Komatsu D155AX-7 Install guide

BULLDOZER
SEN05653-03
D155AX
-7
SERIAL NUMBERS
90001
and up

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SHOP MANUAL
BULLDOZER
D155AX-7
Model
D155AX-7
Serial Number
90001 and up
00 Index and foreword
1 00 Index and foreword
D155AX-7 00-1
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00 Index and foreword
Index
Index (ALL-0310-001-A-00-A)
00 Index and foreword .......................................................................................................................00-1
Index .........................................................................................................................................00-2
Foreword, safety and general information ................................................................................... 00-17
Important safety notice .......................................................................................................00-17
How to read the shop manual..............................................................................................00-24
Explanation of terms for maintenance standard .................................................................... 00-26
Handling equipment of fuel system devices .......................................................................... 00-28
Handling of intake system parts........................................................................................... 00-29
Handling of hydraulic equipment.......................................................................................... 00-30
Method of disconnecting and connecting of push-pull type coupler ......................................... 00-32
Handling of electrical equipment.......................................................................................... 00-35
How to read electric wire code............................................................................................. 00-43
Precautions when performing operation ............................................................................... 00-46
Practical use of KOMTRAX................................................................................................. 00-51
Standard tightening torque table.......................................................................................... 00-52
List of abbreviation ............................................................................................................. 00-58
Conversion table................................................................................................................ 00-63
01 Specification.................................................................................................................................01-1
Table of contents ........................................................................................................................01-2
Specifications.............................................................................................................................01-3
Specification drawing ...........................................................................................................01-3
Specification........................................................................................................................01-5
Weight table ...................................................................................................................... 01-13
Table of fuel, coolant, and lubricants .................................................................................... 01-15
10 Structure and function ...................................................................................................................10-1
Table of contents ........................................................................................................................10-2
Engine and cooling system..........................................................................................................10-4
Engine related parts .............................................................................................................10-4
KVGT..................................................................................................................................10-6
EGR system piping drawing................................................................................................ 10-12
EGR system circuit diagram................................................................................................10-14
EGR valve......................................................................................................................... 10-15
EGR cooler........................................................................................................................ 10-17
KCCV layout drawing ......................................................................................................... 10-19
KCCV ventilator ................................................................................................................. 10-21
KDPF................................................................................................................................ 10-23
Damper............................................................................................................................. 10-27
Cooling system .................................................................................................................. 10-29
Cooling fan pump............................................................................................................... 10-32
Cooling fan motor............................................................................................................... 10-42
Power train............................................................................................................................... 10-50
Power train system............................................................................................................. 10-50
HSS system ...................................................................................................................... 10-53
Overall drawing of power train unit....................................................................................... 10-55
Power train mount.............................................................................................................. 10-57
Layout of power train hydraulic piping .................................................................................. 10-59
Transmission, steering, and brake control ............................................................................ 10-61
Universal joint.................................................................................................................... 10-63
Torque converter and PTO.................................................................................................. 10-64
Torque converter control valve............................................................................................. 10-72
Lockup clutch ECMV.......................................................................................................... 10-73
Stator clutch ECMV............................................................................................................ 10-78
Transmission ..................................................................................................................... 10-82
Transmission ECMV........................................................................................................... 10-96
Main relief valve and torque converter relief valve ............................................................... 10-105
Transmission lubrication relief valve................................................................................... 10-107
Bevel gear shaft, HSS, and brake...................................................................................... 10-108
Brake control valve........................................................................................................... 10-126
00-2 D155AX-7
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00 Index and foreword
Index
Brake ECMV ................................................................................................................... 10-129
Brake solenoid valve ........................................................................................................ 10-133
Sudden stop prevention valve ........................................................................................... 10-135
Final drive ....................................................................................................................... 10-137
Undercarriage and frame......................................................................................................... 10-140
Main frame ...................................................................................................................... 10-140
Suspension ..................................................................................................................... 10-142
Track frame and idler cushion ........................................................................................... 10-144
Hydraulic system .................................................................................................................... 10-146
Hydraulic component layout.............................................................................................. 10-146
Work equipment control.................................................................................................... 10-149
Hydraulic tank.................................................................................................................. 10-152
CLSS.............................................................................................................................. 10-154
Scavenging pump ............................................................................................................ 10-158
Steering lubrication pump and power train pump................................................................. 10-159
Work equipment and HSS pump ....................................................................................... 10-161
HSS motor ...................................................................................................................... 10-185
Control valve ................................................................................................................... 10-193
Quick drop valve .............................................................................................................. 10-231
Work equipment lock solenoid valve .................................................................................. 10-237
Hydraulic oil cooler bypass valve....................................................................................... 10-238
Accumulator .................................................................................................................... 10-239
Self-pressure reducing valve............................................................................................. 10-241
Work equipment ..................................................................................................................... 10-248
Cylinder stay.................................................................................................................... 10-248
Blade .............................................................................................................................. 10-249
Ripper............................................................................................................................. 10-250
Piston valve..................................................................................................................... 10-252
Cab and its attachments.......................................................................................................... 10-253
ROPS cab....................................................................................................................... 10-253
Function.......................................................................................................................... 10-254
Cab mount ...................................................................................................................... 10-255
Electrical system .................................................................................................................... 10-256
Engine control.................................................................................................................. 10-256
Engine control system ...................................................................................................... 10-257
Palm command control system.......................................................................................... 10-258
System operating lamp function......................................................................................... 10-262
Battery disconnect switch function ..................................................................................... 10-264
Machine monitor system................................................................................................... 10-266
KOMTRAX system........................................................................................................... 10-288
System component parts .................................................................................................. 10-290
Sensor ............................................................................................................................ 10-308
20 Standard value tables....................................................................................................................20-1
Table of contents ........................................................................................................................20-2
Standard service value table........................................................................................................20-3
Standard value table for engine.............................................................................................20-3
Standard value table for machine ..........................................................................................20-5
Standard value table for electrical system............................................................................. 20-16
30 Testing and adjusting ....................................................................................................................30-1
Table of contents ........................................................................................................................30-2
Related information on testing and adjusting ................................................................................. 30-4
Tools for testing and adjusting ...............................................................................................30-4
Sketch of tools for testing and adjusting ................................................................................. 30-7
Engine and cooling system..........................................................................................................30-9
Testing engine speed ...........................................................................................................30-9
Testing boost pressure ....................................................................................................... 30-11
Testing exhaust gas temperature......................................................................................... 30-12
Testing exhaust gas color ...................................................................................................30-15
Adjusting valve clearance ................................................................................................... 30-17
D155AX-7 00-3
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00 Index and foreword
Index
Measuring compression pressure........................................................................................ 30-19
Testing blowby pressure ..................................................................................................... 30-22
Testing engine oil pressure ................................................................................................. 30-23
Testing EGR valve and KVGT driving oil pressure ................................................................. 30-24
Measuring fuel pressure ..................................................................................................... 30-26
Testing fuel return rate and leakage .....................................................................................30-27
Bleeding air from fuel system .............................................................................................. 30-30
Testing fuel circuit for leakage .............................................................................................30-32
Handling cylinder cutout mode operation.............................................................................. 30-33
Handling no-injection cranking operation.............................................................................. 30-34
Replacing belt for alternator and air conditioner compressor, adjusting belt tension.................. 30-35
Adjusting fuel control dial and decelerator pedal ................................................................... 30-36
Procedures for cleaning fuel doser....................................................................................... 30-38
Writing compensation values at replacement of injector and engine controller ......................... 30-41
Power train............................................................................................................................... 30-45
Testing power train oil pressure ........................................................................................... 30-45
Adjusting transmission output shaft speed sensor (replacement procedure) ............................ 30-51
Simple test procedure for brake performance ....................................................................... 30-52
Adjusting brake pedal......................................................................................................... 30-53
Adjusting parking brake lever .............................................................................................. 30-55
Retrieval of disabled machine by using brake release device ................................................. 30-57
Undercarriage and frame........................................................................................................... 30-60
Adjusting idler clearance..................................................................................................... 30-60
Testing and adjusting track tension ...................................................................................... 30-62
Hydraulic system ...................................................................................................................... 30-63
Releasing remaining pressure in work equipment cylinder ..................................................... 30-63
Testing and adjusting work equipment and HSS oil pressures ................................................ 30-64
Bleeding air from work equipment and HSS pump................................................................. 30-68
Testing source pressure of control circuit.............................................................................. 30-69
Testing work equipment lock solenoid valve output pressure.................................................. 30-70
Isolating the parts causing hydraulic drift in blade and ripper .................................................. 30-71
Checking fan speed ........................................................................................................... 30-72
Testing fan circuit oil pressure .............................................................................................30-73
Bleeding air from fan pump ................................................................................................. 30-75
Testing internal oil leakage of work equipment cylinder .......................................................... 30-76
Bleeding air from work equipment cylinders.......................................................................... 30-77
Emergency operating method when work equipment has trouble ........................................... 30-78
Testing ripper pin puller solenoid valve output pressure ......................................................... 30-80
Work equipment ....................................................................................................................... 30-81
Adjusting work equipment lock lever .................................................................................... 30-81
Adjusting blade .................................................................................................................. 30-83
Cab and its attachments............................................................................................................ 30-85
Adjusting operator's cab ..................................................................................................... 30-85
Electrical system ...................................................................................................................... 30-88
Special functions of machine monitor................................................................................... 30-88
Angle adjustment of rear view camera ............................................................................... 30-167
Handling voltage circuit of engine controller........................................................................ 30-168
Handling battery disconnect switch .................................................................................... 30-169
Testing diodes ................................................................................................................. 30-170
Pm clinic ................................................................................................................................ 30-171
Pm Clinic service ............................................................................................................. 30-171
Check sheet .................................................................................................................... 30-176
40 Troubleshooting............................................................................................................................40-1
Table of contents ........................................................................................................................40-2
Related information on troubleshooting....................................................................................... 40-11
Troubleshooting points ....................................................................................................... 40-11
Sequence of events in troubleshooting................................................................................. 40-13
Checks before troubleshooting............................................................................................ 40-15
Inspection procedure before troubleshooting ........................................................................ 40-17
00-4 D155AX-7
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00 Index and foreword
Index
Preparation for troubleshooting of electrical system............................................................... 40-35
Classification and procedures for troubleshooting ................................................................. 40-40
Symptom and troubleshooting numbers ............................................................................... 40-42
Information in troubleshooting table ..................................................................................... 40-45
Connector list and layout .................................................................................................... 40-47
Connector contact identification........................................................................................... 40-61
T-branch box and T-branch adapter table ........................................................................... 40-100
Fuse location table ........................................................................................................... 40-105
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ................................. 40-109
Preparation of dummy temperature sensor (for KDOC and KDPF temperature
sensors)............................................................................................................. 40-112
Preparation of short circuit electrical connector (for failure codes [CA1883] and
[CA3135]) .......................................................................................................... 40-113
Failure codes table........................................................................................................... 40-114
Troubleshooting by failure code (Display of code) ...................................................................... 40-128
Failure code [1500L0] Transmission clutch: Abnormal ......................................................... 40-128
Failure code [15SAL1] Forward clutch: Fill High .................................................................. 40-129
Failure code [15SALH] Forward clutch: Fill Low .................................................................. 40-131
Failure code [15SBL1] Reverse clutch: Fill High.................................................................. 40-133
Failure code [15SBLH] Reverse clutch: Fill Low .................................................................. 40-135
Failure code [15SEL1] Speed 1st clutch: Fill High ............................................................... 40-137
Failure code [15SELH] Speed 1st clutch: Fill Low ............................................................... 40-139
Failure code [15SFL1] Speed 2nd clutch: Fill High .............................................................. 40-141
Failure code [15SFLH] Speed 2nd clutch: Fill Low .............................................................. 40-143
Failure code [15SGL1] Speed 3rd clutch: Fill High............................................................... 40-145
Failure code [15SGLH] Speed 3rd clutch: Fill Low............................................................... 40-147
Failure code [15SJL1] L/U: Fill High ................................................................................... 40-149
Failure code [15SJLH] L/U: Fill Low ................................................................................... 40-151
Failure code [1800MW] P/T clutch:Slip ............................................................................... 40-153
Failure code [2300NR] Brake Thermal Load Abnormality..................................................... 40-154
Failure code [2301L1] Right brake: Fill High ....................................................................... 40-155
Failure code [2301LH] Right brake: Fill low......................................................................... 40-157
Failure code [2302L1] Left brake: Fill High.......................................................................... 40-159
Failure code [2302LH] Left brake: Fill low ........................................................................... 40-161
Failure code [879AKA] A/C Inner Sensor Open Circuit ........................................................ 40-163
Failure code [879AKB] A/C Inner Sensor Short Circuit......................................................... 40-164
Failure code [879BKA] A/C Outer Sensor Open Circuit........................................................ 40-165
Failure code [879BKB] A/C Outer Sensor Short Circuit........................................................ 40-166
Failure code [879CKA] Ventilating Sensor Open Circuit....................................................... 40-167
Failure code [879CKB] Ventilating Sensor Short Circuit ....................................................... 40-168
Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit ............................................. 40-169
Failure code [879EMC] Ventilation Damper Abnormality ...................................................... 40-170
Failure code [879FMC] Air Mix Damper Abnormality ........................................................... 40-171
Failure code [879GKX] Refrigerant Abnormality.................................................................. 40-172
Failure code [989L00] Engine Controller Lock Caution 1...................................................... 40-173
Failure code [989M00] Engine Controller Lock Caution 2..................................................... 40-174
Failure code [989N00] Engine Controller Lock Caution 3 ..................................................... 40-175
Failure code [A1U0N3] HC Desorb Request 1 .................................................................... 40-176
Failure code [A1U0N4] HC Desorb Request 2 .................................................................... 40-178
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40-180
Failure code [AB00KE] Charge Voltage Low....................................................................... 40-182
Failure code [B@BAZG] Eng Oil Press Low ....................................................................... 40-183
Failure code [B@BCNS] Eng Water Overheat .................................................................... 40-184
Failure code [B@BCZK] Eng Water Level Low ................................................................... 40-185
Failure code [B@CENS] P/L Oil Overheat .......................................................................... 40-187
Failure code [B@HANS] Hyd Oil Overheat ......................................................................... 40-188
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................. 40-189
Failure code [CA122] Chg Air Press Sensor High Error ....................................................... 40-190
Failure code [CA123] Chg Air Press Sensor Low Error ........................................................ 40-192
D155AX-7 00-5
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00 Index and foreword
Index
Failure code [CA131] Throttle Sensor High Error................................................................. 40-194
Failure code [CA132] Throttle Sensor Low Error ................................................................. 40-196
Failure code [CA135] Eng Oil Press Sensor High Error........................................................ 40-198
Failure code [CA141] Eng Oil Press Sensor Low Error ........................................................ 40-200
Failure code [CA144] Coolant Temp Sens High Error .......................................................... 40-202
Failure code [CA145] Coolant Temp Sens Low Error ........................................................... 40-204
Failure code [CA153] Chg Air Temp Sensor High Error........................................................ 40-206
Failure code [CA154] Chg Air Temp Sensor Low Error......................................................... 40-208
Failure code [CA187] Sensor 2 Supply Volt Low Error ......................................................... 40-210
Failure code [CA221] Ambient Press Sens High Error ......................................................... 40-212
Failure code [CA222] Ambient Press Sens Low Error .......................................................... 40-214
Failure code [CA227] Sensor 2 Supply Volt High Error......................................................... 40-216
Failure code [CA234] Eng Overspeed ................................................................................ 40-217
Failure code [CA238] Ne Speed Sensor Supply Volt Error ................................................... 40-218
Failure code [CA239] Ne Speed Sens Supply Volt High Error............................................... 40-219
Failure code [CA271] IMV/PCV1 Short Error ...................................................................... 40-220
Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40-221
Failure code [CA273] PCV2 Short Error ............................................................................. 40-222
Failure code [CA274] PCV2 Open Error ............................................................................. 40-223
Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................. 40-224
Failure code [CA323] Inj #5(L#5) Open/Short Error ............................................................. 40-226
Failure code [CA324] Inj #3(L#3) Open/Short Error ............................................................. 40-228
Failure code [CA325] Inj #6(L#6) Open/Short Error ............................................................. 40-230
Failure code [CA331] Inj #2(L#2) Open/Short Error ............................................................. 40-232
Failure code [CA332] Inj #4(L#4) Open/Short Error ............................................................. 40-234
Failure code [CA343] ECM Critical Internal Failure.............................................................. 40-236
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40-237
Failure code [CA352] Sensor 1 Supply Volt Low Error ......................................................... 40-238
Failure code [CA356] Mass Air Flow Sensor High Error ....................................................... 40-240
Failure code [CA357] Mass Air Flow Sensor Low Error........................................................ 40-242
Failure code [CA386] Sensor 1 Supply Volt High Error......................................................... 40-244
Failure code [CA441] Battery Voltage Low Error ................................................................. 40-245
Failure code [CA442] Battery Voltage High Error................................................................. 40-248
Failure code [CA449] Rail Press Very High Error................................................................. 40-249
Failure code [CA451] Rail Press Sensor High Error............................................................. 40-250
Failure code [CA452] Rail Press Sensor Low Error ............................................................. 40-252
Failure code [CA515] Rail Press Sens Sup Volt High Error .................................................. 40-254
Failure code [CA516] Rail Press Sens Sup Volt Low Error ................................................... 40-256
Failure code [CA553] Rail Press High Error ........................................................................ 40-258
Failure code [CA555] Crankcase Press High Error 2 ........................................................... 40-259
Failure code [CA556] Crankcase Press High Error 3 ........................................................... 40-260
Failure code [CA559] Rail Press Low Error......................................................................... 40-261
Failure code [CA595] Turbo Speed High Error 2 ................................................................. 40-265
Failure code [CA687] Turbo Speed Low Error..................................................................... 40-266
Failure code [CA689] Eng Ne Speed Sensor Error .............................................................. 40-268
Failure code [CA691] Intake Air Temp Sens High Error........................................................ 40-270
Failure code [CA692] Intake Air Temp Sens Low Error......................................................... 40-272
Failure code [CA697] ECM Internal Temp Sensor High Error................................................ 40-274
Failure code [CA698] ECM Int Temp Sensor Low Error........................................................ 40-275
Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................... 40-276
Failure code [CA778] Eng Bkup Speed Sensor Error........................................................... 40-277
Failure code [CA1117] Persistent Data Lost Error................................................................ 40-279
Failure code [CA1664] KDOC Malfunction.......................................................................... 40-280
Failure code [CA1691] Regeneration Ineffective ................................................................. 40-283
Failure code [CA1695] Sensor 5 Supply Volt High Error....................................................... 40-286
Failure code [CA1696] Sensor 5 Supply Volt Low Error ....................................................... 40-288
Failure code [CA1843] Crankcase Press Sens High Error.................................................... 40-290
Failure code [CA1844] Crankcase Press Sens Low Error .................................................... 40-292
Failure code [CA1879] KDPF Delta P Sensor High Error ..................................................... 40-294
00-6 D155AX-7
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00 Index and foreword
Index
Failure code [CA1881] KDPF Delta P Sensor Low Error ...................................................... 40-296
Failure code [CA1883] KDPF Delta P Sens In Range Error.................................................. 40-298
Failure code [CA1921] KDPF Soot Load High Error 1.......................................................... 40-302
Failure code [CA1922] KDPF Soot Load High Error 2.......................................................... 40-305
Failure code [CA1923] Dosing Fuel Valve 1 High Error ........................................................ 40-310
Failure code [CA1924] Dosing Fuel Valve 1 Low Error......................................................... 40-312
Failure code [CA1925] Dosing Fuel Valve 1 In Range Error ................................................. 40-314
Failure code [CA1927] Dosing Fuel Press Sens High Error.................................................. 40-316
Failure code [CA1928] Dosing Fuel Press Sens Low Error................................................... 40-318
Failure code [CA1942] Crankcase Press Sens In Range Error ............................................. 40-320
Failure code [CA1963] Dosing Fuel Valve 1 Servo Error ...................................................... 40-321
Failure code [CA1977] Fuel Doser Open/Short Error ........................................................... 40-324
Failure code [CA1993] KDPF Delta Pressure Low Error ...................................................... 40-326
Failure code [CA2185] Throt Sensor Sup Volt High Error ..................................................... 40-328
Failure code [CA2186] Throt Sensor Sup Volt Low Error...................................................... 40-330
Failure code [CA2249] Rail Press Very Low Error ............................................................... 40-332
Failure code [CA2265] Fuel Feed Pump Open Error............................................................ 40-333
Failure code [CA2266] Fuel Feed Pump Short Error............................................................ 40-335
Failure code [CA2271] EGR Valve Pos Sens High Error ...................................................... 40-337
Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................... 40-339
Failure code [CA2349] EGR Valve Solenoid Open Error ...................................................... 40-341
Failure code [CA2353] EGR Valve Solenoid Short Error ...................................................... 40-343
Failure code [CA2357] EGR Valve Servo Error ................................................................... 40-345
Failure code [CA2381] KVGT Pos Sens High Error ............................................................. 40-346
Failure code [CA2382] KVGT Pos Sens Low Error .............................................................. 40-348
Failure code [CA2383] KVGT Solenoid Open Error ............................................................. 40-350
Failure code [CA2386] KVGT Solenoid Short Error ............................................................. 40-352
Failure code [CA2387] KVGT Servo Error .......................................................................... 40-354
Failure code [CA2555] Grid Htr Relay Volt Low Error ........................................................... 40-355
Failure code [CA2556] Grid Htr Relay Volt High Error .......................................................... 40-357
Failure code [CA2637] KDOC Face Plugging ..................................................................... 40-359
Failure code [CA2639] Manual Stationary Regeneration Request......................................... 40-361
Failure code [CA2732] Dosing Fuel Valve 2 High Error ........................................................ 40-364
Failure code [CA2733] Dosing Fuel Valve 2 Low Error......................................................... 40-366
Failure code [CA2741] Dosing Fuel Valve Swap Error ......................................................... 40-368
Failure code [CA2765] Inj Trim Data Error .......................................................................... 40-369
Failure code [CA2878] Dosing Fuel Valve 2 Servo Error ...................................................... 40-370
Failure code [CA2881] Dosing Fuel Pressure Low Error 1.................................................... 40-373
Failure code [CA3133] KDPF Outlet Press Sens High Error ................................................. 40-378
Failure code [CA3134] KDPF Outlet Press Sens Low Error.................................................. 40-380
Failure code [CA3135] KDPF Outlet Press Sens In Range Error .......................................... 40-382
Failure code [CA3167] Fuel Doser Degradation .................................................................. 40-386
Failure code [CA3251] KDOC Inlet Temp High Error............................................................ 40-389
Failure code [CA3253] KDOC Temp Error - Non Regeneration............................................. 40-392
Failure code [CA3254] KDOC Outlet Temp High Error 1 ...................................................... 40-395
Failure code [CA3255] KDPF Temp Error - Non Regeneration.............................................. 40-398
Failure code [CA3256] KDPF Outlet Temp High Error 1 ....................................................... 40-401
Failure code [CA3311] KDOC Outlet Temp High Error 2....................................................... 40-404
Failure code [CA3312] KDPF Outlet Temp High Error 2 ....................................................... 40-407
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ................................................. 40-410
Failure code [CA3314] KDOC Inlet Temp Sens High Error ................................................... 40-413
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error............................................. 40-417
Failure code [CA3316] KDOC Outlet Temp Sens Low Error ................................................. 40-422
Failure code [CA3317] KDOC Outlet Temp Sens High Error................................................. 40-425
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error .......................................... 40-429
Failure code [CA3319] KDPF Outlet Temp Sens High Error ................................................. 40-434
Failure code [CA3321] KDPF Outlet Temp Sens Low Error .................................................. 40-438
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error........................................... 40-441
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ........................................ 40-446
D155AX-7 00-7
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00 Index and foreword
Index
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ......................................... 40-448
Failure code [D130KA] Neutral relay:Open ......................................................................... 40-450
Failure code [D130KB] Neutral relay:Short circuit................................................................ 40-452
Failure code [D190KA] ECM ACC signal HOLD relay: Open ................................................ 40-454
Failure code [D190KB] ECM ACC signal HOLD relay: Short circuit....................................... 40-456
Failure code [D19JKZ] Personal Code Relay Abnormality.................................................... 40-458
Failure code [D811MC] KOMTRAX Error............................................................................ 40-461
Failure code [D862KA] GPS Antenna Open Circuit ............................................................. 40-462
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ...................................... 40-463
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ...................................... 40-465
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ............................................................ 40-467
Failure code [DAF0MB] Monitor ROM Abnormality.............................................................. 40-468
Failure code [DAF0MC] Monitor Error ................................................................................ 40-469
Failure code [DAF8KB] Camera Power Supply Short Circuit ................................................ 40-470
Failure code [DAF9KQ] Model Selection Abnormality .......................................................... 40-471
Failure code [DAFGMC] GPS Module Error........................................................................ 40-472
Failure code [DAFLKA] Operating Lamp Open Circuit (Mon)................................................ 40-473
Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor)............................................ 40-475
Failure code [DAFQKR] CAN2 Discon (Monitor) ................................................................. 40-477
Failure code [DAZ9KQ] A/C Model Selection Abnormality.................................................... 40-478
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ........................................................... 40-479
Failure code [DB2QKR] CAN2 Discon (Engine Con) ........................................................... 40-480
Failure code [DB2RKR] CAN1 Discon (Engine Con) ........................................................... 40-485
Failure code [DB90KT] WE controller: Abnormality in controller............................................ 40-491
Failure code [DB90MC] WE Con Error ............................................................................... 40-492
Failure code [DB91KK] WE controller:Source voltage low.................................................... 40-493
Failure code [DB92KK] WE controller: Output voltage low ................................................... 40-496
Failure code [DB95KK] WE:Sensor volt 5V (0) Out of normal range...................................... 40-498
Failure code [DB97KK] WE: Sensor volt 5V (1) Out of normal range ..................................... 40-500
Failure code [DB99KQ] WE controller: Type select signal .................................................... 40-502
Failure code [DB9LKA] Operating Lamp Open Circuit (WE Con) .......................................... 40-504
Failure code [DB9LKB] Operating Lamp Short Circuit (WE Con) .......................................... 40-506
Failure code [DB9QKR] CAN2 Discon (WE Con) ................................................................ 40-508
Failure code [DB9RKR] CAN1 Discon (WE Con) ................................................................ 40-509
Failure code [DBE0KT] PT controller: Abnormality in controller............................................. 40-511
Failure code [DBE1KK] PT controller:Source voltage low..................................................... 40-512
Failure code [DBE2KK] PT controller: Output voltage low..................................................... 40-514
Failure code [DBE5KK] PT:Sensor volt 5V (0) Out of normal range ....................................... 40-516
Failure code [DBE6KK] PT: Sensor volt 24 V Out of normal range ........................................ 40-518
Failure code [DBE9KQ] PT controller: Type select signal ..................................................... 40-520
Failure code [DBELKA] Operating Lamp Open Circuit (PT Con) ........................................... 40-521
Failure code [DBELKB] Operating Lamp Short Circuit (PT Con) ........................................... 40-523
Failure code [DBEQKR] CAN2 Discon (PT Con) ................................................................. 40-525
Failure code [DBERKR] CAN1 Discon (PT Con) ................................................................. 40-526
Failure code [DD12KA] Shift up Sw: Open.......................................................................... 40-528
Failure code [DD12KB] Shift up SW: Short Circuit ............................................................... 40-530
Failure code [DD13KA] Shift down SW: Open..................................................................... 40-532
Failure code [DD13KB] Shift down SW: Short Circuit........................................................... 40-534
Failure code [DD14KA] Parking lever SW: Open................................................................. 40-536
Failure code [DD14KB] Parking lever SW: Short circuit........................................................ 40-538
Failure code [DDDDKA] Brake pedal SW: Open ................................................................. 40-540
Failure code [DDDDKB] Brake pedal SW: Short circuit ........................................................ 40-542
Failure code [DDDDKX] Brake pedal Sw: Mismatch ............................................................ 40-544
Failure code [DDKAKA] Blade float Sw:Open ..................................................................... 40-545
Failure code [DDKAKB] Blade float Sw:Short circuit ............................................................ 40-547
Failure code [DDKBKA] Blade auto pitch Sw:Open ............................................................. 40-549
Failure code [DDKBKB] Blade auto pitch Sw:Short circuit .................................................... 40-551
Failure code [DDKCL4] Ripper tilt in Sw:Signal mismatch .................................................... 40-553
Failure code [DDKEL4] Ripper tilt back Sw:Signal mismatch................................................ 40-555
00-8 D155AX-7
Find manuals at https://best-manuals.com

00 Index and foreword
Index
Failure code [DDN7L4] Blade pitch back Sw:Signal mismatch.............................................. 40-557
Failure code [DDN8L4] Blade pitch dump Sw:Signal mismatch ............................................ 40-559
Failure code [DDNLKA] Weq lock Sw:Open ....................................................................... 40-561
Failure code [DDNLKB] Weq lock Sw:Short circuit .............................................................. 40-563
Failure code [DDTSL1] S/C :Fill High ................................................................................. 40-565
Failure code [DDTSLH] S/C :Fill Low ................................................................................. 40-567
Failure code [DFA4KX] Blade lift lever:Main and Sub Error .................................................. 40-569
Failure code [DFA4KZ] Blade lift lever:Main and Sub Error................................................... 40-570
Failure code [DFA4L8] Blade lift lever:Signal mismatch ....................................................... 40-571
Failure code [DFA5KA] Blade lift lever1:Open..................................................................... 40-572
Failure code [DFA5KB] Blade lift lever1:Hot Short ............................................................... 40-574
Failure code [DFA6KA] Blade lift lever2:Open..................................................................... 40-576
Failure code [DFA6KB] Blade lift lever2:Hot Short ............................................................... 40-578
Failure code [DFA7KX] Blade tilt lever:Main and Sub Error .................................................. 40-580
Failure code [DFA7KZ] Blade tilt lever:Main and Sub Error................................................... 40-581
Failure code [DFA7L8] Blade tilt lever:Signal mismatch ....................................................... 40-582
Failure code [DFA8KA] Blade tilt lever1:Open..................................................................... 40-583
Failure code [DFA8KB] Blade tilt lever1:Hot Short ............................................................... 40-585
Failure code [DFA9KA] Blade tilt lever2:Open..................................................................... 40-587
Failure code [DFA9KB] Blade tilt lever2:Hot Short ............................................................... 40-590
Failure code [DFAAKX] Ripper lift lever:Main and Sub Error................................................. 40-592
Failure code [DFAAKZ] Ripper lift lever:Main and Sub Error ................................................. 40-593
Failure code [DFAAL8] Ripper lift lever:Signal mismatch...................................................... 40-594
Failure code [DFABKA] Ripper lift lever1:Open ................................................................... 40-595
Failure code [DFABKB] Ripper lift lever1:Hot Short ............................................................. 40-597
Failure code [DFACKA] Ripper lift lever2:Open ................................................................... 40-599
Failure code [DFACKB] Ripper lift lever2:Hot Short ............................................................. 40-602
Failure code [DGS1KA] Hyd oil temp sensor:Open ............................................................. 40-604
Failure code [DGS1KX] Hyd oil temp:Out of normal range ................................................... 40-606
Failure code [DGT1KA] T/C oil temp sensor:Open .............................................................. 40-607
Failure code [DGT1KX] T/C oil temp sensor:Out of normal range ......................................... 40-609
Failure code [DH21KA] Weq pressure sensor:Open............................................................ 40-611
Failure code [DH21KB] Weq pressure sensor:Hot Short ...................................................... 40-613
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit ............................................. 40-615
Failure code [DHT5KA] T/C in-pressure sensor:Open ......................................................... 40-616
Failure code [DHT5KB] T/C in-pressure sensor:Hot Short.................................................... 40-618
Failure code [DHT7KA] T/C out-pressure sensor:Open ....................................................... 40-620
Failure code [DHT7KB] T/C out-pressure sensor:Hot Short.................................................. 40-622
Failure code [DK10KA] Fuel control Dial:Open ................................................................... 40-624
Failure code [DK10KB] Fuel control Dial:Short circuit .......................................................... 40-627
Failure code [DK30KA] ST lever1:Open ............................................................................. 40-629
Failure code [DK30KB] ST lever1:Hot Short ....................................................................... 40-631
Failure code [DK30KX] ST lever:Main and Sub Error........................................................... 40-633
Failure code [DK30KZ] ST lever:Main and Sub Error ........................................................... 40-634
Failure code [DK30L8] ST lever:Signal mismatch................................................................ 40-635
Failure code [DK31KA] ST lever2:Open ............................................................................. 40-636
Failure code [DK31KB] ST lever2:Hot Short ....................................................................... 40-638
Failure code [DK40KA] Brake potentiometer:Open.............................................................. 40-640
Failure code [DK40KB] Brake potentiometer:Hot Short........................................................ 40-642
Failure code [DK55KX] FR lever:Main and Sub Error .......................................................... 40-644
Failure code [DK55KZ] FR lever:Main and Sub Error........................................................... 40-645
Failure code [DK55L8] FR lever:Signal mismatch ............................................................... 40-646
Failure code [DK56KA] FR lever1:Open ............................................................................. 40-647
Failure code [DK56KB] FR lever1:Hot Short ....................................................................... 40-649
Failure code [DK57KA] FR lever2:Open ............................................................................. 40-651
Failure code [DK57KB] FR lever2:Hot Short ....................................................................... 40-653
Failure code [DKH1KA] Pitch angle sensor:Open................................................................ 40-655
Failure code [DKH1KB] Pitch angle sensor:Hot Short.......................................................... 40-657
Failure code [DLM3KA] Fan rev. sensor:Open .................................................................... 40-659
D155AX-7 00-9

00 Index and foreword
Index
Failure code [DLM3MB] Fan control:Mismatch.................................................................... 40-660
Failure code [DLT3KA] T/M out-speed sensor:Open............................................................ 40-661
Failure code [DLT3KB] T/M out-speed sensor:Short circuit .................................................. 40-663
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality ........................................ 40-664
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality ........................................ 40-665
Failure code [DV20KB] Back-up alarm :Short circuit ............................................................ 40-666
Failure code [DW7BKA] Fan Reverse Solenoid Open Circuit ............................................... 40-667
Failure code [DW7BKB] Fan Reverse Solenoid Short Circuit ............................................... 40-669
Failure code [DWN1KA] Hss EPC RH:Open....................................................................... 40-670
Failure code [DWN1KB] Hss EPC RH:Short circuit ............................................................. 40-672
Failure code [DWN1KY] Hss EPC RH:Hot short ................................................................. 40-673
Failure code [DWN2KA] Hss EPC LH:Open ....................................................................... 40-674
Failure code [DWN2KB] Hss EPC LH:Short circuit .............................................................. 40-676
Failure code [DWN2KY] Hss EPC LH:Hot short .................................................................. 40-677
Failure code [DWN3KA] S.S.P.V. solenoid:Open................................................................. 40-678
Failure code [DWN3KB] S.S.P.V. solenoid:Short circuit ....................................................... 40-680
Failure code [DWN3KY] S.S.P.V. solenoid:Hot short............................................................ 40-681
Failure code [DWN5KA] Fan pump solenoid 1:Open ........................................................... 40-682
Failure code [DWN5KB] Fan pump solenoid 1:Short circuit.................................................. 40-683
Failure code [DWN5KY] Fan pump solenoid 1:Hot Short ..................................................... 40-684
Failure code [DXA2KA] TVC solenoid 1:Open .................................................................... 40-686
Failure code [DXA2KB] TVC solenoid 1:Short circuit ........................................................... 40-688
Failure code [DXA2KY] TVC solenoid 1:Hot short ............................................................... 40-689
Failure code [DXH1KA] Lock-up ECMV:Open..................................................................... 40-690
Failure code [DXH1KB] Lock-up ECMV:Short circuit ........................................................... 40-692
Failure code [DXH1KY] Lock-up ECMV:Hot short ............................................................... 40-693
Failure code [DXH4KA] 1st clutch ECMV:Open .................................................................. 40-695
Failure code [DXH4KB] 1st clutch ECMV:Short circuit ......................................................... 40-697
Failure code [DXH4KY] 1st clutch ECMV:Hot short ............................................................. 40-699
Failure code [DXH5KA] 2nd clutch ECMV:Open ................................................................. 40-701
Failure code [DXH5KB] 2nd clutch ECMV:Short circuit ........................................................ 40-702
Failure code [DXH5KY] 2nd clutch ECMV:Hot short ............................................................ 40-703
Failure code [DXH6KA] 3rd clutch ECMV:Open .................................................................. 40-704
Failure code [DXH6KB] 3rd clutch ECMV:Short circuit......................................................... 40-705
Failure code [DXH6KY] 3rd clutch ECMV:Hot short ............................................................. 40-706
Failure code [DXH7KA] R clutch ECMV:Open .................................................................... 40-707
Failure code [DXH7KB] R clutch ECMV:Short circuit ........................................................... 40-708
Failure code [DXH7KY] R clutch ECMV:Hot short ............................................................... 40-709
Failure code [DXH8KA] F clutch ECMV:Open..................................................................... 40-711
Failure code [DXH8KB] F clutch ECMV:Short circuit............................................................ 40-712
Failure code [DXH8KY] F clutch ECMV:Hot short................................................................ 40-713
Failure code [DXHBKA] Right brake ECMV:Open ............................................................... 40-714
Failure code [DXHBKB] Right brake ECMV:Short circuit ...................................................... 40-716
Failure code [DXHBKY] Right brake ECMV:Hot short .......................................................... 40-717
Failure code [DXHCKA] Left brake ECMV:Open ................................................................. 40-719
Failure code [DXHCKB] Left brake ECMV:Short circuit ........................................................ 40-720
Failure code [DXHCKY] Left brake ECMV:Hot short ............................................................ 40-721
Failure code [DXHRKA] Blade lift up EPC:Open ................................................................. 40-723
Failure code [DXHRKB] Blade lift up EPC:Short circuit ........................................................ 40-725
Failure code [DXHRKY] Blade lift up EPC:Hot short ............................................................ 40-726
Failure code [DXHSKA] Blade lift down EPC:Open ............................................................. 40-727
Failure code [DXHSKB] Blade lift down EPC:Short circuit .................................................... 40-729
Failure code [DXHSKY] Blade lift down EPC:Hot short ........................................................ 40-730
Failure code [DXHTKA] Blade tilt right head EPC:Open....................................................... 40-731
Failure code [DXHTKB] Blade tilt right head EPC:Short circuit.............................................. 40-733
Failure code [DXHTKY] Blade tilt right head EPC:Hot short.................................................. 40-734
Failure code [DXHUKA] Blade tilt right bottom EPC:Open.................................................... 40-735
Failure code [DXHUKB] Blade tilt right bottom EPC:Short circuit .......................................... 40-737
Failure code [DXHUKY] Blade tilt right bottom EPC:Hot short .............................................. 40-738
00-10 D155AX-7

00 Index and foreword
Index
Failure code [DXHWKA] Ripper lift up EPC:Open ............................................................... 40-739
Failure code [DXHWKB] Ripper lift up EPC:Short circuit ...................................................... 40-740
Failure code [DXHWKY] Ripper lift up EPC:Hot short .......................................................... 40-741
Failure code [DXHXKA] Ripper lift down EPC:Open ............................................................ 40-742
Failure code [DXHXKB] Ripper lift down EPC:Short circuit................................................... 40-744
Failure code [DXHXKY] Ripper lift down EPC:Hot short....................................................... 40-745
Failure code [DXHYKA] Ripper tilt in EPC:Open ................................................................. 40-746
Failure code [DXHYKB] Ripper tilt in EPC:Short circuit ........................................................ 40-748
Failure code [DXHYKY] Ripper tilt in EPC:Hot short ............................................................ 40-749
Failure code [DXHZKA] Ripper tilt back EPC:Open ............................................................. 40-750
Failure code [DXHZKB] Ripper tilt back EPC:Short circuit.................................................... 40-752
Failure code [DXHZKY] Ripper tilt back EPC:Hot short ........................................................ 40-753
Failure code [DXJ4KA] Weq lock Sol.:Open ....................................................................... 40-754
Failure code [DXJ4KB] Weq lock Sol.:Short circuit .............................................................. 40-756
Failure code [DXJ8KA] Blade tilt left bottom EPC:Open ....................................................... 40-757
Failure code [DXJ8KB] Blade tilt left bottom EPC:Short circuit.............................................. 40-759
Failure code [DXJ8KY] Blade tilt left bottom EPC:Hot .......................................................... 40-760
Failure code [DXJ9KA] Blade tilt left head EPC:Open.......................................................... 40-761
Failure code [DXJ9KB] Blade tilt left head EPC:Short circuit ................................................ 40-763
Failure code [DXJ9KY] Blade tilt left head EPC:Hot short .................................................... 40-764
Failure code [DXJAKA] Quick drop solenoid:Open .............................................................. 40-765
Failure code [DXJAKB] Quick drop solenoid:Short circuit..................................................... 40-766
Failure code [DXJAKY] Quick drop solenoid:Hot short......................................................... 40-767
Failure code [DXJBKA] T/C Stator ECMV:Open.................................................................. 40-768
Failure code [DXJBKB] T/C Stator ECMV:Short circuit ........................................................ 40-770
Failure code [DXJBKY] T/C Stator ECMV:Hot short............................................................. 40-771
Troubleshooting of electrical system (E-mode) .......................................................................... 40-773
E-1 Engine does not start (Engine does not crank) .............................................................. 40-773
E-2 Manual preheating system does not work..................................................................... 40-779
E-3 Automatic preheating system does not work................................................................. 40-782
E-4 While preheating is working, preheating monitor does not light up .................................. 40-784
E-5 When starting switch is turned to ON position, machine monitor displays nothing............. 40-786
E-6 When starting switch is turned to ON position (with engine stopped), radiator coolant level
monitor lights up in yellow.................................................................................... 40-789
E-7 Air cleaner clogging monitor lights up in yellow while engine is running ........................... 40-791
E-8 Charge level monitor lights up in red while engine is running .......................................... 40-792
E-9 Engine coolant temperature monitor lights up in red while engine is running .................... 40-794
E-10 Engine oil pressure monitor lights up in red while engine is running .............................. 40-795
E-11 Power train oil temperature monitor lights up in red while engine is running ................... 40-796
E-12 Hydraulic oil temperature monitor lights up in red while engine is running ...................... 40-797
E-13 Engine coolant temperature gauge does not indicate correct temparature ..................... 40-798
E-14 Fuel level gauge does not indicate correct level .......................................................... 40-799
E-15 Power train oil temperature gauge does not indicate correct temperature ...................... 40-801
E-16 Hydraulic oil temperature gauge does not indicate correct temperature ......................... 40-802
E-17 Operation mode does not change .............................................................................. 40-803
E-18 Gear shift mode does not change .............................................................................. 40-804
E-19 Operating customize switch does not display customize screen ................................... 40-805
E-20 Modifying setting on customize screen does not change setting of machine .................. 40-806
E-21 Some areas of machine monitor screen are not displayed............................................ 40-807
E-22 Alarm buzzer does not sound or does not stop sounding ............................................. 40-808
E-23 While starting switch is in OFF position, service meter is not displayed ......................... 40-809
E-24 Service mode cannot be selected .............................................................................. 40-810
E-25 Horn does not sound ................................................................................................ 40-811
E-26 Horn does not stop sounding..................................................................................... 40-813
E-27 Backup alarm does not sound ................................................................................... 40-814
E-28 Backup alarm does not stop sounding........................................................................ 40-815
E-29 Headlamp does not light up....................................................................................... 40-816
E-30 Rear lamp and ripper point lamp do not light up........................................................... 40-819
E-31 No wiper operates continuously or intermittently.......................................................... 40-822
D155AX-7 00-11

00 Index and foreword
Index
E-32 Front wiper does not operate (failed continuous and intermittent operations) ................. 40-826
E-33 Rear wiper does not operate (failed continuous and intermittent operations) .................. 40-830
E-34 Left door wiper does not operate (failed continuous and intermittent operations) ............ 40-834
E-35 Right door wiper does not operate (failed continuous and intermittent
operations)......................................................................................................... 40-838
E-36 Front washer does not operate .................................................................................. 40-842
E-37 Rear washer does not operate................................................................................... 40-844
E-38 Left door washer does not operate ............................................................................. 40-846
E-39 Right door washer does not operate........................................................................... 40-848
E-40 Ripper pin puller does not work.................................................................................. 40-850
E-41 Fan does not rotate in reverse ................................................................................... 40-852
E-42 Fuel feed pump does not operate or stop automatically ............................................... 40-853
E-43 Gear cannot be shifted.............................................................................................. 40-855
E-44 KOMTRAX system does not operate properly............................................................. 40-856
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................. 40-858
Information described in troubleshooting table (H-mode) ..................................................... 40-858
System chart of hydraulic and mechanical systems............................................................. 40-859
Failure mode and cause table ........................................................................................... 40-863
H-1 Machine lacks power (insufficient drawbar pull) ............................................................ 40-869
H-2 Machine does not travel (at 2nd or 3rd gear speed)....................................................... 40-872
H-3 Machine does not start at all gear speeds..................................................................... 40-874
H-4 Machine travels only in one direction, either forward or in reverse .................................. 40-877
H-5 Large time lag is in gear shifting or directional change................................................... 40-878
H-6 Machine cannot be steered (machine does not turn left or right) ..................................... 40-880
H-7 Steering speed or power is insufficient ......................................................................... 40-881
H-8 Brake does not work .................................................................................................. 40-882
H-9 Torque converter lockup clutch does not engage .......................................................... 40-883
H-10 Power train oil overheats .......................................................................................... 40-884
H-11 Unusual noise is heard from around HSS pump or HSS motor ..................................... 40-886
H-12 All work equipment operates slowly ........................................................................... 40-887
H-13 All work equipment do not operate ............................................................................. 40-888
H-14 Blade lift speed or power is low ................................................................................. 40-889
H-15 Blade tilt speed or power is low ................................................................................. 40-891
H-16 Ripper lift speed or power is low ................................................................................ 40-893
H-17 Ripper tilt speed or power is low ................................................................................ 40-895
H-18 Hydraulic drift of lifted blade is large........................................................................... 40-897
H-19 Hydraulic drift of tilted blade is large........................................................................... 40-898
H-20 Hydraulic drift of lifted ripper is large .......................................................................... 40-899
H-21 Ripper pin puller cylinder does not operate ................................................................. 40-900
H-22 Blade pitch cylinder does not operate......................................................................... 40-901
H-23 Unusual noise is heard from around work equipment pump ......................................... 40-902
H-24 Fan speed is abnormal (too high or low, or stationary) ................................................. 40-903
H-25 Unusual noise is heard from around fan ..................................................................... 40-904
Troubleshooting of engine (S-mode)......................................................................................... 40-905
Information mentioned in troubleshooting table (S mode)..................................................... 40-905
S-1 When starting switch is turned to START position, engine is not cranked......................... 40-906
S-2 The engine cranks but exhaust smoke does not come out ............................................. 40-907
S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start
but does not) ...................................................................................................... 40-908
S-4 Engine startability is poor............................................................................................ 40-909
S-5 Engine does not pick-up smoothly ............................................................................... 40-911
S-6 Engine stops during operation ..................................................................................... 40-913
S-7 Engine runs rough or is unstable ................................................................................. 40-915
S-8 Engine lacks power .................................................................................................... 40-916
S-9 KDPF gets clogged in a short time............................................................................... 40-918
S-10 Engine oil consumption is excessive .......................................................................... 40-920
S-11 Engine oil becomes contaminated early...................................................................... 40-921
S-12 Fuel consumption is excessive .................................................................................. 40-922
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)...................................... 40-923
00-12 D155AX-7

00 Index and foreword
Index
S-14 Oil pressure drops.................................................................................................... 40-924
S-15 Fuel mixes into engine oil.......................................................................................... 40-925
S-16 Water mixes into engine oil (milky) ............................................................................. 40-926
S-17 Coolant temperature rises too high (overheating) ........................................................ 40-927
S-18 Unusual noise is heard ............................................................................................. 40-928
S-19 Vibration is excessive ............................................................................................... 40-929
S-20 Air cannot be bled from fuel circuit ............................................................................. 40-930
S-21 Active regeneration is executed frequently ................................................................. 40-931
S-22 Active regeneration takes a long time......................................................................... 40-932
S-23 White smoke is exhausted during active regeneration ................................................. 40-933
50 Disassembly and Assembly ...........................................................................................................50-1
Table of contents ........................................................................................................................50-2
Related information on disassembly and assembly ........................................................................ 50-4
How to read this manual .......................................................................................................50-4
Coating materials list ............................................................................................................50-6
Special tools list ................................................................................................................. 50-10
Sketches of special tools .................................................................................................... 50-18
Engine and cooling system........................................................................................................ 50-32
Removal and installation of fuel supply pump assembly......................................................... 50-32
Removal and installation of fuel injector assembly................................................................. 50-37
Removal and installation of cylinder head assembly.............................................................. 50-49
Removal and installation of air cleaner assembly .................................................................. 50-67
Removal and installation of KDPF assembly......................................................................... 50-69
Disassembly and assembly of KDPF assembly .................................................................... 50-72
Removal and installation of KCCV assembly ........................................................................ 50-82
Removal and installation of engine assembly ....................................................................... 50-83
Removal and installation of engine front seal ........................................................................ 50-89
Removal and installation of engine rear seal......................................................................... 50-93
Removal and installation of radiator assembly ...................................................................... 50-98
Removal and installation of aftercooler assembly ................................................................ 50-102
Removal and installation of hydraulic oil cooler assembly .................................................... 50-104
Removal and installation of cooling fan drive assembly ....................................................... 50-106
Removal and installation of cooling in fan motor assembly ................................................... 50-108
Removal and installation of engine hood assembly ............................................................. 50-109
Removal and installation of fuel tank assembly ................................................................... 50-112
Power train............................................................................................................................. 50-114
Removal and installation of damper assembly .................................................................... 50-114
Disassembly and assembly of damper assembly ................................................................ 50-117
Removal and installation of power train unit assembly ......................................................... 50-124
Disconnection and connection of power train unit assembly................................................. 50-128
Disassembly and assembly of PTO assembly..................................................................... 50-132
Disassembly and assembly of torque converter assembly ................................................... 50-139
Disassembly and assembly of transmission assembly......................................................... 50-148
Disassembly and assembly of HSS assembly .................................................................... 50-164
Removal and installation of HSS motor assembly ............................................................... 50-180
Removal and installation of final drive assembly ................................................................. 50-181
Disassembly and assembly of final drive ............................................................................ 50-183
Undercarriage and frame......................................................................................................... 50-196
Removal and installation of track frame assembly ............................................................... 50-196
Removal and installation of idler assembly ......................................................................... 50-200
Disassembly and assembly of idler assembly ..................................................................... 50-202
Removal and installation of recoil spring assembly.............................................................. 50-206
Disassembly and assembly of recoil spring assembly.......................................................... 50-207
Removal and installation of track roller assembly ................................................................ 50-212
Disassembly and assembly of track roller assembly ............................................................ 50-214
Removal and installation of 1st bogie assembly .................................................................. 50-217
Removal and installation of 2nd, 3rd, or 4th bogie assembly ................................................ 50-222
Disassembly and assembly of bogie assembly ................................................................... 50-227
Removal and installation of carrier roller assembly .............................................................. 50-229
D155AX-7 00-13

00 Index and foreword
Index
Disassembly and assembly of carrier roller assembly.......................................................... 50-230
Removal and installation of pivot shaft assembly ................................................................ 50-233
Separation and connection of track shoe assembly............................................................. 50-235
Overall disassembly and assembly of track shoe assembly ................................................. 50-238
Field disassembly and assembly of one link ....................................................................... 50-251
Disassembly and assembly of master link .......................................................................... 50-255
Removal and installation of equalizer bar assembly ............................................................ 50-258
Disassembly and assembly of equalizer bar bushing........................................................... 50-260
Removal and installation of segment teeth ......................................................................... 50-262
Hydraulic system .................................................................................................................... 50-263
Removal and installation of hydraulic tank assembly ........................................................... 50-263
Removal and installation of control valve assembly ............................................................. 50-265
Removal and installation of work equipment pump and HSS pump assembly........................ 50-267
Removal and installation of power train pump and steering lubrication pump
assembly ........................................................................................................... 50-269
Removal and installation of cooling fan pump assembly ...................................................... 50-271
Removal and installation of scavenging pump assembly...................................................... 50-273
Disassembly and assembly of hydraulic cylinder assembly.................................................. 50-274
Work equipment ..................................................................................................................... 50-281
Removal and installation of blade assembly ....................................................................... 50-281
Disassembly and assembly of blade assembly ................................................................... 50-283
Disassembly and assembly of multi-shank ripper assembly ................................................. 50-287
Disassembly and assembly of giant ripper assembly ........................................................... 50-291
Cab and its attachments.......................................................................................................... 50-295
Removal and installation of operator's cab assembly........................................................... 50-295
Removal and installation of operator's cab glass (adhesion glass) ........................................ 50-300
Removal and installation of operator's seat......................................................................... 50-306
Removal and installation of seat belt .................................................................................. 50-307
Removal and installation of air conditioner unit assembly..................................................... 50-308
Removal and installation of air conditioner compressor assembly......................................... 50-312
Removal and installation of air conditioner condenser assembly .......................................... 50-314
Electrical system .................................................................................................................... 50-316
Removal and installation of machine monitor assembly ....................................................... 50-316
Removal and installation of engine controller assembly ....................................................... 50-317
Removal and installation of power train controller assembly................................................. 50-319
Removal and installation of work equipment controller assembly.......................................... 50-320
Removal and installation of mass air flow and temperature sensor ....................................... 50-321
Removal and installation of KOMTRAX terminal ................................................................. 50-322
60 Maintenance standard...................................................................................................................60-1
Table of contents ........................................................................................................................60-2
Engine and cooling system..........................................................................................................60-3
Engine mount ......................................................................................................................60-3
Damper...............................................................................................................................60-4
Cooling system ....................................................................................................................60-6
Cooling fan pump.................................................................................................................60-9
Cooling fan motor............................................................................................................... 60-13
Power train............................................................................................................................... 60-15
Power train mount.............................................................................................................. 60-15
Universal joint.................................................................................................................... 60-17
Torque converter and PTO.................................................................................................. 60-18
Torque converter control valve............................................................................................. 60-24
Lockup clutch ECMV.......................................................................................................... 60-25
Stator cluch ECMV............................................................................................................. 60-26
Transmission ..................................................................................................................... 60-27
Transmission ECMV........................................................................................................... 60-32
Main relief valve and torque converter relief valve ................................................................. 60-33
Transmission lubrication relief valve..................................................................................... 60-34
Bevel gear shaft, HSS, and brake........................................................................................ 60-35
Brake control valve............................................................................................................. 60-41
00-14 D155AX-7

00 Index and foreword
Index
Brake ECMV ..................................................................................................................... 60-43
Brake solenoid valve ..........................................................................................................60-44
Sudden stop prevention valve ............................................................................................. 60-45
Final drive ......................................................................................................................... 60-46
Sprocket............................................................................................................................ 60-49
Full-scale drawing of sprocket tooth profile ........................................................................... 60-50
Undercarriage and frame........................................................................................................... 60-51
Main frame ........................................................................................................................ 60-51
Suspension ....................................................................................................................... 60-53
Track frame and idler cushion ............................................................................................. 60-55
Idler .................................................................................................................................. 60-57
Track roller ........................................................................................................................ 60-59
Carrier roller ...................................................................................................................... 60-61
Track shoe ........................................................................................................................ 60-62
Hydraulic system ...................................................................................................................... 60-66
Hydraulic tank.................................................................................................................... 60-66
Scavenging pump .............................................................................................................. 60-67
Steering lubrication pump and power train pump................................................................... 60-68
Work equipment and HSS pump ......................................................................................... 60-70
PC-EPC valve ................................................................................................................... 60-72
HSS motor ........................................................................................................................ 60-73
Control valve ..................................................................................................................... 60-76
Quick drop valve ................................................................................................................ 60-89
Self-pressure reducing valve............................................................................................... 60-91
Work equipment ....................................................................................................................... 60-93
Cylinder stay...................................................................................................................... 60-93
Blade ................................................................................................................................ 60-94
Cutting edge and end bit.....................................................................................................60-96
Ripper............................................................................................................................... 60-97
Blade lift cylinder.............................................................................................................. 60-101
Blade tilt cylinder.............................................................................................................. 60-102
Ripper lift cylinder............................................................................................................. 60-103
Ripper tilt cylinder............................................................................................................. 60-104
Cab and its attachments.......................................................................................................... 60-105
Cab mount ...................................................................................................................... 60-105
80 Appendix......................................................................................................................................80-1
Table of contents ........................................................................................................................80-2
Air conditioner components .........................................................................................................80-3
Precautions for refrigerant.....................................................................................................80-3
Air conditioner component ....................................................................................................80-4
Configuration and function of refrigeration cycle...................................................................... 80-6
Outline of refrigeration cycle..................................................................................................80-7
Air conditioner unit ...............................................................................................................80-9
Air conditioner controller ..................................................................................................... 80-16
Compressor....................................................................................................................... 80-17
Condenser ........................................................................................................................ 80-18
Receiver drier .................................................................................................................... 80-19
Sunlight sensor.................................................................................................................. 80-20
Outer temperature sensor (outside air temperature sensor) ................................................... 80-21
Procedure for testing and troubleshooting ............................................................................ 80-22
Circuit diagram and arrangement of connector pins............................................................... 80-24
System diagram................................................................................................................. 80-26
Parts and connectors layout................................................................................................80-29
Testing air leakage (duct).................................................................................................... 80-37
Testing with self-diagnosis function ...................................................................................... 80-40
Testing vent (mode) changeover.......................................................................................... 80-43
Testing FRESH/RECIRC air changeover.............................................................................. 80-44
Testing sunlight sensor ....................................................................................................... 80-45
Testing (dual) pressure switch for refrigerant......................................................................... 80-46
D155AX-7 00-15

00 Index and foreword
Index
Testing relays .................................................................................................................... 80-48
Troubleshooting chart 1 ...................................................................................................... 80-49
Troubleshooting chart 2 ...................................................................................................... 80-50
Information in troubleshooting table ..................................................................................... 80-52
Failure code list related to air conditioner.............................................................................. 80-53
Failure code [879AKA] A/C Inner Sensor Open Circuit .......................................................... 80-54
Failure code [879AKB] A/C Inner Sensor Short Circuit........................................................... 80-55
Failure code [879BKA] A/C Outer Sensor Open Circuit.......................................................... 80-56
Failure code [879BKB] A/C Outer Sensor Short Circuit.......................................................... 80-58
Failure code [879CKA] Ventilating Sensor Open Circuit......................................................... 80-60
Failure code [879CKB] Ventilating Sensor Short Circuit ......................................................... 80-61
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ................................................ 80-62
Failure code [879EMC] Ventilation Damper Abnormality ........................................................ 80-64
Failure code [879FMC] Air Mix Damper Abnormality ............................................................. 80-65
Failure code [879GKX] Refrigerant Abnormality.................................................................... 80-66
A-1 Troubleshooting for power supply system (Air conditioner does not operate) ..................... 80-67
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ........................ 80-69
A-3 Troubleshooting for blower motor system (No air comes out or air flow is
abnormal) ............................................................................................................ 80-73
A-4 Troubleshooting for FRESH/RECIRC air changeover ...................................................... 80-75
Troubleshooting with gauge pressure................................................................................... 80-77
Connection of service tool................................................................................................... 80-80
Precautions for disconnecting and connecting refrigerant piping............................................. 80-82
Handling of compressor oil.................................................................................................. 80-84
90 Drawings......................................................................................................................................90-1
Table of contents ........................................................................................................................90-2
Hydraulic circuit diagram .............................................................................................................90-3
Symbols in hydraulic circuit diagram ...................................................................................... 90-3
Power train hydraulic circuit diagram...................................................................................... 90-7
Hydraulic circuit diagram.......................................................................................................90-9
Electric circuit diagram .............................................................................................................. 90-13
Symbols in electric circuit diagram....................................................................................... 90-13
Electrical circuit diagram..................................................................................................... 90-17
Air conditioner electrical circuit diagram ............................................................................... 90-43
Index.................................................................................................................................................................... 1
00-16 D155AX-7

00 Index and foreword
Foreword, safety and general information
Foreword, safety and general information (ALL-0370-001-A-00-A)
Important safety notice (ALL-1120-012-A-01-A)
(Rev. 2014/08)
•Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The
shop manual describes the effective and safe servicing and repair methods recommended by Komatsu.
Some of these methods require the use of the special tools designed by Komatsu for the specific purpose.
•The symbol mark kis used for such matters that require special cautions during the work. The work
indicated by the caution mark should be performed according to the instructions with special attention to
the cautions. Should hazardous situation occur or be anticipated during such work, be sure to keep safe
first and take every necessary measure.
Safety points
•Good arrangement
•Correct work clothes
•Observance of work standard
•Practice of making and checking signals
•Prohibition of operation and handling by
unlicensed workers
•Safety check before starting work
•Wearing protective goggles (for cleaning or
grinding work)
•Wearing shielding goggles and protectors (for
welding work)
•Good physical condition and preparation
•Precautions against work which you are not
used to or you are used to too much
General precautions
kk Inappropriate handling causes an extreme
danger. Read and understand what is
described in the operation and maintenance
manual before operating the machine. Read
and understand what is described in this
manual before starting the work.
•Before performing any greasing or repairs, read
all the safety labels stuck to the machine. For
the locations of the safety labels and detailed
explanation of precautions, see the operation
and maintenance manual.
•Locate a place in the repair workshop to keep
the tools and removed parts. Always keep the
tools and parts in their correct places. Always
keep the work area clean and make sure that
there is no dirt, water or oil on the floor. Smoke
only in the areas provided for smoking. Never
smoke while working.
•When performing any work, always wear the
safety shoes and helmet. Do not wear loose
work cloths, or clothes with buttons missing.
1. Always wear the protective eyeglasses when
hitting parts with a hammer.
2. Always wear the protective eyeglasses when
grinding parts with a grinder, etc.
•When performing any work with 2 or more
workers, always agree on the working procedure
before starting. While working, always keep
conversations of the work between your fellow
workers and your self on any step of the work.
During the work, hang the warning tag of
"UNDER WORKING" in the operator's
compartment.
•Only qualified workers must perform the work
and operation which require license or
qualification.
•Keep the tools in good condition. And learn the
correct way to use the tools, and use the proper
ones among them. Before starting the work,
thoroughly check the tools, lift truck, service
vehicle, etc.
•If welding repairs is required, always have a
trained and experienced welder with good
knowledge of welding perform the work. When
performing welding work, always wear welding
gloves, apron, shielding goggles, cap, etc.
•Before starting work, warm up your body
thoroughly to start work under good condition.
•Avoid continuing work for long hours and take
rests with proper intervals to keep your body in
good condition. Take a rest in a specified safe
place.
Preparation
•Before adding oil or making any repairs, place
the machine on a firm and level ground, and
apply the parking brake and chock the wheels or
tracks to prevent the machine from moving.
•Before starting work, lower the work equipment
(blade, ripper, bucket, etc.) to the ground. If it is
not possible to lower the equipment to the
ground, insert the lock pin or use blocks to
prevent the work equipment from falling. And be
sure to lock all the work equipment control levers
and hang a warning tag on them.
•When performing the disassembling or
assembling work, support the machine securely
with blocks, jacks, or stands before starting the
work.
•Remove all of mud and oil from the steps or
other places used to get on and off the machine
completely. Always use the handrails, ladders of
steps when getting on or off the machine. Never
D155AX-7 00-17

00 Index and foreword
Foreword, safety and general information
jump on or off the machine. When the scaffold is
not provided, use steps or stepladder to secure
your footing.
Precautions during work
•For the machine equipped with the battery
disconnect switch, check that the system
operating lamp is turned off before starting the
work. Then, turn the battery disconnect switch to
OFF (Q) position and remove the switch key. For
the machine not equipped with the battery
disconnect switch, remove the cable from the
battery before starting the work. Be sure to
remove the negative end (-) of the battery cable
first.
•Release the remaining pressure in the circuits
completely before the work when the parts in the
circuits of oil, fuel, coolant and air are
disconnected or removed. When the cap of the
oil filter, drain plug or oil pressure pickup plug is
removed, loose them slowly to prevent the oil
from spurting out.
•When removing or installing the checking plug or
the piping in the fuel circuit, wait 30 seconds or
longer after the engine is shut down and start
the work after the remaining pressure is
released from the fuel circuit.
•Immediately after the engine is shut down, the
coolant and oil in the circuits are hot. Be careful
not to get scalded by the hot coolant and oil.
Start the work after checking that the coolant
and oil are cooled down sufficiently.
•Start the work after the engine is shut down. Be
sure to shut down the engine when working on
or around the rotating parts in particular. When
checking the machine without shutting down the
engine (measuring oil pressure, rotational speed,
oil or coolant temperature), take extreme care
not to get caught in the rotating parts or the
working equipment.
•The hoist or crane must be used to sling the
components weighing 25 kg or heavier. Check
the slings (wire rope, nylon sling, chain and
hook) for damage before the work. Use the
slings with ample capacity and install them to
the proper places. Operate the hoist or crane
slowly to prevent the component from hitting any
other part. Do not work with any part still raised
by the hoist or crane.
•When removing the part which is under internal
pressure or reaction force of the spring, always
leave 2 bolts in diagonal positions. Loosen those
2 bolts gradually and alternately and release the
pressure, then, remove the part.
•When removing the part, be careful not to break
or damage the electrical wiring. The damaged
wiring may cause electrical fires.
•When removing piping, prevent the fuel or oil
from spilling out. If any fuel or oil drips onto the
floor, wipe it off immediately. Fuel or oil on the
floor can cause you to slip and can even cause
fires.
•As a general rule, do not use gasoline to wash
parts. Do not use gasoline to clean the electrical
parts, in particular.
•Reinstall the parts removed to their original
places. Replace the damaged parts and the
parts which must not be used with new ones.
When installing the hoses and wiring harnesses,
be careful that they are not damaged by
contacting with other parts when the machine is
operated.
•When connecting the high pressure hoses and
tubes, make sure that they are not twisted. The
damaged high pressure hoses and tubes are
very dangerous when they are installed. So, be
extremely careful when connecting the high
pressure pipings. In addition, check that their
connections are correct.
•When assembling or installing the parts, be sure
to tighten the bolts to the specified torque. When
installing the protective parts such as guards, or
the parts which vibrate violently or rotate at high
speeds, be sure to check that they are installed
correctly.
•When aligning 2 holes, never insert your fingers
or hand into the holes. Align the holes with care
so that your fingers are not caught in the hole.
•When measuring hydraulic pressure, check that
the measuring tools are correctly installed.
•Pay attention to safety when removing and
installing the tracks of the track type machines.
When removing the track, it separates suddenly.
The workers should not stand at either end of
the track.
•If the engine is operated for a long time in a
closed place which is not ventilated well, you
may suffer from gas poisoning. Accordingly,
open the windows and doors to ventilate the
place well.
Precautions for slinging work and making
signals
•Only one appointed worker must make signals
and co-worker must communicate with each
other frequently. The appointed signaler must
make specified signals clearly at the place
where the signaler is well seen from the
operator's seat and where the signaler can see
the working condition easily. The signaler must
always stand in front of the load and guide the
operator safely.
1. Do not stand under the load.
2. Do not step on the load.
•Check the slings before starting sling work.
•Keep putting on the gloves during sling work.
(Put on the leather gloves, if available.)
00-18 D155AX-7