pressure is low q
Troubleshooting

code q
When injector unit is tested, spray condition is bad q

Coolant temperature gauge does not indicate normally (if it is installed) q
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
D155A-6 9
S-3 Engine does not pick up smoothly 1

General causes why engine does not pick up smoothly Causes
Malfunction of flow damper (Large leakage from injector)

q
Seized turbocharger or interference of turbocharger

q Defective condition of fuel spray

q Control by controller in derate mode

Defective contact of valve and valve seat
(limiting injection rate (output) because of an error in elec-

trical system)
Clogged injector or defective spray


Improper valve clearance
Clogged fuel filter

Degree of use of
machine
Operated for long period E E E E E
Questions
Engine pick-up suddenly became worse w Q Q Q

Non-specified fuel is used w w w w
Filters have not been replaced according to Operation and Maintenance Manual w w w
Oil must be added more frequently w
Dust indicator is red (if indicator is installed) w
Immediately after engine is started, temperature of exhaust manifold of a cylinder is low Q w
Blue under light load w
Exhaust gas color
Black w Q w w
Check items
When engine is rotated, interference sound comes out from around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w w
Engine hunts (rotation is irregular) Q Q w Q

Inspect valve clearance directly q
Troubleshooting
Turbocharger is heavy to rotate with hand q

Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by code q
change q q
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
10 D155A-6
S-4 Engine stops during operation 1

General causes why engine stops during operation Causes
Seized parts inside engine
Broken dynamic valve system (valve, rocker arm, etc.)

q
Broken auxiliary equipment (pump, compressor, etc.)
Trouble in drive devices on applicable machine side

q Overheating
q Trouble in drive devices on applicable machine
Broken or seized piston or connecting rod

side
o Carry out troubleshooting for devices on appli-

Broken or seized crankshaft bearing
cable machine
Broken supply pump shaft or key

Leaking or clogged fuel piping
Broken or seized feed pump

Broken or seized gear train
Clogged fuel filter

Degree of use of
machine Operated for long period E E
Made abnormal noise stopped suddenly w w w w Q w Q w w

w Q Q
Questions
Overheated and stopped

Engine
Stopped slowly w Q Q
Hunted and stopped w Q Q Q Q
Non-specified fuel is used Q Q Q Q
Filters have not been replaced according to Operation and Maintenance
Manual w w
Fuel level monitor indicates low level (if monitor is installed) w

There are metal particles in oil drained from oil pan w w Q Q
Check items
Engine does not rotate at all w w

When engine is Engine rotates in opposite direction w
rotated with hand Engine moves by gear backlash w w
Supply pump shaft does not turn w
Engine rotates, but stops when load is applied to machine w

Inspect piston and connecting rod directly q

on applicable machine
Inspect crankshaft bearing directly q

Troubleshooting
Inspect gear train directly q

Inspect feed pump directly q
Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" q q
indicated by code
Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is
removed q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
—
Add
D155A-6 11
S-5 Engine does not rotate smoothly 1

General causes why engine does not rotate smoothly Causes
Air in fuel system
Malfunction of flow damper (Large leakage from injector)

q
q Defective speed sensor
Clogged injector or defective spray (dirt in injector)

(Error at degree that it is not indicated)
Defective Bkup speed sensor or wiring harness

Defective Ne speed sensor or wiring harness

Low setting of low idle speed
Clogged fuel filter

Degree of use of machine Operated for long period E E
Q Q Q
Questions
At a certain speed range

At low idle w Q Q Q Q Q Q Q
Engine hunts
Even when speed is raised Q Q Q
On slopes w Q Q
Filters have not been replaced according to Operation and Maintenance Manual w w
Check items
There are rust and water in fuel drained from fuel tank Q Q

q
Troubleshooting
Inspect feed pump gauze filter directly

q q
change
Carry out troubleshooting according to "Eng Ne Speed Sensor Error (*1)" indicated by code q
Carry out troubleshooting according to "Eng Bkup Speed Sensor Error (*2)" indicated by code q
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
Add
*1: Displayed failure code [CA689]

*2: Displayed failure code [CA778]
12 D155A-6
S-6 Engine lack output (or lacks power) 1

General causes why engine lacks output Causes
Defective installation of charge pressure sensor (air leakage)

q
q Defective spray condition of fuel
Defective fuel temperature sensor or wiring harness

Defective charge pressure sensor or wiring harness
Clogged injector or defective spray (dirt in injector)

q Overheating
Defective drive of injector (signal or solenoid)

o See "S-14 Coolant temperature becomes too

high (Overheating)"

Air leakage from air intake piping

(limiting injection rate (output) because of an
Leaking or clogged fuel piping

error in electrical system)
Clogged fuel filter

Degree of use of machine Operated for long period E E E E E
Suddenly Q Q Q Q
Questions
Power was lost

Gradually Q Q Q Q Q Q Q
Filters have not been replaced according to Operation and Maintenance
Manual w
Engine oil must be added more frequently Q Q Q
Output becomes insufficient after short stop of operation w
Black w w
Exhaust gas is
Immediately after engine is started, temperature of exhaust manifold of a
cylinder is low w
When engine is rotated, interference sound comes out from around
w
Check items
turbocharger
High idle speed is too high Q
High idle speed under no load is normal, but speed suddenly drops when load
is applied w w Q
Engine does not pick up smoothly and combustion is irregular w Q Q w
Engine hunts (rotation is irregular) Q Q Q Q

Inspect air intake piping directly q
Boost pressure is low q q q
Troubleshooting

Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)"
indicated by code q
When a cylinder is cut out for reduced cylinder mode operation, engine speed
does not change q q
Inspect boost pressure sensor mount directly q
Carry out troubleshooting according to "Chg Air Press Sensor High (Low)
Error (*2)" indicated by code q
Carry out troubleshooting according to "Fuel Temp Sensor High (Low) Error
(*3)" indicated by code q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
*1: Displayed failure code [CA559] and [CA2249]

Adjust
Clean
Clean
Clean
Remedy
D155A-6 13
S-7 Exhaust gas is black (incomplete combustion) 1

General causes why exhaust gas is black Causes
Leakage of air between turbocharger and cylinder head

q
q Excessive injection of fuel

q Defective condition of fuel injection
Clogged fuel spill piping (on cylinder head side)

Overheating

q
o See "S-14 Coolant temperature becomes too

high (Overheating)"
Improper fuel injection pressure

Improper fuel injection timing

Crushed or clogged muffler

(limiting injection rate (output) because of an error in
Clogged or seized injector

Abnormally worn injector

electrical system)

Suddenly became black w Q Q
w Q Q Q
Questions
Exhaust gas color Gradually became black

Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Air leaks between turbocharger and cylinder head or clamp is loosened w
Engine is operated in low-temperature mode at normal temperature Q Q Q
Immediately after engine is started, temperature of exhaust manifold of a cylinder is
low Q w
Check items
Torque converter stall speed or pump relief speed is high (Fuel is injected
excessively) Q Q
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q w
When spill hose from injector is disconnected, abnormally much fuel spills w

Troubleshooting
When muffler is removed, exhaust gas color improves q

code q q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
not change q
Inspect fuel spill piping (on cylinder head side) directly q
Carry out troubleshooting according to "Coolant Temp Sens High (Low) Error (*2)"
indicated by code q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Adjust
Clean
Remedy

14 D155A-6
S-8 Oil consumption is excessive (or exhaust gas is blue) 1

General causes why oil consumption is excessive Causes
q Abnormal consumption of oil
Turbocharger
Worn or damaged valve (stem, guide, or seal)
Oil leakage from oil pan, cylinder head, etc.

q Long-time operation of engine at low idle or high
idle (Do not run engine at idle for more than 20
minutes continuously)
Clogged breather or breather hose

Dust sucked in from intake system
Oil leakage from EGR valve stem

q External leakage of oil

Worn seal at turbocharger end
Worn or damaged rear oil seal
Oil leakage from oil drain plug

q Wear of parts in lubrication system
Oil leakage from oil cooler
Oil leakage from oil piping

Worn seal at blower end
Oil leakage from oil filter

Broken piston ring
Broken oil cooler

E E E E E
Questions
Degree of use of machine Operated for long period

Oil consumption suddenly increased w Q
Oil must be added more frequently Q w Q
Oil becomes dirty quickly Q Q w
Outside of engine is dirty with oil w w w w w
There are loose piping clamps in intake system w
Inside of turbocharger intake outlet pipe is dirty with oil w
Inside of turbocharger exhaust outlet pipe is dirty with oil Q w
Check items
There is oil in coolant w

Oil level in damper chamber is high w
Exhaust gas is blue under light load Q w w
Excessive Q Q w w
Amount of blow-by gas
None w
There is dust in intake manifold q

Inside of intake manifold is abnormally dirty q
Play of turbocharger shaft is excessive q q
Troubleshooting
Exhaust port of EGR valve is dirty with oil q

Check breather and breather hose directly q
Inspect rear oil seal directly q
Leakage from oil cooler is detected by pressure test q q
Oil leaks out of engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
D155A-6 15
S-9 Oil becomes dirty quickly 1

General causes why oil becomes dirty quickly Causes
q Entry of exhaust gas into oil due to internal wear
Clogged turbocharger lubrication drain tube

Defective seal at turbocharger turbine end
q Clogging of lubrication passage
q Use of improper fuel
Clogged breather or breather hose

q Use of improper oil

q Overload operation
Defective oil filter safety valve

Worn valve or valve guide
Exhaust gas color is bad

Worn EGR valve guide
Clogged oil cooler

Clogged oil filter
Questions

Non-specified fuel is used Q
Engine oil must be added more frequently Q w
Even when engine oil temperature rises, oil filter clogging monitor indicates clogging w Q
(if monitor is installed)
There are metal particles in oil drained from oil pan Q Q w
Inside of exhaust pipe is dirty with oil w
Engine oil temperature rises quickly w
Check items
Exhaust gas is
Black w
Comes out excessively Q Q w Q
Blow-by gas
Does not come out at all w
Play of turbocharger shaft is excessive q

Exhaust port of EGR valve is dirty with oil q
Troubleshooting
See S-7
Check breather and breather hose directly q
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
—
16 D155A-6
S-10 Fuel consumption is excessive 1

General causes why fuel consumption is excessive Causes
Leakage of fuel

q
q Defective condition of fuel injection (fuel pressure or injection timing)
q Excessive injection of fuel
Fuel leakage from fuel filter, piping, etc.
Defective common rail pressure

Fuel leakage inside head cover
Defective supply pump plunger

Defective feed pump oil seal
Defective spray by injector

Malfunction of injector
E E E
Questions

Is large compared to other machines of same model Q Q Q Q
Fuel consumption Gradually increased Q Q
Suddenly increased Q Q
There is external leakage of fuel from engine w
Combustion is irregular w
Engine oil level rises and oil smells of diesel fuel w w
Check items
Low idle speed is high Q

Torque converter stall speed or pump relief speed is high Q
Black Q Q Q Q
Exhaust gas is
White Q
Remove head cover and inspect inside directly q

Inspect feed pump oil seal directly q
Troubleshooting
Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by code q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change q
When spill hose from injector is disconnected, much fuel spills q
Carry out troubleshooting according to "Coolant Temp Sens High (Low) Error (*2)" indicated by
q
code
Confirm with monitoring function on applicable machine side q q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Remedy

D155A-6 17
S-11 Oil is in coolant

(or coolant spurts back or coolant level goes down) 1
General causes why oil is in coolant Causes
q Leakage in lubrication system
Damaged cylinder liner O-ring or holes caused by pitting
Broken hydraulic oil cooler or power train oil cooler on

q Leakage in cooling system
Insufficient protrusion of cylinder liner

Broken cylinder head or head gasket
Broken oil cooler core or O-ring
applicable machine side

Crack in cylinder block
E E
Questions

Suddenly increased Q Q Q
Oil level
Gradually increased Q Q
Hard water is used as coolant Q Q
Oil level has risen and oil is milky Q Q w
There are excessive air bubbles in radiator and coolant spurts back w w
Check items
Hydraulic oil or power train oil on applicable machine side is milky w
When hydraulic oil or power train oil is drained, water flows out w
Carry out troubleshooting on

Leakage from cylinder head is detected by pressure test q
applicable machine side

Troubleshooting
Inspect cylinder block and liner directly q q
Inspect cylinder liner directly q
Leakage from oil cooler is detected by pressure test q

Replace
Replace
Replace
Replace
Replace
Remedy
—
18 D155A-6
S-12 Oil pressure drops 1

General causes why oil pressure drops Causes
q Leakage from, clogging, or wear of lubrication system
Defective oil pressure sensor or wiring harness

Leaking, crushed, or clogged hydraulic piping
q Defective oil pressure control
q Selection of oil by the temperature etc. specified in the Opera-
tion and Maintenance Manual is not observed.
q Deterioration of oil due to overheating
Clogged or broken pipe in oil pan
Defective oil pump relief valve

Clogged strainer in oil pan
Worn journal of bearing
Coolant or fuel in oil

Lack of oil in oil pan
Defective oil pump
Clogged oil filter

E E E
Questions

Oil pressure monitor indicates low oil pressure (if monitor is installed) Q w
Non-specified oil is used Q Q
Filters have not been replaced according to Operation and Maintenance Manual w
Indicates pressure drop at low idle w Q
Oil pressure monitor Indicates pressure drop at low, high idle Q w w w Q
(if installed) Indicates pressure drop on slopes w
Sometimes indicates pressure drop w Q
Oil level monitor indicates oil lever drop (if monitor is installed) w
Oil level in oil pan is low w
External hydraulic piping is leaking or crushed w
Check items
Oil is milky or smells of diesel oil w

There are metal particles in oil drained from oil pan w
There are metal particles in oil drained from oil filter w Q
There are metal particles in oil filter q

q q
Troubleshooting
Inspect oil pan strainer and pipe directly

See S-13
Oil pump is heavy to rotate or it has play q

Valve spring of oil pump relief valve is fatigued or damaged q
Inspect oil filter directly q
Carry out troubleshooting according to "Eng Oil Press Sensor High (Low) Error (*1)" indicated
q
by code
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Remedy
—
Add
*1: Displayed codes [CA135] and [CA141]
D155A-6 19
S-13 Oil level rises (Entry of coolant or fuel) 1

General causes why oil level rises Causes
q Coolant in oil (milky)
Clogged water pump drain hole (breather hole) or defective seal
Defective seal of auxiliary equipment (pump and compressor)

q Fuel in oil (smells diluted diesel fuel)
a If oil is in coolant, carry out troubleshooting for "S-11 Oil is in

coolant"

Fuel leakage inside cylinder block
Broken oil cooler core or O-ring

Worn or damaged rear oil seal
Cracks inside cylinder block
Defective thermostat seat

Defects in supply pump
Questions

Fuel consumption has increased w w
Coolant must be added more frequently Q w
There is oil in coolant Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q w
When engine is started, water drops from muffler Q
When radiator cap is removed and engine is run at low idle, abnormally many bubbles come w Q
Check items
out or coolant spurts back

Exhaust gas is white Q Q
Water pump drain hole (breather hole) is clogged w
When water pump drain hole (breather hole) is cleaned, coolant flows out w
Oil level in damper chamber on applicable machine side is low w
Oil level in hydraulic tank on applicable machine is low w

Remove and inspect head cover directly q
Inspect cylinder block and liner directly q q
Troubleshooting
Inspect rear oil seal directly q

Leakage from oil cooler is detected by pressure test q
Remove and inspect water pump directly q
Remove and inspect thermostat cover directly q
Remove and inspect supply pump directly q
Inspect seal of auxiliary equipment directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
20 D155A-6
S-14 Coolant temperature becomes too high (Overheating) 1

General causes why coolant temperature becomes too high Causes
q Lack of cooling air (deformation or damage of fan)
Rise of power train oil temperature on applicable machine side

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
Defective radiator cap (pressure valve)
Defective coolant temperature gauge

Clogged or crushed radiator fins

Clogged or broken oil cooler
Malfunction of thermostat
Clogged radiator core

Broken water pump
Malfunction of fan
Low coolant level
Questions
Occurred suddenly Q w Q
Overheating
Has continued at low level Q w w Q
Coolant temperature Rises quickly Q w
gauge (if installed) Does not go down from red range w
Radiator coolant level monitor indicates low (if monitor is installed) w
Engine oil level has risen and oil is milky w Q
Milky oil is floating on coolant w
There are many bubbles in radiator and coolant spurts back w
When light applied to radiator core, no light passes through w
Check items
Dirt and mud are accumulated in radiator shroud and undercover on applicable
w w
machine side
Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Power train oil temperature enters red range faster than engine coolant temperature
w
(if oil temperature gauge and coolant temperature gauge are installed)

on applicable machine side
Inspect cylinder liner directly q

Inspect oil cooler directly q
Troubleshooting
Temperature difference between upper and lower tanks of radiator is large q

Thermostat does not open at cracking temperature q
Temperature difference between upper and lower tanks of radiator is slight q
Inspect radiator core directly q
Cracking pressure of radiator cap is low q
Inspect fan directly q
Coolant temperature is normal q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
—
Add
D155A-6 21
S-15 Abnormal noise is made 1

General causes why abnormal noise is made Causes
Abnormality due to defective parts
Leakage of air between turbocharger and cylinder head

q
Broken dynamic valve system (valve, rocker lever, etc.)

q Abnormal combustion
Interference of turbocharger or seized turbocharger
Defective inside of muffler (Removal of bulkhead)

q Air sucked in from intake system
a Judge if the noise is an internal noise or an external
Excessive wear of piston ring or cylinder liner

noise before starting troubleshooting.
a The engine is operated in the low-temperature mode
(Defective coolant temperature sensor)

Removed or seized gear train bushing
while it is not warmed up sufficiently. Accordingly, the
engine sound becomes a little larger. This does not

indicate abnormality, however
Improper gear train backlash
Clogged or seized injector

a When the engine is accelerated, it is operated in the

acceleration mode and its sound becomes a little larger
Deformed cooling fan
Dirt caught in injector

for up to about 5 seconds. This does not indicate abnor-
mality, however

Degree of use of machine Operated for long period E
Questions
Gradually increased Q Q
Abnormal noise
Suddenly increased Q Q Q
Non-specified fuel is used Q
There are metal particles in oil drained from oil filter w w
Air leaks between turbocharger and cylinder head w
When engine is rotated, abnormal sound comes out from around cylinder head w w
When engine is rotated, beat noise comes out from around muffler w
Check items
Immediately after engine is started, temperature of exhaust manifold of a cylinder is w Q

low
Exhaust gas is
Black Q w Q
Engine does not pick up smoothly and combustion is irregular w
Abnormal noise is loud when engine is accelerated Q Q Q Q

When muffler is removed, abnormal noise disappears q
q
Troubleshooting
Inspect valve clearance directly

Inspect gear train directly q q
Inspect fan directly q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
q q
not change
Abnormal noise comes out only at start of engine q
Confirm with monitoring function on applicable machine side q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Adjust
Remedy
22 D155A-6
S-16 Vibration is excessive 1

General causes why vibration is excessive Causes
q Defective parts (abnormal wear, breakage, etc.)
Misalignment between engine and devices on applicable machine side

q Misalignment between engine and applicable machine
q Abnormal combustion
a If abnormal noise is made and vibration is excessive, carry out trou-
bleshooting for "S-15 Abnormal noise is made", too
Stuck dynamic valve system (valve, rocker lever, etc.)
Broken parts in damper on applicable machine side

Loose engine mounting bolts or broken cushions
Worn main bearing or connecting rod bearing
Worn front support spigot joint

Improper gear train backlash
Improper injection timing

Worn camshaft bushing
E E E E
Questions

Suddenly increased Q Q
Vibration
Gradually increased Q Q Q Q
There are metal particles in oil drained from oil filter w w
There are metal particles in oil drained from oil pan w w
Oil pressure is low at low idle Q Q
Check items
Vibration occurs at medium speed Q Q

Vibration follows engine speed Q Q Q Q Q
Exhaust gas is black w

Inspect main bearing and connecting rod bearing directly q
Inspect gear train directly q
Troubleshooting
Inspect camshaft bushing directly q

Confirm with monitoring function on applicable machine side q
Inspect engine mounting bolts and cushions directly q
Radial runout or facial runout is detected q
Inspect front support spigot joint directly q
Inspect inside of damper directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Remedy
D155A-6 23
S-17 Air cannot be bled from fuel circuit 1

(After filter is replaced or fuel is used up and then air is bled, engine does not start
or it starts but stalls.)
General causes why air cannot be bled Causes

q Electric priming pump does not operate.
Defective wiring harness of electric priming pump

Fuel is not supplied or is supplied very little.
Improper setting of air bleeding valve (Closed)

q
Fuel valve or air bleeding valve is not set properly.
Malfunction of electric priming pump switch

q
Leaking or clogged fuel piping or air in it

q Air bleeding piping is clogged.
Improper setting of fuel valve (Closed)

Fuel return piping is clogged.
Malfunction of electric priming pump

q
Clogged fuel tank cap breather hole
Clogged water separator screen

Clogged air bleeding piping
Low battery charge level

Clogged fuel filter
Low fuel level
Questions
Degree of use of
machine
Operated for long period EE
Fuel tank cap breather hole is clogged Q w
Switch lamp does not blink w w Q
Check items
When electric prim-

ing pump switch is Lamp blinks but pump operation sound is not heard w w
operated Pump operation sound is heard but fuel does not flow out of
hose soon Q Q w w w Q Q
Air bleeding valve is closed q

Fuel valve (supply side) is closed q
Fuel valve (return side) is closed q
Water drain valve and air intake plug of water separator are loosened q
Troubleshooting
Water drain valve of fuel prefilter is loosened q

There is flaw or dirt on sealing face of fuel prefilter or main filter q
Check air bleeding piping and orifice directly (See Note 1) q
Check fuel piping (supply side and return side) directly (for clogging and breakage) q
Check electric priming pump directly q
Check electric priming system directly (See E-33 in E-mode) q q
Check water separator screen directly q
Check fuel filter for clogging (Failure code CA559, Note 2) q
Replace
Replace
Replace
Replace
Charge
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
Add
24 D155A-6
Note 1: Check of air bleeding piping for clogging
• Remove joint bolt (1) and blow clean compressed air into hole [b] of the orifice to check for clogging.
D155A-6 25
D155A-6 Bulldozer
© 2008 KOMATSU
All Rights Reserved
26 D155A-6
SEN03366-02
D155A-6
Machine Model Serial Number

D155A-6 85001 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 .............................................................................................................................. 13
D155A-6 1
SEN03366-02 50 Disassembly and assembly
How to read this manual 1

(Rev. 2009.01)
1. Removal and installation of assemblies
Special tools Removal

q Special tools which are necessary for q In "Removal" section, the work procedures,
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 precautions and know-how to do the work, and
described as A1,•••X1 etc. and their parts the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for removal
q Also the following information is described are described as [1], [2] ••• etc. and their part
in the special tool list. numbers, part names and quantities are not
1) Necessity described.
t : Special tools that cannot be substi- q Various symbols used in "Removal" section
tuted and should always be used are explained and listed below.
k
q : Special tools that will be useful if avail-
: Precautions related to work safety
able and are substitutable with tools
available on the market a: Guidance or precautions for the work
2) Distinction of new and existing special tools [*1] : This mark shows that instructions or precau-
N: Tools newly developed for this tions for parts installation work are given in
model. They have a new part num- "Installation" section.
ber respectively.
R: Tools made available by redesign- 6 : Amount of oil or coolant to be drained
ing the existing tools which were 4 : Weight of part or component
developed for other models. Each
of them has a new part number
assigned by setting forward the Installation
part number of the existing tool. q Unless otherwise instructed, installation of parts
Blank: Tools already available for other is to be done in the reverse order to removal.
models. They can be used without q Instructions and precautions for parts installa-
any modification. tion is shown with the mark ([*1], [*2]...) which
3) Circle mark Q in sketch column: corresponds to the mark in "Removal" section.
q The sketch of the special tool is pre- q Common tools that are necessary for installa-
sented in the section of "Sketches of tion are described as [1], [2] ••• etc. and their
special tools". part numbers, part names and quantities are not
q Part No. of special tools starting with described.
79*T-***-****: q Marks shown in the "Installation" section stand
means that they are not available for the following.
k
from Komatsu Ltd. (i.e. tools to be
made locally).
a: Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
5 : Amount of oil or coolant to be replenished
Sketches of special tools

q Various special tools are illustrated for the local
manufacture.
2 D155A-6
2. Disassembly and assembly of assemblies
Special tools Disassembly

q Special tools which are necessary for dis- q In "Disassembly" section, the work procedures,
assembly and assembly of parts are precautions and know-how to do the work, and
described as A1,•••X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for disas-
q Also the following information is described sembly are described as [1], [2] ••• etc. and
in the special tool list. their part numbers, part names and quantities
1) Necessity are not described.
t : Special tools that cannot be substituted q The meanings of the symbols used in "Disas-
and should always be used. sembly" section are as follows.
k
q : Special tools that will be useful if avail-
able and are substitutable with tools
available on the market. a: Guidance or precautions for the work
2) Distinction of new and existing special tools 6: Amount of oil or coolant drained
N : Tools newly developed for this
model. They have a new part
number respectively. Assembly
R : Tools made available by redesign- q In "Assembly" section, the work procedures,
ing the existing tools which were precautions and know-how to do the work, and
developed for other models. Each the amount of oil and coolant to be replenished
of them has a new part number are described.
assigned by setting forward the q Common tools that are necessary for assem-
part number of the existing tool. bly are described as [1], [2] ••• etc. and their
Blank : Tools already available for other part numbers, part names and quantities are
models. They can be used without not described.
any modification. q The meanings of the symbols used in "Assem-
3) Circle mark Q in sketch column: bly" section are as follows.
k
q The sketch of the special tool is pre- : Precautions related to work safety
sented in the section of "Sketches of
special tools". a: Guidance or precautions for the work
2
q Part No. of special tools starting with : Type of coating material
79*T-***-****:
means that they are not available 3 : Tightening torque
5
from Komatsu Ltd. (i.e. tools to be : Amount of oil or coolant to be replenished
made locally).
Sketches of special tools

q Various special tools are illustrated for the local
manufacture.
D155A-6 3
Coating materials list 1

(Rev. 2009.02)
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
tant sealant.
LG-6 790-129-9160 200 g Tube • Used to seal flange surfaces and threaded
portions.
• Used to seal oil pan, final drive case, etc.
Gasket sealant
• Features: Silicon-based quick-setting sealant.

LG-7 790-129-9170 1 kg Tube • Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
• Features: Silicon-based, heat and cold-resis-
LG-8
tant, vibration-resistant, impact-resistant seal-
ThreeBond 419-15-18131 100 g Tube
ant.
1207B
• Used to seal transfer case, etc.
• Used for rough surfaces such as the circle
LG-9 gear top seal which does not need to be
ThreeBond 790-129-9310 200 g Tube clamped, water resistance of the clearance at
1206D the welded area, etc.
• Can be coated with paint.
4 D155A-6
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
LG-10 • Used as lubricant/sealant when the radiator
ThreeBond 790-129-9320 200 g Tube hoses are inserted.
Gasket sealant
1206E • Can be coated with paint.

LG-11 • Feature: Can be used together with gaskets.
ThreeBond 790-129-9330 200 g Tube • Used for covers of the transmission case and
1121 steering case etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
• Used to prevent scuffing and seizure of press-fit-
ted portions, shrink-fitted portions, and threaded
LM-P 09940-00040 200 g Tube
portions.
Molybdenum
• Used to lubricate linkages, bearings, etc.

lubricant
disulfide
• Spray type
• Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuff-
— 09995-00250 190 g Can
ing each other.
• Applicable for the propeller shaft splines, needle
bearings, pins and bolts of various links, etc.
• Feature: Seizure and scuffing prevention com-
prevention
compound
pound with metallic super-fine-grain, etc.

Seizure
LC-G
— — Can • Used for the mounting bolt in the high tempera-
NEVER-SEEZ
ture area of the exhaust manifold and the turbo-
charger, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI • Feature: Lithium grease with extreme pressure
SYG2-160LI
G0-LI Various Various lubrication performance.
SYGA-160CNLI
*: For cold district • General purpose type.
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
• Used for parts under heavy load.
Caution:
Molybdenum SYG2-400M 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like
disulfide grease SYG2-400M-A 400 g x 20 container swing circle bearings, etc. and spline.
LM-G (G2-M) SYGA-16CNM 16 kg Can • The grease should be applied to work equipment
pins at their assembly only, not applied for
greasing afterwards.
• Seizure resistance, heat resistance and water
Hyper White SYG2-400T-A
Grease
400 g Bellows-type resistance higher than molybdenum disulfide

Grease G2-T, SYG2-16CNT
container grease.
G0-T (*) SYG0-400T-A (*)
16 kg Can • Not conspicuous on machine since color is
*: For cold district SYG0-16CNT (*)
white.
Biogrease SYG2-400B
G2-B, G2-BT (*) SYGA-16CNB 400 g Bellows-type • Since this grease is decomposed by natural bac-
*: For use at high SYG2-400BT (*) container teria in short period, it has less effects on micro-
temperature and SYGA-16CNBT 16 kg Can organisms, animals, and plants.
under high load (*)
• Feature: Silicone grease with wide using tem-
G2-S perature range, high resistance to thermal-oxi-
ThreeBond — 200 g Tube dative degradation and performance to prevent
1855 deterioration of rubber and plastic parts.
• Used for oil seals of the transmission, etc.
• Feature: Urea (organic system) grease with heat
G2-U-S resistance and long life. Enclosed type.
427-12-11871 2 kg Can
ENS grease • Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
D155A-6 5
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
SUNSTAR • Used as primer for cab side.
Glass
PAINT PRIMER 20 ml (Using limit: 4 months after date of manu-
container
580 SUPER facture)
SUNSTAR 417-926-3910
• Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 container
facture)
Adhesive for cab glass

SUPER
• Used as primer for painted surface on cab
SUNSTAR
Glass side.
Primer
PAINT PRIMER 22M-54-27230 20 ml

container (Using limit: 4 months after date of manu-
435-95
facture)
• Used as primer for black ceramic-coated
SUNSTAR
surface on glass side and for hard polycar-
GLASS
22M-54-27240 150 ml Can bonate-coated surface.
PRIMER
(Using limit: 4 months after date of manu-
435-41
facture)
SUNSTAR • Used as primer for sash (Almite).
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months after date of manu-
container
GP-402 facture)
SUNSTAR • “S” is used for high-temperature season
PENGUINE and “W” for low-temperature season as
Polyethylene
SEAL 580 417-926-3910 320 ml adhesive for glass.
container
SUPER “S” or (Using limit: 4 months after date of manu-
“W” facture)
Adhesive
• Used as adhesive for glass.

Sika Japan, Polyethylene
20Y-54-39850 310 ml (Using limit: 6 months after date of manu-
Sikaflex 256HV container
Adhesive for cab glass
facture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months after date of manu-
container
SEAL No. 2505 facture)
Caulking material
SEKISUI • Used to seal front window.

Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months after date of manu-
container
SEALANT facture)
• Used to seal joint of glasses.
GE TOSHIBA
Translucent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Using limit: 12 months after date of manu-
TOSSEAL 381
facture)
6 D155A-6
Special tool list 1

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.
: R. . . . . . Tools remodeled from tools already available for other models and given
upgraded part Nos.
: Blank . . Tools already available for other models, usable without any modification
a Tools marked with Q in the sketch column are tools introduced in the sketches of the special tools (See
Sketches of special tools).
New/Remodel
Sym-
Necessity
Work item Part No. Part name Nature of work and remarks
bol
Sketch
Q'ty
Removal and installation 1 795-630-5500 Standard puller t 1
of fuel supply pump 2 01010-81090 Bolt t 2 Separation of drive gear
assembly A 3 01643-31032 Washer t 2
Removal and installation Tightening of cylinder head
4 790-331-1110 Wrench q 1
of cylinder head assembly bolt
795T-521-1111 Push tool t 1 R Q
Installation of Engine front
2 01050-31655 Bolt t 3
seal
01050-31635 Bolt t 3
3 795-931-1100 Seal puller t 1
795T-421-1270 Push tool t 1 Q Installation of Engine rear
4 01050-31645 Bolt t 4 seal
Removal and installation 01643-31645 Washer t 8

of engine front seal, rear C 795T-421-1240 Push tool t 1 Q
seal Installation of Engine rear
5 01050-31645 Bolt t 4
seal (Press fit of sleeve)
01643-31645 Washer t 4
795T-521-1150 Push tool t 1 Q Installation of Engine front
8
01050-31635 Bolt t 4 seal (Press fit of sleeve)
795T-421-1250 Push tool t 1 Q
Installation of Engine rear
9 01050-31645 Bolt t 4
seal
01643-31645 Washer t 8
791-612-1100 Installer t 1
Disassembly and assem-
F 790-101-4200 Puller (294 kN {30 ton}) t 1 Press fitting of bearing
bly of damper assembly
790-101-1102 Hydraulic pump t 1
791T-615-1300 Puller assembly t 1 N
Disassembly and assem- 1 791T-615-1310 • Plate 1 N Q Operation check of clutch
bly of transmission G
01010-82040 • Bolt 1 piston
assembly
2 799-301-1600 Oil leak tester kit (A) t 1
791-662-1110 Bracket t 1
Removal and installation of
1 01010-31685 Bolt t 1
Disassembly and assem- brake and carrier assembly
H 01017-31620 Bolt t 1
bly of HSS case assembly
790-302-1500 Spanner kit t 1 Removal and installation of
2
09003-09200 • Spanner 1 nut (bevel pinion side)
D155A-6 7
New/Remodel
Sym-
Necessity
bol
Sketch
Q'ty
790-337-1032 Lifting tool t 1
Removal and installation 791-627-1320 Shackle t 2 Removal and installation of
J
of final drive assembly 791T-627-1910 Plate t 1 N Q final drive assembly
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
1 Pulling out of pinion shaft
790-101-2480 Adapter t 2
791T-627-1920 Plate t 1 N Q
790-101-2102 Puller t 1
790-431-1031 Block t 1
791-520-4140 Screw t 1
791-112-1180 Nut t 2
01643-32460 Washer t 2 Pulling out and press fitting
2 of sprocket and hub assem-
791T-627-1930 Plate t 1 N Q bly
791T-627-1940 Push tool t 1 N Q
790-101-2102 Puller t 1
3 791-627-1280 Installer t 1 Installation of floating seal
Disassembly and assem- 790-101-5401 Push tool kit t 1
K
bly of final drive assembly 790-101-5441 • Plate 1
4 Press fitting of oil seal
790-101-5421 • Grip 1
01010-51240 • Bolt 1
790-101-5401 Push tool kit t 1
790-101-5451 • Plate 1
790-101-5421 • Grip 1
5 Press fitting of bearing
01010-51240 • Bolt 1
791T-627-1950 Plate t 1 N Q
791T-627-1960 Plate t 1 N Q
790-201-1680 • Plate 1
6 Press fitting of bearing
790-101-5021 • Grip 1
01010-50816 • Bolt 1
791-520-4140 Screw t 1
790-101-2420 Adapter t 1
7 791-112-1180 Nut t 1 Press fitting of bearing
01643-22460 Washer t 1
792-785-1120 Plate t 1
8 D155A-6
New/Remodel
Sym-
Necessity
bol
Sketch
Q'ty
791-830-1410 Push tool t 1
K 7 790-101-2102 Puller t 1 Press fitting of bearing
bly of final drive assembly
791-630-1220 Rod t 2
790-101-2510 Block t 1
790-101-2570 Washer t 2
1 01580-01411 Nut t 2 Press fitting of idler bushing
L 01643-31445 Washer t 2
bly of idler assembly
790-101-2102 Puller (294 kN {30 ton}) t 1
2 791-651-1510 Installer t 1 Installation of floating seal
3 791-601-1000 Oil pump t 1 Refilling with oil
791-685-8006 Compressor t 1
Disassembly and assem- 791-635-3160 Extension t 1

Compression of recoil
bly of recoil spring assem- M 2 791T-630-2610 Spacer t 1
spring
bly 790-101-1300 Cylinder t 1
bly of track roller assem- L 2 791-651-1510 Installer t 1 Installation of floating seal
bly
1 790-102-1891 Nut wrench t 1
nut
bly of carrier roller assem- R 2 791-651-1510 Installer t 1 Installation of floating seal
bly 3 791T-630-1350 Spacer t 1 Q Press fitting of ring
791-675-9701 Remover and installer t 1
791-101-4300 Cylinder (196 kN {20 ton}) t 1 Disassembly and assembly
1
791-101-4200 Puller (294 kN {30 ton}) t 1 of track shoe assembly
General disassembly and 2 791-932-1110 Plug push tool t 1 Driving of plug (small)
general assembly of track S 3 791-660-7460 Pin brush t 1 Cleaning of pin
shoe assembly
4 791-432-1110 Plug push tool t 1 Driving of plug (large)
5 791-632-1052 Installer t 1 Insertion of link seal
Check of oil supply and air-
6 790-701-3000 Seal checker t 1
tightness
791-675-9581 Adapter t 1
Field disassembly and 791-675-9590 Guide t 1 Disassembly and assembly
T 1
assembly of 1 link 01010-52460 Bolt t 2 of track shoe assembly
01010-51440 Bolt t 2
D155A-6 9
New/Remodel
Sym-
Necessity
bol
Sketch
Q'ty
790-101-1102 Pump t 1
2 Cylinder Disassembly of 1 link
790-101-4300 t 1
(1,470 kN {150 ton})
791-685-9510 Frame t 1
791-685-9520 Frame t 1
791-685-9530 Rod t 1
791-685-9550 Nut t 1
791-685-9560 Bolt t 1
3 Disassembly of 1 link
791-675-9570 Adapter t 1
04530-12030 Eyebolt t 1
790-101-1102 Pump t 1
Cylinder
790-101-4300 t 1
(1,470 kN {150 ton})
791-685-9540 Rod t 1
791-685-9550 Nut t 3
791-675-5520 Guide t 1
791-675-5530 Pusher t 1
01010-51030 Bolt t 1
791-685-9620 Extension t 1
790-101-1102 Pump t 1
790-101-4200 Puller (294 kN {30 ton}) t 1
Field disassembly and
T 791-675-5542 Adapter t 1
assembly of 1 link
791-675-5571 Adapter t 1
7 790-101-1102 Pump t 1 Assembly of 1 link
Cylinder
790-101-4300 t 1
(1,470 kN {150 ton})
8 791-675-5580 Guide t 1 Assembly of 1 link
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
9 Assembly of 1 link
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
Cylinder
790-101-4300 t 1
(1,470 kN {150 ton})
791-675-5560 Guide t 1
791-675-5542 Adapter t 1
10 D155A-6
New/Remodel
Sym-
Necessity
bol
Sketch
Q'ty
790-101-1102 Pump t 1
790-101-4200 Puller (294 kN {30 ton}) t 1
12 791-670-3270 Guide t 1 Assembly of 1 link
Field disassembly and
T 791-126-0150 Adapter t 1
assembly of 1 link
791-675-5560 Guide t 1
791-675-9570 Adapter t 1
01010-51030 Bolt t 1
790-101-1102 Pump t 1
1 Expansion of link
790-101-4200 Puller (294 kN {30 ton}) t 1
791-675-9701 Remover and installer t 1
790-101-1102 Pump t 1
2 790-101-4200 Puller (294 kN {30 ton}) t 1
Disassembly and assem- Disassembly and assembly
U Cylinder
bly of master link 790-101-4300 t 1 of track shoe assembly
(1,470 kN {150 ton})
3 791-432-1110 Plug push tool t 1 Driving of plug (large)
Check of oil supply and air-
4 790-701-3000 Seal checker t 1
tightness
5 791-932-1110 Plug push tool t 1 Driving of plug (small)
791T-650-2110 Sleeve t 1 Q
790-201-2770 Spacer t 1
791T-650-2120 Plate t 1 Q
792-104-3940 Bolt t 2
Removal and installation 790-101-2510 Block t 1
V Press fitting of ring
of pivot shaft assembly 790-101-2570 Washer t 2
01580-01613 Nut t 1
Jack assembly
790-105-2300 t 1
(196 kN {20 ton})
791T-650-2130 Sleeve t 1 Q
790-101-2420 Adapter t 1
791-502-4140 Screw t 1
Removal and installation
W 790-101-2540 Washer t 2 Pulling out of center pin
of equalizer bar assembly
790-112-1180 Nut t 2
790-101-4000 Puller (294 kN {50 ton}) t 1
Removal and installation
of operator's cab X 1 793-498-1210 Lifter (Suction cup) t 2 Installation of window glass
(stuck glass)
Disassembly and assembly
790-502-1003 Cylinder repair stand t 1
Disassembly and assem- 1 of hydraulic cylinder
bly of hydraulic cylinder Y 790-101-1102 Hydraulic pump t 1
assembly Installation of round head
2 790-102-3802 Multi-wrench t 1
(Blade lift)
D155A-6 11
New/Remodel
Sym-
Necessity
bol
Sketch
Q'ty
790-201-1702 Push tool kit t 1 Press fitting of bushing
790-201-1721 • Push tool 1
790-201-1821 • Push tool 1 Blade lift
790-201-1841 • Push tool 1 Blade tilt
3
790-201-1851 • Push tool 1 Ripper lift
790-201-1861 • Push tool 1 Ripper tilt
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1500 Push tool kit t 1 Press fitting of dust seal
790-201-1630 • Plate 1 Blade lift
790-201-1650 • Plate 1 Blade tilt
Disassembly and assem- 4 790-201-1660 • Plate 1 Ripper lift
bly of hydraulic cylinder Y
assembly 790-201-1670 • Plate 1 Ripper tilt
790-101-5021 • Grip 1
Press fitting of dust seal
01010-50816 • Bolt 1
790-720-1000 Expander t 1 Installation of piston ring
796-720-1670 Ring t 1
Blade lift
07281-01279 Clamp t 1
5 796-720-1690 Ring t 1 Blade tilt
07281-01919 Clamp t 1 Ripper lift
796-720-1720 Ring t 1
Ripper tilt
07281-02429 Clamp t 1
790-102-4300 Wrench t 1 Removal and installation of
6
790-102-4310 Pin t 2 screw-type piston
12 D155A-6
Sketches of special tools 1

Note) We will not be liable for any result of use of special tools
manufactured according to the following drawings.
C2: Push tool
C4: Push tool
D155A-6 13
C5: Push tool
C8: Push tool
14 D155A-6
C9: Push tool
G1: Plate (791T-615-1310)
D155A-6 15
Component of J: Plate (791T-627-1910)
K1: Plate (791-627-1920)
16 D155A-6
Component of K2: Plate (791T-627-1930)
Component of K2: Push tool (791T-627-1940)
D155A-6 17
18 D155A-6
Component of M2: Spacer (791T-630-2610)
Component of V: Sleeve (791T-650-2110)
D155A-6 19
Component of V: Plate (791T-650-2120)
Component of W: Sleeve (791T-650-2130)
20 D155A-6
D155A-6 21
D155A-6 Bulldozer
© 2009 KOMATSU
All Rights Reserved
22 D155A-6
SEN03367-02
D155A-6

D155A-6 85001 and up

Engine and cooling system
Removal and installation of fuel supply pump assembly ................................................................................ 2
Removal and installation of fuel injector assembly ......................................................................................... 7
Removal and installation of cylinder head assembly .................................................................................... 13
Removal and installation of radiator assembly ............................................................................................. 24
Removal and installation of aftercooler assembly......................................................................................... 27
Removal and installation of engine assembly ............................................................................................... 30
Removal and installation of engine hood assembly ...................................................................................... 35
Removal and installation of engine front seal ............................................................................................... 37
Removal and installation of engine rear seal ................................................................................................ 41
Removal and installation of fuel tank assembly ............................................................................................ 46
Removal and installation of fan drive assembly ............................................................................................ 48
Removal and installation of fan motor assembly .......................................................................................... 49
D155A-6 1
Removal and installation of fuel 3. Remove the fuel filter and filter head assembly
supply pump assembly 1 according to the following procedure.
1) Loosen joint (5) at the top of the fuel air
Special tools bleeding tube. [*1]
2) Disconnect joint (6) at the bottom of the
New/Remodel
fuel air bleeding tube. [*2]
3) Disconnect fuel filter inlet tube (7) and fuel
Necessity
Sym-
Part No. Part name
filter outlet tube (8) from the filter. [*3]
Sketch
bol
4) Remove clamp (9) of the engine oil level
Q'ty
gauge guide.
1 795-630-5500 Standard puller t 1
5) Remove fuel filter and filter head assem-
A 2 01010-81090 Bolt t 2 bly (10).
3 01643-31032 Washer t 2
Removal
k Disconnect the cable from the negative (–)
terminal of the battery.
1. Open engine left side cover (1) and remove

covers (2) and (3).
4. Loosen mounting nut (11) of the engine oil

level gauge guide. [*4]
2. Open undercover (4).

k Using a floor jack, a wire rope, etc.,
open the undercover carefully.
2 D155A-6
5. Disconnect the following wiring connectors. 7. Remove the high-pressure pipes according to
1) Wiring fixing bracket mounting bolts (12) the following procedure.
and (13). 1) Remove the clamp and stay (28).
2) Wiring connectors PCV1 (14), CPV2 (15) 2) Remove the clamp and stay (29).
and backup sensor (16). 3) Remove the clamp and stay (30).
4) Remove 4 boots (31) (2 pieces each on
the supply pump side and common rail
side). [*11]
6. Disconnect or remove the following tubes

around the supply pump.
1) Remove tube clamp (17) between the
pump and fuel filter. 5) Loosen sleeve nuts (32) (2 pieces on the
2) Remove tube (18) between the pump and common rail side) and (33) (2 pieces on
fuel filter. (This tube was disconnected the supply pump side) and remove high-
from the fuel filter in step 3-3).) [*5] pressure pipes (34) and (35).
3) Remove tube clip (19) between the feed
pump and priming pump.
4) Disconnect tube (20) between the feed
pump and priming pump. [*6]
a Tube (21) is also clamped.
5) Remove tube (22) between the feed pump
and cooling plate. [*7]
a Tube (21) is removed, too.
6) Remove 2 fuel return tube clamps (23).
[*8]
7) Remove fuel return tube clip (24).
8) Remove fuel return tubes (25) and (26).
[*9]
9) Remove lubrication tube (27). [*10]
D155A-6 3
8. Rotate crank shaft forward so that the middle 12. Remove bracket (40), and loosen four mount-
position (a) of "2.5 TOP" stamp line of damper ing bolts (41).
(36) and "3.4 TOP" stamp line aligns to the
pointer (37). 13. Set tools A1, A2 and A3 on drive gear (42),
a Crank the crankshaft at hexagonal part (b) and tighten the center bolt of tool A1 to remove
of water pump drive shaft tip. drive gear (42) from the shaft (43).
14. Remove mounting bolts (41) and remove fuel

supply pump assembly (44).
a Keep tool A1, A2 and A3 set on drive gear
(42) until fuel supply pump assembly is
installed, for the drive gear falls off without
the tools.
9. Remove engine front cover (38).
10. 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.
11. Remove nut (39). [*12]

a Take care not to drop into the case.
4 D155A-6
Installation 4. Tighten permanently four mounting bolts (41).
1. Set fuel supply pump assembly (44). 5. Tighten bracket (40) permanently.
3 Mounting bolt:
a Before setting, check that key (d) of shaft
aligns to the key slot (e) of drive gear. 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
2. Temporarily tighten four mounting bolts (41)

and bracket (40) with fingers.
2 Mounting bolt: Liquid adhesive (LT-2)
6. Temporarily tighten clamps (45), (46) and (47),

and stays (28), (29) and (30), with fingers.
7. Tighten clamps (45), (46) and (47) perma-

nently.
a Tighten clamps in the order of (45), (29)
and (47).
3 Clamping bolt:
9.8 ± 1 Nm {1 ± 0.1 kgm}
8. Tighten stays (28), (29) and (30) permanently.

a Tighten stays in the order of (28), (29) and
(30).
3. Set high pressure pipes (34) and (35), tempo-

rarily tighten sleeve nuts (32) and (33) with fin-
gers 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}
9. Carry out the subsequent procedure in the

reverse order of removal.
D155A-6 5
Assembly [*10]
3 Lubrication tube joint bolt:
[*1], [*2] 7.9 – 12.7 Nm {0.8 – 1.3 kgm}
3 Fuel air bleeding tube joint bolt:
(Supply pump side)
(Air vent side and fuel filter head side) (5), 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
(6): (Block side)
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
[*11]
[*3], [*5] a Install covers (32) and (33) with the notch in
3 Fuel tube joint bolt:
the following direction.
Between fuel filter and supply pump (18): q Cover (32): Common rail side
24.5 – 34.3 Nm {2.5 – 3.5 kgm} q Cover (33): Supply pump side
(Fuel filter side)
14.8 – 19.6 Nm {1.5 – 2.0 kgm} [*12]
3
(Supply pump side) Nut (39): 176 – 196 Nm {18 – 20 kgm}
Between fuel filter and supply pump (17):
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
(Fuel filter side)
[*4]
3 Gauge guide mounting nut:
19.6 – 34.3 Nm {2 – 3.5 kgm}
[*6]
3 Tube joint bolt between feed pump and prim-
ing pump:
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
(Feed pump side)
43 – 47 Nm {4.4 – 4.8 kgm}
(Priming pump side)
[*7]
3 Tube joint bolt between feed pump and cool-
ing plate:
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
(Feed pump side)
43 – 47 Nm {4.4 – 4.8 kgm}
(Cooling plate side)
[*8]
3 Fuel return tube clamp bolt:
9.8 ± 1 Nm {1.0 – 0.1 kgm}
[*9]
3 Fuel return tube joint bolt:
Between supply pump and priming pump
(25)
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
(Supply pump side)
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
(Priming pump side of (25))
Between supply pump and common rail (26)
17.7 – 22.6 Nm {1.8 – 2.3 kgm}
(Common rail side)
6 D155A-6
Removal and installation of fuel

injector assembly 1
Removal
1. Remove the engine hood. For details, see

"Removal and installation of engine hood
assembly".
2. Remove the corrosion resistor assembly, fuel

filter assembly, prefilter assembly and oil filter
assembly according to the following proce- 3. Remove high-pressure pipe clamp (12)
dure. between the common rail and supply pump
1) Corrosion resistor and then remove stay (13).
1] Disconnect 2 corrosion resistor inlet/
outlet tubes (1). [*1] 4. Remove common rail cover (14).
2] Remove corrosion resistor bracket
assembly (2).
2) Fuel filter
1] Remove oil level gauge guide clamp
(3).
2] Loosen the upper joint bolt (on the air
vent assembly side) of fuel air bleed-
ing tube (4), remove the lower joint
bolt, and disconnect fuel air bleeding
t u be ( 4) f r o m f ue l fi l te r b r ac k e t
assembly (5). [*2]
3] Disconnect 2 fuel filter inlet/outlet
tubes (6). [*3]
4] Remove fuel filter bracket assembly
(5).
3) Prefilter a The following is the removal procedure for the
1] Remove prefilter inlet hose (7) and No. 1 fuel injector assembly.
outlet tube (8). [*4]
2] Remove prefilter bracket assembly 5. Remove stay (15).
(9). a If bracket (16) is removed, you can work
4) Oil filter easily.
1] Remove tube assembly (10) between
the oil filter and cylinder block. [*5]
2] Remove oil filter bracket assembly
(11).
a When removing the No. 1 fuel injector

assembly, you do not need to remove the
prefilter assembly.
a When removing one other than the No. 1
fuel injector assembly, you do not need to
remove the corrosion resistor assembly
and fuel filter assembly.
D155A-6 7
6. Remove clamp (17). 11. Rotate crankshaft forward, align damper

"1.6TOP" stamp line (c) to pointer (P), and then
7. Remove boot (18). set the No.1 cylinder to the compression top
dead center.
8. Loosen sleeve nut (19). a Crank the crankshaft at hexagonal part (d)
of water pump drive shaft tip.
9. Remove stays (20) – (23).
12. Remove cover (25). [*7]
13. Remove mounting bolts (26) through (28), and

remove rocker arm and rocker shaft assembly
(29). [*8]
a Loosen lock nut (31), and loosen adjust-
ment screw (32) two or three turns to pre-
vent excessive force applied to push rod
(30), when installing rocker arm and
rocker shaft assembly.
10. Remove cylinder head cover (24). [*6]
8 D155A-6
14. Loosen sleeve nut (33), and remove high pres-

sure pipe (34) from injector.
15. Remove wiring harness clamping bolt (35) and

clip (36). [*9]
16. Remove two wiring harness capture nuts (37)

from fuel injector assembly. [*10]
a Tighten nuts alternately.
17. Remove holder mounting bolt (38).
18. Set L type bar [1] under fuel injector assembly

inlet connector (a), and remove slowly fuel
injector assembly (39) with holder (40) using
leverage action.
a Do not pull out solenoid valve portion at
the top of injector by pinching with pliers,
etc.
D155A-6 9
Installation 6) Tighten bolts (38) to the specified torque.

3 Bolt (38):
1. Install fuel injector assembly. 58.8 – 73.5 Nm {6 – 7.5 kgm}
1) Check that no foreign material stays inside 7) Tighten sleeve nuts (33) and (19).
3 Sleeve nuts (33) and (19):
injector sleeve.
2) Install O-rings (41) and (42), and gasket 39.2 – 49 Nm {4 – 5 kgm}
(43) to injector.
a Take care not to install O-ring to
groove (b).
3) Set fuel injector assembly (39) with holder

(40) to cylinder head.
4) Attach spherical washer (44) to bolt (38),
and tighten temporarily bolt (38).
2 Spherical washer: Engine oil
5) Tighten temporarily high pressure pipe
sleeve nuts (33) and (19).
k Install high pressure pipe after
checking th e f ollowings. If an
abnormality takes place, it may
cause fuel leakage, and replace
high pressure pipe.
q Check visually taper seal portion (a
portion: within 2 mm from the tip) at
the joint section for visible vertical slit
scar (b) or patchy dent (c).
q Check the difference at (d) portion (tip
of taper seal portion: within 2 mm
from the tip) for any catches on a fin-
ger nail (no fatigue).
10 D155A-6
2. Install high pressure pipe clamp and stay. 3. Install the subsequent procedure in the reverse
1) Temporarily tighten high pressure pipe order of removal.
clamp, stay (23), clamping bolts (45)
through (49), and stay mounting bolt, with [*1]
fingers. 3 Corrosion resistor tube joint bolt:
2) Tighten permanently high pressure pipe 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
clamping bolt. (Inlet and outlet)
3 Clamping bolt:
9.8 ± 1 Nm {1 ± 0.1 kgm} [*2]
3) Tighten permanently stay mounting bolt. 3 Fuel air bleeding tube joint bolt
4) Temporarily tighten high pressure pipe (Upper and lower):
clamp, stay (22), clamping bolts (50) 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
through (54), and stay mounting bolt, with
fingers. [*3]
5) Install boot (18). 3 Fuel filter tube joint bolt:
a Install with the notch toward cylinder 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
block side. (Inlet and outlet)
6) Install high pressure pipe clamp (17) and
gate type frame (14) temporarily. [*4]
7) Tighten clamping bolt for high pressure 3 Prefilter inlet hose sleeve nut (7):
pipe clamp (17) permanently. 84 – 132 Nm {8.5 – 13.5 kgm}
3 Clamping bolt: Prefilter outlet tube sleeve nut (8):
9.8 ± 1 Nm {1 ± 0.1 kgm} (Bracket side)
8) Tighten gate type frame (14) permanently. 84 – 132 Nm {8.5 – 13.5 kgm}
9) Tighten high pressure pipe clamp, stay (Tube side)
(22) and clamping bolts (50) through (54), 43 – 47 Nm {4.4 – 4.7 kgm}
permanently.
3 Clamping bolt: [*5]
9.8 ± 1 Nm {1 ± 0.1 kgm} Installation procedure for oil filter tube
10) Tighten permanently stay mounting bolt. 1. Install tubes (55) and (56) temporarily to
bracket (58) with clip (57).
2. Install flange (59) and tubes (55) and (56) tem-
porarily.
3. Install the oil filter end of tubes (55) and (56) in
the hole of the oil filter bracket and tighten
bolts (60) temporarily.
4. Install flange (59) to the cylinder block tempo-
rarily with bolts (61).
5. Tighten bolts (60) on the oil filter side perma-
nently.
6. Tighten bolts (61) of flange (59) permanently.
D155A-6 11
[*6] [*9] [*10]

3 Cylinder head cover mounting bolt: a Install wiring harness according to the follow-
29.4 – 34.3 Nm {3.0 – 3.5 kgm} ing procedure.
a Eliminate the slack of the injector wiring har-
[*7] ness and press it against the injector body so
a Install with the notch downward. that it will not interfere with the rocker arm.
Tighten the nuts alternately.
[*8] 1) Install clip (36).
a When installing rocker arm and rocker shaft 2) Tighten two capture nuts (37).
assembly (29), check the ball portion of adjust- a Tighten capture nuts alternately.
ment screw (32) to be inserted securely into 3 Capture nut:
socket of push rod (30), and tighten mounting 2 ± 0.2 Nm {0.2 ± 0.02 kgm}
bolts. 3) Tighten wiring harness clamping bolt (35).
a As 3 mounting bolts are different each other,
install them referring to the followings.
q Mounting bolt (26): Stem length 120mm
q Mounting bolt (27): Stem length 90 mm
q Mounting bolt (28): Stem length 75.2 mm
3 Mounting bolts (26), (27) and (28):
93 – 103 Nm {9.5 – 10.5 kgm}
a Adjust valve clearance referring to the section
of Testing and adjusting, "Adjusting valve
clearance".
12 D155A-6
Removal and installation of 3. Disconnect or remove the hoses according to

cylinder head assembly 1 1) Remove priming pump cover (12).
Removal 2) Remove clips (13), (14) and (14a) and fuel
return tube (15). [*6]
k Disconnect the cable from the negative (–) 3) Remove clamps (16) and (17) and then
terminal of the battery. remove fuel tube (18) between the fuel fil-
ter and supply pump. [*7]
assembly".
2. Remove the corrosion resistor assembly, fuel

filter assembly, prefilter assembly and oil filter
assembly according to the following proce-
dure.
1) Corrosion resistor
1] Disconnect 2 corrosion resistor inlet/
outlet tubes (1). [*1]
2] Remove corrosion resistor bracket
assembly (2).
2) Fuel filter
1] Remove oil level gauge guide clamp
(3).
2] Loosen the upper joint bolt (on the air
vent assembly side) of fuel air bleed-
ing tube (4), remove the lower joint
bolt, and disconnect fuel air bleeding
t u be ( 4) f r o m f ue l fi l te r b r ac k e t
assembly (5). [*2]
3] Disconnect 2 fuel filter inlet/outlet
tubes (6). [*3]
4] Remove fuel filter bracket assembly
(5).
3) Prefilter
1] Remove prefilter inlet hose (7) and
outlet tube (8). [*4]
2] Remove prefilter bracket assembly
(9).
4) Oil filter
1] Remove tube assembly (10) between
the oil filter and cylinder block. [*5]
2] Remove oil filter bracket assembly
(11).
D155A-6 13
4. Disconnect wiring clips (19) and (20) and 8. Remove breather tube (40).
remove heater wiring connector RHT (21).
9. Remove aftercooler outlet hose (41) and air
5. Remove wiring clips (22) – (34) and move the intake connector (42) together. [*8]
wiring aside.
10. Remove water tube (corrosion resistor outlet/

inlet tube) (43).
11. Remove venturi connector (44).
12. Remove housing (45).
6. Remove stay (35), air vent assembly (36) and

bracket (37) together.
7. Remove brackets (38) and (39).
13. Disconnect fuel hose (46).
14 D155A-6
14. Remove clamp (47). 18. Remove 2 wiring harness clamps (54), upper
and lower, at the rear of the air intake manifold.
15. Remove mounting bolts of bracket (48) and
move bracket (48) breather (49) together.
19. Remove charge pressure sensor (55), plate

(56) and bracket (57) together.
16. Disconnect connectors TFUEL (50), TIM (51) a These parts must be removed to secure a
and PIM (52). space for loosening the turbocharger lubri-
cation tube clamp.
17. Remove spill tube (53). [*9]

20. Remove 5 stays (58) of the high-pressure pipe
clamps. [*10]
D155A-6 15
21. Remove high-pressure pipe clamp stays (59), 2) Remove bracket (66).
(60), (61), (62) and (63). [*11]
3) Remove 4 muffler mounting bolts (67) and

22. Remove air intake manifold (64). [*12] lift off muffler (68).
4 Air intake manifold: 50 kg 4 Muffler: 55 kg
23. Remove the muffler according to the following 24. Remove the turbocharger assembly according
procedure. to the following procedure.
1) Remove heat insulation plate (65). 1) Remove air connector (69). [*13]
2) Remove heat insulation plates (70), (71)
and (72).
3) Remove bracket (73).
4) Remove muffler drain tube (74).
5) Remove water tube (75).
6) Remove the turbocharger-end mounting
bolt of oil tube (76).
16 D155A-6
7) Remove bracket (77). 25. Disconnect connectors CN1 (79), CN2 (80),
CN3 (81), CN4 (82), CN5 (83) and CN6 (84),
and move wiring harnesses (85) and (86).
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).
8) Remove oil tube (78). [*14]

9) Remove water tube (79).
10) Sling turbocharger and exhaust manifold

assembly (80).
11) Remove 24 mounting bolts (81) and lift off
tu rb o ch ar g er an d e x ha us t m an if ol d
assembly (80). [*15] 26. Remove gate type frame (87) and clamp (88).
4
[*16]
Turbocharger and exhaust manifold
assembly: 80 kg
27. Remove spill tube (89). [*17]
28. Remove cover (90) and high pressure pipe

(91) depending on the cylinder head assembly
to be removed. [*18] [*19]
D155A-6 17
29. Remove water tube (92). [*20] 32. Remove three mounting bolts (95) through
(97), and remove rocker arm and rocker shaft
30. Remove cylinder head cover (93). [*21] assembly (98).
a Loosen lock nut (100), and loosen adjust-
ment screw (101) two or three turns to
prevent excessive force applied to push
rod (99), when installing rocker arm and
rocker shaft assembly. [*22]
31. Rotate crankshaft forward, align damper

"1.6TOP" stamp line (c) to pointer (P), 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. 33. Remove fuel injector assembly.
1) Remove wiring harness clamping bolt
(102) and clip (103). [*23]
2) Remove two wiring harness capture nuts
(104) from fuel injector assembly. [*24]
a Loosen nuts alternately.
3) Unscrew bolt (105) to remove holder
(106).
4) Push connecter (107) into rocker housing,
and remove injector wiring harness (108).
[*25]
a O-ring is installed in connector (107).
18 D155A-6
5) Remove mounting bolt (110) of holder. Installation

[*26]
6) Set L type bar [2] under fuel injector 1. Install cylinder head assembly.
assembly inlet connector (e), and remove 1) Install cylinder head gasket (118).
slowly fuel injector assembly (111) with a Check that the mounting surface of
holder using leverage action. [*27] cylinder head and the inside of cylin-
a Do not grip the solenoid valve at the ders are free from foreign material.
top of the injector to pull off the injec- a Check that the gasket is free from
tor. peeling or coming off of grommet.
34. Remove two push rods (99). 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
less.
(The number of punch mark at the
head of bolt should be 5 or less.)
q Bolt under head length service limit
(a)
Short bolt:Less than 170.8 mm
Long bolt: Less than 205.8 mm
35. Remove crosshead (113).
36. Remove three mounting bolts (114), three bolts

(115) and auxiliary bolt (116), and remove cyl-
inder head assembly (117).
D155A-6 19
3) Install cylinder head assembly.

4) Tighten each 3 mounting bolts (114) and
(115) in order 1 through 6 as shown in the
figure.
2 Mounting bolt:
Lubricant with molybdenum dis-
ulfide (LM-P)
3 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 A4.
a When tool A4 is not available, put 2. After installing cross head (113), make adjust-
marks (a) and (b) to bolt and cylinder ment as follows.
head, and retighten bolt 90° (+30°/0). 1) Loosen lock nut (100), and loosen adjust-
5) Tighten auxiliary bolt (116) (tightening ment screw (101).
order: 7th) with the following torque. 2) Lightly push cross head (113) contact sur-
3 Auxiliary bolt: face (h) with rocker arm, and hold cross
66.6 ± 7.4 Nm {6.8 ± 0.8 kgm} head to contact with push rod (99) side
valve stem (119).
3) Screw slowly adjustment screw (101), and
check the position where adjustment
screw touches valve stem (120).
4) From the above condition, screw adjust-
ment screw (101) 20°.
5) While holding adjustment screw (101) with
a flat-head screwdriver, tighten locknut
(100).
3 Locknut:
58.7 ± 5.9 Nm {6.0 ± 0.6 kgm}
20 D155A-6
3. Install push rod (99).

a Raise push rod slightly, and check that
push rod is securely inserted in cam fol-
lower.
[*7]
3 Supply pump-end joint bolt of fuel tube
between fuel filter and supply pump:
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
4. carry out the rest of installation in the reverse
order of removal. [*8] [*13]
a Replace the MIKALOR clamps with new ones.
[*1] a Install each MIKALOR clamp according to the
3 Corrosion resistor tube joint bolt: following procedure.
24.5 – 34.3 Nm {2.5 – 3.5 kgm} 1) Set the hose to its original position.
2) Set the bridge (BR) under the bolt (BC)
[*2] and reduce lapping area (b) over the band
3 Fuel air bleeding tube joint bolt (Upper and (BD) to a minimum of 5 mm.
lower): 7.8 – 9.8 Nm {0.8 – 1.0 kgm} 3) Tighten bolt (BC).
a Do not use an impact wrench.
[*3] 2 Threaded part of bolt: Lubricating
3 Fuel filter tube joint bolt (Inlet and outlet): oil (THREEBOND, PANDO 18B)
24.5 – 34.3 Nm {2.5 – 3.5 kgm} q When reusing the hose, install it to the
clamp mark on it.
[*4] 3 Bolt (BC):
3 Prefilter inlet hose sleeve nut (7): 25 ± 5 Nm {2.55 ± 0.5 kgm}
84 – 132 Nm {8.5 – 13.5 kgm} q When using a new hose, tighten until
3 Prefilter outlet tube sleeve nut (8): dimension BDG is as follows.
(Bracket side) a Dimension BDG: 8 – 10 mm
84 – 132 Nm {8.5 – 13.5 kgm}
(Tube side)
43 – 47 Nm {4.4 – 4.7 kgm}
[*5]
Installation procedure for oil filter tube
Install the oil filter tube according to [*5] in
"Removal and installation of fuel injector assem-
bly".
[*6]
3 Fuel return tube joint bolts
Upper joint bolt (15a):
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
Lower joint bolt (15b):
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
D155A-6 21
[*9]
3 Joint bolt (53a):
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
3 Joint bolt (53b):
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
[*17]
3 Spill tube joint bolt:
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
[*18]
[*10] [*11] [*16] [*19] a Install cover with the notch downward.
a Install high pressure pipe, clamp, stay and gate
type frame referring to the section, "Removal [*20]
and installation of fuel injector assembly". 3 Water tube joint bolt:
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
[*12]
a Tighten intake manifold (64) mounting bolts in [*21]
the numerical order shown below. 3 Cylinder head cover mounting bolt:
3 Mounting bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm} 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
[*14]
3 Oil tube cylinder block side joint bolt:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
[*15]
a Tighten exhaust manifold mounting bolts in the
numerical order shown below.
2 Threads of mounting bolt:
Lubricant with molybdenum disulfide
(LM-P)
3 Mounting bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm}
22 D155A-6
[*22] [*23] [*24] [*25]

a When installing rocker arm and rocker shaft a Install injector wiring harness according to the
assembly (98), check the ball portion of adjust- following procedure.
ment screw (101) to be inserted securely into 1) Install O-ring to injector wiring harness (108).
socket of push rod (99), and tighten mounting 2) Install injector wiring harness (108) in rocker
bolts. housing, install holder (106) and tighten bolt
a As three mounting bolts are different each (105).
other, install them referring the followings. 3) Install clip (103).
q Mounting bolt (95): Stem length 120 mm 4) Tighten two capture nuts (104).
q Mounting bolt (96): Stem length 90 mm a Tighten capture nuts alternately.
q Mounting bolt (97): Stem length 75.2 mm 3 Capture nut: 2 ± 0.2 Nm {0.2 ± 0.02 kgm}
3 Mounting bolt: 5) Install wiring harness clamping bolt (102).
93 – 103 Nm {9.5 – 10.5 kgm}
a Adjust valve clearance referring to the section
of Testing and adjusting, "Adjusting valve
clearance".
[*26] [*27]
a Install the fuel injector assembly referring to
the section, "Removal and installation of fuel
injector assembly".
a Eliminate the slack of the injector wiring har-
ness and press it against the injector body so
that it will not interfere with the rocker arm.
Tighten the nuts alternately.
D155A-6 23

radiator assembly 1
Removal
k Disconnect the negative terminal (–) of the
battery.
1. Drain the coolant.

6 Coolant: 82l
2. Remove cover at the top of radiator, and dis-

connect connector LHD (1).
6. Sling radiator assembly (12) and remove it.

[*3]
4 Radiator assembly: 25 kg

4 Cover: 50 kg
4. Disconnect hoses (3) through (7). [*1]

a Remove mounting bolts for hoses (5)
through (7), and disconnect hoses with
tubes.
5. Remove bracket (8) through (11). [*2]

a Remove bracket (8) when removing left
radiator assembly.
24 D155A-6
Installation
q Carry out installation in the reverse order of
removal.
[*1]
a Install hoses (5) and (7) with the red circle
paint upward.
2 Tube flange: gasket sealant
3 Hose clamp: 8.8 ± 0.5 Nm {90 ± 5 kgcm}
a Tighten two parallel clamps for hose (6) with its
bolt location rotated 180° each other.
2 Tube flange: gasket sealant
[*2]
a Install radiator mounting brackets (9 – 11) and
cushion (19) according to the following proce-
dure.
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).
D155A-6 25
[*3]
a Set radiator assembly according to the follow-
ing procedure.
1) Set rubber (13) with its stepped portion (a)
downward.
a Apply appropriate amount of grease
to prevent drop down when lifted up.
2) Install O-ring (14).
2 O-ring periphery: Grease (G2-LI)
3) Open radiator grill, remove fan net and

install four cushions (15) to lower tank
(16).
4) Sling the radiator assembly and set it on

the lower tank slowly.
a Check visually the installation condi-
tion from the machine front.
26 D155A-6
Removal and installation of 4. Remove four mounting bolts for tube (4). [*2]
aftercooler assembly 1
5. Remove brackets, (5), (6) and (7).
Removal
k Disconnect the negative terminal (–) of the
battery.
1. Remove cover at the top of radiator, and dis-

connect connector LHD (1).
6. Sling aftercooler assembly (8) and remove it.

4 Aftercooler assembly: 35 kg

4 Cover: 50 kg
3. Disconnect the tube (3) from the lower part of

the after cooler. [*1]
D155A-6 27
Installation a Assemble the duct and tube in 30 minutes

after applying the gasket sealant.
q Carry out installation in the reverse order of
removal.
a 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
5. Assemble the charged air cooler, duct and
water to check for air leakage.
tube so that the faces coated with LG-6 will be
a Check for air leakage for 3 minutes while
stuck to both sides of the new gasket.
running the engine at full throttle.
a When installing the duct and tube, take
care not to misalign them. After assem-
bling 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 nar-
row 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
3. If air leaks, remove the engine upper hood,

side cover, air cleaner and right and left mud-
guards.
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 nar-
row places of the flange with a spatula.
Spread it thinly on the inside to prevent it
from projecting into the duct or tube.
28 D155A-6
7. 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 assem-
bling 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]
a When loosened hose 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 a minimum of 5 mm.
3) Tighten bolt (BC).
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
D155A-6 29
Removal and installation of 5. Remove air intake connector and air hose
engine assembly 1 assembly (2). [*2]
Removal 6. Remove stay (3).
1. 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 atmo-
sphere.
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 fill-
ing the air conditioner circuit with the
refrigerant. Collecting and filling work
must be conducted by a qualified per-
7. Remove the muffler according to the following
son.
procedure.
1) Remove heat insulation plate (4).
2. Drain the coolant.
6 Coolant: 82 l

assembly".
4. Open the undercover (1).

k Using a floor jack, a wire rope, etc.,
open the undercover carefully.
2) Remove bracket (5).
30 D155A-6
3) Remove 4 muffler mounting bolts (6) and 12. Disconnect fuel hose (11) between the fuel
lift off muffler (7). tank and prefilter. [*3]
4 Muffler: 55 kg
13. Disconnect return hose (12).

8. Remove the radiator assembly. For details,
see "Removal and installation of radiator
assembly".
9. Remove the aftercooler assembly. For details,

see "Removal and installation of aftercooler
assembly".
10. Remove reservoir tank (8) and bracket (9)

together.
14. Remove aftercooler tube (13). [*4]
11. Disconnect ground wire (10).
D155A-6 31
15. Remove heater hose (15). 22. Disconnect connectors AC05 (24), EG2 (25)
and EG1 (26).
16. Lift off water tube (16).
23. Remove and move receiver tank (27).
17. Disconnect starting motor B-terminal ST/B

(17). 24. Disconnect hose (28) from radiator lower tank.
[*5]
18. Remove heater hose (18).
19. Remove 3 clamps (19) of the heater hose dis-

connected in step 15 and disconnect the hose
from the engine.
25. Separate universal joint (29) at the engine

side. [*6]
20. Remove the 2 hoses from each of air condi-

tioner condenser (20) and oil cooler (21) and
remove frame (22).
21. Remove frame (23).
32 D155A-6
26. Temporarily sling engine assembly. Installation

27. Remove mounting bolts (30) and (31), four q Carry out installation in the reverse order to
pcs.each. [*7] removal.
[*1]
a When installing the hoses of the air conditioner
circuit, take care that dirt, dust, water, etc. will
not enter them.
a When installing each air conditioner hose,
check that O-ring (70) is fitted to it.
a Check O-ring (70) for a flaw and deterioration.
a When connecting each refrigerant pipe, apply
compressor oil for new refrigerant (R134a)
(DENSO: ND-OIL8 or ZEXEL ZXL100PT
(equivalent to PAG46) to O-ring (70)).
3 Apply engine oil (EO15W-40) to threaded
part and seat of mounting bolt.
3 Threaded part of hose (M16 x 1.5):
28. Sling engine assembly (32) and remove it. 12 – 15 Nm {1.2 – 1.5 kgm}
a Check all wires and pipes are removed.
a Remove carefully to avoid any interfer- 20 – 25 Nm {2.0 – 2.5 kgm}
ence with the machine body.
30 – 35 Nm {3.0 – 3.5 kgm}
q Filling air conditioner circuit with refriger-

ant (R134a)
Fill the air conditioner circuit with refrigerant
(R134a).
a Quantity of refrigerant: 1,200 ± 50 g
[*2] [*4]
(MIKALOR clamp)
a Use a new MIKALOR clamp.
a Installation procedure of hose
1) Set the hose to the original position.
2) Set the bridge (BR) under the clamp bolt
(BC) and lap it over band (BD) at least (b)
reaches 5 mm.
3) Tighten the clamp.
2 Clamp bolt (BC): Lubricating oil
(THREEBOND PANDO18B)
D155A-6 33
q When reusing the hose

Install the clamp to the calmp mark made
on the hose.
3 Clamp bolt (BC):
25 ± 5 Nm {2.55 ± 0.5 kgm}
q When using a new hose

Tighten until dimension (BDG) is 8 – 10
mm.
[*3]
3 Hose mounting sleeve nut:
84 – 132 Nm {8.5 – 13.5 kgm}
[*5]
[*6]
3 Universal joint mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
[*7]
3 Engine mounting bolt:
823.8 – 1,029 Nm {84 – 105 kgm}
34 D155A-6
Removal and installation of 4. Remove the 4 front hood mounting bolts and lift
engine hood assembly 1 off front hood (7).
4 Front hood: 55 kg
Removal
2. Open side cover (2) and remove covers (3) –

(5).
a Work on the opposite side similarly.
5. Remove two mounting bolts (9) for tube (8).
3. Disconnect headlamp wiring connector CN-

LHD (6).
6. Remove hose (10). [*1]
D155A-6 35
7. Disconnect connector AF1 (11). Installation

q Carry out installation in the reverse order to
removal
[*1]
8. Sling engine hood (12) and remove it.

4 Engine hood: 170 kg
36 D155A-6
Removal and installation of Removal with tool C1

engine front seal 1 a Remove all the chips.
a Take care in the removal not to damage front
Special tools seal (3) installation position on front cover (4)
and the seal contact face on crankshaft (5).
New/Remodel
a Before removing, slightly drive the front seal in
Necessity
Sym- once to free it from fixation.
Part No. Part name
Sketch
bol a When front seal (3) is fixed too hard to the front
Q'ty
cover (4), carry out the following procedure.
1) Drill through a hole of approx. 3 mm dia.
795T-521-1111 Push tool t 1 R Q
on front seal (3).
2 01050-31655 Bolt t 3 2) Replace the tip of tool C3 with the drill
01050-31635 Bolt t 3 type one.
C 3) Insert the top end of tool C3 into the drilled
3 795-931-1100 Seal puller t 1
hole, and remove the front seal by the
795T-521-1150 Push tool t 1 Q impact of slide hammer (SH). (Apply the
8
01050-31635 Bolt t 4 slide hammer evenly not to tilt the front
seal.)
a Remove the metal powders completely.
Removal a When the sleeve is attached, cut sleeve (6)
1. Remove the radiator and oil cooler guard using a gad and hammer to remove it.
assembly. a Take care not to damage crankshaft (5).
2. Remove damper (1) and flange (2).
q Tool C3
3. Remove front seal (3).
D155A-6 37
Installation 1. Procedure for installing standard seal

a Before installing the seal, check that the
a Check the seal by checking the wear of the end corners and lip sliding surfaces of the
shaft and replace it with the "standard seal" or crankshaft are free from flaw, burr, and
"sleeved seal". rust of the front cover.
a If the shaft is worn to the degree of luster (If a When installing the seal, do not apply oil
wear which you feel with your finger is less or grease to the shaft and seal lip. Wipe
than 10 mmm) and does not have any flaw, off the oil from the shaft.
install "standard seal A". In other cases, install a Never remove installation guide (7) of the
"sleeved seal B". replacement seal before installing the
a (7): Plastic inside cylinder which is also used seal.
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) Set large inside diameter side (b) of instal-

lation guide (7) to the end of crankshaft
(5).
a Take care not to mistake the direction
of the plastic inside cylinder.
38 D155A-6
2) Push in the metal ring of seal (3) evenly as 2. Procedure for installing sleeved seal
if you are passing over the large diameter a When installing the front seal, do not apply
side of plastic inside cylinder (7). oil or grease to the shaft, inside cylinder
3) After pushing in the seal to a depth where surface of sleeve (6) and seal lip.
it does not come off the front cover, 1) Set sleeve and front seal assembly (8) to
remove plastic inside cylinder (7). tool C8 (for fitting the sleeved seal).
a When removing the inside cylinder, 2 Sleeve inside cylinder surface (6):
take care not to damage the seal lip. Gasket sealant (LG-7)
4) Tighten tool C2 until the bolts (55 mm)
reach the end.
2) Set the sleeve of the front seal assembly

(8) to the end of crankshaft (5) and tighten
5) Tighten tool C2 with the bolts (35 mm) the 3 bolts evenly to press fit sleeve and
again to press fit seal (3) until the end of rear seal assembly (8) until the end of tool
tool C2 reaches the end of crankshaft (5). C8 (for press fitting the sleeved seal)
a Seal driving distance (a) from crank- reaches the end of crankshaft (5).
shaft: 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.
D155A-6 39
3) Remove tool C8 (for press fitting the

sleeved seal) and install tool C2 (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 C2 reaches the
end of crankshaft (5)
a Seal driving distance (a) from crank-
shaft: 9.1 – 10.1 mm
not to damage the lip of the seal with
the tool set etc.
3. Install flange (2).

3 Flange mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
4. Install damper (1).
40 D155A-6
Removal and installation of 3. Install eyebolt [1] to flywheel (2), sling flywheel
engine rear seal 1 (2), and remove bolts (3).
Special tools 4. While moving flywheel (2) toward this side, lift
it off.
k Since the socket part of the flywheel is
New/Remodel
shallow, it may fall suddenly. Take care
Necessity
Sym-
Part No. Part name
not to catch your fingers in the fly-
Sketch
bol
wheel.
Q'ty
3 795-931-1100 Seal puller t 1 4 Flywheel: 60 kg
795T-421-1270 Push tool t 1 Q
4 01050-31645 Bolt t 4
01643-31645 Washer t 8
795T-421-1240 Push tool t 1 Q
C
5 01050-31645 Bolt t 4
01643-31645 Washer t 4
795T-421-1250 Push tool t 1 Q
9 01050-31645 Bolt t 4
01643-31645 Washer t 8
Removal
5. Remove rear seal (4) according to the follow-
1. Remove the engine assembly. For details, see ing procedure.
"Removal and installation of engine assembly". a Measure the distance from the end of the
housing.
2. Remove damper assembly (1). For details, 1) Before pulling out rear seal (4), drive it in a
see "Removal and installation of damper little to separate it from housing (FWH).
assembly".
D155A-6 41
2) If the seal is sleeved, cut and remove Installation

sleeve (5) with a chisel and a hammer.
a When cutting, take care extremely not a Check the wear of the shaft and select the
to damage crankshaft (6). "standard" or "sleeved" Teflon seal (Laydown
3) Hitch the end of tool C3 to the metal ring lip seal) to replace the used seal.
of rear seal (4) and pull out the seal with If the shaft is worn to the degree of luster (If the
impacts of slide hammer (SH). wear depth which you feel with your finger is
a Do not use a drill etc. since chips may less than 10 mm) and does not have any flaw,
enter the engine. install "standard seal (A)". In other cases,
a If chips were made, remove all of install "sleeved seal (B)".
them. a (7): Plastic inside cylinder which is also used
q Tool C3 as installation guide.
a (5): Sleeve.
a Do not remove installation guide (7) from rear
seal (4) before installing the rear seal.
a Handle rear seal (4) and sleeve (5) as an
assembly and never separate them from each
other.
q Standard spare seal q Sleeved seal
a Left: Standard seal, Right: Sleeved seal
a Clean, degrease, and dry the contact surface

of the seal to the flywheel housing side.
a Clean, degrease, and dry the seal lip surface
(periphery of the crankshaft).
a Check that the end corners and lip sliding sur-
face of the crankshaft and the housing are free
from flaw, burr and rust.
42 D155A-6
1. Procedure for installing standard seal 4) Tighten the 3 bolts evenly to press fit rear
a When installing rear seal (4), do not apply seal (4) until the end of tool C4 (for press
oil or grease to the shaft and seal lip. fitting the seal) reaches the end of crank-
1) Set large inside diameter side (b) of plas- shaft (6).
tic inside cylinder (7) of rear seal (4) to the a Tighten tool C4 (for press fitting the
end of crankshaft (6). s ea l) fi r st w it hou t in s er ti ng a ny
a Take care not to mistake the direction washer until the bolts reach the end
of the plastic inside cylinder. and then tighten with 2 washers
inserted (in each bolt).
not to damage the lip on the PTO side
with the tool set etc.
2) Push in the metal ring of rear seal (4)

evenly as if you are passing over the large
diameter side of plastic inside cylinder (7).
3) After pushing in rear seal (4) to a depth
where it does not come off the housing,
remove plastic inside cylinder (7).
a When removing the inside cylinder, 2. Procedure for installing sleeved seal
take care not to damage the seal lip. a When installing the rear seal, do not apply
oil or grease to the shaft and inside cylin-
der (C) and seal lip of the sleeve.
1) Set sleeve and rear seal assembly (8) to
tool C5 (for fitting the sleeved seal).
2 Sleeve inside cylinder surface (C):
Gasket sealant (LG-7)
D155A-6 43
2) Set sleeve of the rear seal to the end of 3. Flywheel

crankshaft (6) and tighten the 4 bolts of Using eyebolt [1] (12 mm, P = 1.75), sling fly-
tool C5 evenly to press fit sleeve and rear wheel (2), install it to the crankshaft, and
seal assembly (8). tighten bolts (3).
a Tighten tool C5 (for press fitting the a If there are 5 punch marks on a bolt, do
sleeved seal) with 1 washer inserted not use that bolt but replace it.
in each bolt until the bolts reach the 2 Threaded part and seat of bolt:
end. Engine oil SAE No. 30
3) Remove tool C5 (for press fitting the a Tighten the mounting bolts according to
sleeved seal) and install tool C9 (for press the following procedure.
fitting the seal). 3 Flywheel mounting bolts
4) Tighten the 3 bolts evenly to press fit 1st time: 118 ± 4.9 Nm {12 ± 0.5 kgm}
sleeve and rear seal assembly (8) until the 2nd time:1)When using tool A4
end of tool C9 reaches the end of crank- (See the tools list) Retighten
shaft (6). each bolt by 90 (+30°/0) in
a Tighten the bolt of tool C9 (for press the order of [1] – [8].
fitting the seal) without washer until it 2) When not using tool A4
reaches, and then tighten the bolt Make marks on each bolt
using 2 washers (for each bolt). and flywheel withpaint,then
a After press fitting the seal, remove the retighten each bolt by 90
red sealant layer from its periphery. (+30°/0) in the order of [1] –
a Rear seal driving depth: [8].
13.2 ± 0.2 mm from end of crankshaft
a When installing, set the dowel pin of

the crankshaft to the dowel hole of
the flywheel.
44 D155A-6
a After tightening, make 1 punch mark (9)

on each bolt head to indicate the number
of tightening time.
a After installing the flywheel, measure the

facial runout and radial runout with tool [2].
a Radial runout: Max. 0.30 mm
a Facial runout: Max. 0.30 mm
q Carry out the following installation in the

reverse order to removal.
D155A-6 45
Removal and installation of fuel 4. Remove cover (4).

tank assembly 1
5. Remove fuel hoses (5), (6) and (7).
Removal
1. Open the water separator inspection cover and

turn the fuel drain lever (1) in the direction of
(L) to drain the fuel.
2. Remove line filter assembly (2).
6. Sling water separator storage box (8) and

remove 5 mounting bolts (9).
7. Lift off water separator storage box (8).
3. Remove pin puller drive hose mounting bracket

(3). (Machine with giant ripper)
8. Open the inspection cover and disconnect wir-

ing harness connector (10).
46 D155A-6
9. Remove 6 fuel tank mounting bolts (11) on the Installation

right and left sides.
removal.
10. Sling the fuel tank assembly, move it back

about 100 mm, and disconnect hoses (12) and
(13).
v
11. Remove fuel tank assembly (14).

4 Fuel tank assembly:
410 kg (When empty)
915 kg (When full)
D155A-6 47
Removal and installation of fan 4. Disconnect wiring harness connector FAR (5)
drive assembly 1 and remove wiring harness clamp.
Removal 5. Disconnect fan motor hoses (6), (7) and (8).

a Plug the hoses so that foreign matter will
k Disconnect the cable from the negative (–) not enter them.
1. Drain the hydraulic oil.

6 Hydraulic tank: Approx. 85 l
2. Remove 4 mounting bolts (1) and open mask

(2).
6. Using eyebolts [1], sling fan drive assembly (9)

and remove mounting bolts (10).
7. Lift off fan drive assembly (9).

4 Fan drive assembly: 125 kg
3. Remove 4 mounting bolts (3) and remove

guard (4).
Installation
removal.
q Refilling with oil

Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.
48 D155A-6
Removal and installation of fan Installation

motor assembly 1 q Carry out installation in the reverse order to
removal.
Removal
1. Remove the fan motor assembly. For details, [*1]
see "Removal and installation of fan drive Be sure to align the hole of lock plate (1) by turning
assembly". nut (2) in the tightening direction.
2. Remove the mounting bolt and lock plate (1). [*2]

[*1] 3 Mounting nut (2):
441 – 539 Nm {45 – 55 kgm}
3. Remove nut (2). [*2]
[*3]
a Clean and degrease the fitting areas of the fan
motor and fan.
4. Using puller [1], remove fan (3).
5. Remove 4 mounting bolts (4) and fan motor

assembly (5). [*3]
4 Fan motor assembly: 40 kg
D155A-6 49
D155A-6 Bulldozer
© 2009 KOMATSU
All Rights Reserved
50 D155A-6
SEN03368-01
D155A-6

D155A-6 85001 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 ........................................................................ 16
D155A-6 1
Removal and installation of 9. Remove mounting bolts for damper cover

damper assembly 1 assembly (5), and install two guide bolts [1]
diagonally. [*2]
Removal
10. Using forcing bolt [2], pull out damper cover
1. Drain the oil in damper case. assembly (5) so that the lifting tool can be
6 Damper case: 1.5 l applied, and then remove it. [*3]
4 Damper cover assembly: 60 kg
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 refer-

ring to the section, "Removal and installation of
cooling fan pump assembly".
6. Disconnect breather hose (2).
7. Remove oil level gauge (3).
8. Sling universal joint assembly (3) and remove

it. [*1]
4 Universal joint assembly: 20 kg
2 D155A-6
11. Remove damper assembly. Installation

1) Remove two mounting bolts for damper
assembly (6), and set guide bolts [3]. [*4] q Carry out installation in the reverse order of
2) Remove the rest of mounting bolts, and removal.
pull out damper assembly using forcing
bolt [4]. [*5] [*1]
3) Use eyebolt [5] to remove damper assem-
bly (6). Liquid adhesive (LT-2)
4 Damper assembly: 60 kg 98 – 123 Nm {10 – 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:
98.1 – 122.6 Nm {10 – 12.5 kgm}
[*3]
a Install damper cover assembly according to
1) Degrease the spline portion "a" of shaft (7),
apply dry lubricant A, and leave it 2 to 3 min-
utes.
2) Fill "b" portion of inner body (8) with about 80 g
of lithium base extreme pressure grease with
molybdenum disulphide B.
Dry lubricant with Sumiko lubricant Rocol
A
molybdenum disulphide Dry Splay or equivalent
• Kyodo yushi
Molylex No.2 or an
equivalent
Lithium base extreme
• Showa Shell Sekiyu
B pressure grease with
Retinax AM or an equiv-
molybdenum disulphide
alent
• Nippon Oil Corporation
Molytex or an equivalent
D155A-6 3
3) Apply gasket sealant to the flange portion of

damper cover assembly.
a Apply it to the engine side also.
a Apply it with the thickness 0.1 to 0.2 mm.
2 Damper cover mounting face:
4) Install the damper cover assembly to the

engine.
[*4] [*5]
3 Damper mounting bolt:
98 – 122.6 Nm {10 – 12.5 kgm}

5 Damper case: 1.5 l
3 Drain plug: 58.5 – 78.5 Nm {6 – 8 kgm}
4 D155A-6
Disassembly and assembly of damper assembly 1
Special tools
New/Remodel
Necessity
Sym-
Part number Part name
Sketch
bol
Q'ty
791-612-1100 Installer t 1
Puller
F 790-101-4200 t 1
(294 kN {30 ton})
D155A-6 5
Disassembly 2) Remove collar (7-2) and O-ring of bearing

(7) from shaft (6), and pull out inner race
Disassembly of damper cover assembly (1) (7-1).
1. Coupling
Remove bolt (3) from cover (2), then remove
holder (4) and coupling (5).
3. Bearing and oil seal

1) Remove oil seal (9) from cover (2), and
pull out inner race (7-3) of bearing (7).
2. Shaft
1) Set damper cover assembly (1) to block
[1], and remove shaft (6) by tapping it from
output side with plastic hammer, etc.
a Shaft (6) will be pulled out with inner
race (7-1) of bearing (7) and oil seal
(8).
2) Remove outer races (7-4) and (7-5) of

bearing (7) from cover (2).
6 D155A-6
Disassembly of damper assembly (10)

1. Unscrew bolt (11) to remove flange (12).
2. Remove outer body (13), inner body (14) and

cushion (15).
3. Pull out plug (17) from flange (16).

a This procedure applies only when replac-
ing plug.
D155A-6 7
Assembly
Assembly of damper assembly (10)
1. Set flange (16) and outer body (13) to cylinder

[1], matching their bolt holes, and install inner
body (14).
2 Mating surface of flange and outer
body: Gasket sealant (LG-6)
2 Outer body inner surface:
Grease (G2-LI)
2 Cushion contact surface of inner body:
Grease (G2-LI)
8 D155A-6
2. 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 – 7.5 kgm}
2. Press fit inner race (7-1) of bearing (7) to shaft

(6) with tool F.
4. Fill (b) portion of inner body (14) with about 80

g of the following grease.
2 : Grease
Grease Supplier part name

• Kyodo yushi Molylex
No.2 or an equivalent
• Showa Shell Sekiyu
Lithium base extreme
Retinax AM or an
pressure grease with
equivalent
molybdenum disulphide
• Nippon Oil Corporation
Molytex or an equiva-
lent
D155A-6 9
3. Install collar (7-2) and O-ring to shaft (6). 6. Install coupling (5) and holder (4), and tighten
bolt (3).
3 Mounting bolt:
245.2 – 308.9 Nm {25 – 31.5 kgm}
4. Set cover (2) to shaft (6), and press fit bearing

inner race (7-3) using tool F.
5. Install oil seals (8) and (9) to cover (2).

2 Press fitting surface of oil seal:
2 Oil seal lip surface: Grease (G2-LI)
a Apply gasket sealant at oil seal surface
thinly, and wipe off extra sealant.
10 D155A-6
Removal and installation of power 12. Remove clamps (14) and (15) and hoses (16)
train unit assembly 1 and (17).
Removal
1. Drain the oil from the hydraulic tank and power

train case.
6 Hydraulic tank: 97 l
6 Power train case: 97 l
2. Remove the cabin and floor frame assembly.

For details, see "Removal and installation of
cabin and floor frame assembly".
13. Remove oil pressure pickup hose mounting
3. Remove the fuel tank assembly. For details, bracket (18).
see "Removal and installation of fuel tank
assembly".
4. Remove oil level detection pipe (1).
5. Remove oil filler pipe (3).
6. Remove return hose (2).
7. Remove stays (4) and (5).
8. Disconnect hoses (6) and (7) from control

valve (8).
14. Remove accumulator and bracket assembly

(19) and disconnect hose (20).
9. Remove 2 clips (9) and hoses (10) and (11).
10. Remove work equipment pump suction tube

(12). [*1]
11. Disconnect hose (13) from control valve.
D155A-6 11
15. Disconnect hose (21). 18. Remove clips (24) – (26).
19. Remove stay (27).
20. Move wiring and piping (28) toward the

machine.
16. Disconnect hose (22) coming from the oil

cooler.
21. Disconnect power train filter hoses (29) and

(30).
22. Remove the 4 bracket mounting bolts (at the

filter bottom) and remove filter and bracket
assembly (31).
4 Power train filter assembly: 30 kg
17. Remove grease tube (23).
12 D155A-6
23. Remove 4 mounting bolts (32) on the engine 27. Remove covers (38) on both sides of the steer-
side and disconnect universal joint (33). [*1] ing case.
a After disconnecting the universal joint,
push the yoke into the torque converter
side to disconnect the universal joint com-
pletely.
28. Remove cap (39). [*2]
29. Loosen coupling clamp (40) and move seal

(41) out a little. [*3]
24. Remove pin puller hoses (34) and (35).
25. Remove pin puller line unit (36).
30. Remove final drive shaft cover (42).
26. Disconnect additional filter hoses (36) and

(37).
D155A-6 13
31. Using eyebolt [1] (M10 x 1.5), pull out drive 33. Lift off power train assembly (45). [*5]
shaft (43). a Check that all the wiring and piping are
a Pull out the drive shaft until it comes off disconnected.
the spline on the steering case side. a When lifting up the assembly, take care
a If the drive shaft cannot be pulled out eas- that it will not interfere with the machine.
4
ily, raise the shoe grouser with a jack to a
Power train assembly: 2,500 kg
position where the drive shaft can be
pulled out easily.
a Pull out the drive shaft on the opposite
side similarly.
32. Remove 2 mounting bolts (44) each on the

right and left sides of the power train assembly.
[*4]
14 D155A-6
Installation
removal.
[*1]
98 – 123 Nm {10 – 12.5 kgm}
[*2]
3 Cap mounting bolt:
245.8 – 309 Nm {25 – 31.5 kgm}
[*3]
a Clamp the seal ridge of the coupling securely
and install the threaded part of the clamp so
that it will be in parallel with the cap mounting
seat.
[*4]
3 Mount mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
[*5]
a When installing the power train unit assembly,
take care not to damage seal (40).

again.
5 Hydraulic tank: 85 l
5 Power train case: 90 l
D155A-6 15
Disconnection and connection of 4. Remove hoses (5) – (11).

power train unit assembly 1
Disconnection
1. Set power train unit assembly (1) on block [1].
4 Power train unit assembly: 2,500 kg
5. Remove hoses (12) – (14).
2. Referring to circuit diagram collection "Electric

circuit diagrams and connector location dia-
grams", disconnect all the connectors from the
power train unit and remove all the wiring har-
nesses.
3. Remove covers (2) and (3) and remove oil

pressure pickup hose assembly (4). [*1]
a Disconnect the 12 oil pressure pickup
hoses from the power train unit.
6. Remove hoses (15) – (17).
7. Remove block (18).
8. Remove hose (19).
9. Remove bracket (20).
16 D155A-6
10. Remove hoses (21) and (22). 16. Disconnect suction tube (30) from the fan
pump.
11. Remove tube (23).
17. Remove work equipment pump suction tube
mounting bolt (31) and lift off work equipment
pump suction tube (28) and fan pump suction
tube (30) together.
12. Remove hoses (24) and (25).
18. Remove work equipment pump assembly (32).

4 Work equipment pump assembly:
100 kg
13. Remove hose and tube assembly (26).
14. Remove tube (27).
15. Sling work equipment pump suction tube (28)

and remove clamp (29).
D155A-6 17
19. Remove power train and lubricating oil pump 22. Remove coupling (36).
assembly (33).
4 Power train and lubricating oil pump
assembly: 25 kg
23. Remove right and left front mounts (48).
20. Remove cooling fan pump assembly (34).

4 Cooling fan pump assembly: 30 kg
24. Sling power train unit assembly (37) and set

block [2].
25. Remove the 18 mounting bolts and lift off

steering case assembly. [*2]
21. Remove scavenging pump assembly (35). 4 Steering case assembly: 1,000 kg
4 Scavenging pump assembly: 20 kg
18 D155A-6
26. Set PTO and torque converter and transmis-

sion assembly (38) on block [3] with the PTO
side up.
29. Remove pressure sensor block (43) and 2

sleeves (44).
27. Remove inside strainer and block (39)

together.
28. Remove cover (40), spring (41) and magnet

assembly (42).
D155A-6 19
30. Remove the 19 mounting bolts and lift off PTO

assembly (45). [*3]
4 PTO assembly: 300 kg
31. Remove 10 torque converter assembly mount-

ing bolts (46). [*4]
32. Sling torque converter assembly (47) and pull

it out by using 2 forcing screws [4] (M12 x
1.75).
33. Lift off torque converter assembly (47).
20 D155A-6
Connection
q Carry out connection in the reverse order to
disconnection.
[*1]
a The oil pressure pickup hoses have color
bands on their adapters. Referring to the
table, connect those hoses to the power train
unit.
Sym-
Pressure pick up point Band color
bol
a 1st transmission clutch pressure Red
Yellow/
b 3rd transmission clutch pressure
Black
Reverse transmission clutch pres-
c Red/Blue
sure
White/
d 2nd transmission clutch pressure
Yellow
Forward transmission clutch pres-
e White/Blue
sure
f Transmission main relief pressure No band
g Torque converter inlet pressure Blue/Black
Yellow/
h Torque converter outlet pressure
Black
i Left brake pressure White
White/
j Right clutch pressure
Black [*2]
3 Steering case mounting bolt:
k Left clutch pressure Black
98 – 123 Nm {10 – 12.5 kgm}
l Right brake pressure Yellow
[*3]
3 PTO assembly mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
[*4]
3 Torque converter mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
D155A-6 21
D155A-6 Bulldozer
© 2008 KOMATSU
All Rights Reserved
22 D155A-6
SEN03369-01
D155A-6

D155A-6 85001 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 ................................................................................. 14
Disassembly and assembly of steering case assembly................................................................................ 31
D155A-6 1
Disassembly and assembly of 3) While supporting cover (5) with block,

PTO assembly 1 push in gear (6) to separate it from the
cover.
Disassembly
1. Lubrication tube
1) Remove shaft lubrication tube (1).
4) Remove inner race (7) from gear (6).
2) Remove pump drive gear lubrication tube

(2).
5) Remove snap ring (14) and remove bear-

ing (8) from cover (5).
2. Work equipment and pump drive gear and

cover assembly
1) Remove 4 mounting bolts (3) and set the
guide bolt.
2) Tighten forcing screws into hole (a) to
remove gear and cover assembly (4).
2 D155A-6
6) Remove bearing (40) from case (17). 4) Remove inner race (41) from gear (13).
3. Cooling fan pump drive gear and cover 5) Remove snap ring (14) and remove bear-
assembly ing (15) from cover (12).
1) Remove 6 mounting bolts (10) and set a
guide bolt.
2) Tighten forcing screws into hole (c) to
remove gear and cover assembly (11).
6) Remove case (17) from bearing (16).
3) While supporting cover (12) with block [1],

push in gear (13) to separate it from the
cover.
D155A-6 3
4. Scavenging pump drive gear assembly 2) Remove the mounting bolts and set guide
1) Remove snap ring (18). bolt [2].
2) Remove gear (19) by pushing it into the 3) Using forcing screws [3], remove shaft
case. (23).
a Keep holding the gear in the case.

ing (21) from the case. 1] 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.
2] Remove outer race (27) and snap
ring (28) from gear (24).
5. Idler gear assembly

1) Remove the mounting bolt and plate (22).
6. Input shaft outer race

Remove snap ring (29) and input shaft outer
race (30).
4 D155A-6
Assembly 1) Install snap ring (28) to gear (24) and

press fit outer race (27).
a Clean all the parts thoroughly and check them
for dirt or damage before installing.
a After press fitting each bearing, drop 6 cc of
TO30 or TO10 onto it and rotate it about 10
turns.
a Check that each snap ring is fitted to the
groove.
1. Input shaft outer race

Press fit input shaft outer race (30) and install
snap ring (29).
2) Using 3 guide bolts [4], insert shaft (23) to

the position shown in the figure.
a If shaft (23) is inserted all the way,
gear (24) cannot be installed.
2 O-ring: Grease (G2-LI)
2. Idle gear assembly

a Match the serial Nos. and match marks of
the bearing, outer race and spacer at
places [A] – [C] and use them as an
assembly.
3) Install bearing (25) to shaft (23).

4) Install spacer (26).
D155A-6 5
5) Install gear (24). 2) While holding the inner race side of the
6) Install bearing (25) and tighten plate (22) bearing with push tool [5], install drive
with the bolt to press fit the bearing to the gear (19).
shaft.
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
245.0 – 308.7 Nm {25.0 – 31.5 kgm}
3) Install snap ring (18).
7) Fix shaft (23) with the mounting bolts.
4. Cooling fan pump drive gear and cover

assembly
1) Press fit bearing (16) to case (17).
3. Scavenging pump drive gear

1) Press fit bearing (21) to the case and
install snap ring (20).
6 D155A-6
2) Press fit bearing (15) to cover (12) and 5) Install gear and cover assembly (11),
install snap ring (14). meshing it with the idler gear.
2 Mounting bolt; Adhesive (LT-2)
3 Mounting bolt:
98.0 – 122.5 Nm {10.0 – 12.5 kgm}
3) Press fit inner race (41) to gear (13).
5. Work equipment and HST pump drive gear

and cover assembly
1) Press fit bearing (40) to case (17).
4) Using the push tool, press fit gear (13) to

cover (12).
2) Press fit bearing (8) to cover (5).
D155A-6 7
3) Press fit inner race (7) to gear (6). 6) Install gear and cover assembly (4) to the
case.
3 Mounting bolt:
98.0 – 122.5 Nm {10.0 – 12.5 kgm}
4) Press fit bearing (7) and inner race (8) to

gear (9).
6. Lubrication tube
1) Install lubrication tube (2).
3 Joint bolt:
34.3 – 44.2 Nm {3.5 – 4.5 kgm}
5) Install gear and bearing assembly (6) to

cover (5).
2) Install lubrication tube (1).

3 Joint bolt:
34.3 – 44.2 Nm {3.5 – 4.5 kgm}
8 D155A-6
Disassembly and assembly of 3. Case

torque converter assembly 1 1) Remove snap ring (6).
2) Remove spacer (7).
Disassembly
1. Input shaft
1) Remove 18 bolts (1) from input shaft (2).
2) Use eyebolt [1], and remove input shaft
(2) from case and turbine assembly (3).
3) Using puller [2] and plate [3] disconnect

case assembly (8) and turbine (9).
3) Remove snap ring (4), then remove inner

race (5).
4) Remove bearing (11) from case (10).
2. Case, turbine assembly

Remove 30 bolts (1a) from below, then use
eyebolts [4], and remove case and turbine
assembly (3).
D155A-6 9
4. Stator and race assembly 5. Pump

1) Remove snap ring (12) and stator and 1) Remove snap ring (18) and spacer (19).
race assembly (13). 2) Remove pump assembly (21) from stator
shaft assembly (20).
2) Remove 2 snap rings (14) and remove

race (15) from stator (16). 3) Remove 12 mounting bolts (22) and
remove pump (24) from retainer (23).
ing (26) from retainer (23).
10 D155A-6
Assembly 4) Install pump assembly (21) to stator shaft

assembly (20).
a Clean all the parts and check them for dirt or 5) Install spacer (19) and snap ring (18).
damage. Coat their sliding surfaces with 6) Install snap ring (17) to the shaft.
engine oil before installing.
a After press fitting each bearing, drop 10 cc of
TO30 or TO10 onto it and rotate it about 10
turns.
a When installing a bearing by expansion fit,
drop 10 cc of TO30 or TO10 onto it and rotate
it about 10 turns before freezing it in dry ice
etc.
a Check that each snap ring is fitted to the
groove.
1. Pump
1) Press fit bearing (26) to retainer (23) and
install snap ring (25).
2) Install retainer (23) to pump (24).
2. Stator and race assembly
3 Mounting bolt:
1) Install race (15) to stator (16) and install 2
58.8 – 73.6 Nm {6.0 – 7.5 kgm} snap rings (14).
3) Install seal ring (27) to stator shaft (20). 2) Install stator and race assembly (13) and
snap ring (12).
D155A-6 11
3. Case 4. Input shaft

1) Install bearing (11) to case (10). 1) Press fit inner race (5), and install snap
ring (4).
2) Using push tool [4], push inner race end of

bearing, then install case assembly (8) to 2) Install input shaft (2) to case and turbine
boss portion of turbine (9). assembly (3).
2 Mounting bolt:
Thread tightener (LT-2)
3 Mounting bolt:
110.3 ± 12.3 Nm {11.25 ± 1.25 kgm}

12 D155A-6
5. Case, turbine assembly

1) Using eyebolts [1], align groove of case
with drain plug, and install case and tur-
bine assembly (1).
2 Mounting bolt:
Thread tightener (LT-2)
3 Mounting bolt:
53.9 ± 4.9 Nm {5.5 ± 0.5 kgm}
2) Install drain plug.
3 Drain plug:
7.4 ± 1.5 Nm {0.75 ± 0.15 kgm}
D155A-6 13
Disassembly and assembly of 3) Remove sleeve (3) and flanges (4) and
transmission assembly 1 (5).
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
791T-615-1300 Puller assembly t 1 N
1 791T-615-1310 • Plate 1 N Q
G 01010-82040 • Bolt 1
Oil leak tester kit
2 799-301-1600 t 1
(A)
Disassembly 4) Remove control valve assembly (6).
a Keep the removed discs and plates on a flat

place so that they will not warp.
1. Relief valve assembly

Remove relief valve assembly (1).
3. Snap ring
Remove snap ring (123) from output shaft
(124).
a Remove the snap ring at this time.
2. Control valve assembly

1) Remove cover assembly (2).
2) Remove the nut of wiring harness connec-
tor (2A) and push in the connector.
14 D155A-6
4. Transmission case 6. Input shaft-front cover-No. 1 carrier assem-

1) Set the block with the torque converter bly
side up. 1) Using sling bar [3], remove input shaft-
2) Remove sleeve (7). front cover-No. 1 carrier assembly (11).
3) Using eyebolts [2], sling transmission case 2) Disassemble the input shaft-front cover-
(8), remove 13 tie bolts (9) (used to clamp No. 1 carrier assembly according to the
the transmission case, too), and remove following procedure.
case (8). 1] Remove snap ring (12), No. 2 sun
gear (13) and snap ring (14).
2] Remove snap ring (15), No. 1 sun
gear (16) and collar (17).
5. Tie bolts
Remove 4 remaining tie bolts (9).
3] Remove snap rings (18) and (126).

4] Drive out input shaft toward the
torque converter and remove front
cover (19).
D155A-6 15
5] Remove snap ring (20) and drive out 8. No. 1 housing assembly
input shaft (21) toward the torque 1) Using eyebolts [4], remove No. 1 housing
converter. assembly (33).
2) Remove No. 1 piston (34) from the hous-
ing.
6] Remove collar (128).

7] Remove snap ring (22) and No. 1 ring
gear (23). 9. Guide pin
8] Pull out shaft (24) and remove thrust Remove guide pins (35).
washer (25), gear (26), bearing (27)
and ball (28). 10. No. 2 disc, plate and spring
a Take care not to lose the ball. 1) Remove spring (36).
2) Remove springs (37), discs (38) and
plates (39).
7. No. 1 disc, plate and spring

1) Remove spring (29).
2) Remove springs (30), discs (31) and 11. Remove through bolt guide (40), lubricating oil
plates (32). relief valve (41) and spring (130).
16 D155A-6
12. Snap ring 2] Remove spacer (47) from No. 2 car-

Remove snap ring (125). rier assembly (49).
3] Pull out shaft (50) and remove thrust
and ball (54).
a Take care not to lose the ball.
13. No. 2 housing and No. 2 carrier assembly

1) Using eyebolts [5], remove No. 2 housing
and No. 2 carrier assembly (42).
2) Remove No. 2 piston (43).
4] Remove snap ring (55) and ring gear
(56).
a Push the snap ring inward with a
pin (Diameter: Max. 3 mm) from
outside to warp and remove it.
3) Disassemble No. 2 housing and No. 2 car-

rier assembly according to the following
procedure.
1] Remove snap ring [44] and pull out
No. 2 carrier assembly (45) from No.
2 housing (46). 5] Remove seal ring (57) and snap ring
(58) from No. 2 housing (46) and
remove bearing (59).
D155A-6 17
14. No. 3 disc, plate and spring 16. Output shaft and No. 4 sun gear
1) Remove springs (60). 1) Pull out output shaft (73).
2) Remove springs (61), discs (62) and 2) Remove snap ring (74) from the output
plates (63). shaft.
3) Remove No. 4 sun gear (75).
15. No. 3 carrier assembly

1) Remove No. 3 carrier assembly (64). 17. No. 4 carrier and No. 3 ring gear assembly
1) Remove No. 4 carrier and No. 3 ring gear
assembly (76).
2) Disassemble No. 3 carrier assembly

1] Remove seal ring (65).
2] Pull out shaft (66).
3] Remove thrust washer (67), planetary
gear (68), bearing (69) and ball (70).
4] Remove snap ring (71) and bearing
(72).
18 D155A-6
2) Disassemble the No. 4 carrier and No. 3 19. No. 4 disc, plate, spring and guide pin
ring gear assembly according to the fol- 1) Remove spring (89).
lowing procedure. 2) Remove springs (90), No. 4 discs (91) and
1] Remove snap ring (77) and ring gear plates (92).
(127). 3) Remove guide pin (93).
a Push the snap ring inward with a
pin (Diameter: Max. 3 mm) from
outside to warp and remove it.
2] Remove seal rings (78) and (79).
3] Drive in roll pin (80) to pull out shaft
(80A).
4] Remove thrust washer (81), planetary
gear (82) and bearing (83).
5] Remove snap ring (84) to remove
bearing (85) and spacer (86) as an
assembly.
6] Remove bearing (85) from spacer
(86).
20. No. 5 carrier and No. 4 ring gear assembly

1) Remove mounting bolts (94).
2) Remove No. 5 carrier and No. 4 ring gear
assembly (95).
18. No. 3 housing

1) Remove No. 3 housing (87).
3) Disassemble No. 5 carrier and No. 4 ring

gear assembly according to the following
procedure.
1] Drive out shaft (96) to remove thrust
and ball (100).
D155A-6 19
2] Remove snap ring (101) and remove 23. No. 5 disc, plate and spring
No. 4 ring gear (102) from carrier 1) Remove springs (107).
(103). 2) Remove discs (108), plates (109) and
springs (110).
21. No. 5 sun gear

Remove No. 5 sun gear (104). 24. No. 5 ring gear
Remove No. 5 ring gear (111).
25. No. 5 piston

Remove No. 5 piston (112).
22. No. 4 housing assembly

1) Remove No. 4 housing assembly (105).
26. Cover assembly

1) Remove snap ring (113) and remove
cover assembly (114) from output housing
assembly (115).
20 D155A-6
2) Remove seal rings (116) and (117) from Assembly

cover (118).
3) Remove bearing (119) from cover (118). q Precautions for assembly
a Coat the sliding surfaces of each part with
a When installing piston seal ring (a), direct the
pressure receiving side (b) toward housing (c).
a When installing a metallic seal ring, apply
grease (G2-LI) to it and fit it evenly.
27. Output housing

1) Remove snap ring (120) and remove
bearing (121) and spacer (122) from out-
put housing (123).
2) Remove bearing (121) from spacer (122).
1. Output housing
1) Using the push tool, press fit bearing (121)
to spacer (122).
D155A-6 21
2) Using the push tool, press fit spacer (122) 3. No. 5 piston
and bearing assembly (121) to output Install No. 5 piston (112) to the output housing.
housing (123).
3) Install snap ring (120). 4. No. 5 ring gear
Install No. 5 ring gear (111).
2. Cover assembly
1) Using the push tool, press fit bearing (119) 5. Guide pin
to cover (118). Install guide pin (93).
2) Install seal rings (117) and (116) to cover
(118). 6. No. 5 disc, plate and spring
1) Install discs (108), plates (109) and
springs (110).
a Install the 3 discs and 2 plates.
2) 2) Install springs (107).
a Free length of spring: 66 mm
3) Using the push tool, install cover assem-

bly (114) to output housing assembly
(115).
a Press fit the inner race side of the
bearing to install.
22 D155A-6
7. No. 4 housing assembly 2) Using guide bolts, set No. 5 carrier and
1) Fit the seal ring and install No. 4 piston No. 4 ring gear assembly (95) and tighten
(106). mounting bolts (94).
2) Install No. 4 housing assembly (105). 2 Threaded part of mounting bolt:
a Check that the springs are fitted to Adhesive (LT-2)
the grooves. 3 Mounting bolt:
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}

1) Assemble the No. 5 carrier and No. 4 ring 9. No. 5 sun gear
gear assembly according to the following Install No. 5 sun gear (104).
procedure.
1] Set No. 4 ring gear (102) to carrier
(103) and install snap ring (101).
10. No. 4 discs, plates and springs

1) Install No. 4 discs (91), plates (92) and
springs (90).
2] Install bearing (99) to gear (98). a Install the 4 discs and 3 plates.
While fitting thrust washers (97) to 2) Install springs (89).
both sides of them, set them to the a Free length of spring: 70 mm
carrier.
3] Fit ball (100) and install shaft (96).
D155A-6 23
11. No. 3 housing assembly 8] Set the No. 3 ring gear to No. 4 car-
1) Fit the seal ring and install No. 3 piston rier and install snap ring (77).
(88). a Check that the snap ring is fitted
2) Install No. 3 housing (87). to the groove.
a Check that the springs are fitted to
the grooves.
2) Install No. 4 carrier and No. 3 ring gear

assembly (76).
1) Assemble No. 4 carrier and No. 3 ring
gear assembly according to the following
procedure.
1] Using the push tool, press fit bearing
(85) to spacer (86).
13. No. 4 sun gear

Install No. 4 sun gear (75).
14. Output shaft

1) Install snap ring (74) to the output shaft.
2) While setting output shaft (73) to the
2] Using the push tool, press fit spacer spline of the sun gear, push it in.
(86) and bearing assembly (85) to the
No. 4 carrier.
3] Install snap ring (84).
4] Install bearing (83) to planetary gear
(82). While fitting thrust washers (81)
to both sides of them, set them to the
carrier.
5] While setting the shaft pin hole to the
carrier pin hole, install shaft (80A).
6] Check that the pin holes are aligned
and drive roll pin (80).
7] Install seal rings (79) and (78).
24 D155A-6
15. No. 3 carrier assembly 16. No. 3 discs, plates and springs
1) Assemble the No. 3 carrier assembly 1) Install discs (62), plates (63) and springs
according to the following procedure. (61).
1] Using the push tool, press fit bearing a Install the 4 discs and 3 plates.
(72) to the carrier and install snap ring 2) Install springs (60).
(71). a Free length of spring: 70 mm
2] Install bearing (69) to planetary gear
(68). While fitting thrust washers (67)
to both sides of them, set them to the
carrier.
4] Install seal ring (65).
17. No. 2 housing and No. 2 carrier assembly

1) Assemble the No. 2 housing and No. 2
carrier assembly according to the follow-
ing procedure.
1] Press fit bearing (59) to No. 2 housing
(46) and install snap ring (58).
2) Install No. 3 carrier assembly (64). 2] Install seal ring (57).
3] Set No. 1 ring gear (56) and No. 2

carrier (45) and install snap ring (55).
D155A-6 25
4] Install bearing (53) to gear (52). 2) Using eyebolts [5], install No. 2 housing
While fitting thrust washers (51) to and No. 2 carrier assembly (42).
both sides of them, set them to the a Check that the springs are fitted to
carrier. the grooves.
5] Fit ball (54) and install shaft (50). 3) Fit the seal ring and install No. 2 piston
(43).
6] Install No. 2 ring gear (48).

7] Install spacer (47). 4) Install tool G1 to the inside groove of the
a Direct the side of the cut inside No. 3 carrier, pull it up, and install snap
toward the carrier. ring (125).
8] Install No. 2 housing (46) to No. 2 car- 18. Install through bolt guide (40), spring (130) and
rier assembly (45). lubricating oil relief valve (41).
a Press fit the inner race side of
the housing bearing.
26 D155A-6
19. Guide pin 3] Set No. 1 ring gear (23) to No. 1 car-
Install guide pins (35). rier and install snap ring (22).

springs (37).
a Install the 7 discs and 6 plates.
2) Install springs (36).
a Free length of spring: 81.7 mm
4] Press fit bearing (117) to input shaft

(21).
5] Install No. 1 carrier assembly (118) to
input shaft (21) and install snap ring
(18).
21. No. 1 housing assembly

1) Fit the seal ring and install No. 1 piston
(34).
2) Using eyebolts [4], install No. 1 housing
assembly (33), while aligning it with the
No. 2 piston.
a Press the housing to push in the
dowel pins.
6] Install collar (17).

7] Install No. 1 sun gear (16) and snap
ring (15).
22. Input shaft and No. 1 carrier assembly

1) Assemble the input shaft and No. 1 carrier
assembly according to the following pro-
cedure.
1] Install bearing (27) to gear (26).
While fitting thrust washers (25) to
both sides of them, set them to the
carrier.
D155A-6 27
9] Install No. 2 sun gear (13) and snap 24. Front cover
ring (12). 1) Install seal ring (121) to front cover (122).
2) Sling input shaft and No. 1 carrier assem- 2) Using eyebolts [6], install front cover
bly (119) and install it, while meshing the (122), while aligning it with the guide pins
No. 2 sun gear with No. 2 planetary gear. and springs. Press fit the inner race side
of bearing (123) and install snap ring (24).
a Check that the springs are fitted to
the cover.

1) Install collar (128).
spring (30). 25. Tie bolts
a Install 6 discs and 5 plates. Install tie bolts (9) (4 pieces). (The 4 bolts
3) Install springs (29). marked with * in the attached drawing).
a Free length of spring: 81.7 mm 3 166.7 ± 9.8 Nm {17 ± 1 kgm}
28 D155A-6
26. Operation check of piston 29. Snap ring

Using tool G2, check the operating condition Raise the case assembly and install snap ring
and stroke of each piston. (123) to output shaft (124).
Piston Standard stroke (mm)
No. 1 7.2
No. 2 7
No. 3 5
No. 4 5
No. 5 6
30. Control valve assembly

1) Install control valve assembly (6).
3 Mounting bolt:
49.1 ± 4.9 Nm {5.0 ± 0.5 kgm}
27. Transmission case

Fit the O-ring. Using eyebolts [2], install trans-
mission case (8) and remaining 13 tie bolts (9).
3 Tie bolt: 166.7 ± 9.8 Nm {17 ± 1 kgm}
2) Install flanges (4) and (5) and sleeve (3).
28. Sleeve
Install sleeve (7).
D155A-6 29
3) Install cover assembly (2).

2 Threaded part of mounting bolt:
Gasket sealant (LG-11 or LG-5)
31. Main relief valve assembly

Install main relief valve assembly (1).
3 Mounting bolt:
49.1 ± 4.9 Nm {5.0 ± 0.5 kgm}
30 D155A-6
Disassembly and assembly of 2. Clutch, brake assembly

steering case assembly 1 1) Angle the steering case assembly approx.
15° so that tool H1 is perpendicular to
Special tools ground surface.
2) Remove mounting bolts, then using tool
New/Remodel
H1, remove clutch and brake assembly
(2).
Necessity
Sym-
Part No. Part name
a Do not remove the hexagon socket
Sketch
bol
head bolt.
Q'ty
a Remove the clutch and brake assembly
791-662-1110 Bracket t 1
on the other side in the same way.
1 01010-31685 Bolt t 1
H 01017-31620 Bolt t 1
790-302-1500 Spanner kit t 1
2
09003-09200 • Spanner 1
Disassembly
1. Steering valve assembly, reducing valve
Remove steering valve assembly (1).
q EDisassembly of clutch, brake assembly

1) Disassembly of brake assembly
i) Remove flange (3) and seal ring (4).
ii) Remove plate (5).
D155A-6 31
iii)Loosen 4 hexagon socket head bolts ix) Using eyebolts, remove drum (12)
uniformly and remove, then using together with disc and plate.
eyebolts [1], remove cover (6). x) Remove 6 discs (13), 5 plates (14),
a The inner race of the bearing will and 6 springs (15) from drum (12).
come out.
iv) Remove bearing (7) from cover (6).
2) Disassembly of clutch assembly

i) Remove mounting bolts, then remove
v) Remove 2 brake springs (8). cover (16).
vi) Remove brake piston (9). a The cover is being pushed by the
clutch spring, so loosen the bolts
uniformly.
ii) Remove 5 discs (17) and 5 plates
(18).
vii) Using puller [2], remove cage (10).

a The outer race of the bearing will
come out.
viii) Remove 3 seal rings (11) from hub.
32 D155A-6
iii)Remove snap ring (19), then remove ix) Remove clutch spring (25).
inner drum (20). x) Remove clutch outer drum (26) from
a Remove the snap ring from the brake hub (27).
ring groove, then fit it in the inner
drum groove.
iv) Remove snap ring (21).
xi) Remove bearing (28) from brake hub

(27).
xii) Remove snap ring (27) from brake
v) Using puller [3], remove bearing (22) hub, then remove stopper (30).
from inner drum (20).
vi) Remove snap ring (19) from inner
drum.
3. Pipes
Remove 6 pipes (31).
a When removing the pipes, be careful not
vii) Remove mounting bolts, then remove to damage the O-rings.
cage (23).
viii) Remove clutch piston (24).
D155A-6 33
4. Lubrication tubes 8. Bevel pinion assembly

Remove 3 lubrication tubes (32). 1) Using guide bolts [4] and forcing screws
[5], remove bevel pinion assembly (37)
and shim (38).
a Check the number and thickness of
the shims, and keep in a safe place.
5. Case cover
Remove cover (33).
2) Disassembly of bevel pinion assembly

i) Hold with press to prevent pinion from
moving, then use tool H2 to remove
locknut (39).
ii) Using push tool [6], remove bevel pin-
ion (40) from cage (41).
6. Suction tube, dipstick tube

Remove suction tube (34) and dipstick tube
(35).
7. Lubrication tubes
Remove left and right lubrication tubes (36).
iii) Remove bearing (42).

iv) Remove outer races (43) and (44)
from cage (41).
34 D155A-6
v) Remove bearing (45) from bevel pin- 3) Lift off bevel gear shaft, bevel gear assem-
ion (40). bly (49).
9. Bevel gear shaft, bevel gear assembly 4) Disassembly of bevel gear shaft, bevel
1) Turn over steering case so that right cage gear assembly
is at top, then remove cage (46) and shim i) Using puller [7], remove bearing (51)
(47). from bevel gear shaft (50).
a Check the number and thickness of ii) Remove reamer bolt (52), then
the shims, and keep in a safe place. remove bevel gear (53) from bevel
gear shaft (50).
2) Lift off right cover (48).

iii) Using puller [8], remove bearing (54)
from bevel gear shaft (50).
D155A-6 35
5) Turn over steering case, then remove left Assembly

cage (55) and shim (56).
a Check the number and thickness of q Precautions when assembling
the shims, and keep in a safe place. a Clean all parts, and check for dirt or damage.
a After press fitting the bearing, apply 6 cc of
EO10CD or EO30CD in drops, then rotate 10
times.
a Coat the sliding surfaces of all parts with
a Assemble the piston seal rings with the side
receiving the pressure facing the housing, coat
with grease (G2-LI) and install uniformly, tak-
ing care that they do not move to one side.
a Fix the rotation seal ring in position with
grease (G2-LI) and be extremely careful
not to get it caught when assembling.
Check that the snap ring is fitted securely in
the groove.
6) Remove outer race (57) from cage (55). 1. Nipple
Install nipple (58).
10. Nipple
Remove nipple (58). 2. Bevel gear shaft, bevel gear assembly
1) Using push tool [9], press fit outer race
(57) to cage (55).
36 D155A-6
2) Assemble shim (56) and install cage (55). 4) Turn over steering case so that right side
a There are four types of shim: 0.05, is at top, then install bevel gear shaft and
0.1, 0.2, 0.5 mm bevel gear assembly (49).
3 Cage mounting bolt:
110.3 ± 12.3 Nm {11.25 ± 1.25 kgm}
5) Raise right cover (48) and install.

3 Mounting bolt:
3) Assembly of bevel gear shaft, bevel gear 110.3 ± 12.3 Nm {11.25 ± 1.25 kgm}
assembly
i) Set bevel gear (53) to bevel gear
shaft (50), then fit reamer bolt (52)
and tighten nut.
3 Nut:
245.2 ± 29.4 Nm {25 ± 3 kgm}
6) Assemble shim (47) and install cage (46).

a There are four types of shim: 0.05,
0.1, 0.2, 0.5 mm
3 Cage mounting bolt:
110.3 ± 12.3 Nm {11.25 ± 1.25 kgm}
ii) Using push tool [10], press fit bearing

(54) to bevel gear shaft (50).
iii) Using push tool [11], press fit bearing
(51) to bevel gear shaft (50).
D155A-6 37
3. Adjusting preload of bevel gear shaft iv) Press fit bearing (42) to cage (41)
1) Adjust thickness of shims at cage to adjust with press.
turning torque of bevel gear shaft. v) Hold in press so that pinion does not
a Turning torque move, then use tool H2 and tighten
(bevel pinion not meshed): locknut (39).
4.2 – 5.1 Nm {0.43 – 0.52 kgm} 2 Locknut:
(At tip of bevel gear teeth: Thread tightener (LT-2)
22.6 – 26.5 N {2.3 – 2.7 kg}) 3 Locknut:
a Rotate the bevel gear 2 – 3 times 779.6 ± 83.4 Nm {79.5 ± 8.5 kgm}
when measuring the turning torque. a Rotate the cage when tightening.
4. Bevel pinion assembly

1) Assemble bevel pinion as follows.
i) Using push tool, press fit bearing (45)
to bevel pinion (40).
2) Using guide bolt [12], assemble shim (38)

and install bevel pinion assembly (37).
a There are four types of shim:
0.05, 0.1, 0.2, 0.5 mm
ii) Using push tool, press fit outer races

(44) and (43) to cage (41).
iii) Put bevel pinion (40) on press stand,
and set cage (41) in position.
38 D155A-6
5. Adjustment of backlash and tooth contact q When backlash is too large

1) Adjustment of backlash Decrease the thickness of the shim
Apply the probe of dial gauge [13] to the on the left side of the machine and
tooth tip at the end of the bevel gear per- increase the thickness on the right
pendicularly. While fixing the bevel pinion, side by the same quantity. (Move the
move the bevel gear forward and back- bevel gear in direction (B).)
ward 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 2) Adjustment of tooth contact
increase the thickness on the left side Testing
by the same quantity. (Move the bevel 1] Apply red lead thinly to the tooth sur-
gear in direction (A).) faces 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.
D155A-6 39
2] The tooth contact must be as follows. Adjustment

(The standard distance is measured If the tooth contact pattern is not proper,
from the tooth tip of the bevel pinion.) adjust the tooth contact according to the
a) Center of tooth contact: 20 – following procedure.
40% of face width (from small 1) If the bevel pinion is too far from the
end) center line of the bevel gear, the con-
b) Width of tooth contact: 30 – 50% tact is at the small end of the bevel
of face width gear tooth faces curved outward and
c) Center of tooth contact: 35 – at the large end of the bevel gear
65% of tooth depth tooth faces curved inward.
d) Width of tooth contact: 60 – 80% q In this case, adjust the tooth contact
of tooth depth according to the following procedure.
Check that there is not a strong Adjust the thickness of the shims on
contact at tips (A), roots (B), the bevel pinion side to move the
small end (C) or large end (D). bevel pinion in direction (A). Move
a If the bevel gear and bevel pinion the bevel gear in direction (B) and
are adjusted in this way, their then check the tooth contact pattern
teeth come in contact with each and backlash again.
other correctly when they are
loaded.
2) If the bevel pinion is too close to the

center line of the bevel gear, the con-
tact 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.
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), then
check the tooth contact pattern and
backlash again.
a Do not change the total thickness of
the shims on the right and left sides.
40 D155A-6
3) When adjustment is finished, tighten 9. Lubrication tubes

the mounting bolts of the cage and Install 3 lubrication tubes (32).
bevel pinion assembly to the speci-
fied torque.
2 Mounting bolts of cage and
bevel pinion assembly:
98 – 122.5 Nm {10 – 12.5 kgm}
10. Pipes
Install 6 pipes (31).
6. Lubrication tubes
Install left and right lubrication tubes (36).
7. Suction tube, dipstick tube

Install suction tube (34) and dipstick tube (35).
11. Clutch, brake assembly

Assembly of clutch, brake assembly
1) Assembly of clutch assembly
i) Assemble stopper (30) to brake hub
(27), and install snap ring (29).
ii) Using push tool, press fit bearing (28)
to brake hub.
8. Case cover
Install cover (33).
D155A-6 41
iii)Install clutch outer drum (26) to brake ix) Press fit inner drum (20) to cage (23),
hub (27). then install snap ring (19) assembled
3 Mounting bolt: to inner drum.
110.3 ± 12.3 Nm{11.25 ± 1.25 kgm} a The outer race of bearing (22)
iv) Set clutch outer drum facing up, then (installed in Step 1) -viii)) is press
assemble clutch spring (25). fitted.
v) Assemble clutch piston (24). x) Assemble plate (18) and disc (17).
vi) Fit seal ring and install cage (23). a Assemble the plate to the piston
3 Mounting bolt: end.
110.3 ± 12.3 Nm{11.25 ± 1.25 kgm} a Pistons: 5, Plates: 5
xi) Install cover (16).
a The cover is being pushed by the
clutch spring, so tighten the bolts
uniformly.
3 Mounting bolt:
66.19 ± 7.35 Nm {6.75 ± 0.75 kgm}
vii) Assemble snap ring (19) in groove of

inner drum (20).
viii) Press fit bearing (22) to inner drum
(20), and install snap ring (21).
42 D155A-6
2) Assembly of brake assembly vii) Using push tool, press fit bearing (7)
i) Install 3 seal rings (11) to brake hub to cover (6).
(27).
ii) Install cage (10) to brake hub (27).
a The outer race of the bearing is
press fitted.
viii) Install guide bolts [14] and [15] to

brake piston (9) and brake cage (10).
a Guide bolt [14] is for releasing
the brake.
iii)Set brake outer drum (12) to clutch
outer drum.
iv) Assemble discs (13), plates (14), and
springs (15).
a Discs: 6, Plates: 5, Springs: 6
ix) Using eyebolts [1], align with guide

bolts, and set cover (6) in position.
x) Compress spring with bolt and press
fit bearing (7) at same time.
v) Fit seal ring to brake cage and install

brake piston (9).
vi) assemble brake spring (8).
D155A-6 43
xi) Remove guide bolts and install plate 12. Steering valve, reducing valve
(5). Install steering valve (1).
xii) Install seal ring (4) and flange (3). 3 Mounting bolt:
a Assemble the clutch and brake 49.0 ± 4.9 Nm {5 ± 0.5 kgm}
assembly on the opposite side in
the same way.
3 Flange mounting bolt:
66.19 ± 7.35 Nm {6.75 ± 0.75 kgm}
a When removing cover (61) of steering

case (59) rear surface, install new gasket
(60).
3) Angle the steering case assembly approx. 2 Gasket (apply to both sides):
15° so that tool H1 is perpendicular to Gasket sealant (LG-11)
ground surface.
4) Using tool H1, install clutch and brake
assembly (2).
a Assemble the clutch brake assembly
on the opposite side in the same way.
3 Mounting bolt:
110.32 ± 12.26 Nm {11.25 ± 1.25 kgm}
44 D155A-6
D155A-6 45
D155A-6 Bulldozer
© 2009 KOMATSU
All Rights Reserved
46 D155A-6
SEN03370-00
D155A-6

D155A-6 85001 and up

Power train, Part 3
Removal and installation of final drive assembly ............................................................................................ 2
Disassembly and assembly of final drive assembly........................................................................................ 4
D155A-6 1
Removal and installation of final 3. Raising of machine

k 1) Using a jack (686 kN {70 ton}) [2]
drive assembly 1
and the ripper of the work equip-
Special tools ment, raise the machine and set
right and left support stands [1]
New/Remodel
under the steering case.
2) Set right and left support stands [3]
Necessity
Sym-
Part No. Part name
under the main frame on the front
Sketch
bol
side of the machine.
Q'ty
a After setting support stands [1] and [3], set
790-337-1032 Lifting tool t 1
the hydraulic jack and ripper as auxiliary
791-627-1320 Shackle t 2 supports.
J
791T-627-1910 Plate t 1 N Q
01010-82080 Bolt t 2
Removal
1. Spread the track assembly. For details, see
"Spreading and installation of track assembly".
2. Remove 8 mounting bolts (2) on the inside of

final drive assembly (1). [*1]
4. Remove guards (3) and (4).
2 D155A-6
5. Remove drive shaft cover (5). 8. Using tool J, sling final drive assembly (1) and
remove the remaining bolts.
k First, loosen 1 bolt on each of both
sides of the final drive so that the final
drive will not jump out. Then, loosen
all the bolts gradually to pull out the
final drive assembly.
9. Lift off final drive assembly (1).

4 Final drive assembly: 1,400 kg
6. Pull out drive shaft (6).

a Using forcing screws, pull out the drive
shaft until the spline can be pulled out.
a If the shaft cannot be pulled out, move the
sprocket forward or backward to a position
where the shaft can be pulled out.
Installation
removal.
[*1], [*2]
3 Final drive mounting bolt:
1,150 – 1,440 Nm {118 – 147 kgm}
7. Remove the upper mounting bolts of the final

drive assembly and install tool J. [*2]
D155A-6 3
Disassembly and assembly of Disassembly

final drive assembly 1 1. Draining oil
Remove the drain plug to drain the oil in the
Special tools final drive case.
6 Final drive case: Approx. 31 l
New/Remodel
Necessity
Sym- 2. Drive shaft
Part No. Part name
Sketch
bol
Remove drive shaft (1).
Q'ty
790-431-1031 Block t 1
791-520-4140 Screw t 2
790-101-2360 Plate t 2
791-112-1180 Nut t 2
1
790-101-2480 Adapter t 2
791T-627-1920 Plate t 1 N Q
790-101-2102 Puller t 1
790-431-1031 Block t 1
791-520-4140 Screw t 1
791-112-1180 Nut t 2
3. Shaft
01643-32460 Washer t 2
2 1) Set the final drive assembly to the block.
791T-627-1930 Plate t 1 N Q 2) Remove mounting bolts (2).
791T-627-1940 Push tool t 1 N Q
790-101-2102 Puller t 1
3 791-627-1280 Installer t 1
790-101-5441 • Plate 1
4
K 790-101-5421 • Grip 1
01010-51240 • Bolt 1
790-101-5451 • Plate 1
790-101-5421 • Grip 1
5
01010-51240 • Bolt 1
791T-627-1950 Plate t 1 N Q
791T-627-1960 Plate t 1 N Q
790-201-1680 • Plate 1
6
790-101-5021 • Grip 1
01010-50816 • Bolt 1
791-520-4140 Screw t 1
790-101-2420 Adapter t 1
791-112-1180 Nut t 1
01643-22460 Washer t 1
7
792-785-1120 Plate t 1
791-830-1410 Push tool t 1
790-101-2102 Puller t 1
4 D155A-6
3) Using eyebolts [1], remove shaft (3). 4) Remove floating seal (8) and bearing
outer races (9) and (10).
a Keep the floating seal in a safe place
so that it will not be damaged.
4. Sprocket hub assembly

1) Remove mounting bolts (4) and plate (5).
5) Reverse the sprocket hub assembly and

remove 9 sprockets (11).
2) Using tool K1, pull out sprocket hub

assembly (6).
a Bearing (7) comes off, too.
3) Using eyebolts [2], remove sprocket hub
assembly (6). 5. Wear guard
Remove wear guard (12).
D155A-6 5
6. Cover assembly 6) Reverse the cover assembly and remove

1) Remove spacer (13). 6 lock plates (19).
2) Remove floating seal (14). 7) Remove ring gear (20).
a Keep the floating seal in a safe place
so that it will not be damaged.
3) Remove mounting bolts (15).
7. Carrier assembly
1) Using 3 eyebolts [5], remove carrier
assembly (21).
4) Using eyebolts [3], sling cover assembly
(16). Using 3 forcing screws [4], remove
the cover assembly.
2) Disassemble the carrier assembly accord-

ing to the following procedure.
1] Remove bolts (22) and holders (23).
5) Remove bearing (17) and spacer (18). 2] Pull out planetary gear shaft (24).
6 D155A-6
3] Remove planetary gear (25), bear- 9. Holder

ings (26) and (27) and spacer (28) Remove mounting bolt (33) and holder (34).
from the carrier.
10. Gear
4] Remove bearing outer races (29) and 1) Remove the gear according to the follow-
(30) from the planetary gear. ing procedure.
1] Sling case-hub-case assembly (35) a
little.
2] Push the shaft of case (36) to make a
clearance between bearing (37) and
case shaft.
a Take care not to damage the
bearing holding area on the pin-
ion side.
8. Sun gear
Remove thrust washer (31) and sun gear (32).
3] Remove mounting bolts (38).

4] Using eyebolts [6], sling gear (39),
and slant the hub to remove the gear.
D155A-6 7
11. Hub and case assembly 4) Remove collar (43) and remove bearing
1) Using tool K2, remove hub assembly (40) (44) from case (36).
and bearing (37).
5) Remove sump plate (45) from case (36).

2) Using eyebolts [7], remove hub assembly
(40).
12. Cage assembly

1) Remove the mounting bolts of cage
3) Remove 2 bearing outer races (42) from assembly (46). Using forcing screws [8],
hub (41). remove the cage assembly from case
(36).
8 D155A-6
2) Remove outer race (48) and oil seal (49) 14. Outer race and oil seal
from cage (47). Remove outer race (55) and oil seal (56) from
case (36).
3) Remove shims (50).
13. Gear assembly

1) Remove gear assembly (51).
2) Using puller [9], remove bearings (52) and
(53) from gear (54).
D155A-6 9
Assembly 2. Gear assembly

1) Using the push tool [11], press fit bearings
(52) and (53) to gear (54).
q Bearing press fitting force:
a Coat the sliding surfaces of each part with
6 – 17 kN {0.6 – 1.7 ton}
2) Install the drive shaft cover.
3) Install gear assembly (51).
1. Oil seal and outer race
1) Using tool K4, press fit oil seal (56) to
case (36).
a When press fitting the oil seal, take
care of its direction.
a Apply gasket sealant thinly to the
inside wall of the housing and wipe off
projected part.
2 Oil seal lip: Grease (G2-LI)
2 Oil seal press fitting area:
3. Cage assembly
1) Using tool K4, press fit oil seal (49) to
cage (47).
a When press fitting the oil seal, take
care of its direction.
a Apply gasket sealant thinly to the
inside wall of the housing and wipe off
projected part.
2 Oil seal lip: Grease (G2-LI)
2 Oil seal press fitting area:
2) Using tool K5, press fit outer race (55) to
case (36).
q Outer race press fitting force:
1 – 13 kN {0.1 – 1.4 ton}
10 D155A-6
2) Using tool K5, press fit bearing outer race 4] Install determined shim (50) to the
(48) to cage (47). cage and tighten the 6 mounting bolts
q Bearing press fitting force: of cage (47) evenly.
1 – 13 kN {0.1 – 1.4 ton} 3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
3) Fit the O-ring to cage assembly (46),

install them, and adjust shim (50).
a When installing the cage assembly,
lower it gradually not to damage the
oil seal lip.
4) Adjustment of shim
q Adjust the pinion bearing clearance
1] Tighten mounting bolts (D), (E), (G)
and (H) of cage (40) evenly.
3 Mounting bolt: 20 Nm {2 kgm}
2] Using a thickness gauge, measure
clearances (a) and (b) between cage
(47) and case (36).
3] Referring to Table 1, determine quan-
tity (c) of the shim from the total of
clearances (a) and (b).
D155A-6 11
Table 1 4. Hub and case assembly

Total 1) Install oil sump plate (45) to case (36).
Number of shims
a + b (mm)
to be used shim a When installing the plate, press its
thick- surface against case faces (a) and
Above Below t = 0.15 t = 0.5 t = 1.0 ness (b).
(mm) 2 Mounting bolt: Adhesive (LT-2)
3.05 3.15 5 1 1.75
3.15 3.25 2 1 1 1.80
3.25 3.35 9 1 1.85
3.35 3.45 6 1 1.90
3.45 3.55 3 1 1 1.95
3.55 3.65 2 2.00
3.65 3.75 7 1 2.05
3.75 3.85 4 1 1 2.10
3.85 3.95 1 2 2.15
3.95 4.05 8 1 2.20
4.05 4.15 5 1 1 2.25
4.15 4.25 2 2 2.30
4.25 4.35 9 1 2.35
4.35 4.45 6 1 1 2.40
4.45 4.55 3 2 2.45
4.55 4.65 1 2 2.50
4.65 4.75 7 1 1 2.55
4.75 4.85 4 2 2.60
4.85 4.95 1 1 2 2.65
4.95 5.05 8 1 1 2.70
5.05 5.15 5 2 2.75
5.15 5.25 2 1 2 2.80
5.25 5.35 9 1 1 2.85
5.35 5.45 6 2 2.90
2) Using tool K5, press fit bearing (44) to
5.45 5.55 3 1 2 2.95
case (36).
5.55 5.65 3 3.00 q Bearing press fitting force:
5.65 5.75 7 2 3.05 21 – 54 kN {2.1 – 5.5 ton}
5.75 5.85 4 1 2 3.10 3) Install collar (43).
5.85 5.95 1 3 3.15
5.95 6.05 8 2 3.20
6.05 6.15 5 1 2 3.25
6.15 6.25 2 3 3.30
6.25 6.35 9 2 3.35
6.35 6.45 6 1 2 3.40
6.45 6.55 3 3 3.45
6.55 6.65 1 3 3.50
6.65 6.75 7 1 2 3.55
6.75 6.85 4 3 3.60
6.85 6.95 1 1 3 3.65
6.95 7.05 8 1 2 3.70
7.05 7.15 5 3 3.75
7.15 7.25 2 1 3 3.80
7.25 7.35 9 1 2 3.85
12 D155A-6
4) Using tool K5, press fit 2 bearing outer 2) Tighten gear mounting bolts (38).
races (42) to hub (41). 2 Mounting bolt: Adhesive (LT-2)
q Bearing press fitting force: 3 Mounting bolt:
3 – 18 kN {0.3 – 1.8 ton} 230 – 289 Nm {23.5 – 29.5 kgm}
5) Using eyebolts [7], set hub assembly (40) 3) Using tool K7, press fit bearing (37) to
to the shaft. case (36).
21 – 54 kN {2.1 – 5.5 ton}
5. Gear
1) Using eyebolts [6], sling gear (39). While
slanting the hub, set the gear to the hub. 6. Holder
Install holder (34) and tighten mounting bolt
(35).
3 Mounting bolt:
230 – 289 Nm {23.5 – 29.5 kgm}
D155A-6 13
7. Sun gear 3) Set the planetary gear assembly to the

Install sun gear (32) and thrust washer (31). carrier and press fit shaft (24).
a While aligning the holes of the bear-
ing spacer, press fit the shaft gradu-
ally.
8. Carrier assembly
a Since each planetary gear bearing is an
assembly, assemble it from the inner race,
outer race and spacer of the same identifi- 4) Install holders (23) and tighten bolts (22).
cation mark. 2 Mounting bolt: Adhesive (LT-2)
1) Using tool K6, press fit bearing outer 3 Mounting bolt:
races (29) and (30) to the planetary gear. 230 – 289 Nm {23.5 – 29.5 kgm}
10 – 35 kN {1.0 – 3.6 ton}
5) Using 3 eyebolts [4], install carrier assem-

bly (21).
2) Install bearings (26) and (27) and spacer
(28) to planetary gear (25).
14 D155A-6
9. Cover assembly 5) Using eyebolts [3], fit the O-ring to cover

1) Install ring gear (20) and 6 lock plates (19) assembly (16) and install them to the case
and tighten the mounting bolts. assembly.
2 Mounting bolt: Adhesive (LT-2) a The mating faces of the case and
cover must be free from a dent, rust,
oil, dirt and water.
a Apply the gasket sealant all around
the mating face (1 side) of the case
without breakage.
2 Mating face of case:
a Tighten the bolts within 20 minutes

3) Using tool K3, press fit bearing (17).
15 – 43 kN {1.5 – 4.4 ton}
6) Tighten mounting bolts (15).

3 Mounting bolt:
455 – 565 Nm {46.5 – 58 kgm}
4) Using tool K4, press fit floating seal (14).

a Degrease and dry the O-ring and O-
ring contact surface before installing
the floating seal.
a After installing the floating seal, check
that its tilt is 1 mm or less.
D155A-6 15
10. Wear guard 3) Using tool K3, press fit floating seal (8).
Install wear guard (12). a Degrease and dry the O-ring and O-
3 Mounting bolt: ring contact surface before installing
824 – 1,030 Nm {84 – 105 kgm} the floating seal.
a After installing the floating seal, check
that its tilt is 1 mm or less.
11. Sprocket hub assembly

1) Using tool K5, press fit bearing outer
races (9) and (10). 4) Using eyebolts [2], install sprocket hub
q Bearing press fitting force: assembly (6) to the cover assembly.
14 – 59 kN {1.5 – 4.4 ton} a Check that the sliding surface of the
floating seal is free from dirt and
apply engine oil thinly.
2) Install 9 sprockets (11) to the sprocket

hub.
3 Mounting bolt:
1,176 ± 98 Nm {120 ± 10 kgm}
16 D155A-6
5) Using tool [10], press fit bearing (7). 2) Tighten mounting bolts (2).
a While rotating the sprocket hub 3 Mounting bolt:
assembly, press fit the bearing. 1,225 – 1,470 Nm {125 – 150 kgm}
15 – 43 kN {1.5 – 4.4 ton}
13. Drive shaft

Install drive shaft (1).
6) Install plate (5) and tighten mounting bolts
(4).
3 Mounting bolt: 2
30 – 289 Nm {23.5 – 29.5 kgm}

Tighten the drain plug and add oil through the
oil filler.
a After installing the final drive assembly to the
machine, check the oil level again.
5
12. Shaft
Final drive case: Approx. 31 l
1) Fit the O-ring to the sprocket hub assem-
bly. Using eyebolts [1], install shaft (3). 3 Oil filler/Drain plug:
127 – 176 Nm {13 – 18 kgm}
3 Oil level gauge plug:
58.8 – 76.4 Nm {6 – 8 kgm}
D155A-6 17
D155A-6 Bulldozer
© 2007 KOMATSU
All Rights Reserved
18 D155A-6
SEN03371-00
D155A-6

D155A-6 85001 and up

Undercarriage and frame
Removal and installation of track frame assembly.......................................................................................... 3
Removal and installation of idler assembly ..................................................................................................... 6
Disassembly and assembly of idler assembly ................................................................................................ 7
Removal and installation of recoil spring assembly .......................................................................................11
Disassembly and assembly of recoil spring assembly .................................................................................. 12
Removal and installation of track roller assembly ......................................................................................... 17
Disassembly and assembly of track roller assembly .................................................................................... 18
Removal and installation of carrier roller assembly ...................................................................................... 20
Disassembly and assembly of carrier roller assembly .................................................................................. 21
Removal and installation of pivot shaft assembly ......................................................................................... 25
Spreading and installation of track shoe assembly ....................................................................................... 27
General disassembly and assembly of track shoe........................................................................................ 30
Disassembly and assembly of 1 link in field.................................................................................................. 44
Disassembly and assembly of master link .................................................................................................... 48
Removal and installation of equalizer bar assembly ..................................................................................... 51
Disassembly and assembly of equalizer bar assembly ................................................................................ 53
D155A-6 1
Removal and installation of segment teeth ................................................................................................... 55
2 D155A-6
Removal and installation of track 4. Disconnection of equalizer bar

frame assembly 1 1) Sling track frame assembly, and 2 bolts (1)
and remove cover (2) of equalizer bar.
Removal 2) Remove 2 bolts (3) and lock plate (4).
3) Remove equalizer bar side pin (5).
1. Remove blade assembly. For details, see
"Removal and installation of blade assembly".
2. Spread track shoe assembly. For details, see

"Spreading and installation of track shoe
assembly".
3. Jacking up chassis machine according to the

following procedure
k 1) Using hydraulic jack (686 kN {70 ton})
[2] and ripper of machine, jack up
machine and set stands [1] under
steering case on left and right.
2) Set stands [3] on left and right under
main frame at front of machine.
5. Disconnection of track frame assembly
3) Set blocks under front of raised track
1) Remove cover mounting bolt and install
frame to ensure safety during opera-
guide bar [4].
tion.
2) Remove remaining bolts, and disconnect
a After setting stands [1] and [3], set the
cover (6).
hydraulic jack and ripper again to act
as extra support.
3) Disconnect 4 hoses (7).
D155A-6 3
4) Remove 2 mounting bolts (8) and remove 6. Lift off track frame assembly (14). [*2]
washer (9). a When lifting off the track frame assembly,
take care extremely not to damage the
seal surface.
4 Track frame assembly: 3,960 kg
5) Remove seal (10). [*1]

6) Remove 6 mounting bolts (11) and washer
(12).
7) Remove spacer (13)
7. Remove seal (15) from pivot shaft (16). [*3]
4 D155A-6
Installation [*3]
a Install seal (15) according to the following pro-
cedure.
removal.
1) Reverse seal (15) so that the molded let-
ter (c) face will be on the inside.
[*1]
2) With the seal reversed, insert seal (15) in
pivot shaft (16).
cedure.
3) Apply oil (EO-30) to face (d) of track frame
1) Reverse seal (10) so that the molded let-
assembly (14).
ter (a) face will be on the inside.
4) Install track frame assembly to the pivot
2) With the seal reversed, insert the seal in
shaft.
washer (12).
3) Apply oil (EO-30) to face (b) of washer (9)
at the shaft end.
4) Install washer (9) to the shaft end.
q Refilling with oil (Pivot chamber)

5 Pivot chamber: 9 l (EO-30)
[*2]
a When inserting the track frame assembly, take
care extremely not to damage the seal surface.
D155A-6 5
Removal and installation of idler Installation

assembly 1 q Carry out installation in the reverse order to
removal.
Removal
1. Remove blade assembly. For details, see [*1]
"Removal and installation of blade assembly" a Standard thickness (Upper) (Tu): 8 mm
a Standard thickness (Lower) (Te): 4 mm
2. Spread track shoe assembly. For details, see
"Spread and installation of track shoe assem- [*2]
bly" a Standard thickness (Ts): 6.5 mm
3 Mounting bolt:
3. Remove seat support bolt (1), and remove 662 – 829 Nm {67.5 – 84.5kgm}
plate (2) and shim (3). [*1] a Set clearance (Tc): 2.0 – 3.4 mm
(Including endplay)
4. Loosen support mounting bolts (4), and a Endplay (Ep): 0.49 – 0.72 mm
remove shim (5). [*2] (Total of both side)
4 Idler assembly: 460 kg
5. Remove 4 yoke mounting bolts (6), then sling

idler assembly (7), and pull it out forward to
remove.
6. Remove spring seat and spring.

a These parts are installed between support
and track frame.
6 D155A-6
Disassembly and assembly of

idler assembly 1
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
791-630-1220 Rod t 2
790-101-2510 Block t 1
790-101-2570 Washer t 2
01580-01411 Nut t 2
1
01643-31445 Washer t 2
L
Puller
790-101-2102 t 1
(294 kN {30 ton})
2 791-651-1510 Installer t 1
3 791-601-1000 Oil pump t 1
Disassembly
1. Remove the oil drain plug to drain the oil.
6 Idler: Approx. 390 – 450 cc
2. Set idler assembly (1) to blocks [1].

4 Idler assembly: 500 kg
3. Remove nut (2) and pull out bolt (3).
4. Lift off support assembly (4).

4 Support assembly: 100kg
5. Remove floating seal (5a) from bushing (6).
6. Remove floating seal (5b) from support assem-

bly (4).
7. Remove 6 pieces of bolts (7) from bushing (6).
D155A-6 7
8. Reverse the idler assembly (1) and set it to 14. Using tool L1, remove shaft (14) and bushing
blocks [1]. (12).
4 Idler assembly: 400kg
15. Remove bushing (12) from shaft (14).
a Do not remove inner bushing from outer
9. Remove nut (8) and pull out bolt (9).
bushing. [*1]
10. Lift off support assembly (10).
4 Support assembly: 100kg
12. Remove floating seal (11b) from support

assembly (10).
13. Remove 6 pieces of bolts (13) from bushing

(12).
16. Reverse the idler assembly (1) and set it to

blocks [1].
17. Using push tool [2] and tool L1, remove bush-
ing (6).
a Do not remove inner bushing from outer
bushing. [*2]
8 D155A-6
Assembly 6. Tighten 6 pieces of bolts (7) to bushing (6).
a Clean all the parts thoroughly and check them 7. Using tool L2, install floating seal (5a) to bush-
for dirt or damage. ing (6).
1. Set idler (1) to blocks [1].
2. Using plate [3] and tool L1, press fit bushing

(12).
a Bushing (12) is supplied with a set inner
bushing and outer bushing.
8. Using tool L2, install floating seal (5b) to sup-

port assembly (4).
3. Tighten 6 pieces of bolts (13) to bushing (12).

blocks [1].
5. Using tool L1, press fit shaft (14) and bushing

(6).
D155A-6 9
9. Assemble support assembly (4) to idler assem-

bly (1).
10. Install bolt (3) and tighten nut (2).

blocks [1].
12. Assemble floating seal (11a),(11b) and support

assembly (10) to idler assembly (1) as a same
procedure step 7 to step 10.
13. Using tool L3, add oil to the specified level and
tighten the plug.
6 Idler: 390 – 450 cc (GO140B)
10 D155A-6
Removal and installation of recoil Installation

spring assembly 1 q Carry out installation in the reverse order to
removal.
Removal
1. Remove the idler assembly. For details, see a While checking the recoil spring assembly
"Removal and installation of idler assembly". through the lubricator adjustment window,
install in the track frame.
2. Pull out the recoil spring assembly (1) forward
to remove.
4 Recoil spring assembly: 450 kg
D155A-6 11
Disassembly and assembly of 3) Using push tool [1], pull out piston (9) from
recoil spring assembly 1 yoke (8) with a press.
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
791-685-8006 Compressor t 1
791-635-3160 Extension t 1
M 2 791T-630-2610 Spacer t 1 Q
790-101-1300 Cylinder t 1
q If cylinder (10) has not been broken

Disassembly and shaft end nut (11) has not come
1. Remove yoke and piston assembly (2) from off, disassemble according to the fol-
recoil spring assembly (1). lowing procedure.
2. Disassembly of yoke and piston assembly 3. Remove holder (13) from recoil spring case
1) Remove snap ring (3), packing (4) and (12).
k Never stand in front of or at the rear of
ring (5).
2) Remove bolt (6) and plate (7). the recoil spring assembly to avoid
danger.
12 D155A-6
4. Disassembly of holder 7. Apply hydraulic pressure gradually to tool M2

1) Remove cover (15) from holder (14). to compress the spring and tighten nut (11)
2) Remove seal (16) and bushing (17) from until spacer (19) comes off and then remove
holder (14). the spacer.
8. Remove nut (11) and release the hydraulic oil

gradually to release the spring tension.
5. Remove the lock plate from cylinder (10) and

remove lubricator (18).
9. Remove recoil spring (20) and cylinder (10)

from recoil spring case (12).
10. Remove bushing (21) from cylinder (10).
11. Remove seal (22) and bushing (23) from recoil

spring case (12).
6. Set recoil spring assembly (1) to tool M2.

k Set the spring securely since its installed
load is heavy and dangerous.
a Installed load of spring:
314 kN {32,000 kg}
D155A-6 13
q If cylinder (10) has been broken or shaft Assembly

end nut (11) has come off and the mount-
ing bolt of holder (13) is removed, recoil 1. Using the push tool, press fit bushing (23) to
spring (20) will jump out forward. In this recoil spring case (12) and install seal (22).
2 Bushing: Grease (G2-LI)
case, disassemble according to the follow-
ing procedure.
k Never stand in front of or at the rear of 2. Using the push tool, press fit bushing (21) to
the recoil spring assembly to avoid cylinder (10).
2 Bushing: Grease (G2-LI)
danger until holder (13) and recoil
spring case (12) are separated and the
recoil spring is taken out and safety is
confirmed.
3. Temporarily install recoil spring (20) and cylin-

der (10) to recoil spring case (12) and set them
to tool M2.
2 Inside of case and parts in case:
1) Set recoil spring assembly (1) to tool M2.
k Set the spring securely since its
Grease (Apply G2-LI to minimum
installed load is heavy and danger- thickness of 3 mm)
k Set the spring securely since its installed
ous.
a Installed load of spring: load is heavy and dangerous.
314 kN {32,000 kg} a Installed load of spring:
2) Apply hydraulic oil gradually and fix recoil 314 kN {32,000 kg}
spring assembly (1). 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
3) Remove the mounting bolts of holder (13).

4) Release the hydraulic oil gradually to
release the spring tension.
14 D155A-6
4. Install nut (11) and spacer (19). 6. Install lubricator (18) to cylinder (10) and install
a Eliminate the clearance between the nut the lock plate.
and spacer. a Install the grease fitting at 45° ± 5° out.
(Reference) If there is any clearance, the
spring load is applied to the
threaded part of the nut. The nut
may be damaged and may not be
able to be disassembled next
time.
7. Assembly of holder
1) Using the push tool, press fit bushing (17)
to holder (14) and install seal (16).
2 Bushing and oil seal:
Grease (G2-LI)
2) Install cover (15) to holder (14).
5. Release the hydraulic pressure gradually to
release the spring tension completely and then
remove recoil spring assembly (1) from tool
M2.
8. Install holder (13) to recoil spring case (12).

2 Mating faces of holder and case:
Grease (G2-LI)
D155A-6 15
9. Assembly of yoke and piston assembly

1) Using the push tool and press, press fit
piston (9) to yoke (8).
q Yoke press fitting force:
392 kN {40 ton}
2) Install plate (7) and tighten bolt (6).

a Check that the plate is not on the
yoke.
3) Install ring (5), packing (4) and snap ring
(3).
2 Packing and ring: Grease (G2-LI)
10. Install yoke and piston assembly (2) to recoil

spring assembly (1).
16 D155A-6
Removal and installation of track Installation

roller assembly 1 q Carry out installation in the reverse order to
removal.
Removal
1. Remove track frame assembly. For details, see [*1]
"Removal and installation of track frame" 2 Retainer mounting bolt: Adhesive (LT-2)
3 Retainer mounting bolt:
2. Reverse the track frame assembly (1). 445 – 565 Nm {46.5 – 58 kgm}
3. Remove 2 mounting bolts (2) and retainer (3). [*2]

[*1] 2 Guard mounting bolt: Adhesive (LT-2)
3 Guard mounting bolt:
4. Remove 4 mounting bolts (4) and guard (5). 445 – 565 Nm {46.5 – 58 kgm}
[*2]
[*3]
5. Remove 14 mounting bolts (6) and guard (7). 2 Guard mounting bolt : Adhesive (LT-2)
[*3] 3 Guard mounting bolt (side and upper):
784 – 981 Nm {80 –100kgm}
4 Track roller guard: 145 kg
[*4]
2 Track roller mounting bolt : Adhesive (LT-2)
3 Track roller mounting bolt :
784 – 981 Nm {80 – 100kgm}
6. Remove 4 mounting bolts (8) and lift off track

roller assembly (9). [*4]
4 Track roller (single flange): 115 kg
4 Track roller (double flange): 125 kg
D155A-6 17
Disassembly and assembly of 7. Reverse track roller assembly (8) and set to
track roller assembly 1 press.
Special tools 8. Remove 6 bolts (9).
New/Remodel
9. Using press, push out shaft (10) and bushing
(4).
Necessity
Sym-
Part No. Part name
Sketch
bol
10. Remove bushing (11) from shaft (10).
Q'ty
a Do not separate inner bushing and outer
L 2 791-651-1510 Installer t 1
bushing. [*1]
Disassembly
1. Remove plug and drain oil.
2. Remove ring (1), then remove collar (2).

a Remove collar (5) same as collar (2).
4. Remove floating seal (3b) from collar (2).
5. Remove floating seal (6a), (6b) same as pro-

cedure 3 and 4.
11. Reverse track roller assembly (8) and set to

press.
12. Using push tool [1], push out bushing (11).

a Do not separate inner bushing and outer
bushing. [*2]
6. Remove 6 bolts (7) from track roller (8).
18 D155A-6
Assembly 9. Fix bushing (11) with 6 bolts.

2 Mounting bolt :
1. Set track roller assembly (8) to press. Molybdenum disulfide lubricant (LM-P)
3 Mounting bolt:
2. Set bushing (4) to track roller (8) with o-ring. 1st step : 735 ± 10 Nm {74 ± 1kgm}
2nd step(angle tightning): 90 ± 5°
3. Using plate [2], press fit bushing (4) to track
roller (8).
4. Fix bushing(4) with 6 mounting bolts.

2 Mounting bolt :
Molybdenum disulfide lubricant (LM-P)
3 Mounting bolt :
1st step : 735 ± 10 Nm {74 ± 1kgm}
2nd step(angle tightning): 90 ± 5°
10. Using tool L2, assemble floating seal (3a) to

bushing (4).
a Before installing the floating seal, roughly
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
5. Reverse track roller assembly (8) and set to the seal is 7 –11 mm.
block [3].
6. Sling shaft (10) and install it to bushing (4).

a Do not damage inside of bushing.
11. PUsing tool L2, assemble floating seal (3a) to

collar (9).
7. Set bushing (11) to track roller assembly with

o-ring.
8. Using push tool [4], press fit bushin (11).
D155A-6 19
Removal and installation of 4. Pass rope [2] through the link hole and wind it
carrier roller assembly 1 onto carrier roller (3) and stretch it. Loosen the
rope gradually to pull out carrier roller (3) from
Removal support (4). [*1]
4 Carrier roller: 45 kg
1. 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 suffi-
ciently after the lubricator is loosened,
move the mach ine forward an d in
reverse.
Installation
removal.
[*1]
When installing the carrier roller to the support,
make clearance (a) shown in the figure.
2. Using hydraulic jacks [1], raise the track shoe. q Clearance (a): 1.2 mm
2 Support mounting bolt: Adhesive (LT-2)
3. Remove mounting bolts (2).
q Adjust the track shoe assembly tension. For
details, see Testing and adjusting, "Testing and
adjusting track shoe assembly tension".
20 D155A-6
Disassembly and assembly of 5. Using tool R1, remove nut (4).

carrier roller assembly 1
6. Using puller [2], remove the ring press fitting
Special tools part. Using eyebolts, remove bearing (5) and
roller (6) together.
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
1 790-102-1891 Nut wrench t 1
2 791-651-1510 Installer t 1
R
3 791T-630-1350 Spacer t 1 Q
4 791-601-1000 Oil pump t 1
Disassembly
1. Remove the plug to drain the oil.
a While rotating the shaft, drain the oil.
7. Remove outer race (7) from the roller.
6 Carrier roller: 570 – 680 cc
8. Using puller [3], remove ring (8) and the inner
2. Set carrier roller assembly (1) to block [1]. race of bearing (9) together.
3. Remove the mounting bolts and cover (2).
4. Remove ring (3).
9. Remove floating seal (10) from ring (8).
D155A-6 21
10. Using push tool [4], remove ring (11). Assembly

11. Remove floating seal (12) from ring (11). a Clean all the parts thoroughly and check them
for dirt or damage.
1. Using push tool [5], press fit the inner race of

bearing (9) to the shaft.
2. Using push tool [6], press fit outer race (7) of

the bearing to the roller.
3. Set the inner races of roller (6) and bearing (5)

to the shaft.
4. Using push tool [7], press fit the inner race of

bearing (5) to the shaft.
a While rotating the roller, press fit the bear-
ing until the roller becomes a little heavy to
rotate.
22 D155A-6
5. Using tool R1, tighten nut (4) to "58.8 Nm {6 9. Using tool R2, install floating seal (10) to ring
kgm}". (8).
a After tightening the nut, if the nut hole is
not aligned with the shaft hole, align it by 10. Fit the O-ring and install ring (8) while setting it
loosening it. to the dowel pin.
6. Install ring (3).
11. Using tool R2, install floating seal (12) to ring

(11).
7. Fit the O-ring and install cover (2) and then
tighten the mounting bolts.
a Tighten the oil filler plug temporarily.
a Before installing the floating seal, thor-

oughly clean, degrease and dry the O-ring
and O-ring contact surface (hatched
8. Reverse roller (6) and add oil between the areas).
shaft and roller. a After inserting the floating seal, check that
5
its tilt is 1 mm or less and projection (a) of
Refill capacity: 570 – 680 cc (GO140)
the seal is 7 – 11 mm.
a Coat the sliding surfaces of the floating
seal and take care that dirt will not stick to
them.
D155A-6 23
12. Using tool R3, press fit ring (11). 14. After checking for air leakage, check again that
a Press fit the ring so that dimension (a) the oil supplied in step 8 is still at a proper
from the shaft end to the ring top will be level.
131.95 ± 0.2 mm. a Check of oil level
Remove the oil filler plug, slant the carrier
roller approx. 10°, and check the oil level.
15. Tighten the oil filler plug

3 Plug:
157.0 – 255.0 Nm {16.0 – 26.0 kgm}
13. Using tool R4, apply the standard pressure to

the roller oil filler to check the seal for air leak-
age.
a Standard pressure: 0.1 MPa {1 kg/cm2}
a Check method
Keep the standard pressure for 10 sec-
onds and confirm that the gauge pointer
does not lower.
24 D155A-6
Removal and installation of pivot 3. Sling pivot shaft assembly (3) and remove the
shaft assembly 1 mounting bolts. Using eyebolts [1], lift off pivot
shaft assembly (3). [*2]
Special tools 4 Pivot shaft assembly: 135 kg
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
791T-650-2110 Sleeve t 1 Q
790-201-2770 Spacer t 1
791T-650-2120 Plate t 1 Q
792-104-3940 Bolt t 2
790-101-2510 Block t 1
V
790-101-2570 Washer t 2
01580-01613 Nut t 1
Jack assembly
790-105-2300 t 1
(196 kN {20 ton})
Removal
1. Remove the track frame assembly. For details,
see "Removal and installation of track frame
assembly".
2. Remove seal (1) and ring (2). [*1]
D155A-6 25
Installation
removal.
[*1]
cedure.
1) Reverse seal (1) so that the molded letter
(a) face will be on the inside.
2) With seal (1) reversed, insert it in pivot
shaft (3).
a Using tool V, press fit ring (2).

q Press fitting force:
8.8 – 22.5 kN {0.9 – 2.3 ton}
q Ring press fitting dimension:
475.5 ± 1 mm
[*2]
2 Pivot shaft mounting bolt: Adhesive (LT-2)
3 Pivot shaft mounting bolt:
784 – 981 Nm {80 – 100 kgm}
26 D155A-6
Spreading and installation of Spreading of track shoe assembly

track shoe assembly 1 (Ordinary)
a If no abnormality is detected by "Check before
Check before spreading track shoe
spreading track shoe assembly", perform the
assembly following procedure.
k Since it may be very dangerous to spread
the track shoe assembly, check the follow- 1. Set the master link in position.
ing items in advance. a Set master link (3) above the idler (a little
k Do not loosen the lubricator more than 1 after the center of the idler).
turn. If the grease does not come out suffi- a Set blocks [1] and [2] at the front of the
ciently, move the machine forward and in idler and between the carrier rollers so
reverse. that the mating part of the master link will
not open until the master bolt is pulled out.
1. Remove cover (1) and loosen lubricator (2) of
the adjustment cylinder to discharge the
grease.
k Do not loosen the lubricator more than
1 turn.
2. Lower the track shoe tension. [*1]

k Do not loosen lubricator (2) more than
1 turn.
a If the track shoe tension is not lowered
after the lubricator is loosened, move the
2. After the shoe is loosened, perform "Spreading machine forward and in reverse.
of track shoe assembly (Ordinary)".
3. If the track shoe is not loosened by the above

work, perform "Spreading of track shoe assem-
bly (When track frame has internal trouble)".
a The track frame may have an internal
trouble (damage of the recoil spring or
recoil spring set bolt, fall of the shaft end
nut, etc.)
D155A-6 27
3. Remove track shoe (4). [*2] Spreading of track shoe assembly

a Loosen the 4 bolts by 1 – 2 turns each and (When track frame has internal trouble)
check that they rotate lightly, and then pull
them out. Do not pull them out one by one a If any abnormality is detected by "Check
without checking their looseness. before spreading track shoe assembly", per-
a If the bolts are loosened forcibly while they form the following procedure.
k If the track shoe is removed while the track
are still tight, their threads and master link
(3) may be damaged. frame has an internal trouble, it may spring
back. Even if the track shoe is removed,
the idler may jump out, and that can cause
a serious accident. Accordingly, spread
the track shoe according to the following
procedure.
1. Remove the work equipment. For details, see

"Removal and installation of blade assembly".
2. Lower the track shoe tension. [*1]

k Do not loosen lubricator more than 1
turn.
a If the track shoe tension is not lowered
after the lubricator is loosened, move the
machine forward and in reverse to dis-
4. Sling the front end of the master link and move charge the grease.
the machine slowly in reverse to spread track a Check that all the grease has been dis-
shoe assembly (5). charged.
a Length of track shoe: Approx. 10.5 m
k Never stand in front of the idler to
3. Move the machine slowly forward against large
avoid danger. block [3] or a wall (or the blade of another
machine of the similar size of the machine to
be repaired, if available) to press the track
shoe (4) 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.
28 D155A-6
Installation
expansion (ordinary).
[*1]
a Adjust the track shoe tension. For details, see
Testing and adjusting, "Testing and adjusting
track shoe tension".
[*2]
a Tighten the shoe mounting bolts for the master
link in the following order.
2 Shoe mounting bolt:
Molybdenum disulfide grease (LM-P)
3 Shoe mounting bolt:
1st time: 590 ± 60 Nm {60 ± 6 kgm}
2nd time: Retighten by 180° ± 10°
a Tighten all the 4 bolts with fingers until the
master link mating faces are fitted.
a If the bolts are tightened forcibly before the
master link mating faces are fitted, their
threads and master link may be damaged.
D155A-6 29
General disassembly and a If it is obliged to cut a shoe nut with gas,

assembly of track shoe 1 keep the seal temperature below 80 °C to
prevent thermal deterioration of the seal
Special tools and take measures to prevent the spatters
from entering through the clearances
New/Remodel
among the links.
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
Remover and
791-675-9701 t 1
installer
Cylinder
791-101-4300 t 1
1 (196 kN {20 ton})
Puller
791-101-4200 t 1
(294 kN {30 ton})
S
2 791-932-1110 Plug push tool t 1
3 791-660-7460 Pin brush t 1
4 791-432-1110 Plug push tool t 1
2. Disassembly of link
5 791-632-1052 Installer t 1 1) Set the link assembly on a link press and
6 790-701-3000 Seal checker t 1 hit it with a hammer so that the bushing
7 791-601-1000 Oil pump t 1 will be fitted to the jaw.
a If the link tread, outside of the bush-
a For the general disassembly of the track shoe, ing, etc. are worn, adjust the height of
see "Parts judgment guide, Undercarriage, Oil jaw [1] or guide plate and align disas-
lubricated track" and "Parts judgment guide, sembly jigs [2] and [3] with the pin
Undercarriage, Reversing procedure for oil and bushing so that the link hole will
lubricated track". not be damaged during disassembly
work.
a If the disassembly jigs are not aligned
General disassembly well, the link hole may be damaged
1. Removal of shoe and the pin and bushing may be bro-
Sling the shoe assembly and set it with the ken during disassembly work.
shoe up on the floor and remove the shoe by
using a shoe bolt impact wrench.
a If a shoe bolt is not loosened after it is
unscrewed by 1 turn (If its torque is not
reduced to 0), loosen the other bolts first,
and it will be removed smoothly.
a If a shoe bolt is turned forcibly while its
torque is not 0, it and link will adhere to
each other and they will need to be
repaired.
a When moving the shoe assembly, take
care not to damage the master link.
30 D155A-6
a Using tool S2, drive the small plug of 4) Return the right cylinder and take out the
the pin inward after the disassembly links, pins, bushings, and spacers on the
work so that the workplace will not right and left sides and feed the next 1 set
become dirty. of the link assembly to the jaw.
a If the bushing ends and sealing sur-
faces are damaged, oil will leak.
Accordingly, handle them carefully.
2) Operate the left cylinder to pull out the pin

and bushing from the left link simulta-
neously.
a Check the pulling out force of the pin 3. Inspection
and bushing to see if press fitting Check the parts for the following items to see if
force for them necessary for reversed they can be used for an oil lubricated track or a
reassembly is obtained. grease lubricated track, then examine them
generally and determine to use them for an oil
lubricated track or a grease lubricated track.
a For judgment of reuse of the parts, see
"Parts judgment guide, Undercarriage, Oil
lubricated track".
1) Check the parts visually for damage. If a
part seems to be damaged, check it by
dye penetrant test or magnaflux inspec-
tion. If it has any crack, it cannot be used
again. Discard it.
3) Return the left cylinder and operate the

right cylinder to pull out the pin and bush-
ing from the right link simultaneously.
D155A-6 31
2) Measure the outside diameters of the General assembly

press fitting parts of the pin and bushing
a For the whole assembly of the track shoe, see
and the inside diameters of the pin and
"Parts judgment guide, Undercarriage, Revers-
bushing fitting parts of the link with a
ing procedure for oil lubricated track".
micrometer and a cylinder gauge to see if
the interference is larger than the limit.
When recycling for oil lubricated track
When using the pin, bushing, and link for
an oil lubricated track, however, secure 1. Preparation work
the standard interference between the pin 1) Cleaning of seal assembly
and link. Remove the seal assembly from the link
a If the interference is less than the and divide it into the seal ring (1) and load
limit, replace the parts with new ones. ring (2), and then clean them.
a For the dimensional criteria, see a Since the seal ring and load ring are
"Maintenance Standard". deteriorated easily by the cleaning liq-
uid (trichloroethylene etc), clean them
quickly. After cleaning them, wipe off
the cleaning liquid from them.
a Precautions for storage

1) Store the seal without removing it from the
link so that the counterbore portion will not
be rusted and take care not to damage the 2) When reusing the pin, chamfer its end cor-
seal lip. ners smoothly with a grinder. Remove the
2) Apply rust-preventive oil to the pin and nodules sticking to the press fitting parts
bushing fitting parts, shoe mating surface with the grinder, too.
and master link mating surface of the link. a If the ends are worn and sharpened,
3) When storing, apply rust-preventive oil to they may scuff the press fitting parts
all the surfaces of the pin, bushing and and cause oil leakage.
spacer. Take care not to damage the ends
of the bushing in particular.
32 D155A-6
3) If the link, pin, bushing and spacer are 5) Installation of seal assembly
dirty, clean them. Remove the nodules Clean the counterbore portion (d) of the
sticking to the link and bushing with the link carefully and push in the seal to the
grinder. bottom by using tool S5.
a Since these parts rust easily, clean a If oil sticks to the counterbore portion
them just before assembling. of the link or seal assembly, the seal
a Do not polish the bushing ends. If will turn and its sealing performance
they are polished, oil may leak. will lower. Accordingly, do not apply
4) If the large plug was pulled out, drive it in any oil. When inserting the seal in the
by using tool S4. counterbore portion, take care that oil
a Clean the pin hole in advance by not stick to the seal.
using tool S3.
6) Adjust the dimensions of the press fitting

1] Insert plug (3) through the plug inser- jig of the link press to keep the projection
tion window into the guide hole. of the pin and bushing constant and keep
2] Push the bar with the hand and insert the installed dimensions of the seal within
the plug until it stops. the standard range.
3] Push the plug with the bar to press a For the standard dimensions, see
the guide against pin (4). "Dimensions table of press fitting jig
a Driving distance (a) from pin end: of link press".
10 ± 1 mm a If the pin end (part P) or the sides of
a If the chamfered part of the pin the link (parts Q and R) are worn, add
hole has been worn, chamfer it the dimensions of the worn parts
with a small-sized grinder (grind- when adjusting the standard dimen-
stone tip angle: 45° – 60°) so that sions so that the projections of the
the plug will not be damaged. pins and bushings on the right and
a Coat the plug with GO90 and left sides will be even.
drive it with the small diameter
end ahead.
D155A-6 33
7) Adjust the relief pressure of the link press

so that the pressing force of the press will
not exceed the standard value.
a If the pressing force is too strong, the
spacer will be pressed forcibly against
the bushing. As a result, the spacer
may be broken and it and bushing
may be worn abnormally.
a Final pressing force for pin and bush-
ing: 862 kN {88 tons}
Final pressing force C 1.8 x Average
press fitting force
(Adjust the relief pressure of the link
press to set the final pressing force.)
3) Using the shoe bolt hole pitch gauge,
2. Assembly of link press fit the master links until the distance
1) Apply oil (GO90) to the mating surfaces of between the shoe bolt holes of both links
the pin and bushing with a clean brush is the standard value.
and assemble them, and then set them a Blow off all the steel chips caused by
before the jaw of the link press. press fitting of the bushing with com-
a When reusing (reversing) the bush- pressed air.
ing, set the worn outside surface of 4) Reverse the master links and check that
the bushing on the shoe fitting side of they are press fitted in parallel.
the link (set the bushing with the worn
outside surface up on the link press).
5) Measure the projections of the bushing on

the right and left sides with a depth gauge.
2) Set shoe mounting faces of the right and a Adjust the press fitting jig of the link
left master links on bushing side up and press so that the projections on the
press fit the bushing. right and left sides will be even.
a At this time, use the master links on
the pin side as supports.
a Bushing press fitting force:
88 – 304 kN {9 – 31 ton}
34 D155A-6
6) Send the master links and set the next pin

and bushing.
a When reusing a pin, install it so that
its side hole will be on the link tread
side similarly to a new one. If it is not
installed so, its strength may be low-
ered. Accordingly, indicate the direc-
tion of side hole (e) on the end face to
prevent a mistake.
9) Using spacer [4] for fine adjustment, press

fit the pin and bushing until the pin end is
fitted to the bottom of the receiving jig.
a Adjust the depth of the receiving jig
hole so that the projections of the pin
on the right and left sides will be
even.
7) Set the right link and install the spacer to

the pin.
a Check that the seal surface and bush-
ing end are free from dirt and apply oil
(GO90) to them with a clean cloth or
brush.
a When installing the spacer, wipe it
with a clean cloth.
10) Set the left link and install the spacer to

the pin.
a Apply oil similarly to the right link.
8) Set the right jig on the receiving side and

the left one on the pushing side and press
fit the pin and bushing simultaneously.
a If the pin and bushing have play when
they are press fitted, the seal may
come off the link. To prevent this,
press fit smoothly. If the seal comes
off the link, stop press fitting and set
the seal to the link correctly, and then
start press fitting again.
a Press fitting force for pin and bushing:
343 – 490 kN {35 – 50 ton}
D155A-6 35
11) Set the left jig on the receiving side and 13) Using a shoe bolt hole pitch gauge, mea-
the right one on the pushing side and sure the distance between the shoe bolt
press fit the left link. holes and check that the result is within
a When press fitting, take care that both the standard range.
seals and spacers will not come off. a If the distance between the shoe bolt
a Link press fitting force: holes is longer than the standard
343 – 490 kN {35 – 50 ton} range, disassemble and check for
abnormality, then press fit again.
a If the distance between the shoe bolt
holes is shorter than the standard
range and the shoe cannot be
installed, the spacer or bushing end
may be worn more than repair limit.
In this case, disassemble and replace
the parts.
12) Press fit until the link, spacer and bushing

are fitted together.
a Actually, you cannot see from outside
if the above parts are fitted. Accord-
ingly, control the hydraulic pressure of
the link press. Set the relief pressure
to a proper level and heighten the
hydraulic pressure to that level.
For setting of the relief pressure, see 14) After each link is assembled, bleed air
Preparation work. from the pin by using tool S6 and check
a Check that adjacent 2 links can turn the sealing performance.
around each other. a Keep the degree of vacuum inside the
pin at 91 – 95 kPa {680 – 710 mmHg}
for 5 seconds and check that the
pressure does not change.
If the pressure changes, disassem-
ble and check the seal. If the seal is
free from abnormality, assemble
again.
36 D155A-6
15) Using tool S7, supply oil (G090) until the 16) After supplying oil, drive in the small plug
oil supply pressure rises to 196 – 294 kPa into the specified position, using tool S2.
{2 – 3 kg/cm2}. a Apply G090 around the small plug.
a In a cold or very cold district, supply a Drive in the small plug to the following
K OM AT SU genu ine oil ( 150- 09- depth.
19270 for cold district or 195-32- Driving depth from end: 7.5 ± 1 mm
61990 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.
17) Assemble the master link on the pin side

at last.
a Check that the master links on the
right and left sides are press fitted in
parallel.
a Determine oil level (a) as follows; 3. Installation of shoe

supply oil (d) so that depth (L) of the 1) Set the link assembly on the bed and
hollow of pin hole (c) will be in the fol- install the shoe with a shoe bolt impact
lowing range when the link is left with wrench and a torque wrench.
small plug side (b) up (with the link a When reusing (reversing) the bush-
assembly on its side) for 30 minutes. ing, set the worn outside face of the
Dimension (L): 35 – 65 mm bushing to the shoe mounting side of
the link (set the bushing with the worn
2 Shoe bolt:
Molybdenum disulfide grease
(LM-P)
3 Shoe bolt (Regular link)
Initial torque:
590 ± 60 Nm {60 ± 6 kgm}
Retightening angle: 120° ± 10°
D155A-6 37
2) When installing a 2-piece shoe, place the When recycling for grease lubricated track
assembled 2-piece shoes on a level place 1. Preparation work
in 1 line with the shoe side up. 1) Cleaning of seal assembly
3) Pull pin-side master link (1) and bushing- Remove the seal assembly from the link
side master link (2) together and set them and divide it into the seal ring (1) and load
to each other by the mating faces. ring (2), and then clean them.
4) Place shoe (3) and fit the mating surfaces a Since the seal ring and load ring are
of the links. deteriorated easily by the cleaning liq-
5) Check that master bolts (4) can be tight- uid, clean them quickly. After clean-
ened easily with the fingers, then connect ing them, wipe off the cleaning liquid
the links with the master bolts. from them.
2 Master bolt:
(LM-P)
3 Master bolt (Master link)
Initial torque:
590 ± 60 Nm {60 ± 6 kgm}
2) When reusing the pin, chamfer its end cor-

ners carefully with a grinder so that it will
be press fitted smoothly.
a Tighten the bolts in the order of 1 – 4.
38 D155A-6
3) Using tools S2 and S4, drive the large and 6) Installation of seal assembly
small plugs (3) into the pin (4). Clean the counterbore portion (d) of the
1] Insert each plug through the plug link carefully. Using tool S5, push in the
insertion window into the guide hole. seal to the bottom.
a Apply oil to the plug. a If grease sticks to the counterbore
2] Push the bar with the hand until the portion of the link or seal assembly,
plug stops. the seal will turn and its sealing per-
3] Push the plug with the bar to press formance will lower. Accordingly, do
the guide against the pin. not apply any grease.
4] Drive in the bar with a hammer.
a Driving distance (a) from pin end:
Small plug: 7.5 ± 1 mm
Large plug: 6.0 ± 2 mm
a If the plugs were not pulled out of
the pin when the shoe was disas-
sembled, reuse them as they
are.
7) Adjust the dimensions of the press fitting

jig of the link press to keep the projection
of the pin and bushing constant and keep
the installed dimensions of the seal within
the standard range.
a For the standard dimensions, see
"Dimensions table of press fitting jig
of link press".
a If the pin end (part P) or the sides of
the link (parts Q and R) are worn, add
the dimensions of the worn parts
when adjusting the standard dimen-
sions so that the projections of the
pins and bushings on the right and
left sides will be even.
4) If the outside of the pin, surfaces of the

spacer, and ends and inside of the bush-
ing are dirty, clean them.
5) Apply grease to the outside of the pin and
surfaces of the spacer.
D155A-6 39
2. Assembly of link 3) Using the shoe bolt hole pitch gauge,

1) Apply lithium grease (G2-LI) to the mating press fit the master links until the distance
surfaces of the pin and bushing and between the shoe bolt holes of both links
assemble them, then set them before the is the standard value.
jaw of the link press. a Blow off all the steel chips caused by
a When reusing (reversing) the bush- press fitting of the bushing with com-
ing, set the worn outside surface of pressed air.
the bushing on the shoe fitting side of 4) Reverse the master links and check that
the link (set the bushing with the worn they are press fitted in parallel.
5) Measure the projections of the bushing on

2) Press fit the master links on both bushing the right and left sides with a depth gauge.
sides to the bushing with the shoe fitting a Adjust the press fitting jig of the link
faces up. press so that the projections on the
a At this time, use the master links on right and left sides will be even.
the pin side as supports.
a Press fitting force for bushing:
88 – 304 kN {9 – 31 ton}
40 D155A-6
6) Send the master links and set the next pin 8) Using a shoe bolt hole pitch gauge, mea-
and bushing. sure the distance between the shoe bolt
a When reusing a pin, install it so that holes. When the distance is in the stan-
its side hole will be on the link tread dard range, stop press fitting.
side similarly to a new one. If it is not
installed so, its strength may be low-
ered. Accordingly, indicate the direc-
tion of the side hole on the end face
to prevent a mistake.
a If the outside of the pin is worn, install
it so that the un-worn surface will be
on the traction side. In this case,
install the pin so that its side hole will
be on the link tread side.
9) Assemble the master link on the pin side

at last.
a Check that the master links on the
right and left sides are press fitted in
parallel.
3. Installation of shoe
1) Set the link assembly on the bed and
install the shoe with a shoe bolt impact
wrench and a torque wrench.
7) Set the right and left links and operate a When reusing (reversing) the bush-
both pushing jigs to press fit the pin and ing, set the worn outside surface of
bushing simultaneously. the bushing on the shoe fitting side of
a If the pin and bushing have play when the link (set the bushing with the worn
they are press fitted, the seal may outside surface up on the link press).
come off the link. To prevent this, 2 Shoe bolt:
press fit smoothly. If the seal comes Molybdenum disulfide grease
off the link, stop press fitting and set (LM-P)
the seal to the link correctly, then start 3 Shoe bolt (Regular link):
press fitting again. Initial torque:
a Final pressing force for pin and bush- 590 ± 60 Nm {60 ± 6 kgm}
ing: 343 – 490 Nm {35 – 50 ton} Retightening angle: 120° ± 10°
Final pressing force C 1.8 x Average
press fitting force
(Adjust the relief pressure of the link
press to set the final pressing force.)
D155A-6 41
2) When installing the assembled 2-piece

track shoes, place them on a level place in
1 line with the shoe side up.
3) Pull pin-side master link (1) and bushing-
side master link (2) together and set them
to each other by the mating faces.
4) Place shoe (3) and fit the mating surfaces
of the links.
5) Check that master bolts (4) can be tight-
ened easily with the fingers, then connect
the links with the master bolts.
2 Master bolt:
(LM-P)
3 Master bolt (Master link)
Initial torque:
590 ± 60 Nm {60 ± 6 kgm}
a Tighten the bolts in the order of 1 – 4.
42 D155A-6
Dimensions table of fitting jig of link press
Adjustment Precaution
Adjust the dimensions of the press fitting jig of the 1. The link receiving faces of jaw (5) must be ver-
link press to keep the projection of the pin and tical.
bushing constant and keep the installed dimen- 2. Wear plate (6) should be replaceable.
sions of the seal within the standard range.
a If the pin end (part P) or the sides of the link
(parts Q and R) are worn, add the dimensions
of the worn parts when adjusting the standard
dimensions so that the projections of the pins
and bushings on the right and left sides will be
even.
Unit: mm
Dimensions of jig
a b c
4.5 3.25 50.6
D155A-6 43
Disassembly and assembly of 1

link in field 1
Special tools
New/Remodel
New/Remodel
Necessity
Necessity
Sym- Sym-
Part No. Part name Part No. Part name
Sketch
Sketch
bol bol
Q'ty
Q'ty
791-675-9581 Adapter t 1 8 791-675-5580 Guide t 1
791-675-9590 Guide t 1 791-685-9510 Frame t 1
1
01010-52460 Bolt t 2 791-685-9520 Frame t 1
01010-51440 Bolt t 2 791-685-9530 Rod t 1
790-101-1102 Pump t 1 791-685-9540 Rod t 1
2 Cylinder 791-685-9550 Nut t 3
790-101-4300 t 1
(1,470 kN {150 ton}) 791-685-9560 Bolt t 4
791-685-9510 Frame t 1 791-126-0150 Adapter t 1
9
791-685-9520 Frame t 1 01010-51030 Bolt t 1
791-685-9530 Rod t 1 791-685-9620 Extension t 1
791-685-9550 Nut t 1 791-675-5542 Adapter t 1
791-685-9560 Bolt t 1 791-675-5560 Guide t 1
3
791-675-9570 Adapter t 1 T 790-101-1102 Pump t 1
04530-12030 Eyebolt t 1 Cylinder
790-101-4300 t 1
790-101-1102 Pump t 1 (1,470 kN {150 ton})
T Cylinder 791-675-5560 Guide t 1
790-101-4300 t 1 10
(1,470 kN {150 ton}) 791-675-5542 Adapter t 1
791-685-9540 Rod t 1 790-101-1102 Pump t 1
4
791-685-9550 Nut t 3 11 Puller
790-101-4200 t 1
791-675-5520 Guide t 1 (294 kN {30 ton})
791-675-5530 Pusher t 1 12 791-670-3270 Guide t 1
5
01010-51030 Bolt t 1 791-126-0150 Adapter t 1
791-685-9620 Extension t 1 791-675-5560 Guide t 1
13
790-101-1102 Pump t 1 791-675-9570 Adapter t 1
6 Puller 01010-51030 Bolt t 1
790-101-4200 t 1
(294 kN {30 ton})
791-675-5542 Adapter t 1
791-675-5571 Adapter t 1
7 790-101-1102 Pump t 1
Cylinder
790-101-4300 t 1
(1,470 kN {150 ton})
44 D155A-6
Disassembly of 1 link in field 3. Insert the rod of tool T4 from the cylinder side
k Only how to use the tools is explained below. and install it with the nuts (2 pieces).
For details of disassembly and assembly, Pass the rod through the hole of link (1) and
see "General disassembly (or assembly) of install it.
track shoe".
1. Using 2 bolts (2), install tool T1 (adapter, guide

and bolt) to link (1).
a The track bolts may be used as 2 bolts (2).
4. Set tool T5 (adapter, guide and pusher) and

apply pressure to pull out pin (3).
When the cylinder reaches the stroke end,
insert tool T5 (extension) between the adapter
and guide and repeat the work.
2. Assemble tool T2 (pump and cylinder of 150
ton) and tool T3 (frame, rod, adapter, 1 bolt
and eyebolt) and sling them together and set
them on the shoe.
5. Set tool T6 (294 kN {30 ton}) puller) and spacer

[1] to the center of the roller tread of the link to
be disassembled and apply hydraulic pressure
to the puller to open and disconnect the link by
5 – 6 mm.
D155A-6 45
Assembly of 1 link in field 3. Set link (4) on the opposite side and support it
1. Assemble the link sub-assembly. with tool T8 (guide).
1) Set tool T7 the link end face and press fit
bushing (1).
a Busing press fitting force:
88 – 304 kN {9 – 31 ton}
4. Set tools T9 and T10 as in the procedure for

pulling out the pin. Using tool T9 (adapter,
extension, guide, adapter and bolt) for (d) on
the bushing side and tool T10 (extension,
2) Set tool T7 to the end face of the link (on guide, adapter and bolt) for (c) on the pin side,
the pin side) and press fit pin (2). press fit (d) and (c) alternately.
a Set the pin with its side hole (a) a Pin press fitting force:
directed toward link tread (b). 284 – 686 kN {29 – 70 ton}
a Pin pressing force: a Bushing press fitting force:
284 – 686 kN {29 – 70 ton} 88 – 304 kN {9 – 31 ton}
2. Set the link to be connected to link sub-assem- 5. Using tool T11 (294 kN {30 ton} puller) as in
bly (3). the disassembly procedure, push open link (5)
on the bushing side.
46 D155A-6
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).
3 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}
D155A-6 47
Disassembly and assembly of 2. Removal of master link

master link 1 1) Cutting and removal of master link on
bushing side with gas
Special tools Cut at (a) with gas and remove the
hatched part. Pull out master links (5) and
New/Remodel
(6) by moving them up and down. Then,
remove pins (8) and (9) from regular link
Necessity
Sym-
Part No. Part name
(7) by pressing them up and down with the
Sketch
bol
press.
Q'ty
Special tool : 1. Gas cutting machine
790-101-1102 Pump t 1
: 2. Tool U2
1 Puller
790-101-4200 t 1
(294 kN {30 ton})
Remover and
791-675-9701 t 1
installer
790-101-1102 Pump t 1
U 2 Puller
790-101-4200 t 1
(294 kN {30 ton})
Cylinder
790-101-4300 t 1
(1,470 kN {150 ton})
3 791-432-1110 Plug push tool t 1
4 790-701-3000 Seal checker t 1
5 791-932-1110 Plug push tool t 1
Disassembly 2) Removal of master link on pin side

Cut at (b) with gas and remove the
a For the using method of tool U2, see "Disas- hatched parts. Remove pin (10) from link
sembly in field". (11) by pressing it down with the press,
1. Removal of track shoe assembly and then remove pin (10) and link (12)
Remove the track shoe assembly from the from bushing (13) simultaneously.
track frame. For details, see "Spreading and Special tool : 1. Gas cutting machine
installation of track shoe assembly". : 2. Tool U2
48 D155A-6
Assembly 2) Set spacer (3) and seal assembly (4) to

the counterbore of the link at the connect-
a For the using method of U2, see "Assembly of ing section.
1 link in field".
1. Assembly of link on bushing side
1) Press fit master link (1) on the bushing
side to bushing (2) with the press.
a When press fitting the right and left
master links, take care extremely that
they will be in parallel.
a Do not damage the mating faces of
the master links and end of the bush-
ing.
Unit: mm
L1 169 ± 0.7
L2 219.8 ± 0.7
D1 27 drill hole
3) Align the holes of the pin and bushing and
D2 24 x 2.0
connect by guide pin [2].
4) Press fit pin (5) with tool U2 and install

2. Installation of link on bushing side master link (1) on the bushing side.
2 Apply gasket sealant (198-32-19890)
1) Push open the central part of the link tread
with tool U1 as shown in the figure (Open to the pin hole of the link.
the link tip by 10 mm). a Direct the side hole of the pin toward
(a): 5 mm the link tread.
D155A-6 49
5) Install the shoe to the link at the connect- 2) Insert pin (9) in bushing (8), set master
ing section. links (10) on the pin side from the right
6) Drive in large plug (6) with tool U3, add oil and left sides, and press fit them with tool
with tool U4, and drive in small plug (7) U2.
with U5. 3) Drive in large plug (11) with tool U3, add
a When press fitting the right and left oil with tool U4, and drive in small plug
master links, take care extremely that (12) with U5.
they will be in parallel (on the bushing
side and pin side).
a Do not damage the mating faces of
the master links and end of the bush-
ing.
a Take care extremely that dirt or sand
will not stick to the seal, spacer, ends
of bushing and tap mating faces of
the master link.
4. Connection of master link

1) Place the assembled 2-piece track shoes
on a level place in 1 line with the shoe side
up.
2) Pull pin-side master link (13) and bushing-
side master link (14) together and set
them to each other by the mating faces.
3) Place the shoe and fit the mating surfaces
of the links.
3. Assembly of link on pin side 4) Check that the master bolts can be tight-
1) Set spacer (3) and seal assembly (4) to ened easily with the fingers, and then con-
the counterbore of the master link. nect the links with the master bolts.
2 Shoe bolt:
(LM-P)
3 Shoe bolt (Master link)
Initial torque:
590 ± 60 Nm {60 ± 6 kgm}
50 D155A-6
Removal and installation of a Repeat steps 3 and 4 to remove the pin on

equalizer bar assembly 1 the opposite side.
k If the track frame assembly on the
Special tools opposite side is floated before the pin
is pulled out, support it on a block, etc.
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
791T-650-2130 Sleeve t 1 Q
790-101-2420 Adapter t 1
791-502-4140 Screw t 1
790-101-2540 Washer t 2
W 790-112-1180 Nut t 2
Puller
790-101-4000 t 1
(294 kN {50 ton})
Hydraulic pump
790-101-1102 t 1
5. Operate hydraulic jacks [2] slowly to lower the
machine until the equalizer bar reaches the
Removal right and left track frames.
1. Remove the engine undercover and power 6 Disconnect grease hose (5).
train undercover.
4 Engine undercover: 220 kg
4 Power train undercover: 270 kg
2. Set a hydraulic jack under the center of the

equalizer bar to raise the machine and set sup-
port stands [1] and hydraulic jacks [2] under
the radiator guard.
7. Remove lock plate (6).
3. Remove 2 bolts (1) and cover (2). [*1]
4. Remove lock plate (3) and side pin (4). [*2]

a If the equalizer bar hole and track frame
hole are not aligned, the pin cannot be
removed easily. Accordingly, adjust the
hanging height of the track frame properly.
D155A-6 51
8. Sling equalizer bar assembly (7) with a crane Installation

and a chain block.
removal.
[*1]
2 Threaded part of cover mounting bolt:
Adhesive (LT-2)
3 Cover mounting bolt:
784 – 981 Nm {80 – 100 kgm}
[*2]
kWhen aligning the pin holes, never insert
your fingers in them.
a Before installing the side pin, adjust the height
of the main frame with the hydraulic jacks to
align the equalizer bar hole with the track
9. Using tool W, pull out center pin (8). [*3] frame hole.
k Do not operate the hydraulic device in
2 Seal lip: Grease (G2-LI)
front of or under the puller, but operate
as far from the puller as possible. [*3]
kWhen aligning the pin holes, never insert
your fingers in them.
a Before installing the center pin, sling the equal-
izer bar to align the equalizer bar hole with the
main frame hole.
2 Equalizer bar center bushing:
Grease (G2-LI)
[*4]
Install the equalizer bar with the grease fitting side
forward.
10. While operating the chain block and crane,

remove equalizer bar assembly (7). [*4]
4 Equalizer bar assembly: 240 kg
k Do not lower the machine after remov-
ing the equalizer bar assembly.
52 D155A-6
Disassembly and assembly of Assembly

equalizer bar assembly 1 1. Center bushing
Using the press, press fit center bushing (5) to
Disassembly equalizer bar (4).
1. Remove the equalizer bar. For details, see a Press fitting force for center bushing:
"Removal and installation of equalizer bar 47.1 – 131.4 kN {4.8 – 13.4 ton}
2 Periphery of spherical bushing:
assembly".
Molybdenum disulfide grease (LM-P)
2. Side bushing
1) Remove seal (1).
2) Remove ring (2).
2. Side bushing
1) Install ring (2) to one side of equalizer bar
(4).
3) Using tool [1], remove spherical bushing 2) Using the press, press fit spherical bush-
(3) from equalizer bar (4). ing (3) to equalizer bar (4).
a Press fitting force for spherical bush-
ing: 27.4 – 64.7 kN {2.8 – 6.6 ton}
2 Periphery of spherical bushing:
(LM-P)
3. Center bushing
Remove center bushing (5) from equalizer bar
(4).
D155A-6 53
3) Install ring (2) on the opposite side.

4) Using the press, press fit seal (1).
a Press fitting force for seal:
6.9 – 18.6 kN {0.7 – 1.9 ton}
a The metallic part of the seal must not
project from the equalizer bar end.
54 D155A-6
Removal and installation of Installation

segment teeth 1 q Carry out installation in the reverse order to
removal.
Removal
1. Stop the machine in a position where the seg- [*1]
ment teeth can be removed easily (between a When installing, press segment teeth (1)
the shoe and track frame). toward the center of sprocket hub (2) and
tighten the nuts in the order of 1 o 2 o 3.
2 Threaded part of segment teeth mounting
2. Remove the mounting bolts and segment teeth
(1). [*1] nut: Adhesive (LT-2)
3 Segment teeth mounting nut:
1,176 ± 98 Nm {120 ± 10 kgm}
D155A-6 55
D155A-6 Bulldozer
© 2007 KOMATSU
All Rights Reserved
56 D155A-6
SEN03372-00
D155A-6

D155A-6 85001 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
D155A-6 1
Removal and installation of 5. Disconnect clamp of oil level gauge (3).

hydraulic tank assembly 1
6. Disconnect clamp of oil filler pipe (4).
Removal
7. Disconnect hoses (5) – (8).
k Lower the work equipment to the ground
and release the residual pressure in the 8. Disconnect suction tube (9).
piping, referring to Testing and adjusting,
"Releasing residual pressure in hydraulic
circuit". Then, loosen the hydraulic tank
cap gradually to release the internal pres-
sure of the hydraulic tank.
1. Drain the oil from the hydraulic tank.

2. Remove the fuel tank assembly. For details,

see "Removal and installation of fuel tank
assembly".
3. Remove control valve cover (1).

9. Remove the 4 mounting bolts at the hydraulic
tank bottom and lift off hydraulic tank assembly
(10).
4 Hydraulic tank assembly: 100 kg
4. Disconnect hose (2) between the control

valves from the hydraulic tank.
2 D155A-6
Installation
removal.
q Refilling with oil (Hydraulic tank)

again.
q Bleeding air
Bleed air from each part. For details, see Test-
ing and adjusting, "Bleeding air from each
part".
D155A-6 3
Removal and installation of 2) Disconnect hoses (3), (4), (5) and (6).
hydraulic pump assembly 1 3) Disconnect accumulator (7) and hose
together.
Removal
k Lower the work equipment to the ground
and release the residual pressure in the
piping, referring to Testing and adjusting,
"Releasing residual pressure in hydraulic
circuit". Then, loosen the hydraulic tank
cap gradually to release the internal pres-
sure of the hydraulic tank.
1. Drain the oil from the hydraulic tank and power

train case.
6 Hydraulic tank: Approx. 85 l 4) Disconnect hoses (8), (9) and (10).
5) Remove block (11).
6 Power train case: Approx. 90 l
2. Remove the floor frame assembly. For details,

see "Removal and installation of floor frame
assembly".
a Remove the floor frame assembly only
when removing the work equipment and
HSS pump assembly and power train and
lubricating oil pump assembly.
q Removal of work equipment pump assem-

bly
1) Disconnect the centralized pressure
pickup ports and block (1) together.
6) Disconnect wiring harness connectors
TVC (12), FAC (13) and HDT (14).
7) Remove wiring harness bracket (15).
4 D155A-6
8) Disconnect suction tube (16). q Removal of power train and steering lubri-
a Remove the suction tube mounting cating oil pump assembly
bolts on the fuel pump side, too. 1) Disconnect tubes (1), (2) and (3).
2) Sling power train and steering lubricating
oil pump assembly (4), remove 2 mount-
ing bolts (5), and lift off pump assembly
(4).
4 Power train and steering lubricating
oil pump assembly: 30 kg
9) Sling work equipment pump assembly

(17), remove 2 mounting bolts (18), and lift
off work equipment pump assembly (17).
4 Work equipment pump assembly:
110 kg
q Removal of cooling fan pump assembly

1) Remove the floor mat and cover.
2) Disconnect wiring harness connector FAC
(1).
D155A-6 5
3) Disconnect hoses (2), (3) and (4). Installation

4) Disconnect suction tube (5).
5) Sling cooling fan pump assembly (6), q Carry out installation in the reverse order to
remove 4 mounting bolts (7), and lift off removal.
cooling fan pump assembly (6).
q Refilling with oil (Hydraulic tank and power
4 Cooling fan pump assembly: 25 kg train case)
again.
q Bleeding air
Bleed air from each part. For details, see Test-
ing and adjusting, "Bleeding air from each
part".
q Removal of scavenging pump assembly

1) Remove suction tube (1).
2) Disconnect outlet tube (2).
3) Remove the 2 mounting bolts and scav-
enging pump assembly (3).
4 Scavenging pump assembly: 20 kg
6 D155A-6
Disassembly and assembly of Disassembly

hydraulic cylinder assembly 1 1. Remove the tubes.
a Blade lift cylinder and ripper cylinder
Special tools
2. Piston rod assembly
New/Remodel
q Blade lift cylinder
Necessity
Sym-
Part No. Part name 1) Set cylinder assembly (1) to tool Y1.
Sketch
bol
2) Using the hydraulic pump or the
Q'ty
power wrench and tool Y2, remove
790-502-1003
Cylinder repair
t 1
head assembly (2).
1 stand 3) Pull piston rod assembly (3).
790-101-1102 Hydraulic pump t 1 a Put an oil pan under the cylinder
2 790-102-3802 Multi-wrench t 1 to receive the oil.
790-201-1721 • Push tool 1
790-201-1821 • Push tool 1
790-201-1841 • Push tool 1
3
790-201-1851 • Push tool 1
790-201-1861 • Push tool 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1630 • Plate 1
Y
790-201-1650 • Plate 1
4 790-201-1660 • Plate 1 q Blade tilt cylinder, ripper lift cylinder, and
790-201-1670 • Plate 1 ripper tilt cylinder
1) Remove the mounting bolt assembly
790-101-5021 • Grip 1
and disconnect head assembly (4).
01010-50816 • Bolt 1 q Width across flats of blade tilt cyl-
790-720-1000 Expander t 1 inder: 16 mm
796-720-1670 Ring t 1 q Width across flats of ripper lift
and tilt cylinders: 18 mm
07281-01279 Clamp t 1
2) Pull piston rod assembly (5).
5 796-720-1690 Ring t 1 a Put an oil pan under the cylinder
07281-01919 Clamp t 1 to receive the oil.
796-720-1720 Ring t 1
07281-02429 Clamp t 1
790-102-4300 Wrench t 1
6
790-102-4310 Pin t 2
D155A-6 7
3. Piston assembly q Ripper tilt cylinders

q Blade lift cylinder 1) Remove the mounting bolts and
1) Remove the mounting bolts and spacer (16).
spacer (6) and pull out valve (7). 2) Pull out piston assembly (17).
2) Pull out piston assembly (8). 3) Remove backup rings (18) and O-ring
3) Remove backup rings (9) and O-ring (19).
(10).
4) Remove retainer (11).
4) Disassembly of piston assembly

1] Remove wear rings (20).
5) Disassembly of piston assembly 2] Remove piston ring (21).
1] Remove wear rings (12).
2] Remove piston ring (13).
a Do not remove seat (14) and
valve (15) from the piston.
q Ripper lift cylinder and ripper tilt cylinder

1) Set piston rod assembly (5) to tool
Y1.
8 D155A-6
2) Remove lock screw (22) of piston

assembly (17).
q Screw size: M12 x Pitch 1.75
4. Head assembly
1) Remove head assembly (2) or (4).
a If screw (22) is crushed so much

that it cannot be removed,
tighten it and cut threads of the
screw hole, and then remove it.
2) Disassembly of head assembly

1] Remove O-ring (27). (Blade lift cylin-
der only)
2] Remove O-ring (28) and backup ring
(29).
3) Using tool Y6, remove piston assem- 3] Remove packing (30).
bly (17) from piston rod (23). 4] Remove ring (31).
5] Remove snap ring (32) and dust seal
(33).
6] Remove snap ring (34) and bushing
(35).
4) Disassembly of piston assembly

1] Remove backup ring and O-ring
(24).
2] Remove wear ring (25).
3] Remove piston ring (26).
D155A-6 9
Assembly 3] Using tool Y4, install dust seal (33).
a Apply engine oil to the sliding surface of each

part. When assembling, take care not to dam-
age the rod packing, dust seal and O-ring.
1. Head assembly
1) Assembly of head assembly
1] Using tool Y3, press fit bushing (35).
5] Install ring (31).

6] Install packing (30).
7] Install O-ring (28) and backup ring
(29).
8] Install O-ring (27). (Blade lift cylinder
only)
10 D155A-6
2) Install head assembly (2) or (4) to the pis- 4] Install wear ring (25).
ton rod. 5] Install backup ring and O-ring
(24).
a Before installing the backup
ring, warm it in water at 50 –
60 °C.
a Apply grease to the O-ring
and backup ring so that the
backup ring will not open.
2. 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 2) Install piston assembly (17) to piston
expand the piston ring. rod (23) and set piston rod assembly
2] Remove piston ring (26) from (5) to tool Y1.
tool Y5 and install it to the piston.
3] Using tool Y5, compress piston
ring (26).
D155A-6 11
3) When reusing piston rod (23) and pis- 4) When either or both of piston rod (23)
t o n a s s e m bl y ( 1 7 ) , i n s ta l l th e m and piston assembly (17) are new,
according to the following procedure. install them according to the following
a Remove burrs and fins from the procedure.
threaded part with a file. 1] Using tool Y6, tighten piston
a Clean the parts thoroughly and assembly (17).
remove metal chips and dirt. 3 Piston assembly:
1] Using tool Y6, tighten piston 294 ± 29.4 Nm {30 ± 3.0 kgm}
assembly (17) into piston rod 2] Make 1 screw hole to install the
(23) until the screw holes are screw.
aligned. 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.
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 – 7.5 kgm}
a After installing the screw,
bend 4 places around it.
12 D155A-6
4] Install screw (22). 2) Install O-ring (19) and backup ring

a Before installing the screw, (18) to the piston rod and then install
degrease and dry it thor- piston assembly (17).
oughly. a Before installing the backup ring,
a After installing the screw, warm it in water at 50 – 60 °C.
bend 4 places around it. a Apply grease to the O-ring and
2 Threaded part: backup ring so that the backup
Adhesive (LOCTITE No. 262) ring will not open.
3 Screw: 3) Fix with spacer (16) and tighten the
58.9 – 73.6 Nm {6 – 7.5 kgm} mounting bolts.
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
98.1 – 122.6 Nm {10 –12.5 kgm}
q Blade tilt cylinder

1) Using tool Y5, install piston ring (21)
and wear ring (20), similarly to steps
2-1)-1] – 4] above.
1) Using tool Y5, install piston ring (13)
and wear ring (12), similarly to steps
2-1)-1] – 4] above.
D155A-6 13
2) Install retainer (11). q Blade tilt cylinder, ripper lift cylinder and
3) Fit O-ring (10) and install backup ring ripper tilt cylinder
(9). 1) Install piston rod assembly (5) to the
a Before installing the backup ring, cylinder.
warm it in water at 50 – 60 °C. 2 Sealing part: Grease (G2-LI)
a Apply grease to the O-ring and a Push in the piston rod to the
backup ring so that the backup stroke end.
ring will not open. 2) Tighten head assembly (4) with the
4) Install piston assembly (8). mounting bolts.
5) Install valve (7) to spacer (6) and 3 Mounting bolt:
install them with the mounting bolts. q Blade tilt
2 Mounting bolt: (343 ± 34.3 Nm {35 ± 3.5 kgm})
Adhesive (LT-2) q Ripper lift
3 Mounting bolt: (343 ± 34.3 Nm {35 ± 3.5 kgm})
98.1 – 122.6 Nm {10 –12.5 kgm} q Ripper tilt
(490 ± 49 Nm {50 ± 5.5 kgm})
3. Piston rod assembly

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}
14 D155A-6
D155A-6 15
D155A-6 Bulldozer
© 2007 KOMATSU
All Rights Reserved
16 D155A-6
SEN03373-00
D155A-6

D155A-6 85001 and up

Work equipment
Removal and installation of blade assembly ................................................................................................... 2
Disassembly and assembly of multi-shank ripper ........................................................................................... 4
D155A-6 1
Removal and installation of blade

assembly 1
Removal
k Lower the work equipment to a level place
and set blocks [1] under the right and left
straight frames securely.
3. Remove right and left covers (3).
4. Disconnect hose (4).

a Plug the hoses so that dirt will not enter
the piping.
5. Remove right and left trunnion caps (5).
1. Remove cap (1) of the lift cylinder assembly. 6. Remove blade assembly (6). [*2]
[*1] a Run the engine and move the machine
a Check the quantity and thickness of the slowly in reverse to disconnect the blade
shims. assembly from the trunnion.
2. Sling lift cylinder assembly (2). Run the engine

and retract the piston fully. Install the cylinder
fixing device and fix the lift cylinder assembly
to the radiator guard.
a Bind the piston rod with wires etc. so that
it will not come out.
q Similarly, disconnect the cylinder on the
opposite side from the blade.
k Release the residual pressure in the
piping, referring to Testing and adjust-
ing, "Releasing residual pressure in
hydraulic circuit". Then, loosen the
hydraulic tank cap gradually to release
the internal pressure of the hydraulic
tank.
2 D155A-6
Installation
removal.
[*1]
a Adjust clearance (a) at the cap mating sur-
faces to the following range with the shim and
check that the cylinder turns smoothly.
q Standard clearance (a): 0.2 – 0.5 mm
q Standard shim thickness: 4 mm
a After installing the blade, adjust the blade tilting
distance. For details, see Testing and adjust-
ing, "Adjusting blade".
again.
[*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
D155A-6 3
Disassembly and assembly of

multi-shank ripper 1
Disassembly
a Plug the disconnected pipings and hoses so
that dirt will not enter them.
1. Run the engine and set the ripper in the maxi-

mum raising and maximum tilt-in position.
2. Sling shank (1), remove the lock pin to remove

mounting pin (2), and lower shank (1) slowly to
remove.
4 Shank: 270 kg 5. Sling tilt cylinder assembly (5), remove the lock
plate, and pull out pin (6) on the rod side.
a Run the engine, retract the piston rod fully,
and lower it to the arm.
a Install the pin to the beam temporarily
since it is used when the beam is
removed.
k Release the residual pressure in the
piping, referring to Testing and adjust-
ing, "Releasing residual pressure in
hydraulic circuit". Then, loosen the
hydraulic tank cap gradually to release
the internal pressure of the hydraulic
tank.
3. Set support stands [1] under the beam, set

block [2] under the arm, and lower the ripper
assembly.
6. Disconnect lift cylinder hose (7) and tilt cylinder

hose (8) and move them toward the fuel tank.
4. Sling lift cylinder assembly (3), remove the lock

plate, and pull out pin (4) on the rod side.
a Run the engine, retract the piston rod fully,
and lower it to the arm.
4 D155A-6
7. Sling lift cylinder assembly (3), remove the lock Assembly

plate, pull out pin (9), and lift off lift cylinder
assembly (3). 1. Sling arm (12), install right and left pins (13),
and fix them with the lock plates.
4 Lift cylinder assembly: 190 kg
4 Arm: 650 kg
8. Sling tilt cylinder assembly (5), pull out pin (9), a Set block [2] under the arm.
and lift off tilt cylinder assembly (5).
4 Tilt cylinder assembly: 260 kg
2. Sling beam (10), install right and left pins (11),

and fix them with the lock plates.
4 Beam: 1,250 kg
9. Sling beam (10), remove the lock plates, pull
out right and left pins (11), and lift off beam a Set support stands [1] under the beam.
(10).
4 Beam: 1,250 kg
10. Sling arm (12), remove the lock plates, pull out
right and left pins (13), and lift off arm (12).
4 Arm: 650 kg
D155A-6 5
3. Sling tilt cylinder assembly (5) and install pin 7. Sling lift cylinder assembly (3), run the engine,
(9). extend the piston rod, align the pin holes,
4
install pin (4), and fix it with the lock plate.
Tilt cylinder assembly: 260 kg
a After installing, lower the rod side to the
arm.
4. Sling lift cylinder assembly (3), push in pin (9),

and fix it with the lock plate.
4 Lift cylinder assembly: 190 kg
a After installing, lower the rod side to the
arm.
8. Run the engine and set the ripper in the maxi-

mum raising and maximum tilt-in position.
9. Pass a wire through the shank mounting hole

of the beam and sling shank (1). Install pin (2)
and fix it with the lock pin.
4 Shank: 270 kg
5. Connect tilt cylinder hose (8) and lift cylinder

hose (7).
6. Sling tilt cylinder assembly (5), run the engine,

extend the piston rod, align the pin holes,
install pin (6), and fix it with the lock plate.
6 D155A-6
10. Greasing
After assembling, supply sufficient amount of
grease to each pin.
2 Pin: Grease (G2-LI)

again.
D155A-6 7
D155A-6 Bulldozer
© 2007 KOMATSU
All Rights Reserved
8 D155A-6
SEN03375-00
D155A-6

D155A-6 85001 and up

Cab and its attachments
Removal and installation of operator's cab assembly ..................................................................................... 2
Removal and installation of operator's cab glass (Stuck glass) ...................................................................... 4
Removal and installation of operator's cab and floor frame assembly.......................................................... 13
D155A-6 1
Removal and installation of 6. Disconnect wiring harness connector DSH (9).

operator's cab assembly 1 [*2]
Removal
1. Remove cigarette lighter cover (1) and discon-

nect wiring harness connector ACC.
2. Remove garnishes (2) – (4).
7. Remove mounting bolts (10) at the bottom of

the operator's cab.
a Remove the bolts on the right and left
side. [*3]
3. Disconnect 4 window washer hoses (5). [*1]
4. Disconnect wiring harness connectors CBPW

(6) and WST (7).
8. Remove mounting bolts (11) in the operator's

cab.
a Remove the bolts on the right, left and
rear side. [*4]
2 D155A-6
9. Lift off operator's cab assembly (12). Installation

4 Operator's cab assembly: 400 kg q Carry out installation in the reverse order to
removal.
[*1]
a Connect the window washer hoses according
to their band colors.
Window washer hoses
Red ................... Right door
Blue................... Left door
Black ................. Rear window
No color band ... Front window
[*2]
a Before installing, check that seal rubber parts
(brown, 2 pieces) are installed to the connector
and they are not broken.
3 Connector mounting bolt:
2.83 ± 0.28 Nm {0.288 ± 0.028 kgm}
[*3], [*4]
1) Tighten bolts (1) – (23) in the numeric order
shown in the attached drawing.
a 3 Part marked with A (M16):

279 ± 27.9 Nm {28.5 ± 2.8 kgm}
Part marked with * (M20):
294 ± 29.4 Nm {30.0 ± 3.0 kgm}
Part marked with a (M24):
294 ± 29.4 Nm {30.0 ± 3.0 kgm}
2) Retighten bolts (1) – (21) (M20, M24) by 60 ° ±

10 °.
D155A-6 3
Removal and installation of operator's cab glass (Stuck glass) 1
* Among the panes of window glass of the opera- (1): Front window glass
tor's cab, the 3 panes of (1) and (2) on both (2): Left door window glass
sides are stuck. In this section, the procedure : Right door window glass
for replacing the stuck glass is explained. (3): Both-sided adhesive tape
(4): Trim seal
(5): Door handle
4 D155A-6
Special tools (The following figure shows the operator's cab of a

wheel loader.)
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
Lifter
X 1 793-498-1210 t 2
(Suction cup)
Removal
* Remove the window glass to be replaced
1. Using seal cutter [1], cut the adhesive between

broken window glass (6) and operator's cab
(metal sheet) (7). a If the window glass is broken finely, it may
be removed with knife [4] and a screw-
driver.
a Widening the cut with a screwdriver, cut
the adhesive and both-sided adhesive
tape with knife [4].
(The following figure shows the operator's cab of a

wheel loader.)
a If a seal cutter is not available, make holes

on the adhesive and both-sided adhesive
tape with a drill and pass a fine wire (piano
wire, etc.) [2] through the holes. Grip the
both ends of the wire with priors [3], etc.
(or hold them by winding them onto some-
thing) and move the wire to the right and
left to cut the adhesive and both-sided
adhesive tape. Since the wire may be 2. Remove the window glass.
broken by the frictional heat, apply lubri-
cant to it.
D155A-6 5
Installation 3. Stick both-sided adhesive tape (3) along the

inside edges of the front window glass sticking
1. Using a knife and scraper [5], remove the section and both door window glass sticking
remaining adhesive and both-sided adhesive sections.
tape from the metal sheets (glass sticking sur- a Do not remove the release tape of the
faces) of the operator's cab. both-sided adhesive tape on the glass
a Remove the adhesive and both-sided sticking side before sticking the glass.
adhesive tape to a degree that they will a When sticking the both-sided adhesive
not affect adhesion of the new adhesive. tape, do not touch the cleaned surface as
Take care not to scratch the painted sur- long as possible.
faces. a Take care that the both-sided adhesive
(If the painted surfaces are scratched, tape will not float at each corner of the
adhesion will be lowered.) window frame.
a Do not lap the finishing end of both-sided
(The following figure shows the operator's cab of a adhesive tape (3) over the starting end but
wheel loader.) make clearance (a) of about 5 mm
between them.
2. Remove oil, dust, dirt, etc. from the sticking

surfaces of cab (7) and window glass (8) with
white gasoline.
a If the sticking surfaces are not cleaned
well, the glass may not be stuck perfectly.
a Clean the all black part on the back side of
the window glass.
a After cleaning the sticking surfaces, leave
them for at least 5 minutes to dry.
6 D155A-6
4. Install trim seals (4) to both door window 5. Position the new window glass.
glasses (2). 1) Using tool X1, set the window glass to the
sticking position. Check the clearance
between the window glass and the opera-
tor's cab on the right, left, upper, and lower
sides, and then adjust it evenly.
a Position front window glass (1) from
inside of operator's cab (7). Adjust it
so that the difference between black
coated part and the metal sheet of
operator's cab (7) will be even on the
right, left, upper, and lower sides.
a When positioning each door window
glass (2), align handle holes (d) of
door (9) (on the glass side and door
metal sheet side) first. Then, adjust
a Install each trim seal (4) so that its finish- the door window glass so that the
ing end and starting end will be jointed at positional relationship between it and
position (c) and dimension (b) between door metal sheet will be even all
the corner and position (c) will be 90 mm. around the window.
2) After positioning the glasses, stick tapes

[6] between front window glass (1) and
operator's cab (7) and the right, left, and
lower parts of each door window glass (2)
and each door (9), and then draw position-
ing line (e).
3) Cut the tapes between window glasses (1)

and (2) and operator's cab (7) with a knife,
and then remove the window glasses.
a Do not remove the tapes left on the
window glasses and operator's cab
before installing the window glasses.
D155A-6 7
1) Break aluminum seal (11) of the outlet of

adhesive cartridge (10) and install the
nozzle.
6. Apply adhesive.
2 Adhesive:Sikaflex 256HV
manufactured by Sika Japan
a Do not use primer. 2) Cut the tip of the adhesive nozzle (12) so
a The using limit of the adhesive is 6 months that dimensions (f) and (g) will be as fol-
after the date of manufacture. Do not use lows.
the adhesive after this limit. q Dimension (f) : 10 mm
a Keep the adhesive in a dark place where q Dimension (g): 15 mm
the temperature is below 25°C.
a Never heat the adhesive higher than
30°C.
a When reusing the adhesive, remove the
all hardened part from the nozzle tip.
3) Set adhesive cartridge (10) to caulking

gun [7].
a An electric caulking gun is more effi-
cient.
8 D155A-6
4) Remove release tape of the both-sided a Apply adhesive (13) to dimensions (h)
adhesive tape (3a) on the glass side. and (j) of both-sided adhesive tape
(3) of operator's cab (7).
q Dimension (h): 10 mm
q Dimension (j) : 15 mm
a Apply adhesive (13) higher than both-
sided adhesive tape (3).
a Apply the adhesive evenly.
5) Apply adhesive (13) to the outside of both-

sided adhesive tape (3) of the operator's
cab.
7. Install 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 install 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.
D155A-6 9
3) Mask front window glass (1) and opera-

tor's cab (7) with masking tapes [8].
4) Fill the clearance between front window
glass (1) and operator's cab (7) with caulk-
ing material (14) all around the window.
2 Caulking material:
SEKISUI SILICONE SEALANT
a The usable period of the following
caulking material is 6 months after the
date of manufacture. Do not use the
caulking material after its usable
period.
8. Install 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 install them
to both doors (9).
a Since the window glass cannot be
removed and stuck again, stick it very
carefully.
a Stick the glass within 5 minutes after
applying the adhesive.
2) After sticking each window glass, press all
around it until it is stuck to the both-sided
5) After applying caulking material (14) to adhesive tape.
front window glass (1), form it with the fin- a Press the corners of each window
gers as shown in the following figure. glass firmly.
a Use rubber spatula [9] to form the
caulking material around the handrail,
etc. where it is difficult to form with the
fingers.
10 D155A-6
a If adhesive (13) is projected from the

trim seals (4) of stuck door window
glasses on both sides, remove it with
rubber spatula [9].
9. Fix the window glasses.

1) Using styrene foam blocks [10] and rubber
bands [11], fix the front window glass to fit
3) Fill the clearance between each door win-
it completely.
dow glass and trim in the range of dimen-
a You may use sealing tapes to fix the
sion (k).
front window glass.
i) Mask the range of dimension (k) of
each door window glass.
(The figure shows the operator's cab of a
ii) Fill clearance (m) between each door
hydraulic excavator.)
window glass (2) and trim seal (4)
with caulking material.
a The usable period of the following
caulking material is 6 months after the
date of manufacture. Do not use the
caulking material after its usable
period.
a Apply the caulking material to joint (c)
of the trim seal, too.
2 Caulking material:
SEKISUI SILICONE SEALANT
D155A-6 11
2) Immediately after sticking both door win-

dow glasses, install door handles (5), and
lock the doors to fix the glasses.
10. After installing the window glasses, remove the

primer and adhesive from them and the opera-
tor's cab.
a Using white gasoline, wipe off the adhe-
sive before it is dried up.
a When cleaning the glasses, do not give an
impact to them.
11. Protect the stuck window glasses.

1) Keep the stopper rubbers, styrene foam
blocks, and rubber bands installed for 10
hours (at temperature of 20°C and humid-
ity of 60%).
2) After applying the adhesive, wait for at
least 24 hours, before operating the
machine actually.
12 D155A-6
Removal and installation of 3. Disconnect 8 PPC hoses (2) – (9).

operator's cab and floor frame a (Color code of each hoses)
(2) Red (6) Black-red
assembly 1 (3) Yellow (7) Black-yellow
(4) Green (8) Black-green
Removal
(5) Brown (9) Black-brown
k In the case that you do not drain the cool-
ant, if you disconnect the heater hose when
the coolant temperature in the radiator is
high, you may be scalded. In this case, wait
until the coolant temperature lowers and
then disconnect the heater hose.
k Collect the air conditioner refrigerant
(R134a) from air conditioner circuit in
advance.
a Ask professional traders for collecting and fill-
ing operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the
atmosphere. 4. Disconnect 4 clamps (10) – (13).
k If refrigerant gas (R134a) gets in your eyes,
you may lose your sight. Accordingly, put
on protective goggles while you are collect-
ing the refrigerant (R134a) or filling the air
conditioner circuit with the refrigerant
(R134a). Collecting and filling work must be
conducted by a qualified person.
1. Remove fuel tank assembly. For details, see

"Removal and installation of fuel tank assem-
bly".
2. Remove control valve cover (1).
5. Open side cover (14), and remove covers (15)

and (16).
a Both side of left and right.
D155A-6 13
6. Disconnect air conditioner hoses (17) and (18). 10. Lift off battery top cover (23).
4 Cover: 75 kg
7. Disconnect heater hoses (19) and (20).

11. Disconnect and remove hose and flange (24)
8. Disconnect battery cable (21).
from flange (25).
9. Remove 2 duct flange mounting bolts (22).

12. Disconnect ground wire (26).
14 D155A-6
13. Disconnect 4 window washer hoses (27). 17. Remove mounting bolts (34) at the rear right
and left of the floor frame. [*3]
14. Disconnect wiring harness (28).
15. Disconnect wiring harness connectors FSB

(29), PL1 (30), FD1 (31) and FD4 (32). [*1] 19. Sling pin (36), tighten the bolt to pull out pin
(37), and lift off pin (36).
20. Remove the pin on the other side at the rear

and the 2 pins at the front according to steps
15 and 16.
16. Remove bracket mounting bolts (33) in front of

the floor frame. [*2]
21. Lift off operator's cab and floor frame assembly

(38).
a When removing, take care extremely that
the floor frame assembly will not interfere
with another part.
4 Floor frame assembly: 1,000 kg
D155A-6 15
Installation
removal.
[*1]
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}
[*2], [*3]
3 Floor frame mounting bolts (19) and (20):
824 – 1,030 Nm {84 – 105 kgm}
[*2]
3 Bracket mounting bolt (33):
153 – 190 Nm {15.5 – 19.5 kgm}
[*3]
3 Floor frame mounting bolt (34):
984 – 980 Nm {80 – 100 kgm}
16 D155A-6
D155A-6 17
D155A-6 Bulldozer
© 2007 KOMATSU
All Rights Reserved
18 D155A-6
SEN03376-01
D155A-6

D155A-6 85001 and up

Electrical system
Removal and installation of air conditioner unit assembly .............................................................................. 2
Removal and installation of engine controller assembly ................................................................................. 4
Removal and installation of power train controller assembly .......................................................................... 5
Removal and installation of KOMTRAX assembly .......................................................................................... 5
D155A-6 1
Removal and installation of air 3. Remove the cover at the right lower part of the
conditioner unit assembly 1 operator's seat.
Removal 4. Lift off operator's seat assembly (1).

1. Collect the air conditioner refrigerant (R134a) 4 Operator's seat assembly: 55 kg
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 atmo-
sphere.
may lose your sight. Accordingly, put
on protective goggles, gloves and
working suits with long sleeves while
you are collecting the refrigerant or fill-
ing the air conditioner circuit with the
refrigerant. Collecting and filling work
must be conducted by a qualified per-
son.
2. Remove the operator's cab assembly. For
details, see "Removal and installation of opera-
tor's cab".
6. Disconnect air conditioner hoses (3) and (4).

[*1]
7. Disconnect heater hoses (5) and (6).
2 D155A-6
8. Remove the 4 mounting bolts of work equip- 11. Disconnect wiring harness connectors AC01
ment controller assembly (7) and disconnect (10) and AC02 (11).
the assembly.
12. Disconnect wiring harness clamp (12) and
move wiring harness (13) aside.
9. Remove filter (8).
13. Disconnect 2 duct hoses (14).
14. Remove the 7 mounting bolts and air condi-

tioner unit assembly (15).
Installation
removal.
[*1]
a When installing the air conditioner hoses, take
care that dirt, dust, water, etc. will not enter
them.
a When installing each air conditioner pipe,
check that the O-ring is fitted to it.
a Check that the O-ring is not damaged or deteri-
orated.
2 O-ring: ND-OIL8
q Filling air conditioner with refrigerant
Fill the air conditioner circuit with refrigerant
(R134a).
a Quantity of refrigerant: 1,200 ± 50 g
D155A-6 3
Removal and installation of 4. Disconnect wiring harness connectors EGC1

engine controller assembly 1 (4), EGC2 (5) and EGC3 (6). [*1]
Removal 5. Remove the engine controller assembly (7).

1. Open the left engine side cover and lift off side
cover assembly (1).
4 Side cover assembly: 40 kg
Installation
removal.
[*1]
3 Connector mounting screw:
2. Remove 2 oil filters (2). 2.82 Nm {0.288 kgm}
4 D155A-6
Removal and installation of power Removal and installation of

train controller assembly 1 KOMTRAX assembly 1
Removal Removal
k Disconnect the cable from the negative (–) k Disconnect the cable from the negative (–)
terminal of the battery. terminal of the battery.
1. Remove the left lower cover of the operator's 1. Remove 4 mounting bolts (1), cover (2).
seat.
2. Remove 4 mounting bolts (1) of the power train

controller assembly.
3. Move the controller, disconnect wiring harness

connectors STC1 (2), STC2 (3) and STC3 (4),
and remove power train controller assembly
(5). [*1]
2. Disconnect wire harness connector (4).
3. Disconnect antenna cable (3).
4. Remove 4 mounting bolts (5), and KOMTRAX

assembly (6).
Installation
Installation
removal.
removal.
[*1]
3 Connector mounting screw:
2.82 Nm {0.288 kgm}
D155A-6 5
D155A-6 Bulldozer
© 2009 KOMATSU
All Rights Reserved
6 D155A-6
SEN04442-00
D155A-6

D155A-6 85001 and up
60 Air conditioner 1
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
D155A-6 1
SEN04442-00 60 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
2 D155A-6
Structure and function 1

Air conditioner component 1
1. Condenser 10. Air outlet for foot

2. Hot water return piping 11. Receiver drier
3. Hot water piping 12. Refrigerant piping
4. Front window defroster 13. Valve (hot water outlet)
5. Side window defroster 14. Air conditioner compressor
6. Air outlet for face 15. Valve (hot water inlet)
7. Air outlet for center 16. (Dual) pressure switch
8. Air outlet for rear
9. Air conditioner unit A. Fresh air filter
B. Recirculated air filter
Specifications
Refrigerant R134a
Refrigerant refilling level (g) 1200 ± 50
D155A-6 3
Configuration and function of refrigerating cycle 1

Component
Compressor Condenser Expansion valve Evaporator
Item
In operator’s cab In operator’s cab
Location Engine compartment Front of radiator
(In air conditioner unit) (In air conditioner unit)
Circulates refrigerant Condenses refrigerant Lowers temperature and Evaporates refrigerant
gas and increases its to discharge heat pressure of refrigerant to absorb heat from (or
temperature and absorbed in evaporator. liquid and gas for easy cool) air around
pressure so that it can evaporation with throttle. evaporator.
Function be liquefied easily in Controls flow rate, too.
condenser.
(Compression of refrig- (condensation of refrig- (Throttle of refrigerant) (Evaporation of refriger-

erant) erant) ant)
Gas o Liquid Liquid and gas o Gas
State of Gas o Gas Liquid o Liquid and gas
Constant pressure Constant pressure
refrigerant Adiabatic compression Adiabatic expansion
change change
4 D155A-6
Outline of refrigerating cycle 1 3. Receiver drier

The refrigerant liquefied in the condenser is
The refrigerating cycle performs the following four reserved in the receiver drier temporarily so
actions. The refrigerant is liquefied and gasified that it can be supplied to the evaporator
repeatedly while it is circulated in the cycle. according to the cooling load. A strainer and a
drying agent are sealed in the receiver drier to
1. Compression (Compressor)
remove “dirt” and “water” in the refrigerating
The refrigerant gas is compressed by the com-
cycle.
pressor to the state where it can be liquefied
If any water is in the refrigerating cycle, it is fro-
easily at the normal temperature (ambient tem-
zen in the small hole of the expansion valve
perature).
and retards the flow of the refrigerant.
The refrigerant evaporated in the evaporator is
It can cause a cooling trouble.
sucked into the compressor.
This action is performed to keep the refrigerant
4. Expansion (Expansion valve)
pressure in the evaporator low so that the
The pressure of the refrigerant liquid is low-
refrigerant liquid can continue evaporation
ered by the restricting action [*1] of the expan-
actively even if the ambient temperature is
sion valve to a level at which the refrigerant is
close to 0°C.
evaporated easily.
The refrigerant gas sucked into the compres-
The action to lower the pressure of the refriger-
sor is compressed in the cylinder and its pres-
ant to a level at which the refrigerant is evapo-
sure and temperature are so changed that is
rated easily before the refrigerant is sent to the
can be liquefied easily when it is cooled with
evaporator is called expansion.
the external air at the normal temperature.
The expansion valve which performs this action
also controls the flow rate of the refrigerant.
2. Condensation (Condenser)
In other words, the quantity of the refrigerant
The refrigerant gas in the condenser is cooled
liquid evaporated in the evaporator is decided
to be liquefied with the external air.
by the quantity of heat to be removed (refriger-
The refrigerant gas of high temperature and
ation load) at the specified evaporation tem-
high pressure discharged from the compressor
perature (evaporation pressure), and the
is cooled to be liquefied with the external air
expansion valve senses it and controls the
and then stored in the receiver drier.
refrigerant flow rate properly.
The heat discharged from the refrigerant of
[*1] Restricting action
high temperature and high pressure dis-
If there is a suddenly narrowed part in a pipe in
charged from the compressor is called the con-
which a liquid is flowing, there is resistance to
densation heat, which is the total of the heat
the flow. Since the sectional area is increased
that the refrigerant absorbed from the opera-
suddenly through this part, the liquid expands
tor’s cab through the evaporator (vaporization
suddenly and its pressure and temperature
heat) and the work performed to compress the
lower. No heat is exchanged between the
refrigerant (the value converted into heat).
inside and outside of the pipe during this
During condensation, the refrigerant gas and
action.
refrigerant liquid are mixed together in the con-
denser. 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 condensa-
tion temperature.
D155A-6 5
5. Evaporation (Evaporator)
The refrigerant changes from liquid to gas
(superheated vapor) in the evaporator.
The refrigerant mist in the evaporator evapo-
rates 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 operator’s cab). The
cooled air is spread in the operator’s cab by
the fan to lower the temperature in the opera-
tor’s 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 rela-
tionship between the pressure (evaporation
pressure) and temperature (evaporation tem-
perature) 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 rela-
tionship between saturation pressure and satu-
ration temperature.
To evaporate the refrigerant at lower tempera-
ture, 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 operator’s 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 evapo-
rator capacity decreases. It can cause a cool-
ing 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.
6 D155A-6
Air conditioner unit 1

a This air conditioner unit is auto temperature control type.
a Inside temp. sensor is the same as inner (air temperature) sensor.
D155A-6 7
Outline
q The air conditioner unit consists of the evapo-
rator, heater core and fan (blower) and gener-
ates cool air and hot air.
q Temperature control
The machine monitor sends temperature set-
ting data to the control amplifier (See “Control
plate”) according to the temperature control
switch operation.
The control amplifier controls the air mix servo-
motor to adjust the angle of the cool door, hot
door and sub hot door for temperature control.
q Over-cooling (Freezing) prevention

The evaporator temperature sensor senses
evaporator temperature by the change of resis-
tance. The control amplifier converts the
change of resistance of the evaporator temper-
ature sensor into a change of voltage and
detects the evaporator temperature by the
change of voltage.
The control amplifier turns OFF the compres-
sor clutch relay so that the evaporator will not
be frozen.
q 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.
q 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.
q Automatic air conditioner

The inner temperature sensor senses the room
temperature by the change of resistance. The
control amplifier converts the change of resis-
tance of the inner temperature sensor into a
change of voltage and detects the room tem-
perature by the change of voltage.
The control amplifier checks the inner air tem-
perature sensor voltage so that the room tem-
perature will be kept at the temperature set
with the machine monitor.
a The 5 A fuse for the air conditioner unit is

installed to the wiring harness.
a The door is the same as the damper.
8 D155A-6
Functions of major components 2) Operation

in the air conditioner unit 1 The thermosensing rod senses the tem-
perature of the refrigerant which passed
q Evaporator the evaporator. The temperature at this
Evaporator fins are cooled by low-pressure, time is conduc ted through the ther-
low-temperature refrigerant gas being sent mosensing rod to the refrigerant gas in the
from the expansion valve. Air from the blower diaphragm chamber (hatched part). As the
motor is cooled and dehumidified when pass- pre-enclosed refrigerant gas temperature
ing through the fins. changes, the gas pressure changes and
pressing force (Fg) also changes. The
q Heater core thermosensing rod attached directly to the
Fins of the heater core are heated by the hot diaphragm so moves that the constant
water (cooling water) being sent from the force of the spring to push the ball will be
engine. Air from the blower motor is heated as balanced with variable force (Fg) to adjust
it passes through the fins. the needle valve opening ratio.
A: When the evaporator outlet tempera-
q Expansion valve ture is high (at start of cooling (air is
This valve converts high-pressure, high-tem- not cooled yet))
perature liquid refrigerant coming from the The gas pressure in the diaphragm
receiver to low-pressure, low-temperature chamber increases and the gas vol-
misty refrigerant through the throttling function. ume increases.
It controls the flow rate of the refrigerant by Pushing force (Fg) of the refrigerant
changing the level of throttling depending on gas increases and the thermosensing
the thermal load (temperature) in the opera- rod (ball) moves to the left and the
tor's cab. As a result, temperature of the air need le v alv e opens wid e. Muc h
blown out of the grill is adjusted depending on refrigerant is supplied to the evapora-
the volume of refrigerant circulated in evaporator and the cooling capacity
tor. increases.
1) Structure
The box-type expansion valve consists of B. When the evaporator outlet tempera-
the diaphragm, thermosensing rod, needle ture is low (during cooling (air is
valve (ball), spring, etc. The outside of dia- cooled already))
phragm (hatched part) is pre-enclosed The gas pressure in the diaphragm
with refrigerant gas. chamber decreases and the gas vol-
The spring is installed on the needle valve ume decreases. Since pushing force
(ball) side of the thermosensing rod. The (Fg) of the refrigerant gas is small,
needle valve opening ratio is decided the thermosensing rod (ball) moves to
when the constant force of the spring to the right and the needle valve is nar-
push the ball to the right is balanced with rowed. Accordingly, refrigerant supply
the force (Fg) of the refrigerant gas to and the cooling capacity decrease.
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.
D155A-6 9
q Power transistor (PTR) 2. There is a variable resistor in the servomotor

It controls the blower motor speed by receiving and its resistance varies with the angle of the
signal current from the air conditioner control motor shaft. The control amplifier applies 5 V
amplifier. (See “Control plate”.) voltage to this variable resistor and judges the
rotation angle of the motor by the potential dif-
q Servomotor ference (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
a This servomotor is used for temperature con- screen of the machine monitor.
trol (AIR MIX) and blowing out (MODE). a The Recirc/Fresh changeover servomotor
does not have this potential difference
1. If the switch on the control panel is operated, (PT). Accordingly, it does not have the
the control amplifier supplies 24 V power self-diagnosis function.
across (6) and (7). (The rotation direction
changes according to the polarities of the sup-
plied power.)
10 D155A-6
Control plate 1 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 loca-
tions”.
a Control amplifier (CNTAMP) (1) con-
trols 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 ampli-
fier 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
1. Control amplifier (CNTAMP)
operation screen of the machine monitor.
5) Adjusts the room temperature to the set
A/C U: Air conditioner unit
temperature on the basis of the data of the
AC01: Intermediate connector to air conditioner
sunlight sensor and inner air sensor in the
control amplifier (CNTAMP)
automatic air conditioner mode.
(GND, sunlight sensor, pressure switch,
connectors for relay)
AC02: Intermediate connector to air conditioner
(24 V, CAN communication with machine
monitor)
D155A-6 11
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 [2] AMP 040-20PF

Input Input
Pin Pin
No. Symbol Signal name and No. Symbol Signal name and
output output
1 — — — Input/
17 CAN (+) CAN communication +
Output
2 A/M P A/M servo potentiometer voltage Input
Input/
3 POT 5V Servo potentiometer 5V power supply Output 18 CAN (–) CAN communication –
Output
PRESS (Dual) pressure switch (Refrigerant
4 SW pressure) Input 19 R/F A
Recirculated air and fresh air servo
Output
terminal A
5 — — —
Recirculated air and fresh air servo
20 R/F B Output
6 +24 V Power supply Input terminal B
7 BLOW F/B Blower feedback signal Input 21 A/M A A/M servo terminal A Output
8 PTR B Power transistor control signal Output 22 A/M B A/M servo terminal B Output
Blowing out (mode) servo 23 MODE A Blowing out (mode) servo terminal A Output
9 MODE P potentiometer voltage Input
24 MODE B Blowing out (mode) servo terminal B Output
10 — — —
25 — — —
11 THI Inner air temperature sensor Input 26 — — —
12 THEVA Evaporator temperature sensor Input
27 GND S Sensor GND Input
13 — — — 28 — — —
14 — — —
29 — — —
15 SS Sunlight sensor Input 30 — — —
16 GND GND Input
31 — — —
32 — — —
33 — — —
34 — — —
35 CCRL Compressor clutch relay Output
36 BLOW RL Blower main relay Output
q A/M: Air mix

q F/B: Feedback
q R/F: Recirculation/Fresh
12 D155A-6
Compressor 1
A: Refrigerant inlet port from air conditioner unit Function

B: Refrigerant outlet port to condenser q Other than circulating the refrigerant, compres-
C: Pulley sor compresses the refrigerant gas from the
D: Relief valve evaporator to a high-pressure, high-tempera-
ture 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 temper-
ature and refrigerant pressure.
If the magnetic clutch is engaged, the shaft in
the compressor rotates to operate the com-
pressor.
Specifications
Piston capacity (cc/rev) 157.3
Allowable maximum speed
6,000
(rpm)
Denso: ND-OIL8
Refrigerant oil used
(For R134a)
Refrigerant oil refilling volume
180
(cc)
D155A-6 13
Condenser
1. Condenser
A: Refrigerant inlet from compressor

B: Refrigerant outlet to receiver drier
Function
Condenser (1)
q Condenser cools and liquefies the high-pres-
sure, 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 unavail-
able. As a result, pressure in the refrigerant cir-
culation 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
3.6 {36}
(MPa {kg/cm2})
14 D155A-6
Receiver drier 1
1. Receiver drier q (Dual) pressure switch (2)

2. (Dual) pressure switch a Connector is AC05
If abnormally low or high pressure is generated
A: Refrigerant inlet from condenser in the refrigerant circulation circuit, the (dual)
B: Refrigerant outlet to air conditioner unit pressure switch is turned “OFF”. (it is normally
turned “ON”.) When the (dual) pressure switch
SG: Sight glass become “OFF”, the control amplifier turns the
compressor clutch relay “OFF”. So the mag-
Function netic clutch of the compressor is disengaged
Receiver drier (1) and the devices related to the air conditioner
q It is used to store liquefied high-pressure, high- are protected.
temperature misty refrigerant from the con-
denser. It is capable of completely liquefying
the refrigerant even when bubbles are con-
tained in the refrigerant due to the condenser
condition in heat dissipation.
q It eliminates foreign substances in the circula-
tion 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 refriger-
ant 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
LA: 0.20 MPa {2 kg/cm2}
the refrigerant is insufficient.
LB: 0.02 MPa {0.2 kg/cm2}
If the amount of the refrigerant is proper, no
HA: 3.14 MPa {32 kg/cm2}
bubbles are seen there.
HB: 0.59 MPa {6 kg/cm2}
a If there is no (or excessive) refrigerant in
the refrigerating cycle, no bubbles are
seen through sight glass (1), too.
Specifications
Weight of desiccating agent (g) 370
D155A-6 15
16 D155A-6
Testing, adjusting and troubleshooting 1

Caution about refrigerant 1
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.
a Ask a qualified shop for collecting, adding and
filling operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the
atmosphere.
k 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 quali-
fied person.
q Refrigerant (R134a) filling up quantity:
1200 g ± 50 g
D155A-6 17
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
1. After basic check, find the troubled section according to the detected trouble of the air conditioner.
2. 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.
3. 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
1. Battery voltage (24 V)
2. Tension of compressor belt
Basic check 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

operate? conditioner does not operate)
Inspection with self-diagnosis

function (*1) and with each switch
Troubleshooting with
Troubleshooting with E mode
troubleshooting chart 1
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 D155A-6
Block diagram 1
a This air conditioner unit is auto temperature control type.
D155A-6 19
Circuit diagram and arrangement of connector pins 1
20 D155A-6
a INSIDE TEMP. SENSOR means “Inner sensor” on “Abnormality Record” screen: “03 Air-conditioning
System”.
a BLOWING OUT (MODE) SERVOMOTOR means BLOWING OUT (MODE) CHANGEOVER SERVO-
MOTOR.
D155A-6 21
Detail of air conditioner unit 1
22 D155A-6
D155A-6 23
Part and connector locations 1 3. Remove foot duct (2).
a There are a circuit breaker and a fuse. The cir-

cuit 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.
a The air conditioner unit is at the rear of the
operator seat.
1. Open the battery cover on the left side of the

machine. (See the fuse locations in Trouble-
shooting Volume.)
q Circuit breaker CB3 (5th from left) (20 A):
For power supply for air conditioner com-
pressor 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.)
2. Remove recirculated air filter (1) from the rear

of the operator seat.
24 D155A-6
a State without cover (3)

q A/C U: Air conditioner unit
q CNTAMP: Control amplifier
q [1] and [2]: Control amplifier connec-
tors
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 com-
mon to engine controller and pump
controller)
5. 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) ser-
vomotor connector
D155A-6 25
q [3]: Blower (Fan) motor connector

q [4]: Power transistor (PTR) connector
q [5]: Blowingout (Mode) servomotor
connector
q [6]: Temperature control (Air mix) ser-
vomotor connector
q [7]: Recirc/Fresh changeover servo-
motor connector
q [8]: Recirculated air sensor connector
q [9]: Evaporator temperature sensor
connector
26 D155A-6
8. Relays and diodes q AC05: Pressure switch connector

The relays and diodes are at the left rear of the q RD: Receiver drier
operator seat. q SG: Sight glass
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
9. Pressure switch
Open engine left cover (6) and remove covers
(7) – (9).
D155A-6 27
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 condi-
tioner compressor
28 D155A-6
11. Sunlight sensor connector SLS and machine 5) Float dashboard (14) and pull it out
monitor connector CM02 (CAN communication toward you.
connector) a Since the wiring harness is con-
a If the machine monitor connector CM02 is nected, pull out the dashboard
disconnected, the engine controller and slowly.
other controller(s) can not perform the q DSH: Intermediate connector of
CAN communication. Accordingly, failure machine monitor
code: [DAFRMC] is displayed. a Connector DSH is DRC-70.
If the screen changes to the air condi- Take care in handling it. See the
tioner operation screen at this time, “A/C next page.
Controller error” is displayed red. If the
above error is not displayed, no check is
necessary.
Note: “A/C Controller error” on the air con-
ditioner 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) con-
nector (SLS). 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
3) Remove duct (11).

4) Remove covers (12) and (13).
D155A-6 29
7) Inspect connectors CM01, CM02, q How to disconnect connector DSH

CM03 and GPS from the backside of Disconnect the connector straight slowly and
dashboard (14). check the seal for breakage, peeling and stick-
a CM02 and CM03 can be con- ing foreign matter.
nected reversely. Take care. a If the seal is damaged, replace it.
CM03 is green.
q 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
12. Intermediate connector and the fitted receptacle will be even when
1) Open cover (21). 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.
2) Disconnect battery ground cable.

3) Inspect connectors FSB, FD1 and FD4.
30 D155A-6
Testing air leakage (duct) 1 3. Remove cover (3).
1. Remove recirculated air filter (1) from the rear 4. Remove cover (4).
of the operator seat.
5. Ensure that the following are not removed.
1) Duct (5)
2) Front duct (FD)
3) Defroster duct (DD)
q A1 and A2: Front blowingout route
q C1, C2 and C3: Defroster blowingout
route
2. Remove foot duct (2).
D155A-6 31
6. For air leakage through the defroster blow-

ingout 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 dash-
board (8), referring to “Part and con-
nector locations”, Item 11.
5) Inspect duct (9).
32 D155A-6
Testing with self-diagnosis Explanation of machine monitor operating pro-

function 1 cedure
Outline 1. While pressing numeral key [4] on the normal

On the air conditioner operation screen of the screen, press [1], [2] and [3] in order.
machine monitor, the system performs self-diagno-
sis 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 refriger-
ant pressure switch is turned OFF” will be abol-
ished in the future.
a Once a problem is detected, its indication is

not reset even if it becomes normal. The indi-
cation can be reset after the starting switch is
turned OFF.
2. On the service menu screen, press [F3] (R)
On the air conditioner “Abnormality Record” screen once to select “02 Abnormality Record”.
in the service mode of the machine monitor, the
system performs self-diagnosis for various sensors, 3. Press [F6] ( ) to confirm.
in addition to the above items, and displays “Error”
red if any problem is detected.
a The system does not have self-diagnosis func-
tion for the Recirc/Fresh changeover servomo-
tor.
q 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
D155A-6 33
4. On the “Abnormality Record” screen, press q Clearing “Abnormality Record” by machine

[F3] (R) twice to select “03 Air-conditioning monitor
System”. While the “Abnormality Record” screen is dis-
played, press [F2], and the number of occur-
5. Press [F6] ( ) to confirm. rence 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 evapo-
rator temperature sensor is short circuit or discon-
nected.
“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
q Information displayed on Abnormality voltage.
Record screen: “03 Air-conditioning Sys- a Damper is the same as door.
tem” screen “Air Mix is abnormal” means servomotor
(a): System/Component name for Air Mix (temperature adjustment)
(b): Number of occurrence time damper does not rotate judging from the
(c): Condition (Normal or abnormal) servomotor potentiometer voltage.
(d): If CAN status is abnormal in condition, “Refrigerant” means refrigerant pressure
CAN communication cannot be carried out from (dual) pressure switch. Namely,
normally but air conditioner unit is discon- “refrigerant is abnormal” means that (dual)
nected. Accordingly, the conditions (d) of pressure switch of refrigerant is OFF.
other items are not displayed.
(e): If [E] is displayed on the left of a condition, 1. CAN Status (communication) is abnormal
the abnormality is still occurring or clear- The CAN communication between the
ing of it has not been confirmed. machine monitor and air conditioner control
q [F2]: Clear “Abnormality Record” amplifier (CNTAMP) is not carried out normally.
q [F5]: Return to “Abnormality Record” a If failure code [DAFRMC] (Error of CAN
screen 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.
34 D155A-6
3. Inner Sensor abnormal 6. Ventilation is abnormal

a Inner Sensor is the same as inside tem- Servomotor for blowing out changeover
perature sensor on “block diagram” or “cir- (mode) damper does not rotate judging from
cuit diagram”. the servomotor potentiometer voltage.
a There is a Disconnection or a short circuit a Damper is the same as door.
in the line between the control amplifier a Trouble: Blowing out is not changed.
and Inside temperature sensor. a Action of control amplifier:
a Action of air conditioner amplifier: The control amplifier stops outputting to
The air conditioner amplifier controls with the servomotor for blowing out
only the set temperature since the data of changeover (mode).
the Inside temperature sensor are not a Even if the link is disconnected and the
available. damper does not rotate, the self-diagnosis
a Trouble: The air conditioner does not func- system judges the damper normal since
tion automatically but functions when the servomotor potentiometer voltage
operated manually. changes normally.
a See “Testing Inner Sensor”. (For mechanical troubles, see “Testing
vent (mode) changeover”.
4. Ventilating Sensor abnormal
a Ventilating Sensor is the same as evapo- 7. Air Mix is abnormal
rator temperature sensor. Servomotor for Air Mix (temperature adjust-
a There is a disconnection or a short circuit ment) damper does not rotate judging from the
in the line between the control amplifier servomotor potentiometer voltage.
and evaporator temperature sensor. a Damper is the same as door.
a Action of control amplifier: a Trouble: The temperature control system
The control amplifier stops outputting to does not work.
the compressor. a Action of control amplifier:
a Trouble: The air conditioner does not The control amplifier stops outputting to
work. the air mix servomotor.
(See “Testing evaporator temperature a Even if the link is disconnected and the
sensor”.) damper does not rotate, the self-diagnosis
system judges the damper normal since
5. Sunlight Sensor abnormal the servomotor potentiometer voltage
There is a short circuit between the control changes normally.
amplifier and Sunlight Sensor. (For mechanical troubles, see “Testing
a Action of control amplifier: temperature control”.
The control amplifier controls without the
Sunlight Sensor. 8. Refrigerant is abnormal
a Trouble: The automatic air conditioner (Dual) pressure switch signal for refrigerant is
does not work when the machine is abnormal. Namely pressure switch for refriger-
exposed to the direct sunlight in the auto- ant is OFF.
matic air conditioner mode. a Trouble: The air conditioner does not
a See “Testing sunlight sensor”. work.
a Action of control amplifier:
The control amplifier stops outputting to
the compressor.
k When replacing the pressure switch,

be sure to collect the refrigerant. See
“Cautions about refrigerant”.
a See “Testing (dual) pressure switch for

refrigerant”.
D155A-6 35
Testing temperature control 1 2. Remove foot duct (2).
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 If lever 5 (L5) and lever 6 (L6) move smoothly

between COOL MAX and HOT MAX, plate 3. Remove cover (3).
(P1) and lever 1 (L1) – lever 4 (L4) operate
normally, too.
a Control amplifier (CNTAMP) control tempera-
ture is automatically based on inside tempera-
ture sensor. So to operate between COOL
MAX and HOT MAX inside temperature sensor
connector may have to be disconnected.
a To reset the self-diagnosis system (To clear the
air conditioner error displayed on the air condi-
tioner 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).
1. Remove recirculated air filter (1) from the rear

of the operator seat. a State with cover (3) removed
q CNTAMP: Control amplifier
4. Check contacts of connector [6] of the air mix

servomotor (for disconnection).
36 D155A-6
5. Check the rod (RODAM) for disconnection. a Plate (P1), lever 1 (L1) – lever 4 (L4) are
not seen from outside.
6. Start the engine and turn the air conditioner
power ON.
7. Set the temperature to 18°C and 32°C 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.
q 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) Retry steps 6 and 7.

a After checking the operation and con-
nect [8], confirm “Inner sensor is nor-
mal” on Abnormality Record screen:
"03 Air-conditioning System" screen.
D155A-6 37
q 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 ser-
vomotor will be exchanged with each
other later.)
6) Remove servomotors (5) and (6).
7) Remove cover (7).

a 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”.
38 D155A-6
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 fig-
ure, 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 trou-
ble, 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 servo-

motor (for disconnection).
3. Check the defroster rod (RODD) and foot rod

(RODF) for disconnection.

power ON.
5. Press the vent selector switch on the air condi-

tioner 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).
D155A-6 39

power ON.
10. Press the vent selector switch on the air condi-

tioner screen of the monitor and check the
opening and closing operations of the front
face door and rear face door (damper).
q 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) Disconnect connectors [5] and [6] of the

servomotor.
2) Make match marks on servomotors (5)
and (6) to show which servomotor has
been installed. (The servomotor will be
exchanged with each other later.)
3) Remove servomotors (5) and (6).
4) Remove cover (7).
a Figure is PC200-8 type, so duct is dif-
ferent from this type.
40 D155A-6
5) Rotate plate (P2) with the hand to see a F. Face door position will change from “OPEN”
where lever 7 (L7) – lever 12 (L12) are to “Half” gradually when raising the setting
hitched and then repair. temperature from 18°C to 32°C gradually.
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 trou-
ble. In this case, exchange servomotors
(5) and (6) and operate them.
a The figures of the foot mode and
defroster mode are shown before.
a For electrical problem, see “E-5 Vent (mode)
cannot be changed over”.
D155A-6 41
Testing Recirc/Fresh changeover1 Reference

q How to remove fresh air duct.
Outline
1. Remove duct (4).
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 clos-
ing operations of the door (damper) visually.
a The system does not have self-diagnosis func-
tion for the Recirc/Fresh changeover servomo-
tor.
1. Remove recirculation air filter from behind the

operator seat.

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.”, recircu-
lated filter (1), duct (2) and cover (3).
a For electric problems, see “E-6 Recirc/

Fresh cannot be changed over”.
42 D155A-6
q Method of replacing Recirc/Fresh changeover

servomotor
a 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).
D155A-6 43
Testing inner sensor 1 8. Check that the resistance between female con-
nector [8] (2) (PB) (on the wiring harness side)
a Inner Sensor is the same as inside tempera- and connector [1] (11) (PB) (on the wiring har-
ture sensor on “block diagram” or “circuit dia- ness side) is 1 z or below. (If not, the wiring
gram”. harness is defective.)
q If “Inner Sensor abnormal” is displayed by the
self-diagnosis (“Abnormality Record” screen 9. Check that the resistance between female con-
on machine monitor: “03 Air-conditioning Sys- nector [8] (1) (BrR) (on the wiring harness side)
tem”), test the inner sensor. and connector [2] (27) (BrR) (on the wiring har-
q To reset the self-diagnosis system (detection of ness side) is 1 z or below. (If not, the wiring
abnormality), the starting switch must be harness is defective.)
turned OFF.
1. Referring to “Testing temperature control, 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 assem-
bly (11).
10. Connect all the connectors.
5. Resistance between terminals on sensor side
11. Turn the starting switch ON and carry out self-
of connector [8]:
diagnosis (“Abnormality Record” screen on the
Normal value:
machine monitor: “03 Air-conditioning Sys-
0°C ----- 1.6 kz
tem”). If “Inner Sensor abnormal” is still dis-
25°C --- 5 kz
played, replace the control amplifier.
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
harness is defective.)
44 D155A-6
Testing evaporator temperature 6. Disconnect connector [9].

sensor 1
7. Measure the resistance between the mate
q If “Ventilating Sensor abnormal” is displayed by (female) of connector [9] and the terminal on
the self-diagnosis (“Abnormality Record” the evaporator temperature sensor side.
screen on machine monitor: “03 Air-condition- Normal value:
ing System”), test the evaporator temperature 0°C ----- 4.8 kz
sensor. 15°C --- 2.3 kz
q To reset the self-diagnosis system (detection of
abnormality), the starting switch must be
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. a If an error is detected by the self-diagnosis
and evaporator temperature sensor is nor-
mal, control amplifier (CNTAMP) or the
wiring harness is defective.
8. Disconnect connectors [1] and [2] from control

amplifier (CNTAMP). (Connect connector [9].)
Resistance between terminal (11) (PB) of con-
nector [1] and (27) (BrR) of [2]:
Normal value:
0°C ----- 4.8 kz
15°C --- 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
5. Ensure contact of connector [9] along wiring result of 7. is normal, the wiring harness is
harness (H). (Check for disconnection.) defective.
D155A-6 45
a If the evaporator temperature sensor is defec-

tive, replace it according to the following proce-
dure.
q Replacing evaporator temperature sensor.

1. Remove air conditioner unit assembly (A/C U).
For details, see Shop Manual, Chapter 50,
“Removal and installation of air conditioner unit
assembly”.
2. Remove wiring harness. (For each connector,

see the “Part and connector locations”.)
3. Remove servomotors (2) and (3).
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 D155A-6
7. Remove the evaporator.
8. Remove the holder from part (P) and remove

the evaporator temperature sensor.
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.
D155A-6 47
Testing sunlight sensor 1 3. Referring to “Testing temperature control, 1. –

3.,” recirculated filter (1), duct (2) and cover
q If “Sunlight Sensor abnormal” is displayed by (3).
the self-diagnosis (“Abnormality Record”
screen on machine monitor: “03 Air-condition- 4. Referring to “Testing evaporator temperature
ing System”), test sunlight sensor connector sensor item 1, 5.”, disconnect connector [1]
SLS. from control amplifier (CNTAMP).
q To reset the self-diagnosis system (detection of
abnormality), the starting switch must be 5. Ensure that the terminals of female connector
turned OFF. SLS (on the wiring harness side) are not
a A short circuit between the terminals of shorted to each other. (If they are shorted, the
the sunlight sensor unit is a defect. wiring harness is defective.)
Whether the sunlight sensor is normal
cannot be checked by measuring resis- 6. Check that the resistance between female con-
tance, etc., however. Accordingly, if the nector SLS (2) (L) (on the wiring harness side)
wiring is normal, presume the sunlight and connector [1] (3) (YW) (on the wiring har-
sensor to be abnormal and replace it. If ness side) is 1 z or below. (If not, the wiring
“Sunlight Sensor abnormal” is still dis- harness is defective.)
played, replace the control amplifier. a If the result of item 6 or item 7 is abnormal,
check the contact of connector CN-AC01.
1. Remove cover (10) and check connector SLS (See “Part and connector locations.”)
of sunlight sensor (S) on the rear side of the
cover (for disconnection). 7. Check that the resistance between female con-
nector SLS (1) (O) (on the wiring harness side)
2. Disconnect SLS connector and measure volt- and connector [1] (15) (RB) (on the wiring har-
age between male terminals on sunlight sen- ness side) is 1 z or below. (If not, the wiring
sor (S) at voltage range of tester because the harness is defective.)
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
8. Connect all the connectors.
9. Turn the starting switch ON and carry out self-

diagnosis (on the air conditioner fault history
screen of the machine monitor). If “Sunlight
Sensor abnormal” is still displayed, replace the
control amplifier.
48 D155A-6
Testing (dual) pressure switch for 3. Ensure that the terminals on the switch side of
refrigerant 1 connector AC05 are shorted to each other
(ON). (When they are not shorted (OFF), the
q If “Refrigerant abnormal” is displayed by the pressure switch detects abnormal refrigerant
self-diagnosis (“Abnormality Record” screen pressure.)
on machine monitor: “03 Air-conditioning Sys- a When the pressure switch is OFF, connect
tem”), test pressure switch connector AC05. a pressure gauge to the high pressure
q To reset the self-diagnosis system (detection of side of the air conditioner compressor and
abnormality), the starting switch must be check the refrigerant pressure.
turned OFF. See “Connection of service tool” and
q The pressure switch unit is turned ON when “Troubleshooting with gauge pressure.”
the refrigerant pressure is normal and OFF a If refrigerant pressure is normal, the pres-
when the refrigerant pressure is abnormal. sure switch is defective.
a The pressure switch unit may be OFF when
ambient temperature below 0°C because the q (Dual) pressure switch
refrigerant pressure becomes down. The pres-
sure switch unit is not defective but normal.
1. 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 When replacing the pressure switch, be

2. Disconnect pressure switch connector AC05.
RD: Receiver drier sure to collect the refrigerant.
SG: Sight glass
D155A-6 49
q 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 har-
ness 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 har-
ness 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 CN-
AC01. (See “Part and connector loca-
tions.”)
5) Connect all the connectors.
6) Turn the starting switch ON and carry out

self-diagnosis (“Abnormality Record”
screen on machine monitor: “03 Air-condi-
tioning System”). If “Refrigerant abnormal”
is still displayed, replace the control ampli-
fier.
50 D155A-6
Testing relays and diodes 1 q Checking relay unit

a Since no T-adapter is available, it is
a If the air conditioner compressor is normal (air impossible to check the relay while the
is cooled) and air comes out, the relays are voltage is applied to the coil actually.
normal. Accordingly, skip these relay tests.
a Bring your ear to each relay to check its opera- Blower main relay (AC03)
tion by sound.
1) The resistance of the coil between termi-
nals (1) and (2) is 140 – 340 z.
There are two relays.
2) While the voltage (DC20 – 30 V) is not
q Blower main relay (connector AC03): Used to
applied between terminals (1) (+) and (2),
turn the fan motor ON/OFF.
terminals (3) and (4) are disconnected
q Compressor clutch relay (connector AC04):
from each other and terminals (3) and (5)
Used to turn the air conditioner compressor
are connected to each other.
(clutch) ON/OFF
3) While the voltage (DC20 – 30 V) is applied
between terminals (1) (+) and (2), termi-
1. Check contacts of connectors AC03 and AC04
nals (3) and (4) are connected to each
(for disconnection) from left behind of operator
other and terminals (3) and (5) are discon-
seat.
nected from each other.
2. Turn the starting switch ON (do not start the
engine) and turn the main power of the air con-
ditioner 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°C (depending on the input
voltage from the evaporator tempera-
ture sensor). Compressor clutch relay (AC04)
2) When the pressure switch detects 1) The resistance of the coil between termi-
abnormality (it is turned OFF). nals (1) and (3) is 140 – 340 z.
a If the fan sound is too loud to hear the 2) Without voltage (DC20 – 30 V) applied
compressor relay sound, disconnect con- between terminals (1) (+) and (3), termi-
nector AC03 with the starting switch in the nals (2) and (4) are disconnected from
OFF position, and then check. each other.
IF: Recirculated air filter 3) With the voltage (DC20 – 30 V) applied
between terminals (1) (+) and (3), termi-
nals (2) and (4) are connected to each
other.
D155A-6 51
q 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.
52 D155A-6
Troubleshooting chart 1 1
a The numbers in the boxes are the item numbers in the troubleshooting table.
a E-2, E-3 means Troubleshooting for electrical system (E mode).
1. Cooling trouble
2. Heating trouble
D155A-6 53
Troubleshooting chart 2 1
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 trou-
bleshooting for the electrical system.
Possible cause Check method Remedy

Defective BLOWER MAIN RELAY See “Testing relays and diodes” Replace
Disconnection of wire or defective Check connector of blower fan motor for disconnec- Repair broken parts and con-
connection tion. See E-3 and “Part and connector locations” nect correctly
Check two lead wires of motor with circuit tester. If
Defective blower motor there is not continuity, motor is defective. See E-3 Replace
and “Part and connector locations”
Defective POWER TRANSISTOR
Move fan switches in sequence and check fan speed. Replace
(PTR)
Check diode (ACD1).
Defective diode (ACD1) Replace
See E-3 and “Testing relays and diodes”.
2. Blower fan motor is normal but air flow is insufficient.

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
Check evaporator for stain and obstruction Remove obstruction and clean
evaporator
Defective evaporator tempera- Evaporator is frozen. Check sensor clip. Check sen- Repair or replace
ture sensor, defective contact of sor for dirt. (Evaporator temperature sen-
evaporator temperature sensor or Check the frost on the hose near pressure switch sor and expansion valve are in
defective expansion valve (when freezing advances furthermore) air conditioner unit)
3. Low/high pressure

Collect refrigerant, then
Excessive or insufficient refriger-
charge with proper quantity of
ant
refrigerant again
If R-134a is used as refrigerant, its quantity cannot
Repair leaking part, then
be checked through sight glass.
Insufficient refrigerant charge with proper quantity of
Accordingly, check by connecting gauge manifold.
refrigerant again
Purpose of sight glass is to check refrigerant flow.
Collect refrigerant, then
Overcharge with refrigerant charge with proper quantity of
refrigerant again
Normal pressure range
Low pressure:
Approx. 0.13 – 0.2 MPa {1.3 – 2.0 kg/cm2}
Judgment by pressure at inlet/ High pressure: See Troubleshooting with
outlet of compressor Appox. 1.5 – 1.7 MPa {15 – 17 kg/cm2} gauge pressure
These values are for following condition, however.
Temperature in cab: 30 – 35°C
Engine speed: Appox. 1500 rpm
54 D155A-6
4. 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 Check method Remedy

Compressor belt Loosened compressor belt Vibration amplitude of belt is large Adjust tension
Trouble in compressor Slip of belt Repair or replace
Compressor Insufficient compressor oil or seizure
Heating of compressor See "Handling compressor oil"
in the compressor
Low battery voltage Slip of clutch Charge battery
Inspect with circuit tester (10 –
Disconnection or short circuit in coil Replace
Magnet clutch 20 z)
Disconnection in wiring or defective Check ground wire and connec-
Repair
connection of ground wire tions
Relay Defective compressor clutch relay See “Testing relays and diodes.” Replace
Refrigerant Low/high pressure Troubleshooting with gauge Troubleshooting with gauge
pressure (Operation of pressure switch) pressure pressure
See “Testing (dual) pressure
Pressure switch Defective pressure switch Replace
switch for refrigerant” and E-2
Check diode (ACD2).
Diode Defective diode (ACD2) See E-2 and “Testing relays and Replace
diodes.”
5. Blower fan motor is normal but air flow is insufficient.

Large duct resistance Check duct for crushing and filter for clogging Repair
Check duct joints for defective duct seal and dis-
Air leakage through duct joints Repair
connection of duct
Clogging of heater core fins Check heater core fins for clogging Repair
6. Check of hot water

Warm up engine, and then check engine coolant
Low engine coolant temperature Find out cause
temperature
Low engine coolant level Check coolant level in radiator Add coolant
Insufficient circulation of engine Check engine coolant piping for clogging (Hose,
Bleed air and repair
coolant pipe, and core)
Contrary connection of IN and OUT
Check the destination of heater hoses Repair
heater hoses
7. Fan rotation speed

See "Checking and adjusting air conditioner com-
Fan rotation speed is low pressor belt tension" in chapter 30 "Testing and Repair
adjusting" of shop manual.
D155A-6 55
8. Other items
Possible cause Check method Remark

See "Testing temperature control" and "Trouble-
Temperature cannot be adjusted
shooting for electrical system, E-4"
Vent (mode) cannot be changed See "Testing vent (mode) changeover" and "Trou- Common to cooling and heat-
over bleshooting for electrical system, E-5" ing
Recirc/Fresh cannot be changed See "Testing Recirc/Fresh changeover" and "Trou-
over bleshooting for electrical system, E-6"
Excessive compressor oil See "Handling compressor oil"
Cooling only
Water leakage into the cab Clogging of drain hole
56 D155A-6
Troubleshooting for electrical system (E mode) 1

a The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before troubleshooting, understand the information fully.
Trouble Problem that appears on machine
Related
information
Causes 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>
Possible causes sequence. Perform trouble- (1) Pin number description sequence and tester lead handling
and standard shooting according to these For troubleshooting, connect the plus (+) and minus (–) leads
value in normal 2 numbers, however.) as shown below unless otherwise specified.
state • 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.
3 - defective (2) Example of troubleshooting by inspection of multiple items
a Normal in 1 but abnormal in 2
At this time “- defective” shown at left is applied
a If a wiring harness is burnt, replace it.
<Phenomenon of defective harness>

q 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.
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.
D155A-6 57
E-1 Power supply system (Air conditioner does not operate)

Problem Air conditioner does not operate due to power supply system failure.
Indication of
• “A/C Controller Error” is displayed red on air conditioner screen of machine monitor.
problem on
machine • 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.
• “A/C Controller Error” is displayed on air conditioner operation screen of machine monitor in follow-
ing 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.
Related • Referring to “Testing with self-diagnosis function”, display “Abnormality Record” screen on machine
information 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 electri-
cal 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 Standard value in normal state/Remarks on troubleshooting

1) Turn starting switch OFF.
Defective wiring harness 3) Disconnect connector [1] from control amplifier and carry out
Possible causes 1 troubleshooting without turning starting switch ON.
and standard (ground cable)
value in normal Between (16) (black) on wiring harness side Resis-
Max. 1 z
state of connector [1] – ground tance
Circuit breaker CB3 is OFF, 2) Referring to “Part and connector locations”, check circuit breaker
2
broken fuse CB3 is not OFF (Its reset button is not projected) and check fuse
Fu5A.
58 D155A-6

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 Voltage 20 – 30 V A
[1]
a If fuse is broken again in test A above, perform following proce-
dure. (Replace broken fuse.)
3 Defective wiring harness 2) Disconnect battery ground cable.
3) Disconnect control amplifier connector [1] and carry out
troubleshooting without turning starting switch ON.
a If fuse is broken again in test A above and results B and C below
are normal, blower motor circuit may be cause of trouble. See E-
3.
Between (6) (red) – (16) (black)
Resis-
wiring harness side of connector Min. 1 Mz B
tance
[1]
Between (6) (red) on wiring
Resis-
Possible causes harness side of connector [1] – Min. 1 Mz C
tance
and standard ground
value in normal a If fuse is broken again in test A for cause 3 and result of B or C is
state 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
Ground fault in wiring harness
4 harness (Contact with GND Between (6) (red) – (16) (black)
circuit) Resis-
on wiring harness side of Min. 1 Mz D
tance
connector [1]
Between (6) (red) on wiring
Resis-
harness side of connector [1] – Min. 1 Mz E
tance
ground
Between connector AC02
Resis-
(female) (4) – AC01 (female) (5) Min. 1 Mz F
tance
(black)
Between connector AC01 Resis-
Min. 1 Mz G
(female) (4) (red) – (5) (black) tance
Disconnection in wiring a If fuse described in related information is not broken and test
5
harness result A for cause 3 is abnormal, check with circuit diagram.
D155A-6 59

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 resis-
tance 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.
Between connector [2] (17) – Resis- Approx.
H
Disconnection in CAN (18) tance 60 z
communication circuit a If result H above is abnormal, perform following procedure.
Possible causes 6 (Communication between a If result H above and J below are abnormal, operator cab wiring
and standard control panel and control harness is abnormal.
value in normal amplifier is defective) a If result H above is abnormal and J below is normal, air condi-
state tioner 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 resis-
tance 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.
Between connector AC02 Resis- Approx.
J
(female) (1) – (2) tance 60 z
When test results for causes 1, 2, result A for cause 3 and result H
7 Defective control amplifier
for cause 6 are normal, replace control amplifier.
When test results for causes 1 – 7 are normal, machine monitor is
defective.
60 D155A-6
D155A-6 61
E-2 Compressor system (Air is not cooled)

Problem Air is not cooled due to compressor system failure.
• When engine is started and A/C switch is pressed on air conditioner screen of machine monitor, air is
Indication of not cooled as displayed on screen.
problem on • Air conditioner compressor does not operate.
machine • “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.
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 abnor-
mal, compressor is not turned ON and air is not cooled consequently.
Related a Abnormal refrigerant pressure indicates that “Signal (connector [1] (4)) from pressure switch is not
information grounded”.
• Air conditioner may not be turned ON even when ambient temperature is below 5°C (Normal).
• For each connector, see “Part and connector locations”.

a If “A/C Controller Error” is displayed red on air conditioner opera-
tion 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. Accord-
1 Defective pressure switch
ingly, if following is abnormal (if switch is turned OFF), install pres-
sure gauge to low pressure side of air conditioner compressor
and check refrigerant pressure.
Between (1) – (2) on pressure switch side of Resis-
Max. 1 z
connector AC05 tance
Possible causes k Before replacing pressure switch, collect refrigerant.
and standard 1) Turn starting switch OFF.
value in normal 2) Disconnect connector A/C from air conditioner compressor and
state carry out troubleshooting without turning starting switch ON.
Defective air conditioner a Ensure connection of air conditioner compressor ground cable
2 and GND09. (See “Part and connector locations”.)
compressor
Between (1) on air conditioner compressor Resis- Approx.
side of connector A/C – ground (Air
tance 15 z
conditioner compressor coil resistance)
2) Disconnect connectors ACS, ACD2 and carry out troubleshooting
a Test at diode range.
3 Defective Diode Between ACS (male) (1) (+) – (2) (–) There is no continuity
Between ACS (male) (1) (–) – (2) (+) There is continuity
Between ACD2 (male) (1) (+) – (2) (–) There is no continuity
Between ACD2 (male) (1) (–) – (2) (+) There is continuity
62 D155A-6

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 com-
pressor is normal) and that cause 3 is normal.
4 Between connector [1] (4) – ground Resis-
harness Max. 1 z
(Pressure switch is turned ON) tance
Between connector AC04 (female) (2) – Approx.
Resis-
ground (Air conditioner compressor coil
resistance)
tance 15 z
Resis-
Between connector ACS (male) (2) – ground Max. 1 z
tance
• Referring to “Testing relays”, check sound
made when compressor clutch relay is
turned ON.
Click is
a If blower sound is too large to hear operat- A
heard.
ing sound of compressor clutch relay, turn
starting switch OFF temporarily and dis-
connect connector R30.
a If A above and B below are abnormal and C is normal (relay is
normal), go to causes 7 and 8.
Defective compressor clutch 1) Turn starting switch OFF.
5 2) Disconnect connector AC04.
relay (Does not turn ON)
3) Short (2) (white) and (4) (green) of
Air is
connector AC04 (on wiring harness side) B
cooled.
wire. (Turn compressor ON forcibly without
using relay.)
4) Turn starting switch ON.
Possible causes
and standard 1) Turn starting switch OFF.
2) Disconnect connector AC04 and carry out troubleshooting without
value in normal turning starting switch ON.
state
Approx.
Between AC04 (relay side) (1) – Resis-
140 – C
(3) (coil resistance) tance
340 z
a If fuse is not broken, skip troubleshooting.
2) Disconnect connector AC04 and carry out troubleshooting without
Ground fault in wiring
turning starting switch ON.
6 harness (Contact with GND a Ensure that test result for cause is normal.
circuit)
Between (2) on machine wiring harness side Approx.
Resis-
of connector AC04 – ground (Air conditioner
compressor coil resistance)
tance 15 z
2) Disconnect connector AC04 and [2] and carry out troubleshooting
Short circuit in wiring without turning starting switch ON.
7 harness (with another wiring a Ensure that test result for cause 2 is normal.
harness)
Between (3) – (1) on machine wiring harness Resis-
Min. 1 Mz
side of connector AC04 tance
8 Check with circuit diagram.
harness
2) Disconnect connectors [1] and [2] and insert T-adapter in wiring
harness side.
9 Defective control amplifier 3) Turn starting switch ON.
4) Display air conditioner operation screen on machine monitor and
press A/C switch.
Between connector [2] (35) – [1] (16) Voltage Max. 1 V
Defective machine monitor 2) Display air conditioner operation screen on machine monitor.
10
(Defective switch) “A/C ON” is
Press A/C switch.
displayed.
D155A-6 63
64 D155A-6
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 • LCD of machine monitor on air conditioner operation screen lights normally but air does not come
problem on out.
machine • Air flow does not match fan switch setting on air conditioner operation screen.
• 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.)
Related 3) Expansion valve is adjusted improperly. (Remove air conditioner unit and replace expansion
information 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”.

2) Disconnect connector [3] and carry out troubleshooting without
1 Defective blower (fan) motor turning starting switch ON.
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 turning starting switch ON.
and standard
value in normal Between (2) (+) – (1) of connector [4] (male)
(power transistor) (Internal fuse and resistor
state
must not be broken)
a If test result is abnormal, overcurrent has Approx. 11 kz
2 Defective power transistor
flowed. In this case, replace blower motor,
too.
Between (3) – (4) of connector [4] (male)
(power transistor) (Internal resistor must not Approx. 2.2 kz
be broken)
Between (1) (+) – (3) (–) of connector [4] There is continuity
(male) (power transistor) * Diode range
Between (3) (+) – (1) (–) of connector [4] There is no continuity
(male) (power transistor) * Diode range
D155A-6 65

• Referring to “Testing relay”, check turn-on Click is
A
sound of blower main relay. 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.
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.)
Defective blower main relay
3
(Does not turn ON) Operate fan on air conditioner operation Air comes
B
screen. 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
Approx.
Between (1) – (2) of AC03 (relay Resis-
140 – C
side) (coil resistance) tance
340 z
2) Disconnect connector ACD1 and carry out troubleshooting
4 Defective Diode a Test at diode range.
Between ACD1 (male) (1) (+) – (2) (–) There is no continuity
Possible causes
Between ACD1 (male) (1) (–) – (2) (+) There is continuity
and standard
value in normal 1) Turn starting switch OFF.
state 2) Disconnect connector [4] and carry out troubleshooting without
Defective wiring harness turning starting switch ON.
5
(ground)
Between (1) (black) on wiring harness side Resis-
Max. 1 z
of connector [4] – ground tance
• 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 Approx.
Voltage
side of connector [3] – ground 24 V
• Power transistor input voltage
Check of input and output 2) Disconnect connector [4].
6 (Since no current flows to blower motor, blower motor does not
voltages
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 Voltage Max. 2 V D
connector [4]
Between (3) (black/blue) – (1) Approx.
(black) on wiring harness side of Voltage 24 V E
connector [4] *1
*1: At blower main relay ON
66 D155A-6

• 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.)
Check of input and output
6 a If F below is abnormal, go to causes 7-J and 9.
voltages
a If G below is abnormal, go to causes (9) and (10).
Between (36) – (16) of connector
Voltage Max. 1 V F
[2]
Between (8) – (16) of connector
Voltage Max. 2 V G
[1]
When test results D for cause 6 are normal (voltage is normal but
7 Defective blower (fan) motor
motor does not rotate), blower (fan) motor is defective.
2) Disconnect connectors AC03 and [1] and carry out
Possible causes Short circuit in wiring troubleshooting without turning starting switch ON.
and standard 8 harness (with another wiring Between (2) – (1) on wiring Resis-
value in normal Min. 1 Mz J
harness) harness side of connector AC03 tance
state
Between (6) – (7) on wiring Resis-
Min. 1 Mz
harness side of connector [1] tance
Ground fault in wiring 2) Disconnect connectors [1] and [4] and carry out troubleshooting
9 harness (Contact with GND without turning starting switch ON.
circuit) Between (2) – (1) on wiring Resis-
Min. 1 Mz
harness side of connector [4] tance
10 Check with circuit diagram.
harness
Control amplifier is defective in following cases.
1) F for cause 6 is abnormal, J for cause 8 is normal, and cause 10
11 Defective control amplifier
is normal.
2) G for cause 6 is abnormal and causes 9 and 10 are normal.
12
(Defective switch) Press fan switches from MIN to LCD display of air flow changes
MAX. from MIN to MAX.
D155A-6 67
68 D155A-6
D155A-6 69
E-4 Temperature cannot be controlled

Problem Temperature cannot be controlled.
Indication of • “A/C Controller Error” may be displayed red on air conditioner screen of machine monitor. (See E-1.)
problem on • While air conditioner operation screen of machine monitor is displayed, temperature does not
machine change even if temperature control switch is operated.
a Temperature control means “Air Mix” of cooled air and hot air.
• Referring to “Testing with self-diagnosis function”, display “Abnormality Record” screen on machine
monitor: “03 Air-conditioning System” and check to see if “Air Mix is abnormal” and “Inner sensor is
abnormal”.
See “Testing inner sensor” when “Inner sensor is abnormal”.
• Even if rod etc. is disconnected (See “Testing temperature control”), if current is supplied to air mix
servomotor by operating switches and potentiometer in servomotor reaches normal voltage, self-
diagnosis function judges system normal.
• Referring to “Testing temperature control”, check that there is not contact of connector [6] or mechan-
Related ical trouble (removal or interference of link, etc.)
information • 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.

Between (6) – (7) of connector [6] (on
Resis- 400 –
servomotor side) (There must not be
tance 3000 z
Defective air mix servomotor disconnection or short circuit)
1
(Unit test) Between (1) – (3) of connector [6] (on
Resis-
servomotor side) (There must not be 4 k – 8 kz
tance
disconnection or short circuit)
Resis-
tance
Possible causes 3) Turn starting switch ON.
and standard
Between connector [1] (3) – [2] (27) Voltage 5V
value in normal
state 1) Turn starting switch OFF.
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
2 or defective air conditioner screen to HOT MAX.
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).
Between (21) (+) – (22) (–) of connector [2]
a If temperature is changed from HOT MAX Approx.
Voltage
to COOL MAX, voltage polarities are 24 V
reversed.
Change
Between connector [1] (2) (+) – [2] (27) (–) Voltage
below 5 V
70 D155A-6

a When test result for cause 1 is normal and that for cause 2 is
Defective air conditioner abnormal, perform following procedure.
3
wiring harness
Check with circuit diagram.
Possible causes
and standard a When test result for cause 1 is normal and that for cause 2 is
value in normal 4 Defective control amplifier abnormal and that for cause 3 is normal, control amplifier is
state defective.
5
(Defective switch) LCD display changes
Press temperature control switch.
from 18 to 32 °C.
D155A-6 71
E-5 Vent (mode) cannot be changed over

Problem Vent (mode) cannot be changed over.
Indication of • “A/C Controller Error” may be displayed red on air conditioner screen of machine monitor. (See E-1.)
problem on • When vent selector switch on air conditioner operation screen of machine monitor is operated, vent
machine does not change.
• Referring to “Testing with self-diagnosis function”, display “Abnormality Record” screen on 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 nor-
mal voltage, self-diagnosis function judges system normal.
• Referring to “Testing vent (mode) changeover”, check that there is not contact of connector [5] or
mechanical trouble (removal or interference of link, etc.)
Related • Air mix servomotor and blowing out (mode) servomotor are same. Operating angle of temperature
information control (air mix) is less, however. Accordingly, do not test servomotor to see if it rotates by connect-
ing connector [5] to connector [6]. It is allowed, however, to exchange air mix servomotor and blow-
ing 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.

Resis- 400 –
servomotor side) (There must not be
tance 3000 z
Defective blowing out (mode) disconnection or short circuit)
1
servomotor (Unit test) Between (1) – (3) of connector [5] (on
Resis-
tance
Resis-
tance
Possible causes 2) Disconnect connectors [1] and [2] and insert T-adapter.
and standard 3) Turn starting switch ON.
value in normal Between connector [1] (3) – [2] (27) Voltage 5V
state 1) Turn starting switch OFF.
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).
Between (24) (+) – (23) (–) of connector [2]
a If vent is changed from DEFROST to Approx.
Voltage
24 V
FACE, voltage polarities are reversed.
Changes
Between connector [1] (9) (+) – [2] (27) (–) Voltage
below 5 V
72 D155A-6

a When test result for cause 1 is normal and that for cause 2 is
Defective air conditioner abnormal, perform following procedure.
3
wiring harness
Possible causes a When test result for cause 1 is normal and that for cause 2 is
and standard 4 Defective control amplifier abnormal and that for cause 3 is normal, control amplifier is
value in normal defective.
state 1) Turn starting switch ON.
2) Display air conditioner operation screen on machine monitor.
Defective machine monitor Operate air outlet switch and change LCD
5
(Defective switch) display to FACE, FACE and REAR, FOOT, LCD display changes
FACE and REAR, FOOT, FOOT and to each mode
DEFRSOT, and DEFROST.
D155A-6 73
E-6 Recirc/Fresh air cannot be changed over

Problem Recirc/Fresh air cannot be changed over.
Indication of
• When Recirc/Fresh selector switch of machine monitor is operated, recirculated or fresh air does not
problem on
changeover (Recirc/Fresh changeover door (damper) does not rotate).
machine
• 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.
Related
• Operating angle of Recirc/Fresh changeover servomotor is 90°.
information
operation.

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.
Defective Recirc/Fresh 3) Carry out troubleshooting without turning starting switch ON.
changeover servomotor Between connector [1] (wiring harness side)
1
(Unit test) or defective air (6) – connector [2] (wiring harness side) (19) Resis- 400 –
conditioner wiring harness (There must not be disconnection or short tance 3000 z
circuit)
Between connector [1] (wiring harness side)
(6) – connector [2] (wiring harness side) (20) Resis- 400 –
(There must not be disconnection or short tance 3000 z
circuit)
a When test result for cause 1 is abnormal, perform following pro-
Defective air conditioner cedure.
2
wiring harness
Possible causes 1) Turn starting switch OFF.

and standard
value in normal 4) Set Recirc/Fresh selector switch on air conditioner operation
state screen to Recirc.
5) Set Recirc/Fresh selector switch on air conditioner operation
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).
Defective control amplifier or Between connector [1] (6) (+) and connector Approx.
3 defective Recirc/Fresh Voltage
[2] (20) (–) 24 V
changeover servomotor
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 Approx.
Voltage
[2] (19) (–) 24 V
a When test result for cause 1 is abnormal and that for cause 2 is
Defective Recirc/Fresh normal, Recirc/Fresh changeover servomotor is defective.
4
changeover servomotor (If all test results for causes 1, 2 and 3 are normal, cause may be
mechanical trouble such as hitch.)
74 D155A-6

a When test results for causes 1 and 2 are normal and that for
Possible causes 5 Defective control amplifier
cause 3 is abnormal, control amplifier is defective.
and standard
value in normal 1) Turn starting switch ON.
state Defective machine monitor 2) Display air conditioner operation screen on machine monitor.
6
(Defective switch) Display of Recirc/
Press Recirc/Fresh selector switch.
Fresh changes.
D155A-6 75
Troubleshooting with gauge pressure 1

Referring to “Connection of service tool”, carry out <Measurement condition for pressure>
troubleshooting by reading the high and low gauge Item Condition value
pressures of the cooling cycle.
Atmospheric temperature 20 – 50°C
a The gauge pressure varies largely with the Engine speed Low idle
weather condition and operating condition of Air conditioner switch ON
the machine. Take care. Fan switch Hl
q High pressure is too high: Set temperature Full cool

Above approx. 2.5 MPa {25 kg/cm2}
q High pressure is too low: q Dual pressure switch
Below approx. 1 MPa {10 kg/cm2} a Normally "ON", abnormal pressure "OFF" for
q Low pressure is too high: compressor.
Above approx. 0.3 MPa {3 kg/cm2}
q Low pressure is too low:
Below approx. 0.05 MPa {0.5 kg/cm2}
a (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 Cause Check method Remedy

Air conditioner cycle is operating normally.
If there is any trouble (cooling trouble), there is another
Pressure is normal 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}
Collect refrigerant, then fill
Bubble can be seen in the
Insufficient refrigerant up with proper quantity of
sight glass (*1)
refrigerant again (*2)
There is a temperature dif-
ference between inlet and Replace
Clogging of receiver drier
outlet pipes of receiver drier. (*2)
Tank is frosty
Clean or replace
Clogging of expansion valve Expansion valve is frosty
(*2)
Both high pressure and low
pressure are too low Gas leakage at heat sens- Low pressure gauge Replace
ing tube of expansion valve becomes vacuum (*2)
Low pressure becomes vac- Evaporator is frozen Repair or replace
Defective evaporator sensor
uum Air flow is down by freezing Replace receiver drier
or defective contact of sen-
(At cool max. and HI speed Collect refrigerant, then fill
sor (removal of mounting
of fan, later it becomes not to up with proper quantity of
clip)
cold.) refrigerant again (*2)
Piping between receiver
drier and compressor is
Clogging or flattening or pip- clogged or flattened. If Clean or replace
ing clogged completely, low (*2)
gauge pressure becomes
vacuum
76 D155A-6
Indicated gauge pressure Cause Check method Remedy

Collect refrigerant, then fill
Filling too much with refriger-
Connect gauge manifold up with proper quantity of
ant
refrigerant again (*2)
Stain of condenser, clogging Clean, repair fins, or repair
Defective cooling of con-
or crushing of fins, or defec- or replace condenser
denser
Both high pressure and low tive revolution of cooling fan (*2)
pressure are too high Defective adjustment of
Bubble can be seen in the Replace
expansion valve (Valve is
sight glass (*2)
opened too wide)
Evacuate and then fill up
Bubble can be seen in the
Air in cycle with proper quantity of refrig-
sight glass
erant again (*2)
Clogging or flattening of pip- There is a remarkable tem- Clean inside of cycle or
High pressure is too high
ing between compressor and perature difference between replace
and low pressure is too low
condenser before and after clogged part (*2)
Both high pressure and low
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 (*2)
sor) Compressor has seized and
is extremely hot.
*1 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.
a Sight glass (SG) is on the receiver drier (RD).
D155A-6 77
Connection of service tool 1

X 799-703-1200 Service tool kit
a Use the service tool kit for R134a. Connect the gauge manifold, hoses and other ser-
vice tools according to the following procedure.
Service tool kit
1. Gauge manifold 1. Close the high-pressure valve (HI) and low-
2. High pressure charging hose (red) pressure valve (LO) of gauge manifold (1).
3. Low pressure charging hose (blue) 2. Connect red charging hose (2) to the (HI) side
4. Quick joint (Hi) (Large diameter) and blue charging hose (3) to the (LO) side.
5. Quick joint (Lo) (Small diameter) 3. Connect quick joints (4) and (5) to each hose.
a. The thread is rough. So be careful not to loosen. 4. Connect the quick joints to the service valves
of the high and low-pressure pipings.
78 D155A-6
Precautions for connecting air

conditioner piping 1
q 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.
q 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 dam-
aged.
q Push in each pipe to the stopper (until it clicks)
and tighten the bolt or nut fully with your fin-
gers.
q 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 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}
D155A-6 79
Handling of compressor oil 1 Check compressor oil in the following cases,

and then add new oil if necessary.
1. Control of compressor oil q When much refrigerant is discharged
(Denso: ND-OIL8: For R134a) because of leakage.
Compressor oil does not need to be checked q When the compressor is troubled and
or added so frequently as engine oil. Insuffi- replaced.
ciency or excess of compressor oil can cause q When a cycle parts such as the air condi-
the following troubles. tioner unit, condenser, receiver drier,
Condition Contents evaporator unit, etc. is replaced.
Lubrication trouble and seizure
Insufficiency of oil Quantity of oil to be added when cycle part is
of compressor
replaced
Cooling trouble (Excessive oil
Excess of oil stick to parts and lower heat Quantity to be added
exchange performance) Air conditioner part
(cm3)
Air conditioner unit,
Accordingly, compressor oil must be filled to Approx. 40
evaporator
the specified level, similarly to refrigerant.
Condenser Approx. 40
2. Adding of compressor oil Receiver drier Approx. 20
k Since refrigerant is dangerous and bad Hose (Compressor –
Approx. 10
for environment, collect the refrigerant Condenser)
before disconnecting the air condi- Hose (Condenser –
Approx. 20
tioner hose. See “Caution about refrig- Receiver)
erant”. Each hose (Compressor
Approx. 15
– M24 joint – Cab)
may lose your sight. (Put on protective Hose (Cab – Receiver) Approx. 10
goggles.)
a 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)
a Oil for R134a absorbs moisture very eas-
ily. Accordingly, fit the cap immediately
after using oil to stop the atmosphere.
Store the oil can in a dry and ventilated
place.
a Precautions for using oil
Oil for R134a (Denso: ND-OIL8 in particu-
lar) may dissolve acrylic resin and polysty-
rene (excluding baked polystyrene paint
film).
Accordingly, do not stick oil to those plas-
tics.
80 D155A-6
3. Compressor replacement 4. Applying compressor oil for O-ring

q In case of compressor seizure or break- When connecting a pipe or hose, apply oil
age. (Denso: ND-OIL8) to its O-ring to prevent
Metal chips will circulate through the air refrigerant leakage.
conditioner circuit and contaminate the k When discarding a can which still has
compressor oil extremely. some oil in it, make a hole on it to dis-
In this case, flush the air conditioner circuit charge gas and oil.
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.
q 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) 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.
D155A-6 81
D155A-6 Bulldozer
© 2008 KOMATSU
All Rights Reserved
82 D155A-6
SEN02875-01
D155A-6

D155A-6 85001 and up
90 Diagrams and drawings 1

Hydraulic diagrams and drawings
Power train hydraulic circuit diagram .............................................................................................................. 3
Hydraulic circuit diagram Serial No.: 85001 – 85024...................................................................................... 5
Hydraulic circuit diagram Serial No.: 85025 and up........................................................................................ 7
D155A-6 1
SEN02875-01 90 Diagrams and drawings
2 D155A-6
Power train hydraulic circuit diagram Power train hydraulic circuit diagram
D155A-6
D155A-6 3
Hydraulic circuit diagram Hydraulic circuit diagram 1
Serial No.: 85001 – 85024 D155A-6
SEN02875-01
D155A-6 5
Hydraulic circuit diagram Hydraulic circuit diagram 1
Serial No.: 85025 and up D155A-6
SEN02875-01
D155A-6 7
D155A-6 9
D155A-6 Bulldozer
© 2008 KOMATSU
All Rights Reserved
10 D155A-6
SEN02874-01
D155A-6

D155A-6 85001 and up
90 Diagrams and drawings 1

Electrical diagrams and drawings
Electrical circuit diagram (Cab spec.) ............................................................................................................. 3
Electrical circuit diagram (Cab less spec.) ...................................................................................................... 5
Electrical circuit diagram for inside cab........................................................................................................... 7
Connectors table and arrangement drawing................................................................................................... 9
D155A-6 1
2 D155A-6
Electrical circuit diagram (Cab spec.)
Electrical circuit diagram (Cab spec.) D155A-6
SEN02874-01
D155A-6 3
Electrical circuit diagram (Cab less spec.)
Electrical circuit diagram (Cab less spec.) D155A-6
SEN02874-01
D155A-6 5
Electrical circuit diagram for inside cab Electrical circuit diagram for inside cab
D155A-6
D155A-6 7
Connectors table and arrangement drawing D155A-6 Connectors table and arrangement drawing
D155A-6
Connector Type of Number Connector Type of Number
No. connector of pin Location Address No. connector of pin Location Address
250 Terminal 1 Starting switch (Terminal B) R-9 GND03 Terminal 6 Ground (ROPS) M-5
255 Terminal 1 Starting switch (Terminal R1) R-8 GND06 Terminal 4 Ground (Fender) J-1
256 Terminal 1 Starting switch (Terminal R2) R-8 GND07 Terminal 1 Ground (Bulkhead) G-1
260 Terminal 1 Starting switch (Terminal BR) R-8 GND08 Terminal 4 Ground (Guard) [Additional headlamp specification] —
270 Terminal 1 Starting switch (Terminal ACC) R-9 GND09 Terminal 1 Ground (Engine) AE-2
280 Terminal 1 Starting switch (Terminal C) R-9 GND11 Terminal 6 Ground (Floor) AB-6
A/C DT 2 Air conditioner compressor AE-1 GND12 Terminal 6 Ground (Floor) AB-6
A/C1 DT 2 Intermediate conncector F-7, AG-8 GND20 Terminal 2 Ground (Engine) AF-2
AC01 YAZAKI 8 Intermediate conncector K-8, AB-8 GND21 Terminal 1 Ground (electric air bleeding pump switch) M-4
AC02 SUMITOMO4 4 Intermediate conncector K-9, AB-7 HDT DT 2 Hydraulic oil temperature sensor AI-2
AC03 Relay 5 Air conditioner blower relay AB-5 HHP DT 3 Work equipment and HSS pump pressure sensor AI-4
AC04 Relay 4 Air conditioner compressor relay AB-4 HNSW DT 2 Horn switch V-9
AC05 S090 2 Air conditioner gas pressure sensor I-1 HRN — 1 Horn C-2
ACCN 040 36 Air conditioner controller L-8 HT Terminal 2 Heater relay (Terminal C) A-5
ACD1 DT 2 Diode AB-2 HT/A Terminal 1 Heater relay (Terminal A) B-5
ACD2 DT 2 Diode AB-2 HT/B Terminal 1 Heater relay (Terminal B) A-4
ACS DT 2 Diode AE-2 HTD DT 2 Diode H-1
ACT Relay 5 Engine ACC signal cut relay D-8 INJ DT 12 Intermediate connector (injector) AG-3
AF1 DT 2 Air cleaner clogging switch (If equipped) E-7 J1939 DT 3 Service connector AF-8
AL/B Terminal 1 Alternator terminal B AC-4 JM01 — 5 Junction wiring harness AH-4
AL/R Terminal 1 Alternator terminal R AC-5 JM02 — 6 Junction wiring harness AH-3
AT11 — 1 Machine monitor F-8 JM03 — 4 Junction wiring harness AH-3
AT12 — 1 GPS antenna I-9 JM04 — 4 Junction wiring harness AG-2
AT21 — 1 KOMTRAX communication module H-8 JM05 — 3 Junction wiring harness AH-5
AT22 — 1 ORBCOMM antenna I-9 JM08 — 6 Junction wiring harness AG-8
AUX0 — 1 Service connector K-2 KEY DT 6 Starting switch R-6
B30L Terminal 1 Circuit breaker (30A) L-2 LHD DT 2 Intermediate connector C-3
B30S Terminal 1 Circuit breaker (30A) L-2 LHDL DT 2 Left headlamp C-3
B105HL Terminal 1 Circuit breaker (105A) M-3 LHDL1 DT 2 Additional left headlamp [Additional headlamp specification] —
B105HS Terminal 1 Circuit breaker (105A) M-3 LHDL2 DT 2 Additional left headlamp [Additional headlamp specification] —
B105L Terminal 1 Circuit breaker (105A) L-2 LHDR DT 2 Right headlamp C-4
B105S Terminal 1 Circuit breaker (105A) L-2 LHDR1 DT 2 Additional right headlamp [Additional headlamp specification] —
BKA Relay 5 Backup alarm relay A-8 LHDR2 DT 2 Additional right headlamp [Additional headlamp specification] —
BKAL DT 2 Backup alarm M-5 LMD1 DT 2 Diode Q-8
BKSW DT 3 Brake pedal switch P-6 LMD2 DT 2 Diode Q-8
BRB Terminal 1 Battery relay (Contact input terminal) N-3 LMFL Relay 5 Left headlamp relay C-9
BRC Terminal 3 Battery relay (Contact output terminal) M-3 LMFR Relay 5 Right headlamp relay C-9
BRE Terminal 1 Battery relay (Coil ground terminal) N-1 LMRE Relay 5 Rear lamp relay A-9
BRK DT 3 Brake pedal potentiometer P-5 LMRP Relay 5 Ripper lamp relay D-7
BVRV DT 2 Transmission bevel speed sensor AK-6 LREL DT 2 Left rear lamp M-7
CA1 DT 3 CAN terminal resistance AH-3 LRER DT 2 Right rear lamp I-9
CB1 — 1 Circuit breaker (20A) C-6 LRP2 DT 3 Ripper lamp M-6
CB2 — 1 Circuit breaker (20A) C-6 NE FRAMATONE 3 Engine Ne speed sensor AH-4
CB3 — 1 Circuit breaker (20A) C-6 NSF Relay 5 Neutral safety relay C-9
CB4 — 1 Circuit breaker (20A) B-6 OPPW DT 2 Intermediate connector Z-9
CB5 — 1 Circuit breaker (20A) B-6 PAMB FRAMATONE 4 Ambient pressure sensor AH-3
CB6 — 1 Circuit breaker (20A) B-6 PBD DT 2 Diode AB-6
CB7 — 1 Circuit breaker (20A) B-6 PBS DT 2 Pedal brake solenoid AL-7
CB8 — 1 Circuit breaker (30A) A-6 PCV1 SUMITOMO 2 Supply pump #1 AD-2
CB9 — 1 Circuit breaker (20A) D-6 PCV2 SUMITOMO 2 Supply pump #2 AD-2
CB30 — 2 Circuit breaker (30A) L-2 PFUEL AMP 3 Common rail pressure sensor AF-2
CB105 — 2 Circuit breaker (105A) L-3 PHR Relay 5 Preheat relay B-9
CB105H — 2 Circuit breaker (105A) M-3 PIM CANNON 4 Charge pressure sensor AH-6
CBPW DTP 4 Intermediate connector X-9 PKD DT 2 Diode AB-6
CK01 070 14 KOMTRAX communication module Y-9 PKS DT 2 Parking brake solenoid AL-6
CK02 070 10 KOMTRAX communication module Y-9 PKSW DT 3 Parking brake lever switch L-8, AB-5
CM01 070 18 Machine monitor R-6 PL1 DRC-70A 70 Intermediate connector AB-4, AN-7
CM02 070 12 Machine monitor R-5 PLSW DT 2 Pin puller switch W-9
CM03 070 18 Machine monitor R-5 POIL CANNON 4 Engine oil pressure sensor AG-2
CM04 070 12 Machine monitor — PPL DT 2 Pin puller solenoid valve M-4
CM05 070 8 Machine monitor — PRT DT-A 12 Intermediate connector E-7
CN1 DT 2 Injecter #1 AC-4 PT1 DT 3 Pitch angle sensor D-6
CN2 DT 2 Injecter #2 AC-5 RDG DT-A 12 Intermediate connector C-5
CN3 DT 2 Injecter #3 AD-7 RES DT 2 Service connector AG-7
CN4 DT 2 Injecter #4 AE-7 RHT Terminal 1 Intake air heater (Ribbon heater) AC-6
CN5 DT 2 Injecter #5 AE-7 RLSW SWP 6 Rear lamp switch P-4
CN6 DT 2 Injecter #6 AH-7 RSD DT 2 Diode AB-1
DCL DT 3 Decelerator pedal potentiometer P-6 S1T DT 2 Transmission 1st clutch ECMV (Solenoid) AI-8
DIAL M 3 Fuel control dial AB-8 S2T DT 2 Transmission 2nd clutch ECMV (Solenoid) AJ-7
DSH DRC-70A 70 Intermediate connector P-2, V-1 S3T DT 2 Transmission 3rd clutch ECMV (Solenoid) AI-8
Intermediate connector (used when work equipment controller is SBRL DT 2 Left brake ECMV (Solenoid) AM-7
DTS DT 12 installed) Z-9
SBRR DT 2 Right brake ECMV (Solenoid) AM-7
E22 DT 6 Intermediate connector AG-2
SCLL DT 2 Left steering clutch ECMV (Solenoid) AN-6
EFP DT 2 Electric air bleeding pump AF-2
SCLR DT 2 Right steering clutch ECMV (Solenoid) AN-7
EG1 DTP 2 Intermediate connector H-1, AH-5
SFT DT 2 Transmission F clutch ECMV (Solenoid) AJ-7
EG2 DT-B 12 Intermediate connector H-1, AH-5
SFTD — 3 Shift-down switch X-1
EGC1 DRC-60 60 Engine controller AH-4
SFTU — 3 Shift-up switch Y-1
EGC2 DRC-50 50 Engine controller AH-4
SLS 050 2 Daylight sensor P-7
EGC3 DTP 4 Engine controller AG-3
SRT DT 2 Transmission R clutch ECMV (Solenoid) AI-8
EGPW DTP 2 Intermediate connector L-3
SRV DT-A 12 Service connector (for CAN communication) W-9
EHL Relay 5 Engine hold relay D-9
SSP DT 2 Sudden stop prevent valve AK-6
EPP DT 6 Electric air bleeding pump switch F-7
ST DT 2 Starting motor (Terminal R, S) AC-3
ESD DT 3 Service connector (for engine option) Z-9
ST/B Terminal 1 Starting motor (Terminal B) AD-7
F105 DTHD 1 Intermediate connector K-2
STC1 DRC26-24 24 Power train controller Z-1
F1T DT 2 Transmission 1st clutch ECMV (Fill switch) AJ-9
STC2 DRC26-40A 40 Power train controller Z-1
F2T DT 2 Transmission 2nd clutch ECMV (Fill switch) AJ-7
STC3 DRC26-40B 40 Power train controller AA-1
F3T DT 2 Transmission 3rd clutch ECMV (Fill switch) AI-8
SW Terminal 1 Battery relay (Coil signal terminal) N-1
F30 DTHD 1 Intermediate connector L-3
TCT DT 2 Torque converter oil temperature sensor AM-2
FAC DT 2 Fan pump control valve AI-3
TFUEL PACKARD 2 Fuel temperature sensor AH-7
FAR DT 2 Fan reverse solenoid valve C-1
TIM PACKARD 2 Charge temperature sensor AH-6
FBRL DT 2 Left brake ECMV (Fill switch) AL-7
TLV1 DT-B 8 Steering/directional/gearshift lever (Potentiometer) Y-1
FBRR DT 2 Right brake ECMV (Fill switch) AM-7
TLV2 DT 6 Steering/directional/gearshift lever (Shift switch) Y-1
FCLL DT 2 Left steering clutch ECMV (Fill switch) AN-6
TMV 24-23 23 Intermediate connector AN-3
FCLR DT 2 Right steering clutch ECMV (Fill switch) AN-7
TWTR PACKARD 2 Engine coolant temperature sensor AF-8
FD1 24-31 31 Intermediate connector K-2, AB-4
WELK DT 3 Work equipment lock lever switch W-9
FD2 DT-C 12 Intermediate connector L-3
WLK DT 2 Work equipment lock solenoid valve AJ-6
FD3 DT 6 Intermediate connector M-3
WLV DT 2 Radiator coolant level sensor C-2
FD4 24-31 31 Intermediate connector J-2, AB-3
WSH DT 4 Intermediate connector X-9
FFT DT 2 Transmission F clutch ECMV (Fill switch) AK-9
WSH1 DT 6 Window washer tank (Front, left) J-2
FLSW SWP 6 Headlamp switch P-5
WSH2 DT 6 Window washer tank (Rear, right) I-1
FLV DT 2 Fuel level sensor M-4
FRT DT 2 Transmission R clutch ECMV (Fill switch) AK-9
FS11 — 5 Fuse box A-8
FSB 24-21 21 Intermediate connector B-9, AB-4
FTK DT 6 Intermediate connector M-7
G SUMITOMO 3 Engine Bkup speed sensor AD-2
GND Terminal 1 Ground (ROPS) M-3
SEN02874-01
D155A-6 9
D155A-6 11
D155A-6 Bulldozer
© 2007 KOMATSU
All Rights Reserved
12 D155A-6

Shop D155A-6 PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Shop D155A-6 PDF

Uploaded by

Copyright:

Available Formats

SEN02854-06

BULLDOZER 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

Composition of shop manual 1

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN02854-06

00 Index and foreword SEN02855-06

10 Structure, function and maintenance standard SEN02860-03

20 Standard value table SEN02869-00

30 Testing and adjusting SEN02870-03

Troubleshooting of hydraulic and mechanical system (H-mode) SEN03211-00

50 Disassembly and assembly SEN02872-02

60 Air conditioner SEN04441-00

90 Diagrams and drawings SEN02873-02

Foreword and general information SEN02857-03

10 Structure, function and maintenance standard

Undercarriage and frame SEN02864-00

20 Standard value table

30 Testing and adjusting

Measuring blow-by pressure ....................................................................................................... 18

Troubleshooting by failure and error codes, Part 1 SEN03206-00

Failure code [CA322] Inj #1 Open/Short Error ............................................................................ 14

Failure code [DH21KB] Weq pressure sensor: Short circuit ....................................................... 46

Troubleshooting of electrical system (E-mode) SEN03210-01

Troubleshooting of engine (S-mode) SEN03212-01

50 Disassembly and assembly

Removal and installation of recoil spring assembly..................................................................... 11

Testing evaporator temperature sensor................................................................................... 45

90 Diagrams and drawings

BULLDOZER 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

1. General precautions 7) If welding repairs are needed, always

2. Preparations for work 6) When removing a cover which is under

4. Precautions for sling work and making

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

2 Coat Places to be coated with adhesives, etc. during assembly.

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

q Usually, the size of a hole and the size of

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value or allow-

Handling of electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector

5) Oil or dirt stuck to connector

3. Removing, installing, and drying connec-

2] When removing from clips